A-Car Workshop Manual

Maintenance Manual of Tojoy Sedan Contents
Engine Volume
Chapter 1 Mechanical Part of Engine ............................................................................1
Section 1 Engine Body ...................................................................................................................1
I. General Precautions ....................................................................................................1

II. Precautions on Sealant................................................................................................2
III. Preparation ..................................................................................................................4
IV. Engine Assembly .........................................................................................................7
V. Drive Belt ...................................................................................................................11
VI. Air Cleaner and Air Duct ............................................................................................13
VII. Intake Manifold and Exhaust Manifold .......................................................................16
VIII. Exhaust System.........................................................................................................20
IX. Timing Belt Mechanism..............................................................................................22
X. Rocker Arm and Camshaft.........................................................................................28
XI. Cylinder Cover ...........................................................................................................32
XII. Valves ........................................................................................................................37
XIII. Cylinder Body Assembly ............................................................................................43
XIV. Diagnosis of Common Troubles.................................................................................58
XV. Maintenance Parameters...........................................................................................60
Section II Engine Lubrication System ...........................................................................................64
I. Precautions................................................................................................................64
II. Preparation ................................................................................................................65
III. Engine Oil ..................................................................................................................66
IV. Oil Filter .....................................................................................................................68
V. Oil Pan and Engine Oil Pump ....................................................................................70
Section III Cooling System of Engine............................................................................................75
I. Precautions................................................................................................................75
II. Cooling Circuit ...........................................................................................................77
III. Engine Coolant ..........................................................................................................78
V. Radiator Cooling Fan .................................................................................................83
VI. Water Pump...............................................................................................................84
VII. Thermostat Sub-assembly .........................................................................................85
VIII. Water Piping Sub-assembly.......................................................................................88
IX. Trouble Analysis ........................................................................................................89
X. Maintenance Parameters...........................................................................................90
Section IV Fuel Supply System of Engine ....................................................................................91
I. General Precautions ..................................................................................................91

II. Preparation ................................................................................................................92
III. Fuel System...............................................................................................................92
IV. Fuel Injector and Guide Rail ......................................................................................93
V. Fuel Filter...................................................................................................................97
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VI. Fuel Pump Assembly .................................................................................................99

VII. Fuel Tank Assembly ................................................................................................103
VIII. Acceleration Control Device.....................................................................................105
Section V Emission Control System of Engine ...........................................................................107
I. Fuel Evaporation System.........................................................................................107

II. Forced Ventilating System of Crankcase .................................................................111
Chapter 2 Electrical Part of Engine ........................................................................... 114

Section 1 Ignition System ...........................................................................................................114
I. Ignition coil...............................................................................................................114
II. Diagnosis of Common Troubles...............................................................................117
III. Maintenance Parameters.........................................................................................117
Section 2 Starting and Charging System ....................................................................................118
I. Basic Diagram of Starting and Charging System.....................................................118

II. Storage Battery........................................................................................................118
III. Starting System .......................................................................................................121
IV. Charging System .....................................................................................................129
Chapter III Electronic Control System of Engine......................................................135

Section I Precautions..................................................................................................................135
I. Precautions of Supplement Restraint System (SRS) ...............................................135

II. General Precautions ................................................................................................135
III. Precautions in Maintenance.....................................................................................135
IV. Precautions of On-board Diagnosis (OBD) System .................................................136
Section II Structural Principle and Overhaul of Engine Control System ......................................139
I. System Illustration ...................................................................................................139

II. Multiple-point Fuel Injection System ........................................................................139
III. On-board Diagnosis System ....................................................................................143
IV. Engine Trouble Diagnosis........................................................................................147
Section III Structural Principle and Overhaul of Engine Electronic Elements..............................153
I. Intake Manifold Absolute Pressure (MAP) Sensor...................................................153

II. Engine Coolant Temperature (ECT) Sensor ............................................................155
III. Air Throttle Position Sensor (TPS)...........................................................................157
IV. Camshaft Position Sensor (CMP) ............................................................................159
V. Crankshaft Position Sensor (CKP)...........................................................................160
VI. Heated Oxygen Sensor (HO2S) ..............................................................................162
VII. Fuel Injector (INJ) ....................................................................................................164
VIII. Stepper Motor (IAC).................................................................................................165
IX. Knock Sensor (KS) ..................................................................................................167
X. Air Conditioner Switch and Relay ............................................................................168
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XI. Carbon Canister Solenoid Valve..............................................................................168

XII. Ignition Coil ..............................................................................................................171
XIII. Electric Fuel Pump...................................................................................................172
XIV. Electronic Control Module (ECM) of Engine ............................................................173
Section IV Trouble Diagnosis Procedures for Engine Control System........................................177
I. Diagnosis by Trouble Code......................................................................................177

II. Diagnosis by Trouble Phenomena ...........................................................................205
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Mechanical Part of
Maintenance Manual of Tojoy Sedan Engine
Chapter 1 Mechanical Part of Engine

Section 1 Engine Body
I. General Precautions
1. Precautions on Discharging Engine Coolant
Discharge the engine coolant after the engine has cooled down.
2. Precautions on Disconnecting Fuel Pipeline
1) Before the operation, ensure that the operating area is free of objects which may cause combustion
or sparks.
2) Before disconnecting and disassembling the fuel pipeline, release the fuel pressure.
3) After disconnecting the fuel pipeline, plug the opening to prevent fuel leakage.
3. Precautions on Dismantlement and Disassembly
1) Use special tools when the instructions require so. Always pay attention to safe operation, and
forcible operations or operations against the instructions shall be forbidden.
2) Take particular care not to damage the matching face or the sliding face.
3) Use the adhesive tape or its equivalent to seal the opening of engine system so as to prevent the
entry of foreign bodies, if necessary.
4) For the purpose of troubleshooting and reassembly, methodically mark and neaten the
disassembled parts.
5) When loosening the bolts and nuts, follow this basic principle: “outmost ones first, diagonal ones
second, and so on”. Conduct the operation in compliance with the loosening sequence, if the
sequence is specified.
4. Precautions on Check, Repair and Replacement
Thoroughly check the parts before the repair or replacement. Check the substitutive parts by the same
means, and then replace them, if necessary.
5. Precautions on Assembly and Installation
1) Use the torque spanner to screw up the nuts and bolts.
2) When screwing up the nuts and bolts, follow this basic principle: screw up the central nuts and bolts
with the same tightness and in steps, and then carry out the same operation with the internal and
external diagonal ones. Perform the operation in accordance with the screwing sequence, if it is
specified.
3) Replace the liner, oil seal or O-ring with new ones.
4) Thoroughly rinse, clean and dry every part. Carefully check the engine oil pipeline or engine coolant
pipeline for obstruction.
5) Never damage the sliding face and the matching face. Completely eliminate the foreign bodies,
such as the cloth scraps or the dust. Before the assembly, slick the sliding face with the engine oil.
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Mechanical Part of
6) In case of draining and then adding the engine coolant, release the air from the pipes first.
7) After the repair, start the engine and raise its speed to check it for leakages of the engine coolant,
fuel, engine oil and tail gas.
6. Parts Needed to Be Screwed Up with Specified Angle
1) Use the angle spanner to finally screw up the following engine parts:
- Cylinder cover bolt
- Bolt of main bearing cap
- Connecting rod nut
2) Do not conduct the final tightening in accordance with the torque values.
3) The torque values for these parts are applied to the pre-tightening steps.
4) Ensure that the surfaces of threads and pedestal are clean and coated with the engine oil.
II. Precautions on Sealant

Fig.1.1.001
1. Removal of Sealant
After dismounting the fixing nuts and bolts, use the

scraper to detach the matching faces and remove
the old sealant.
Slide
Attention: Knock
■ Do not damage the matching faces.
■ Insert the scraper, and then knock its side to

slide it as shown in the figure.
■ For the positions where it is difficult to use the

scraper, lightly knock the parts to dismount
Fig.1.1.002
them with a plastic hammer.
Scraper
■ If you have no choice but to use the tools such
as a screwdriver, be carefull not to damage
the matching faces.
2. Application Steps of Sealant
1) Use a scraper to remove the attached old

sealant from the application and matching
faces of liner.
Attention:
■ Thoroughly remove the old sealant from the

surfaces of groove, fixing bolt and bolt hole
where the sealant was applied.
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Mechanical Part of
2) Wipe the matching faces and application faces of sealant with the unleaded petrol, and eliminate the
attached water, lubricating grease and foreign bodies.
3) Put the sealant (with the specified size) in the

specified position. Fig.1.1.003
Attention:
■ Put the sealant into the groove for it, if any.
■ Generally, the sealant is put inside the bolt Fig.1.1.004 Inner

hole; however, it is occasionally put outside Side
the bolt hole.
■ Install the matching elements within 5minutes

Groove Bolt Hole
after the sealant has been applied.
■ Eliminate the dirt from the sealant, if any.
■ Do not re-screw down the nuts or bolts after

their installation. Inner Side
■ Add the engine oil and the engine coolant

30min after the installation has been finished.
Attention:
■ Conduct the operation in accordance with the

instructions specified in this manual.
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Mechanical Part of
III. Preparation
1. Maintenance Tools
List of Special Tools

No. Tool Appearance Code Description
Used to fix
1 End forked clamp the camshaft
timing gear
JAC-T1D001
Used together
2 Pin with the end
forked clamp
Used to install
Locating tool for
3 and dismantle
piston pin
the piston pin
JAC-T1F005
Used together
with the
4 Guide sleeve
locating tool
for piston pin
Used to fix
5 Flywheel chock JAC-T1F011
the flywheel
Used to
Valve spring
6 JAC-T1F012 compress the
compressor
valve spring
4
Mechanical Part of
Used to install
Oxygen sensor and dismantle
7 JAC-T1F015
sleeve the oxygen
sensor
Used to
Dismantlement
8 JAC-T1F017 dismantle the
tool for oil pan
oil pan
Used to install
Installer for valve
9 JAC-T3F001 the valve oil
oil seal
seal
Used to install
Installer for
10 JAC-T3F002 the camshaft oil
camshaft oil seal
seal of engine
Functioning as
Guide for front oil a guide during
11 seal of JAC-T3F003 the installation
crankshaft of front oil seal
of crankshaft
Used to install
Installer for front
the front oil seal
12 oil seal of JAC-T3F004
of engine
crankshaft
crankshaft
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Mechanical Part of
Installer for rear Used to install

13 oil seal of JAC-T3F005 the rear oil seal
crankshaft of crankshaft
2. List of Auxiliary Materials for Assembling Engine
List of Auxiliary Materials for Assembling Engine
No. Name Application Specification and Grade

5W-30 (for winter of north) or
Engine 15W-40 (for summer of north and
1 Used during filling or assembly
oil whole year of south); quality grade:
SJ or above
Silica Engine oil pump, water pump, oil pan and rear
2 LT5699 or equivalent
gel oil seal housing of crankshaft
Oil pressure switch, draining screw plug and
3 Sealant LT243 or equivalent
flywheel bolt
Coolant temperature sensor and water
4 Sealant LT648 or equivalent
temperature warning switch
5 Petrol RON93# unleaded petrol or above
6 Sealant Double-head bolt LT271 or equivalent
3. List of Auxiliary Materials for Assembling Cylinder Cover
List of Auxiliary Materials for Assembling Cylinder Cover
No. Name Present Material and Model Assembly Position

5W-30 (for winter of north) or 15W-40 (for Valve head, camshaft, rocker,
1 Engine oil summer of north and whole year of south); rocker shaft, and camshaft oil
quality grade: SJ or above seal
2 Sealant LT271 or equivalent Double-head bolt
Guide sleeve of spark plug, bowl
3 Sealant LT962T or equivalent patch of cylinder body/cover,
connecting pipe nozzle
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Mechanical Part of
IV. Engine Assembly

1. Precautions on Installation and Dismantlement
Caution:
Operation in violation of the following instructions may incur body injury!
■ Park the vehicle on even and firm ground.
Attention:
■ Always pay attention to safe operation, and do not conduct forcible operations or operations against
the instructions.
■ Do not start the operation before the exhaust system and engine coolant have fully cooled down.
■ If the necessary items or operations are not mentioned in the chapter or section of engine, see the
corresponding chapters.
■ Use the special lifting fulcrum all the time, and select lifters as appropriate.
2. Preparation for Dismounting Engine and Transmission Assembly
1) General
Dismount the engine and transmission assembly from the vehicle first, and then detach the engine and
the transmission.
2) Preparation
① Release the fuel pressure. See “Release of Fuel Pressure”.
② Discharge the engine coolant from the radiator. See “Replacement of Engine Coolant”.
③ Discharge the engine oil, transmission oil and clutch oil. See "Engine Oil", “Transmission Oil” and
“Clutch Pipeline”.
④ Recycle the cooling agent in cooling pipeline.
⑤ Discharge the power steering fluid. See “Power Steering Fluid”.
Attention:
■ Perform this step after the engine has cooled down.
■ Do not splash the engine coolant onto the drive belt.
⑥ Dismount the following parts:
■ Engine trimming cover. See “Intake Manifold”.
■ Engine hood assembly. See “Engine Hood”.
■ Front wheels and tyres. See “Wheels and Tyres”.
■ Engine deflectors (left and right).
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Mechanical Part of
■ Air duct and air cleaner assembly. See “Air Duct”.
■ Storage battery, storage battery base and storage battery base support. See “Storage Battery”.
■ Radiator assembly and radiator fan. See “Radiator”.
3. Dismantlement of Relevant Elements inside Engine Compartment
① Disconnect the following pipelines and put them aside.
Attention:
Use plugs to prevent leakage when disconnecting the pipelines.
■ Inlet pipe of oil injector. See “Oil Injector”.
■ Vacuum hose of braking vacuum booster on engine side. See “Braking Vacuum Booster”.
■ PVC hose. See “Fuel Evaporation Control System”.
■ Oil inlet pipe joint of clutch. See “Hydraulic Pipeline of Clutch”.
■ Oil inlet pipe and oil return pipe of power steering pump; fixing support of oil pipe. See “Power
Steering Pump”.
■ Low and high-pressure pipes at air compressor. See “air compressor”.
② Dismount the throttle wiredrawing. See “Throttle Wiredrawing”.
③ Dismount the steering fluid reservoir.
④ Dismount the gear shifting/selecting wiredrawing. See “Gear Shifting/Selecting Control Mechanism”.
⑤ Disconnect the wire harness connectors and wire harness buckles of the following parts and then
take them away:
■ Oxygen sensor
■ Engine coolant temperature sensor
■ Crankshaft position sensor
■ Camshaft position sensor
■ Vehicle speed sensor
■ Idle stepping motor
■ Air throttle position sensor
■ PCV valve
■ Absolute intake pressure sensor
■ Ignition coil
■ Oil injector
■ Knock sensor
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Mechanical Part of
■ Generator
■ Starter
■ Air conditioner switch
4. Dismantlement of Elements Relevant to Vehicle Chassis
① Dismount the front drive shaft. See “Front Drive Shaft”.
② Dismount the front exhaust pipe. See “Exhaust System”.
③ Dismount the engine supporting beam. See “Engine Supporting Beam”.
5. Dismantlement
Fig.1.1.005
① Mount the hanger on the engine hooks (front and
rear). See Figures 1.1.005 and 1.1.006.
② Lift the engine and fix it in place.
③ Use the manual lifting table or the equivalent tools to

firmly support the bottom of engine and transmission
assembly, and adjust the lifting tension.
Attention:
■ It is permissible to place a soft pad on the supporting

Fig.1.1.006
surface so as to ensure a totally stable state.
④ Detach the left, right, front and rear suspensions of

engine. See “Engine Suspension”.
⑤ Carefully lower the engine and transmission

assembly.
When carrying out the operation, note the following:
■ Ensure that the vehicle is not disturbed.
■ Ensure that all connecting parts have been

disconnected.
■ Remember that the vehicle’s center of gravity may

change. If necessary, use the jack to support the
rear lifting point and to prevent the falling.
6. Detachment
① Dismount the power steering pump assembly and the air conditioner compressor assembly from the
engine and transmission assembly. See “Power Steering Pump”.
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Mechanical Part of
② Dismount the starter. See “Starter”.

③ Use the lifter to lift the engine and the transmission, and then detach them.
Attention:
■ Before and during lifting, always ensure that no wire harness is connected.
7. Installation
Please note the following and perform the installation steps which are contrary to dismantlement steps.
1) Do not damage the soft pad of engine suspension. Meantime, avoid splashing engine oil onto the
soft pad.
2) Ensure that all engine suspensions have been properly fixed. Then, screw down the nuts and bolts.
8. Check after Installation
1) Check whether there is any leakage.
The steps for checking oil and fluid leakage, lubricating oil leakage and the exhaust leakage are listed as
follows:
■ Before starting the engine, check the levels of engine coolant and engine oil. If the levels are lower
than the required amount, refill engine coolant and engine oil to the specified positions.
■ Carry out the following steps to check whether fuel leakage is present.
- Turn the ignition switch to the “ON” position, and check whether there is fuel leakage at the
connecting parts.
- Start the engine, and recheck whether there is fuel leakage at the connecting parts during the
engine acceleration.
■ Run the engine and check whether there is abnormal noise or shake.
■ Thoroughly warm up the engine, and ensure that there is no fuel leakage, exhaust leakage or any oil
and fluid (including engine coolant and engine oil) leakage.
■ Discharge or feed air from/to the corresponding pipelines and hoses.
■ After the engine has cooled down, recheck the levels of oils and fluids (including engine oil and
engine coolant). If necessary, refill them to the specified levels.
2) General of Check Items
List of Leakage Check Items
Item Before Engine During Engine After Engine

Startup Operation Shutdown
Engine coolant Level Leakage Level
Engine oil Level Leakage Level
Transmission oil, brake fluid, power steering Level Leakage Level
fluid and clutch fluid
Fuel Leakage Leakage Leakage
Exhaust — Leakage —
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Mechanical Part of
V. Drive Belt
1. Check of Drive Belt
Caution:
■ Be sure to perform this operation after the engine shutdown.
1) Check whether there are crack, abrasion and smear on the belt. Replace the belt, if necessary.
2) Check the flexibility at the belt midpoint between belt

Fig.1.1.007
pulleys.
■ It is necessary to recheck the belt when the engine is
cold or 30 minutes after the engine has shut down.
■ When measuring the flexibility, apply a force of 98N to
the marked point.
■ If the flexibility exceeds the limit value, adjust the belt.
Note:
Belt flexibility value: 7~10mm
Attention:
■ During the belt flexibility check immediately after the installation, adjust the flexibility to the specified
value first, then rotate the crankshaft for more than two cycles, and finally readjust the flexibility to
the specified value lest the flexibility between belt pulleys would change.
2. Adjustment of Tension
List of Tension Adjustment
Part Adjustment Method

Generator belt Adjust the adjusting bolt on generator
Belts of power steering pump and air conditioner
Adjust the adjusting bolt on power steering pump
compressor
Attention:
■ After the replacement, adjust the belt flexibility to make the new belt adapt to the belt pulley groove.
■ During the belt flexibility check immediately after the installation, adjust the flexibility to the specified
value first, then rotate the crankshaft for more than two cycles, and finally readjust the flexibility to
the specified value lest the flexibility between belt pulleys would change.
■ When installing the belt, ensure the proper engagement between it and the belt pulley groove.
■ Do not splash the engine oil or engine coolant onto the belt.
■ Do not excessively coil or bend the belt.
11
Mechanical Part of
3. Generator Belt Fig.1.1008

1) Loosen the engine kingpin bolt and the
generator nut. Then, use the adjusting bolt to
regulate the tension.
2) Screw down the kingpin bolt and the generator Fig.1.1.00

nut.
■ Tightening torque: 34~54N·m
4. Belt of Power Steering Pump

Fig.1.1.010
1) Loosen fixing bolt and adjusting bolt of the power
steering pump.
2) Select the adjusting rod to regulate the tension.
3) Lock the adjusting rod bolt and the fixing bolt of power
steering pump.
5. Dismantlement of Drive Belt
1) Completely loosen every belt in accordance with the
instructions specified in “Tension Adjustment”.
2) Dismount the belt of power steering pump first, and
then the generator belt.
6. Installation of Drive Belt

1) Mount the belt onto the belt pulley in the installation steps which are contrary to the dismantlement
steps.
Attention:
■ Ensure that the belt has properly engaged with the belt pulley groove.
■ Ensure that no engine oil or engine coolant has splashed onto any belt and any belt pullet groove.
2) Ensure that the tension of every belt is within the standard range. See “Check of Drive Belt”.
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Mechanical Part of
VI. Air Cleaner and Air Duct
1. Elements
Diagram of Element Positions
1- Front Intake Pipe; 2- PVC Hose; 3- Intake Hose; 4- Air Cleaner Assembly
2. Intake Pipe Fig.1.1.011

1) Dismantlement
① Dismount the fixing bolt of front intake pipe,

and take down the front intake pipe assembly.
■ Tightening torque: 8~12 N·m
② Dismount the locking bolt on upper cover of air Fig.1.1.012

cleaner.
13
Mechanical Part of
③ Disconnect the locking clamp of intake hose,

and then take down the upper cover and the Fig.1.1.013
intake hose.
Fig.1.1.014
④ Dismount the fixing bolt of air cleaner base,

Fig.1.1.015
and then take down the base.
2) Check after Dismantlement
Check whether there is any crack or abrasion on the air duct assembly. If any, replace the air duct
assembly.
3) Installation
Perform the installation steps which are contrary to the dismantlement steps.
Attention:
■ Properly mount every joint, and screw up the clamp.
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Mechanical Part of
3. Replacement of Filter Core of Air Cleaner
1) Dismantlement Fig.1.1.016
① Loosen the locking bolt on upper cover of air

cleaner, and lift the upper cover.
② Dismount the filter core of air cleaner. Fig.1.1.017
■ It is required to periodically clean or replace the filter core of air cleaner in compliance with
recommended period. See “Periodical Maintenance”.
■ Blow the filter core of air cleaner from its back side with compressed air, till nothing is blown off.
3) Installation
■ Perform the installation steps which are contrary to the dismantlement steps.
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Mechanical Part of
VII. Intake Manifold and Exhaust Manifold
Decomposition Diagram of Intake and Exhaust Manifolds
1- Absolute intake pressure sensor; 2- Carbon canister solenoid valve; 3- Carbon canister solenoid valve
support; 4- Knock sensor support; 5- Engine lifting lug; 6- Intake manifold support; 7- Intake manifold; 8-
Intake manifold gasket; 9- Adiabatic pad for exhaust; 10- Oxygen sensor; 11- Exhaust manifold; 12-
Exhaust manifold gasket
1. Intake Manifold
1) Dismantlement
Caution:
■ Do not discharge the engine coolant when the engine is hot, lest you would be scalded.
① Discharge the engine coolant. See “Engine Coolant”.
② Release the fuel pressure. See “Release of

Fig.1.1.018
Fuel Pipeline Pressure”.
③ Dismount the engine trimming cover.
■ Tightening torque: 8~1 2 N·m
④ Dismount the air cleaner assembly. See “Air

Cleaner Assembly”.
⑤ Disconnect the wire harness connectors of the

following parts:
16
Mechanical Part of
■ Absolute intake pressure sensor
■ Oil injector
■ Throttle valve position sensor
■ Idle stepping motor
■ Controlling carbon canister solenoid
⑥ Disconnect the following hose joints:
■ Water hose joint (insert a plug to prevent the engine coolant leakage)
■ PCV hose
■ Vacuum hose of braking vacuum booster on intake manifold side
■ Vacuum hose on carbon canister solenoid side
■ Small circulating water hose for throttle valve body
⑦ Disconnect the throttle wiredrawing from the throttle valve body. Dismount the fixing bolt of throttle
valve body and the vacuum hose on carbon canister solenoid (on the side of throttle valve body),
and then take down the throttle valve body assembly.
⑧ Dismount the oil injector assembly. See “Oil Injector”.
■Tightening torque: 10~13 N·m
⑨ Dismount the fixing bracket of intake manifold and Fig.1.1.019

engine cylinder body.
■ Tightening torque: M8 15~20 N·m M10 27~33 N·m
⑩ Dismount the fixing bolt and nut of intake manifold.

⑪ Take down the intake manifold and the intake manifold Fig.1.1.020
gasket.
Check whether there are cracks or other damages on the

intake manifold and whether the matching face is distorted.
If this is the case, repair or replace the intake manifold.
17
Mechanical Part of
3) Installation
Attention:
■ Do not reuse the non-reusable parts.
■ Before starting the engine, check the level of engine coolant. If the level is lower than the required
amount, refill engine coolant to the specified position.
■ Carry out the following steps to check whether fuel leakage is present.
- Turn the ignition switch to the “ON” position, and check whether there is fuel leakage at the
connecting parts.
- Start the engine, and recheck whether there is fuel leakage at the connecting parts during the
engine acceleration.
■ Thoroughly warm up the engine, and ensure that there is no fuel leakage and engine coolant
leakage.
■ After the engine has cooled down, recheck the level of engine coolant. If necessary, refill engine
coolant to the specified level.
2. Exhaust Manifold
1) Dismantlement
Caution:
■ Perform this operation after the exhaust system has completely cooled down.
① Disconnect the wire harness connectors of front oxygen sensor. Dismount the front oxygen sensor
with special tools, if necessary.
Attention:
■ Do not damage the oxygen sensor.
■ It is forbidden to use any oxygen sensor which has dropped to the hard ground from a height above
0.5m. Such an oxygen sensor shall be replaced.
② Dismount the fixing bolt for adiabatic pad of

Fig.1.1.021
exhaust manifold, and then take down the
adiabatic pad.
18
Mechanical Part of
③ Disconnect the connection between three-way

Fig.1.1.022
catalytic converter and exhaust manifold.
④ Dismount the fixing bolt of exhaust manifold, and then take down the exhaust manifold.
■ Tightening torques: For M8, 15~20N·m;

Fig.1.1.023
For M10, 27~33N·m
Check whether the matching face of exhaust

manifold is distorted.
3) Installation
Perform the installation steps which are contrary to

the dismantlement steps.
Attention:
■ Do not reuse the non-reusable parts.
■ Do not excessively screw up the oxygen

sensor, lest it would be damaged.
19
Mechanical Part of
VIII. Exhaust System
1. Elements
Diagram of Exhaust System
1- Rear muffler; 2- Lifting lug; 3- Front muffler; 4- Front exhaust pipe; 5-Three-way Catalytic Converter;
6- Corrugated pipe; 7-Rear oxygen sensor
2. Check of Exhaust System
Check whether the exhaust pipe, the three-way catalytic converter, the muffler and the fixing devices are
properly installed and whether there is any leakage, crack, damage or aging.
■ Repair or replace the damaged part, if necessary.
3. Dismantlement and Installation
Attention:
■ Do not have you hand cut by the edge of adiabatic pad.
■ Do use regular exhaust system parts or equivalent products.
■ Perform the operation after the exhaust system has completely cooled down, for the temperature of
exhaust system remains hot when the engine has just shut down.
1) Dismantlement
Disconnect every joint and fixed part.
2) Installation
■ Replace the exhaust pipe liner when reassembling the exhaust system each time.
■ Repair or replace the seriously distorted adiabatic pad. Eliminate the accumulations from the
adiabatic pad.
20
Mechanical Part of
■ When mounting the adiabatic pad, try to avoid wide clearance or blockage and intervention between
the adiabatic pad and each exhaust pipe.
■ Eliminate the sediments from the sealed face of each joint. Such joints shall be firmly connected to
avoid gas leakage.
■ Pre-tighten the fixing nuts and bolts on exhaust manifold side and those on vehicle side. Check
whether there is any intervention between parts, and then tighten the parts with the specified torque.
■ When mounting the fixing rubber, avoid excessive upward/downward and leftward/rightward twist or
stretch of it.
3) Check after Installation
■ Confirm the clearance between rear muffler and rear bumper.
■ During the engine operation, check the connecting position of exhaust pipe for air leakage and
abnormal noise.
■ Ensure that the fixing support and the fixing rubber have been properly mounted. Do not subject
them to excessive force. Improper installation may lead to considerable noise and shake.
21
Mechanical Part of
IX. Timing Belt Mechanism

1. Elements
Diagram of Timing Belt Mechanism

1- External upper housing of timing belt 2- External lower housing of timing belt 3- Timing belt
4- Tension spring 5- Tension pulley of timing belt 6- Crankshaft timing gear
7- Bolt for camshaft timing bolt 8- Camshaft timing gear 9- Support 10- Right suspension of engine
2. Dismantlement and Installation of Timing Belt

Fig.1.1.024
1) Dismantlement
① Dismount the fixing bolt of water pump belt
pulley.
Note: It is permissible to perform the
dismantlement by means of the friction force of
drive belt when the drive belt has not been
removed yet.
22
Mechanical Part of
② Dismount the support. Fig.1.1.025
③ Dismount the fixing bolt of upper timing

Fig.1.1.026
housing, and then take down the upper timing
housing.
④ Rotate the crankshaft, and align the timing

Fig.1.1.027
mark on camshaft timing gear with that on
cylinder cover side.
Attention:
■ Regularly (clockwise) rotate the crankshaft

only.
■ When the upper marks align with each other,

ensure the timing mark on crankshaft belt disc
and that on lower timing housing align with
each other. See Fig.1.1.028. Fig.1.1.028
⑤ Fix the camshaft timing gear with an end fork

clamp, dismount the fixing bolt of crankshaft
belt disc, and take down the crankshaft belt
disc.
■ Tightening torque: 165N·m
23
Mechanical Part of
⑥ Dismount the fixing bolt of lower timing Fig.1.1.029

housing, and then take down the lower timing
housing.
■ Tightening torque: 10~1 2 N·m
⑦ Appropriately loosen the fixing bolt for tension

Fig.1.1.030
pulley of timing belt, use the pliers to clamp
the extending end of tension pulley spring,
dismount the bolt from the stop block of
engine oil pump housing, and then take down
the tension pulley spring.
⑧ Dismount the tension pulley of timing belt.
Note:
■ If the timing belt is intended to be reused, then before the tension pulley of timing belt is taken down,
make an arrow mark on the timing belt to represent the rotation direction prior to dismantlement.
This mark functions to avoid the failure to properly mount the timing belt.
⑨ Take down the timing belt.
① Timing belt
Fig.1.1.031
Check the timing belt for the following defects. If
the defects are present, replace the timing belt.
■ The rubber of back side hardens (The rubber
of back side is smooth, inelastic and hard
insomuch that no trace appears when it is
scratched with a nail).
■ There are cracks on the rubber surface of
back side.
■ The canvas tears, and (or) the canvas
separates from the rubber.
24
Mechanical Part of
■ There are cracks at tooth root. Fig.1.1.032 Crack Crack
■ There are cracks at the side face of belt.
■ The side face of belt is abnormally abraded. Separation

Crack
Side
■ The tooth no longer exists.
Attention:
If the shape of side face of belt looks like a blade Tooth Root with
Cracks
edge, this face shall be considered normal.
During the initial stage of abnormal tooth abrasion,

the canvas fiber becomes loose, the rubber Fig.1.1.033 Round Angle at Edge
structure disappears, the whiteness fades, and the
canvas structure appears unidentifiable. During the
final stage of such abrasion, the canvas gets
abraded and the rubber is exposed.
Abnormal Abrasion
(Exposed Core)
Fig.1.1.034
Abraded Canvas and
Exposed Rubber
No Teeth
② Tension Pulley
Fig.1.1.035
Check whether the unstable rotation, the play, and
the abnormal noise appear on the tension pulley. If
any, replace the tension pulley.
25
Mechanical Part of
③ Timing Housing
Check whether there are cracks or other damages on the timing housing. If any, replace the housing.
3) Installation
Fig.1.1.036
① Align the timing mark on camshaft timing gear
with that on cylinder cover side.
② Align the timing mark on crankshaft timing Fig.1.1.037

gear with that on engine oil pump housing.
③ Lock the tension pulley of timing belt at the Fig.1.1.038

position shown in the figure.
④ Hook an extending end of tension pulley Fig.1.1.039

spring with the hooked part of tension pulley of
timing belt, and then mount the tension pulley
onto the engine oil pump housing.
26
Mechanical Part of
⑤ Clamp the other extending end of tension

pulley spring, and hook it with the lug of Fig.1.1.040
engine oil pump housing as shown in the
figure.
⑥ Move the tension pulley of the timing belt in

the direction shown in Fig.1.1.040, and then
firmly tension the belt.
⑦ Keep the tensioned side of timing belt as it is,

and mount the timing belt into the crankshaft
timing gear, the camshaft timing gear and
tension pulley of timing belt in sequence. Fig.1.1.041
⑧ Loosen the fixing bolt for tension pulley of

timing belt for1/4~1/2 circle so as to subject
the timing belt to the tension of tension pulley
spring.
⑨ Rotate the crankshaft for 2 circles in the

normal (clockwise) direction, and check
whether the timing marks align with each
other.
Attention:
■ In this way, the tension evenly acts on the timing belt by virtue of the crankshaft drive torque. The
crankshaft must be rotated in the direction forementioned, and the anticlockwise rotation shall not
be carried out on the crankshaft.
⑩ Screw down the fixing mounting bolt for tension pulley of timing belt.
⑪ Mount the lower timing housing, the crankshaft belt disc, the upper timing housing and the support.
⑫ Mount the water pump belt pulley.
27
Mechanical Part of
X. Rocker Arm and Camshaft

1. Elements
Decomposition Diagram of Rocker Arm and Camshaft

1- PCV hose 2- Filler port cover 3- PCV valve 4- PCV valve pad 5- Valve chamber cover 6- Valve chamber
cover pad 7- Sealing gasket for spark plug conduit 8- Front oil seal of camshaft 9- Rocker arm and rocker arm shaft
assembly (for intake) 10- Rocker arm and rocker arm shaft assembly (for exhaust) 11- Rocker arm A 12- Rocker arm
B 13- Rocker arm shaft 14- Adjusting screw 15- Adjusting nut 16- Rocker arm C 17-Rocker arm shaft
18-Adjusting screw 19- Adjusting nut 20- Camshaft

1) Dismantlement
① Dismount the engine trimming cover. See “Intake Manifold”.
② Dismount the ignition coil and the high-pressure wire. See “Ignition Coil”.
③ Disconnect the fixing joint of throttle wiredrawing and high-pressure oil pipe of power steering pump.
④ Disconnect the wire harness connectors of PVC hose and camshaft position sensor.
28
Mechanical Part of
⑤ Dismount the valve chamber cover from the cylinder cover.

⑥ Dismount the valve chamber cover pad from the valve chamber cover, and take down the seal
gasket of spark plug conduit from the spark plug conduit.
⑦ Dismount the timing belt. See “Timing Belt Mechanism”.
⑧ Dismount the camshaft timing gear.
a. Lock the camshaft timing gear at the corresponding position with a special tool shown in
Fig.1.1.042.
b. Loosen the bolt for camshaft timing gear.
■ Tightening torque: 78~98N.m

Fig.1.1.042
c. Take down the camshaft timing gear.
⑨ Dismount the camshaft position sensor JAC-T1D001
support from the rear end of cylinder cover.

Attention:
■ Carefully perform the operation so as not to
damage the elements.
⑩ Dismount the front oil seal of camshaft with
proper tools.
Attention:
■ Do not damage the matching face of cylinder cover and camshaft.
⑪ Dismount the fixing bolt of rocker arm shaft, and then take down the intake and exhaust rocker arms
and the rocker arm shaft assembly.

Fig.1.1.043
a. Loosen these elements in sequence as shown in
Fig.1.1.043.
b. Loosen them in steps, and then take them down.
Note: The dismounted parts shall be placed in
sequence.
⑫ Take out the camshaft from the cylinder cover.
Fig.1.1.044
① Camshaft
■ Measure the height of the cam of the camshaft.
Standard value for intake: 37.298mm
Standard value for exhaust: 37.161mm
Limit value for intake: 36.80mm
Limit value for exhaust: 36.66mm
29
Mechanical Part of
Replace the camshaft, if the measured value exceeds the limit value.
② Rocker Arm and Rocker Arm Shaft
■ Check whether there is abnormal abrasion on the rocker arm and the rocker arm shaft.
■ Check whether there is blockage in the engine oil hole. If any, clean the hole.
3) Installation
① Mount the camshaft.
Attention:
■ It is necessary to apply engine oils to the journal and the cam of camshaft.
■ Pay attention to the mounting direction of camshaft.
② Mount the rocker arm and rocker arm shaft assembly.
a. Place one side (whose inclined plane is larger) of rocker arm shaft towards the timing belt side.
b. Place one side (with oil hole) of rocker arm shaft Timing Belt Side
towards the cylinder cover. Fig.1.1.045
c. Pay attention to the assembly marks on rocker
arm and the rocker arm shaft, and then mount the
assembly on the cylinder cover.
③ Mount the camshaft position sensor support.
Attention:
Identification
■ Apply a layer of sealant to the flange of rear end Mark
cover.
■ Screw down the fixing bolt after the support has Fig.1.1.046
been fully mounted. JAC-T3F002
④ Mount the front oil seal of camshaft with the
special tool shown in Fig.1.1.046.
⑤ Mount the camshaft timing gear.

Fig.1.1.047
a. Lock the camshaft timing gear at the
corresponding position with special tools shown
JAC-T1D001
in Fig.1.1.047.
b. Screw down the camshaft timing gear to the
specified torque.
JAC-T1D001
30
Mechanical Part of
⑥ Please note the following and perform the installation steps which are contrary to the dismantlement
steps.
■ Eliminate all sealant from the cylinder cover before mounting the valve chamber cover.
■ Ensure that the valve chamber cover pad has been placed into the mounting slot for valve chamber
cover intact.
■ Check whether all parts have been mounted in position.
■ Check the level of engine oil before starting the engine. If the engine oil is less than the required
volume, replenish it to the specified level, .
■ Run the engine and then check it for abnormal noise and shake.
■ Ensure that there is no engine oil leakage after thorough engine warm-up.
■ Recheck the level of engine oil after the engine has cooled down. Replenish the engine oil to the
specified level, if necessary.
3. Valve Gap
1) Check
Perform the following checks when you are dismounting or replacing the relevant parts of camshaft or
the rocker arm and rocker arm shaft assembly, or when the engine abnormally runs due to the change of
valve gap.
① Dismount the valve chamber cover. See “Camshaft”.
② Measure the valve gap in the following steps.
a. Fix the compression stroke TDC (Cylinder 1). See Fig.1.1.045.
Clockwise rotate the crankshaft belt disc, and align the timing marks with each other as shown in
Fig.1.1.028. Meanwhile, confirm that the rocker arm of Cylinder 1 can slightly rock. If it can not rock,
rotate the crankshaft for another circle.
b. Measure the gap between valve adjusting screw and valve stem head with a feeler gauge.
Valve Gap:
For intake valve, 0.14±0.03mm
For exhaust valve, 0.19±0.03mm
c. Rotate the crankshaft belt disc for a circle.
③ If the measured value exceeds the standard value, adjust the valve gap. See “Adjustment”.
2) Adjustment
① Loosen the adjusting nuts, and unscrew the adjusting screw.
② Insert the feeler gauge (whose width value is equivalent to the standard valve gap value) between
the adjusting screw and the valve stem head.
③ Fix the adjusting nut, then gradually tighten the adjusting screw till it is not easy to draw the feeler
gauge, and finally screw down the adjusting nut.
31
Mechanical Part of
④ Reconfirm that the valve gap is within the standard range.
⑤ If it is not, repeat Steps 1~4 till it falls within the standard range.
⑥ Rotate the crankshaft by hand, refer to the standard value, and confirm that the valve gap in cold
state falls within the standard value. See “Check”.
⑦ Mount all the dismounted parts in the installation steps which are contrary to dismantlement steps.
See “Installation”.
⑧ Warm up the engine, and then check it for abnormal noise or shake.
XI. Cylinder Cover
1. On-vehicle Maintenance
1) Check the cylinder pressure:
① Thoroughly warm up the engine. Then, shut down the engine.
② Release the fuel pressure. See “Release of Fuel Pressure”.
③ Disconnect the fuse wire of fuel pump, lest the fuel squirts during the measure.
④ Dismount the engine trimming cover. See “Intake Manifold”.
⑤ Dismantle the high-pressure wires and the spark plugs from all cylinders. See “Ignition Coil”
and ”Spark Plug”.
⑥ Mount a cylinder pressure gauge (with joint) on the spark plug hole.
⑦ Tread the accelerator pedal to the end, and turn the ignition switch to the “START” position to start
the engine. After the instrument finger appears stable, read the compression pressure and the
engine speed. Perform these steps and to check other cylinders.
■ Standard pressure: 1500kPa
■ Minimum pressure: 1200kPa
■ Tolerable pressure difference between cylinders: ≤150kPa
Attention:
■ It is required to obtain the specified engine speed always by the storage battery which is fully
charged.
■ Check the valve gap and other relevant parts (such as the valve, the valve seat, the piston, the
piston ring, the cylinder diameter, the cylinder cover and the cylinder cover pad), if the compression
pressure value is lower than the minimum value. Re-measure the compression pressure after the
check. If the pressures in some cylinders are low, add some engine oil to the spark plug holes of
such cylinders and then check the cylinder pressures again.
■ The piston ring may have been abraded or damaged, if the cylinder pressure rises after the engine
oil is added. Check the piston ring, and replace it if necessary.
32
Mechanical Part of
■ The valve may have been faulty, if the compression pressure is still low after the adding of engine oil.
Check whether the valve is damaged. Replace the damaged valve or valve seat.
■ The cylinder cover pad must be leaky, if the compression pressures in two neighboring cylinders are
low and even keep low after the adding of engine oil. Replace the cylinder cover pad.
⑧ After the check, remount the dismounted parts.
⑨ Start the engine, and confirm that the engine runs smoothly.
2. Elements
Diagram of Cylinder Cover
1) Dismantlement
① Release the fuel pressure. See “Release of Fuel Pressure”.
② Discharge the engine coolant and engine oil. See “Replacement of Engine Coolant” and
“Replacement of Engine Oil”.
Attention:
■ Perform these steps after the engine has cooled down.
■ Do not splash the engine coolant and the engine oil onto the drive belt.
③ Dismount the following elements and the relevant parts:
33
Mechanical Part of
■ Drive belt. See “Drive Belt”.

■ Timing belt. See “Timing Belt Mechanism”.
■ Engine trimming cover. See “Intake Manifold”.
■ Valve chamber cover. See “Rocker Arm and Rocker Arm Shaft”.
■ Intake manifold. See “Intake Manifold”.
■ Exhaust manifold. See “Exhaust Manifold”.
■ Thermostat housing. See “Thermostat Components”
■ Oil rule conduit.
④ Loosen the cylinder cover bolt with the special

tool shown in Fig.1.1.048. Fig.1.1.048
The dismantlement steps are contrary to the steps Fig.1.1.049

shown in Fig.1.1.049
A：Intake side
B：Exhaust side
: Front end of engine
⑤ Dismantle the cylinder pad.

① Cylinder Cover Bolt
Measure the length of cylinder cover bolt.
■ Limit value:103.2mm.
Replace the cylinder head bolt, if the measured value exceeds this limit value.
② Cylinder Cover
■ Check whether there are cracks or other damages on the cylinder cover.
■ Check whether there is any blockage in the water channel and the oil channel. If any, clean the
water channel and the oil channel.
34
Mechanical Part of
■ Check the planeness of cylinder cover.
Note: Check the planeness of cylinder body as well when performing this check. See “Planeness of
Cylinder Body”.
a. Wipe away the engine oil from the cylinder cover, and eliminate the sealant and the sedimentary
carbon.
Attention:
■ Do not let the impurities fall into the water channel and oil channel of cylinder cover.
b. Measure the planeness in six directions at Fig.1.1.050

several positions on bottom surface of cylinder
cover.
Standard value: below 0.03mm
Height of cylinder cover (new): 120±0.1mm
If the measured value of planeness exceeds the
standard value, grind or replace the cylinder cover
according to the specification.
Attention:
■ The total grindable tolerance of matching surface between cylinder cover and cylinder body shall
not be greater than 0.2mm.
3) Installation Fig.1.1.051
① Mount the new cylinder cover pad.
② Screw down the cylinder cover bolts in
numerical sequence shown in Fig.1.1.051,
and then mount the cylinder cover in the
following steps.
A: Intake side
B: Exhaust side
: Front end of engine
a. Mount the washer as shown in Fig.1.1.052.

Fig.1.1.052
b. Apply the engine oil to the washer, which is at
the threaded portion of bolt.
35
Mechanical Part of
c. Screw down the bolts in the sequence shown in

Fig.1.1.053
Fig.1.1.053 till the tightening torque for each bolt
reaches 49N·m.
d. Fully unscrew these bolts.
e. Re-screw down these bolts in the sequence shown in

Fig.1.1.053 till the tightening torque for each bolt
reaches 20±2N·m. Timing Belt Side
f. Paint marks on the bolt head and the cylinder cover Fig.1.1.054
(see Fig.1.1.054).
g. Screw each bolt for 90° according to the tightening

sequence.
h. Screw each bolt for a further 90°, and then check

whether the painted marks on bolt head and cylinder
cover align with each other.
Painting
Attention: Mark
■ If the tightening angle of the bolts is less than 90°, the

bolts will not hold enough force to fix the cylinder
cover.
■ If the tightening angle of the bolts is more than 90°, it is necessary to dismount them and then
remount them.
i. If the old cylinder cover bolts are replaced during the maintenance, the maintenance shall be
performed in sequence from “a” to “h”.
j. If the old cylinder cover bolts are not replaced during the maintenance, the maintenance shall be
performed in sequence “a, b, e, f, g and h”.
③ Then, perform the installation steps which are just contrary to the dismantlement steps.
The steps for checking oil leakage, lubricant leakage and tail gas leakage are listed as follows:
■ Before starting the engine, check the engine oil/coolant level. If the level is less than the required
value, replenish the engine oil/coolant till the specified level is reached.
■ Perform the following steps to check whether the oil leakage occurs:
- Turn the ignition switch to the “ON” position (when engine is shut down). With the oil pressure acting
on the oil pipe, check whether there is fuel leakage at the joint.
- Start the engine. With the engine accelerating, recheck whether there is fuel leakage at the joint.
■ Run the engine to check whether the abnormal noise or shake appears.
36
Mechanical Part of
■ Thoroughly warm up the engine, and confirm there is no fuel leakage, tail gas leakage or any
oil/fluid (including engine oil and engine coolant) leakage.
■ After the engine has cooled down, recheck the level of oil/fluid (including engine oil and engine
coolant) level. Replenish the oil/fluid to the specified level, if necessary.
XII. Valves
1. Elements
Diagram of Valve Elements
1- Cylinder cover bolt 2- Cylinder cover assembly 3-Cylinder pad 4- Valve lock plate
5- Retaining seat for intake valve spring 6- Valve spring 7- Valve conduit 8- Valve retainer
9- Intake valve 10- Exhaust valve 11- Cylinder cover
37
Mechanical Part of
2. Disassembly and Assembly
1) Disassembly
① Dismount the spark plug with the spark plug sleeve.
② Dismount the valve lock plate, the valve spring and the valve spring seat.
■ Compress the valve spring with the valve

Fig.1.1.055 JAC-T1F001
spring compressor.
Attention:
■ Pay attention to the position of upper dead

point of piston.
■ Label the dismounted valve, valve spring and

Fig.1.1.056
other parts, and write down their
JAC-T1F012
corresponding cylinder numbers and positions
■ Store the parts reliably.
③ Dismount the valve oil seal.

Fig.1.1.057
④ See “Replacement of Valve Seat” to replace
the valve seat, if required.
⑤ See “Valve Conduit” to replace the valve

conduit, if required.
2) Assembly
① Mount the valve conduit, if it has been dismounted. See “Valve Conduit”.
② Mount the valve seat, if it has been dismounted. See “Valve Seat”.
③ Mount the valve oil seal.
a. Mount the valve spring seat.
38
Mechanical Part of
b. Mount the new valve oil seal with the special tool shown in Fig.1.1.058.
Attention: Fig1.1.058
JAC-T3F001
■ The valve oil seal shall not be reused.
■ The valve oil seal must be mounted with the

proper special tool.
④ Mount the valve.
⑤ Mount the valve spring.
Note: The element with painted mark shall be mounted upwards.
⑥ Mount the retaining seat for valve spring.
⑦ Mount the valve lock plate.
■ Use the valve spring compressor during the installation.
■ After the installation, lightly knock the edge of valve stem with a rubber hammer to check the
mounting condition.
⑧ Mount the spark plug with the spark plug sleeve.
3) Check after Disassembly Fig.1.1.059

1. Valve
■ Check whether the contact between valve Good
surfaces is proper. Trim the surface of valve

seat, if the contact is uneven or incomplete.
Bad Bad
■ Check the thickness of valve edge. Replace

Fig.1.1.060
the valve, if the measured value is less than
the specified value. Contact
(required to be
at the center of
Standard values: surface)
Thickness of
For intake valve: 1.35mm edge
For exhaust valve: 1.85mm
Limit values:
39
Mechanical Part of
For intake valve: 0.85mm
■ Check the total length of valve. Replace the valve, if the measured value is less than the specified
value.
Standard values:
Limit values:
2. Valve Spring
■ Check the free height of valve spring. Replace the valve spring, if the measured value is less than
the specified value.
Standard value: 50.87mm
Limit value: 50.37mm Perpendicularity

Fig.1.1.061
■ Check the perpendicularity of valve spring.
Replace the valve spring, if the measured
value is greater than the limit value.
Free Height
Standard value: 2°
Limit value: 4°
3. Valve Conduit
Fig.1.1.062
■ Check the gap between the valve conduit and
the valve stem. Replace the corresponding
parts, if the measured value exceeds the limit Valve Conduit
value.
For intake valve conduit
Standard value: 0.020~0.036mm Outer Diameter of Valve Stem

Inner Diameter of Valve Conduit
Limit value: 0.10mm
For exhaust conduit
Standard value: 0.030~0.045mm
Limit value: 0.1mm
40
Mechanical Part of
■ Replacement of Valve Conduit

a. Push out the valve conduit towards the cylinder side by the press.
b. Bore the valve conduit hole on cylinder head till the hole matches the air conduit whose size is to be
extended.
Attention:
■ Do not mount the valve conduits with the same sizes of the valve conduit holes.
Diameter of valve conduit hole:

Fig.1.1.063
For the hole diameter of 10.605~10.615mm,
extend the size of valve conduit by 0.05mm.
For the hole diameter of 10.805~10.815mm,
For the hole diameter of 11.055~11.065mm, Protrusion
Height
c. Press the valve conduit till its protrusion height
reaches the specified value.

Attention:
■ The valve conduit must be mounted from the upside of cylinder head.
■ The lengths of valve conduits on intake and exhaust sides shall be different.
■ After pressing the valve conduit, insert a new valve, and then whether the new valve slides
smoothly.
4. Valve Seat
■ Check the valve protrusion height between the end face of valve stem and the surface of valve
spring seat. Replace the valve seat, if the measured value exceeds the limit.
End Face of
Standard values: Valve Stem
Fig.1.1.064
Valve Protrusion
For exhaust valve: 54.10mm Height
Limits:
Surface of Valve
For intake valve: 53.71mm Spring Seat
■ Correct the valve seat.

a. Before correcting the valve seat, check the gap between valve conduit and valve. Replace the valve
conduit, if necessary.
41
Mechanical Part of
b. Correct the valve seat by the proper special tool or the valve seat grinder till the specified seat
surface width and angle are met.
c. After correcting the valve seat, grind the valve

and the valve seat by the grinding cream. Fig.1.1.065
Then, check the protrusion height of valve
stem (refer to the forementioned check steps
of valve seat)
■ Replacement of Valve Seat Fig.1.1.066

a. Cut away the replaced valve seat from its
inner side in order to decrease the wall
thickness. Then, dismount the valve seat.
Cut Away
b. Rebore the valve seat hole on cylinder cover Fig.1.1.067

till the hole matches the selected valve seat
with a extended diameter. See “Maintenance
Parameters” for the detailed size. Valve Seat
Height
c. Do not have the cylinder head hole scratched
by the valve seat cooled by the liquid nitrogen
before it is pressed.
Inner Diameter of Extended Hole
d. Correct the valve seat till its width and angle
meet the specifications (see the operation
instruction of valve seat correction).
42
Mechanical Part of
XIII. Cylinder Body Assembly
1. Element
Disassembly Diagram of Cylinder Body Assembly
1— Flywheel bolt 2— Flywheel assembly 3— Upper division plate 4— Crankshaft oil seal 5— Crankshaft oil
seal housing 6— Bearing cap bolt 7—Fourth bearing cap 8— Bearing cap 9— Intermediate bearing cap 10—
Lower main bearing shell 11— Intermediate main bearing shell (lower) 12— Crankshaft 13—Upper main bearing
shell 14— Intermediate main bearing shell (upper) 15— Knock sensor 16— Engine oil pressure switch 17—
Cylinder body
1) Disassembly
① Dismount the engine assembly from the vehicle, and then detach the transmission from the engine.
See “Engine Assembly” for the detailed dismantlement steps.
② Dismount the following engine accessories. See relevant chapters for the detailed dismantlement
steps.
■ Intake and exhaust manifolds of engine
■ Drive belt
43
Mechanical Part of
■ Generator
■ Timing belt mechanism of engine
■ Water pump
■ Water pump components
■ Support racks of power steering pump, generator and air conditioner compressor
■ Ignition coil
③ Fix the whole engine.
④ Discharge the engine oil. See “Replacing the engine oil”
⑤ Dismount the flywheel assembly. Fix the flywheel by the special tool, and then dismount the fixing
bolt and the upper division plate.
■ Tightening torque: For flywheel: 127~137N·m
For upper division plate: 8~12N·m
Attention:
■ Do not place the signal plate of crankshaft position sensor on flywheel downwards.
■ Loosen the fixing bolts in diagonal sequence.
⑥ Dismount the following systems. See the relevant chapters for the detailed dismantlement steps.
■ Cylinder head
■ Engine oil pump housing
■ Oil pan
⑦ Dismount the knock sensor.
Attention:
■ Do not drop or knock the sensor.
⑧ Dismount the rear oil seal housing.
■ Insert the screwdriver between the crankshaft and the rear oil seal housing to perform the
dismantlement.
Attention:
■ On dismounted, the rear oil seal must not be reused and shall be replaced by a new one.
⑨ Dismount the piston and connecting rod assembly.
Before dismounting the piston and connecting rod assembly, check the gap at the big end of connecting
rod. See “Check after Disassembly” hereinafter.
44
Mechanical Part of
a. Rotate the crankshaft, and place the journal side of crankshaft (which is corresponding to the
connecting rod to be dismounted.) at the center of bottom.
Note: For the purpose of easy reassembly, mark a Fig.1.1.068

sequence number on the side face of big end of
dismounted connecting rod. Sequence
Number of
b. Dismount the connecting rod cover. Cylinder
■ Tightening torque: 16.7±2N·m+90°~94°
c. Push out the piston and connecting rod
assembly from the cylinder head side by the
rubber hammer or the equivalent tool.
Attention:
■ Do not have the cylinder wall and the crankshaft journal damaged by the big end of connecting rod.
⑩ Dismount the connecting rod bearing shell from the connecting rod and the connecting rod cover.
Attention:
■ Identify their mounting positions, and properly place them to avoid confusion.
⑪ Dismount the piston ring from the piston.

Before dismounting the piston ring, check the side gap of piston ring. See “Check after Disassembly”
hereinafter.
Attention:
Fig.1.1.069
■ Use the piston ring expander.
Piston Ring
⑫ Dismount the piston ring from the connecting Expander
rod by the following means:
a. Insert the push rod (a special tool) from the
front arrow-marked side, and then mount the
guide sleeve D.
b. Let the front mark of piston face upwards, and
then mount the piston and connecting rod
Push Rod
Fig.1.1.070
assembly on the mounting base of piston pin
(a special tool).
Front Mark
c. Extrude the piston ring by the press. Front
Mark
d. Detach the connecting rod and the piston from

Guide Sleeve D
the piston and connecting rod assembly.
Base
Attention:
■ After dismounting the piston pin, place the
piston together with the piston pin and the
connecting rod.
45
Mechanical Part of
■ It is forbidden to place the pistons, the piston pins and the connecting rods of different cylinders
together.
Dismount the crankshaft bearing cap.
Before loosing the crankshaft bearing cap, measure the axial gap of crankshaft. See “Check after
Disassembly” hereinafter.
Loosen the bolts of crankshaft bearing cap in the Sequence Number of

Fig.1.1.071 Bearing Cap
following sequence.
■ Tightening torque: 34±2N·m+30°~34°
■ In Fig.1.1.071:
For the upper row, 4→8→10→6 →2
For the lower row, 1→5→9 →7→3
During the dismantlement, it is allowable to jiggle Fig.1.1.072

the crankshaft bearing cap forwards and
backwards by the bolts of crankshaft bearing cap.
See Fig.1.1.072.
Dismount the crankshaft.
2) Check after Disassembly

Fig.1.1.073
① Axial Gap of Crankshaft
Measure the gap between intermediate main

bearing shell and crankshaft arm when the cranks
moves frontward or backwards to the end with the
scale indicator.
Limit: 0.25mm
If the measured value exceeds the limit, replace the intermediate main bearing shell, and then
remeasure the gap. Replace the crankshaft if the remeasured value is still higher than the limit.
46
Mechanical Part of
② Gap of Big End of Connecting Rod
Measure the gap between the connecting rod and

Fig.1.1.074
the crankshaft by the feeler gauge.
Limit: 0.4mm
If the measured value exceeds the limit, replace

the connecting rod, and then remeasure the gap.
Replace the crankshaft if the remeasured value is
still higher than the limit.
③ Side Gap of Piston Ring

Fig.1.1.075
Bad
Measure the side gap between piston ring and
piston ring groove by the feeler gauge.
Standard values: Feeler

Gauge
For 1st piston ring, 0.03~0.07mm Good
For 2nd piston ring, 0.02~0.06mm

Feeler Gauge
Limits:
Piston Ring
st
For 1 piston ring, 0.1mm
For 2nd piston ring, 0.1mm
If the measured value exceeds the limit, replace the piston ring, and then remeasure the gap. Replace
the piston if the remeasured value is still higher than the limit.
④ End Gap of Piston Ring
Ensure that the inner diameter of cylinder stays Fig.1.1.076Piston

Pressed and Fixed
within the specified range. Feeler
Gauge
Piston
See "Cylindricality of Cylinder" Ring
Lubricate the piston and the piston ring by the new

engine oil, then insert the piston ring till the piston
reaches the middle part of cylinder, and measure
the end gap of piston ring by the feeler gauge. Piston
Ring
Measured Point
Standard values:
For 1st piston ring, 0.20~0.35mm
For 2nd piston ring, 0.35~0.50mm
47
Mechanical Part of
Limits:
For 1st piston ring, 0.8mm
For 2nd piston ring, 0.8mm
If the measured value exceeds the limit, replace the piston ring, and then remeasure the gap. Bore to
extend the inner diameter of cylinder and use the corresponding piston and piston ring if the remeasured
value is still higher than the limit.
⑤ Planeness of Cylinder Body
Clean the pad on the surface of cylinder body, and eliminate the engine oil, sediment, carbon or other
contaminants.
Attention:
■ Do not have the pad sheet fall into the engine oil or engine coolant.
Ruler
■ Measure the planeness of cylinder body in the Fig.1.1.077
different directions at six positions by ruler and
the feeler gauge.
Standard values: below 0.03mm
Limits: below 0.1mm

Feeler
If the measure value exceeds the limit, replace the Gauge
cylinder body.
⑥ Cylindricality of Cylinder Fig.1.1.078
Measure the abrasion, ovality and cylindricality of

cylinder bore of each cylinder at six different
positions by the dial indicator.
Standard values:
For inner diameter of cylinder, 71.0mm
For cylindricality, below 0.01mm
⑦ Diameter of Piston Skirt

Fig.1.1.079
Use the dial indicator for outer diameter to check
whether the piston skirt is distorted.
Standard values:71.0mm
Dial Indicator
48
Mechanical Part of
⑧ Gap between Piston and Cylinder Bore
Calculate the gap through the piston skirt and the inner diameter of cylinder.
(Gap) ＝ (inner diameter of cylinder) － (diameter of piston skirt)
Standard values: 0.02~0.04mm
If the calculated value exceeds the limit, replace the piston and piston ring assembly.
⑨ Boring of Cylinder
a. The piston with extended size to be used shall be determined in accordance with the cylinder which
has the widest bore.
Pistons of the following extended sizes, i.e. 0.25mm, 0.50mm, 0.75mm and 1.00mm, are applicable.
b. Measure the diameter of piston to be used.
After boring the cylinder, it is required to make the Fig.1.1.080

gap between piston and cylinder meets the
standard value. The piston diameter shall be
measured at the position shown in the figure.
c. Calculate the boring size based on the piston

diameter.
[Boring size] ＝ [outer diameter of piston] ＋ [gap

between piston and cylinder (0.02~0.04mm)] －
[grinding tolerance (0.02mm)]
d. Boring each cylinder till it obtains the calculated boring size.
Attention:
■ To avoid the distortion due to heat during the boring course, bore the cylinders in the following
sequence: Cylinder 2 → Cylinder 4 → Cylinder 1 → Cylinder 3
e. Grind the cylinder till it meets the final processing size (outer diameter of piston ＋ gap between
piston ring and cylinder)
⑩ Diameter of Main Crankshaft Journal

Measure the main crankshaft journal by the dial indicator for outer diameter.
Replace the main bearing shell if the measured value exceeds the standard value.
49
Mechanical Part of
⑪ Diameter of Main Journal of Connecting Rod

Measure the diameter of main journal of
Fig.1.1.081 Dial Indicator
connecting rod by the dial indicator for outer
diameter.
Standard values:42.0mm
Replace the connecting rod bearing shell if the
measured value exceeds the standard value.
⑫ Gap of Connecting Rod Bearing Shell
Note: Use the plastic wire gauge to perform the
measurement.
a. Wipe the engine oil from the connecting rod
journal and the connecting rod bearing shell.
b. Put the plastic wire gauge on the connecting
Fig.1.1.082
rod journal, and asset it to a length equal to
bearing shell width. The plastic wire gauge
must be placed at the center of connecting rod
journal and be parallel with the axial line of
connecting rod journal.
c. Lightly put the connecting rod cover to its
specified place, and screw down the bolt till it
meets the specified torque.
d. Dismount the bolt, and gradually take down the connecting rod cover.
e. Measure the pressed portion of plastic wire gauge at the widest point by the scale which is printed
on the plastic wire gauge bag.
Standard values:0.02~0.04mm
Limits:0.1mm
⑬ Ovality and Cylindricality of Crankshaft
Measure the sizes of each main crankshaft journal
Fig.1.1.083
and main connecting rod journal at four different
positions as shown in the figure.
■ The difference between “X” and “Y” of “A” and
“B” represents the ovality.
■ The difference between “A” and “B” of “X” and
“Y” represents the cylindricality.
Limits:
For ovality, equal to or less than 0.05mm
For cylindricality: equal to or less than 0.05mm
50
Mechanical Part of
Calibrate or replace the crankshaft if the measured value exceeds the limit.
⑭ Gap of Crankshaft
a. Wipe away the engine oil from the crankshaft journal and the inner surface of bearing shell.
b. Mount the bearing shell.
c. Set the plastic wire gauge till its width equals Fig.1.1.084
to the width of bearing shell. Then, put the
gauge on the journal along the axial line of
journal.
d. Lightly mount the crankshaft bearing shell
cover, and screw down the bolt till it meets the
specified torque.
e. Dismount the bolt and lightly take down the
crankshaft bearing shell cover.
f. Measure the pressed portion of plastic wire
gauge at the widest point by the scale which is
printed on the plastic wire gauge bag.
Standard values: 0.02~0.04mm Fig.1.1.085

Plastic Wire
Limits:0.1mm Gauge
Attention:
Fig.1.1.086 Round-angle Rolling Area
■ The connecting rod journal and main journal of
crankshaft shall be rolled but needn't to be
machined to the reduced size.
⑮ Flywheel
Check whether the flywheel and the signal disk are
distorted or cracked.
Attention:
■ Do not disassemble the flywheel.
■ Do not place the signal disk of flywheel
downwards.
■ Do not damage or scratch the signal disc
during the operation.
■ Do not magnetize the signal disk during the
operation. Replace the flywheel if the disc has
been magnetized.
51
Mechanical Part of
3) Assembly
① Blow away the engine oil and engine coolant from the cylinder body, the cylinder bore and the
crankcase. Eliminate the foreign bodies.
Attention:
■ Use the goggles to protect your eyes.
② Mount the main and the intermediate bearing shells according to the following instruction.
Attention:
■ Select the bearing shells (See the table below) in accordance with the identification marks or the
color codes of crankshaft. If the crankshaft can not be identified, measure the axial diameter of
crankshaft, and then select the corresponding bearing shell to match the crankshaft.
Comparison Table between Crankshaft Identification Marks/ Color Codes and Bearing Shells
Bore of Cylinder Body
Crankshaft Journal Bearing Shell
Bearing Hole
Color Identification Identification
Range Journal Diameter Identification Mark
Code Code Mark
0 1
1 Yellow I 47.995~48.000 1 2
2 3
0 2
2 Colorless II 47.988~47.995 1 3
2 4
0 3
3 Yellow III 47.980~47.985 1 4
2 5
■ The identification mark representing the bore Fig.1.1.087

of cylinder body bearing shell is printed at the
shown position by figure 1 in front of engine. It
is required to select and mount the bearing
shell according to these marks.
■ Select the bearing shell from the
forementioned table on the basis of referring to
the identification marks.
■ Every upper bearing shell but the intermediate
Fig.1.1.088 With Groove
bearing shell is grooved. However, the
Without
intermediate bearing shell has the supporting Groove
flange and the upper and lower portions of
Lower Bearing Shells (No.1,
intermediate are the same. Lower Bearing Shells No, 2, No.4 and No.5)
(No.1, No, 2, No.4 and Without
■ All lower bearing shells are free of groove. No.5)
Groove
a. Eliminate the dust, the dirt and the engine oil

from the matching surface between cylinder Upper and Lower Intermediate Bearing Shell
body and main bearing cap. (No.3)
b. Mount the intermediate and the upper bearing

shells onto the cylinder body
52
Mechanical Part of
c. Pay attention to the mounting direction of bearing shell during the operation.
■ The bearings shell with oil hole and groove shall be placed near the cylinder body, whereas those
without oil hole and groove shall be close to the main bearing cap.
■ Before mounting the bearing shell, apply the engine oil onto the surface of bearing shell. The back
side of bearing shell shall not be coated with the engine oil but shall be thoroughly rinsed.
■ During the installation, align the flange of bearing shell with the cut of cylinder body and main
bearing cap.
■ Ensure that the engine oil hole on cylinder body aligns with that on corresponding bearing shell.
③ Mount the crankshaft onto the cylinder body.
When rotating the crankshaft by hand, check whether the rotation of crankshaft is smooth.
④ Mount the main bearing cap. Arrow Points to Timing Bearing Cap
Fig.1.1.089
Belt Side No
■ The main bearing cap can be identified through

the identification mark.
■ Mount the main bearing caps the in numerical

sequence from the timing bet side.
■ The arrow must point to the timing belt side.
⑤ Screw down the bolts for main bearing cap in

numerical sequence shown in the right figure.
a. Apply the new engine oil onto the thread and fixing surface of bolts for main bearing cap.
b. Screw down the bolts for main bearing cap in steps.
■ Tightening torque: 34±2N·m
c. Clockwise rotate all bearing cap bolts by 30°.
■ After mounting the bolts for main bearing cap, ensure that the crankshaft can be rotated smoothly by
hand.
■ Check the axial gap of crankshaft. See “Axial Gap of Crankshaft”.
⑥ Mount the piston onto the connecting rod

according to the following instructions. Fig.1.1.090
a. Measuring the following lengths (See the figure).
A： Size from piston flange to piston flange outside
Piston
Connecting
B： Size from piston flange to piston flange inside Rod
Pin
Piston
C： Length of piston pin.

D： Thickness of small end of connecting rod.
b. Introduce the measured values to the following
formula:
53
Mechanical Part of
L ＝ [(A － C) － (B － D)]／2
c. Insert the push rod (a special tool) into the piston pin, and then mount the guide sleeve A (also a
special tool).
d. When mounting the piston and the connecting rod, keep the front marks on the same side surface.
e. Apply the engine oil onto the outer circle of piston pin.
f. Press the guide sleeve A, the piston pin and the push rod in sequence to the front mark side.
g. Screw the guide sleeve B into the guide

sleeve A. The value of gap between these two
guide sleeves is obtained by 3mm plus the Fig.1.1.091
value L calculated from Step 2.
h. With the front mark facing downwards, mount
the piston and the connecting rod to mounting
base of piston pin.
i. Mount the piston pin by the press. Guide Guide
Sleeve B Sleeve A
Attention:
■ If the pressing load value exceeds the specified value, replace the piston pin and piston assembly
or/and the connecting rod.
Standard value: 108±54N·m
⑦ Mount the piston pin.
Attention:
■ When mounting the piston ring, do not damage the piston.
■ Do not damage the piston ring due to the excessive expansion.
a. Mount the oil ring Steel Sheet

Fig.1.1.092 Ring
a) Mount the spacer ring for oil ring into the piston ring
groove, and then install the upper and lower steel sheet
rings.
Attention:
■ The spacer ring and the steel sheet ring may be
installed in a discretionary direction.
The upper and lower steel sheet rings are identical. Spacer Ring
■ Sizes and colors of spacer rings and steel sheet rings
List for Sizes and Colors of Spacer Rings and Steel Sheet Rings
Size Color
Standard Colorless
Extended by 0.50mm Blue
Extended by 1.00mm Yellow
54
Mechanical Part of
b) To install the steel sheet ring, mount one end of the steel sheet ring into the groove by hand, and
then press the rest portion of such a ring till it is in position. See Fig.1.1.093.
Attention:
Fig.1.1.093
■ Do not install the steel sheet ring by the piston
ring expander, or else the ring may rupture.
c) After installing the steel sheet rings, check
whether they can move smoothly in two
directions. Piston Ring
Expander
b. Mount the first and second piston rings.

Use the piston ring expander to mount the first and second piston rings, with the identification marks
facing upwards (on the piston top side).
Note:
Identification Mark 1T
Identification marks: Fig.1.1.094
Identification Mark 2T Size Mark
For the first piston ring, 1T

For the first piston ring, 2T
1st Piston Ring
Attention:
2nd Piston
Ring
■ The following size marks are carved on the
piston rings.
List for Size Marks of Piston Rings

Size Size Mark
Standard None
Extended by 0.50mm 50
Extended by 1.00mm 100
⑧ Mount the connecting rod bearing rod onto the connecting rod and the connecting rod cover.
■ Confirm the identification marks on crankshaft and connecting rod at the positions shown in the
following figure, and select the bearing shell according to the following table.
List for Identification Marks of Crankshafts, Connecting Rods and Bearing Shells
Identification Mark of Crankshaft Identification Mark of Connecting Rod Identification Mark of Bearing Shell
1 (White) 1
I (Yellow) 2 (Colorless) 1
3 (Yellow) 2
1 (White) 1
II (Colorless) 2 (Colorless) 2
3 (Yellow) 3
55
Mechanical Part of
1 (White) 2
III (White) 2 (Colorless) 3
3 (Yellow) 3
No.1 No.2 No.3 No.4 No.5

Fig.1.1.095 Journal Journal Journal Journal Journal
Classification Mark
of Main Journal
(Crankshaft Front)
Classification Mark
of Crankshaft Pin
No.1 No.2 No.3 No.4

Crankshaft Crankshaft Crankshaft Crankshaft
Pin Pin Pin Pin
■ Before mounting the connecting rod bearing shell,

Fig.1.1.096
apply the engine oil onto the surface of bearing. Do
not spread the engine oil to the back side of bearing,
but thoroughly rinse the back side.
⑨ Mount the piston and connecting rod assembly onto
the crankshaft.
■ Place the crankshaft journal (which is corresponding
to the connecting rod to be mounted) at the just
center of bottom.
■ Apply the enough engine oil onto the cylinder bore,
the piston and the crankshaft journal.
■ Align the air ring opening with the oil ring opening.
Fig.1.1.097
See Fig.1.1.097. Steel Sheet No.1 Piston
Ring Ring
■ Align the cylinder body position with the mark on
connecting rod to be mounted, and then perform the
installation. Piston Pin
■ Ensure that the front mark on piston top faces the

timing belt side, and then press the piston and
connecting rod assembly into the cylinder from the No.2 Piston Ring Steel Sheet
Ring
cylinder upside.
■ Make the piston ring with front mark facing the front Fig.1.1.098
end of engine by the piston ring compressor or the
appropriate tool, and then mount the piston ring
onto the piston head.
Attention:
■ Do not damage the cylinder wall or the crankshaft
journal by the big end of connecting rod.
56
Mechanical Part of
⑩ Mount the connecting rod cover.
When operating, align the marks which are made

during the disassembly, and mount the connecting Fig.1.1.099
rod cover onto the connecting rod. If the
connecting rod cover is new and unmarked, the
bearing shell locking gaps shall be kept at the
same side.
⑪ Screw down the connecting rod nut. Locking Gap
Attention:
■ If the cylinder head has been installed before

mounting the connecting rod nut, it is required
to dismount the spark plug first.
■ When reusing the bolt, check whether it is scratched. The absence of thread scratch on bolt can be
proved only by the fact that it is allowable to smoothly screw the nut throughout its complete thread.
Or else, the bolt must be replaced.
■ Before mounting the nut, apply the engine oil onto its threaded portion and the seat face.
a. Mount the nut onto be bolt, and screw down them by hand. Later, alternately screw down the nuts to
ensure the correct installation of connecting rod cover.
■ Tightening torque: 16.7±2.0N·m
b. Make the painting mark on the top of each nut. Fig.1.1.100 Painting Mark
See Fig.1.1.100. Painting
Mark
c. Clockwise rotate the nut by 90°~94° from the

painting mark. Make the painting mark on the
bolt, too.
d. Rotate the nut till its painting mark aligns with Nut Bolt
that of bolt.
Attention:
■ The tightening force may be insufficient if the rotation angle of nut is less than 90°.
■ If the rotation angle of nut is more than 94°, completely loosen the nut and then redo the tightening
steps.
■ After screwing down the connecting rod nut, ensure that the crankshaft rotates smoothly.
57
Mechanical Part of
⑫ Mount the rear oil seal housing (with the rear oil seal of crankshaft installed) onto the cylinder body.
Press the rear oil seal onto the housing by the special Oil Seal
JAC-T3F005
tool. See Fig.1.1.10. Fig.1.1.10
⑬ Install the knock sensor.
Attention:
■ Do not screw down the nut when grasping the joint.
■ If the knock sensor is shaken, replace it with a new
one. Oil Seal Housing
Note:
Ensure that there is no foreign body at the matching surface of cylinder body or the back side of knock
sensor.
Notice the following items. Then, perform the installation which is just contrary to the dismantlement
steps.
■ Flywheel
Alternately screw down the fixing bolts till their tightening torques meet the specified values
XIV. Diagnosis of Common Troubles
List for Diagnosis of Common Troubles
Trouble Possible Cause Troubleshooting
The cylinder pad is leaky. Replace the cylinder pad.
The piston ring is damaged or abraded. Replace the piston ring.
Low cylinder pressure The cylinder or the piston is abraded. Repair or replace the piston or the
cylinder body.
The valve seat is abraded or damaged. Repair or replace the valve seat.
The volume of engine oil is insufficient. Check the volume of engine oil.
The engine oil pressure sensor is at fault. Replace the sensor.
The engine oil filter is jammed. Replace the filter.
Low engine oil
The gear or cover of engine oil pump is damaged. Replace it.
pressure
The viscosity of engine oil is low. Check and replace the engine oil.
The plunger of engine oil pressure switch is constantly open. Repair it.
The bearing gap is wide. Replace the bearing.
High engine oil The plunger of engine oil pressure switch is constantly closed. Repair it.
pressure
The engine supporting bolt loosens. Screw down it.
The transmission mounting support loosens. Screw down it.
The engine support loosens Screw down it.

Engine quiver
The adiabatic pad for engine is damaged. Replace it.
The supporting adiabatic pad for engine is damaged. Replace it.
The adiabatic pad for transmission is damaged. Replace it.
58
Mechanical Part of
The engine oil is thin (the oil pressure is low). Replace the engine oil.
Noise from valve The valve or the valve conduit is damaged or Replace the valve or the valve conduit.
abraded.
The volume of engine oil is insufficient. Check the volume of engine oil.
Noise from connecting rod bearing
The engine oil is thin (the oil pressure is low). Replace the engine oil.
shell and the main bearing shell
The bearing gap is wide. Check and then determine the cause.
Noise from gear belt The tension is improper. Regulate the tension.
The radiator or the radiating pipe is leaky. Repair or replace it.
The water tank cover is not sealed. Screw down or replace the cover.
Poor cooling performance The thermostat is leaky. Replace the thermostat pad.
The radiator is leaky. Repair or replace it.
The water pump is leaky. Replace it.
Jam in radiator The coolant contains the impurities. Replace the coolant.
The water tank cover is not strictly sealed. Replace it.
The cooling system is jammed. Rinse or replace it.
The thermostat is at fault. Replace it.
The belt skids. Adjust or replace it.

High temperature of coolant
The water pump is at fault. Replace it.
The sensor is at fault. Repair or replace it.
The fan is at fault. Repair or replace it.
The coolant is insufficient. Add the coolant
The thermostat is at fault. Replace it.

Low temperature of coolant
The sensor or the wire harness is at fault. Repair or replace it.
The sensor or the starter is at fault. Repair or replace it.
Ineffective fan
The fan relay or the wire harness is damaged. Repair or replace it.
The joint loosens. Screw down it

Leaky exhaust pipe
The exhaust pipe or the muffler is damaged. Repair or replace it.
The muffler loosens. Replace it.
The rubber pad falls off. Replace it.

Abnormal noise The exhaust pipe or the muffler connects with Correct them
the vehicle body.
The exhaust pipe or the muffler is damaged. Repair or replace it.
59
Mechanical Part of
XV. Maintenance Parameters
1. List for Technical Parameters of Engine
List for Technical Parameters of Engine
Item Standard Value Limit

Camshaft
Intake 37.298 36.8
Height of camshaft (mm)
Exhaust 37.161 36.66
Diameter of camshaft journal (mm) 44.925~44.94 -
Cylinder head and valve
Planeness of cylinder pad surface (mm) ＜0.03 0.1
Total height of cylinder pad (mm) 119.9~120.1 -
Intake valve 1.35 0.85
Thickness of valve edge (mm)
Exhaust valve 1.85 1.35
Diameter of valve stem (mm) φ5.5 -
Gap between valve stem and valve Intake valve 0.020~0.036 0.10
conduit (mm) Exhaust valve 0.030~0.045 0.15
Conical angle of valve 45°~45.5° -
Protrusion of valve stem (mm)
Total length of valve (mm)
Free height of valve spring (mm) 50.87 50.37
216/44.2 -
Load / mounting height of valve spring (N)/(mm)
588/34.7 -
Perpendicularity of valve spring ＜2° 4°
Contact width of valve seat (mm) 0.9~1.3 -
Inner diameter of valve conduit (mm) φ5.5 -
Protrusion of valve conduit (mm) 23.0 -
Extended by
φ10.605~10.615 -
0.05mm
Diameter of size-extended valve conduit on Extended by
φ10.805~10.815 -
cylinder head (mm) 0.25mm
Extended by
φ11.055~11.065 -
0.50mm
Extended by
φ28.425~28.445 -
0.3mm
Intake
Diameter of Extended by
φ28.725~28.745 -
size-extended 0.6mm
4G13S1
valve seat ring Extended by
hole (mm) φ26.425~26.445 -
0.3mm
Exhaust
Extended by
φ26.725~26.745 -
0.6mm
60
Mechanical Part of
Item Standard Value Limit Limit

Engine oil pump and oil pan
Addendum gap of engine oil pump 0.06~0.18 -
Side gap of engine oil pump(mm) 0.04~0.11 -
Gap of engine oil pump housing 0.10~0.18 0.35
Piston and connecting rod
Reference outer diameter of piston
4G13S1 71.0 -
(mm)
1st piston ring 0.03~0.07 0.1
Side gap of piston ring mm) nd
2 piston ring 0.02~0.06 0.1
st
1 piston ring 0.20~0.35 0.8
nd
Gap of piston ring opening (mm) 2 piston ring 0.35~0.50 0.8
Oil ring 4G13S1 0.20~0.50 1.0
Outer diameter of piston pin (mm) 18.0 -
Pressing load on piston pin (under room temperature) (N) 4900~14700 -
Oil gap of crankshaft pin (Gap of connecting rod journal) (IIⅡ11) 0.02~0.04 0.1
Side gap of big end of connecting rod (mm) 0.10~0.25 0.4
Crankshaft and cylinder body
Axial gap of crankshaft (mm) 0.05~0.18 0.25
Diameter of main journal of crankshaft (mm) 48.0 -
Diameter of connecting rod journal (mm) 42.0 -
Gap of main journal of crankshaft (mm) 0.02~0.04 0.1
Planeness of surface of cylinder body gasket (mm) 0.03 以下 0.1
Total height of cylinder body (mm) 256 -
Cylindricality of cylinder body (mm) 0.01 -
Reference inner diameter of
4G13S1-D2\4G13S1-DL 71.0 -
cylinder body (mm)
Gap between piston and cylinder (mm) 0.02~0.04 -
2. Tightening Torques
List of Tightening Torques
Item N·m
Engine and ignition system
Bolts for water pump belt pulley 7~11
Bolt for generator supporting bar (at the side face of
20~25
generator)
Bolt for generator kingpin 34~54
Oil rule bolt 19~28
165 (for homemade crankshaft) (with bolt head forging mark YM);
Crankshaft bolt M14×1.5
181(for KD crankshaft)
Spark plug 20~29
61
Mechanical Part of
Generator nut 34~54

Ignition coil 8~12
Bolt for camshaft position sensor 7.8~9.8
Bolt for camshaft position sensor support 12~15
Bolt for toothed plate of camshaft position sensor 17~26
Timing belt
Mounting bolt for timing belt housing 10~12
Mounting bolt for camshaft 78~98
Mounting bolt for tension pulley of timing belt 20~27
Mounting bolt for crankshaft rotation angle sensor (rotation
6~10
speed sensor)
Mounting nut and bolt (M10) for right support of engine 30~42
Mounting bolt (M8) for right support of engine 17~25
Fuel injection system
Mounting bolt for throttle valve body assembly 15~22
Mounting bolt for oil rail assembly 10~13
Water pump and inlet pipe
Water temperature alarm switch 10~12
Water inlet joint bolt 17~26
Water temperature sensor 20~40
Thermostat housing bolt 19~28
Water inlet pipe bolt 10~15
Water pump bolt 12~15
Mounting bolt for carbon canister solenoid valve support 8~10
Mounting bolt for knock sensor 15~25
Mounting bolt for other sensors 4~6
Supporting bolt (M8) for intake manifold 15~20
Supporting bolt (M10) for intake manifold 27~34
Intake manifold bolt 15~20
Exhaust manifold bolt (M8) 15~20
Exhaust manifold bolt (M10) 27~33
Bolt for adiabatic pad of exhaust manifold 8~12
Bolt for engine lifting lug 15~20
Rocker arm, rocker arm shaft and camshaft
Bolt for rocker arm chamber housing 3~4
Bolt for rock arm shaft assembly 28~34
Adjusting screw 8~10
Cylinder cap and valve
① Screw down the bolt to 49N·m; ② Loosen the bolt ;
Cylinder head bolt
③20±2Nm; ④ 90°~94°; ⑤ 90°~94°
62
Mechanical Part of
Engine oil pump and oil pan

Oil drain bolt 34~44
Oil pan bolt (M6) 6~8
Oil pan bolt (M8) 22~25
Bolt for engine oil filter 12~16
Mounting bolt for engine oil pump 12~15
Connecting rod
Connecting rod nut 16.7±2.0+90°~94°
Crankshaft and cylinder body
Flywheel bolt 127~137
Bolt for upper division plate 8~12
Bolt for rear oil seal housing of crankshaft 10~12
Bearing cap bolt 34±2+30°~34°
Mounting nut for knock sensor 15~25
Interface between engine and complete vehicle
Mounting bolts for exhaust manifold and front exhaust pipe 50±5
Mounting nuts for right support of engine and support of
57±5
complete vehicle
63
Mechanical Part of
Section II Engine Lubrication System

I. Precautions
Application Steps of Sealant:
1. Clear the used sealant attached on the application surface and matching surface of pad with scraper.
Fig. 1.2.001
Scraper
Attention:
■ Thoroughly clear the used sealant from grooves, fixed bolts and bolt holes on sealant application
surface.
2. Clean the application surface and matching surface of sealant with unleaded petrol, and clear the
attached water, lubricant and foreign substances.
3. Set the complete sealant with specified dimension on appointed position.
1) Mount the connecting element with properly applied sealant within 5min.
2) If there is any dirt on sealant, please clear it as soon as possible.
3) Do not retighten the bolt and nut after installation.
4) Fill engine oil and engine coolant 30min after the installation.
64
Mechanical Part of
II. Preparation
1. Repair Tools
List of repair tools
No. Tool Outline Drawing Illustration
1 Oil pressure gauge Measure oil pressure
Connect oil pressure

2 Hose gauge to cylinder
body
Oil pressure switch Dismount and mount

3
sleeve oil pressure switch
65
Mechanical Part of
III. Engine Oil
1. Check
1) Engine oil level
Note: Before starting the engine, park the vehicle levelly and stably and check the engine oil level. If the
engine has been started, stop the engine and check it after waiting for 10min.
① Pull out the oil rule and clean it .
② Insert the oil rule and make sure the engine oil Fig. 1.2.002
level is within the range shown in the figure.
③ Please adjust the oil level if it is out of range.
2) Appearance of engine oil
① Check the engine oil for white turbidity and Make sure the oil level is
severe pollution. between “L” and “H”.
② If the oil is turbid or polluted, it may be caused by pollution of engine coolant. Please repair or
replace the damaged spare parts.
3) Leakage of engine oil
Check the following areas for engine oil leakage.
■ Oil pan
■ Oil drain bolt for oil pan
■ Oil pressure switch
■ Oil filter
■ Matching surface of cylinder body and cylinder cover
■ Front and rear oil seals of crankshaft
■ Matching surface of oil pump and cylinder body
■ Matching surface of valve chamber cover and cylinder cover
■ Front oil seal of camshaft
4) Check of oil pressure
Attention:
■ As the temperature of engine oil is high, please prevent yourself from being hurt.
■ Check oil pressure after parking the vehicle.
66
Mechanical Part of
① Check oil level. Please refer to “Engine oil level”.
② Lift the vehicle, cut off the harness connector Fig. 1.2.003
at oil pressure switch and dismount the oil
pressure switch.
③ Mount the oil pressure gauge and hose.

Fig. 1.2.004
④ Start the engine and warm it to normal working temperature.
⑤ Check oil pressure when engine operates with no load.
Note: The engine pressure will increase when the temperature of engine oil is low.
■ If there is obvious difference, please check the oil piping and oil pump for leakage.
⑥ Mount the pressure switch in accordance with the following steps after check:
a. Remove the used sealant attached on pressure switch and engine.
b. Apply the sealant according to instructions and tighten the pressure switch.
■ Please apply the specified sealant: LT5699 or equivalent.
c. After the engine is warmed, make sure there is no oil leakage during normal operation of engine.
2. Replace Engine Oil
Attention:
■ As the temperature of engine oil is high, please prevent yourself from being hurt.
■ Please avoid direct contact of your skin with waste oil for a long time. If contact has taken place,
please wash your skin thoroughly with soap or detergent as soon as possible.
① Warm the engine and check the engine compartment for oil leakage. Please refer to “Leakage of
engine oil”.
67
Mechanical Part of
② Stop the engine and wait for 10min.
③ Loosen the engine oil filler cap and dismount the oil drain bolt.
④ Discharge the engine oil.
⑤ Mount the oil drain bolt equipped with new gasket.
Attention:
■ Be sure to clean the oil drain bolt and mount new gasket.
■ Tightening torque of oil drain bolt: 34~44N·m
⑥ Fill new oil.
Please refer to “Maintenance” for specification and viscosity of oil.
■ Oil volume: 2.5~3.5L
Attention:
■ Do not pull out oil rule when filling oil.
■ The oil filling volume varies with oil temperature and oil drainage time, thus the above data are only
for reference.
■ Always use an oil rule to check if the oil filling volume is proper.
⑦ Warm the engine and check the oil drain bolt and oil filter for oil leakage.
⑧ Stop the engine and wait for 10min.
⑨ Check the oil level. Please refer to “Engine Oil Level”.
IV. Oil Filter
1) Dismantlement
Dismount the oil filter with an oil filter spanner.
Attention:
■ Use original oil filter provided by JAC or equivalent.
■ As the temperatures of engine and engine oil are high, please prevent yourself from being hurt.
■ During dismantlement, prepare a cleaning cloth for absorption of leaked or splashed engine oil.
■ Do not make the engine oil stick o drive belt.
■ Thoroughly wipe and dry the engine oil splashed on the engine and vehicle.
68
Mechanical Part of
2) Installation
① Remove the foreign substances attached on

Fig. 1.2.005
mounting surface of oil filter.
② Apply one coating of a suitable of amount of

engine oil on oil seal surface of new oil filter.
③ Tighten the oil filter until the O-ring engages with the mounting surface. Tighten the oil filter for
another circle with a tightening torque of12~20N·m.
Attention:
■ The oil filter must be tightened with filter spanner.
■ If the filter is tightened by hand, oil leakage may occur due to inadequate tightening torque.
1) Check oil level. Please refer to “Engine Oil”.
2) Start the engine and check if there is oil leakage.
3) Stop the engine and wait for 10min.
4) Check oil level and fill engine oil. Please refer to “Engine Oil”.
69
Mechanical Part of
V. Oil Pan and Engine Oil Pump
1. Element
Breakdown drawing of oil pan and oil pump
1-Oil filter 2-Oil drain bolt 3-Oil drain bolt gasket 4-Oil pan 5-Oil pickup 6-Oil pickup gasket
7-Relief valve 8-Relief valve spring 9-Relief valve piston 10-Front oil seal 11-Oil pump casing
12-O-ring 13-Oil pump cover 14-Outer rotor of oil pump 15-Inner rotor of oil pump
2. Dismantlement
Caution:
■ Do not discharge engine oil when engine is hot, so as to avoid being hurt.
1) Discharge engine oil. Please refer to “Replace engine oil”.
70
Mechanical Part of
2) Dismount oil pan. Fig. 1.2.006

a. Loosen the fixed bolts according to following
sequence: center-both sides.
■ Tightening torque: (M6) 6~8N·m
(M8) 22~25 N·m
b. Knock the special tool into the space between Fig. 1.2.007
oil pan and cylinder body as it is shown in Fig.
1.2.007.
c. Slightly knock the side of special tool, make

the tool move along the sealing surface of oil
pan/cylinder body, and then dismount the oil
pan.
Attention:
■ Do not damage the matching surface.
3) Dismount oil pickup.

Fig. 1.2.008
Attention:
■ Do not drop the gasket.
4) Dismount oil pump casing.

Fig. 1.2.009
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Mechanical Part of
5) Dismount the fixed bolt for oil pump casing and take off oil pump cover and oil pump gear.
6) Dismount the front seal of camshaft, relief valve and oil filter from oil pump casing.
3. Check after Dismantlement
1) Oil pickup
■ Clear the oil pickup of attached substances.
2) Oil pump casing
■ Check the oil hole of oil pump casing for blockage, and clean it when necessary.
■ Check the oil pump casing for crack and other damage. If there is any, please replace it.
3) Oil pump
Attention:
■ Check each clearance of oil pump. Replace the oil pump if the clearance is out of specified range.
■ Mount the rotor into front cover before check.
① Check the clearance of tooth crest.

Fig. 1.2.010
② Check the side clearance. Fig. 1.2.011

72
Mechanical Part of
③ Check the casing clearance.

Fig. 1.2.012
Limit value: 0.35mm
4. Installation Fig. 1.2.012

1) Mount oil pump casing
■ Wash the application surface of sealant and

front oil seal housing on cylinder body.
■ Apply 3mm of curling sealant on the whole

outside of oil pan flange.
■ Specified sealant: LT5699 or equivalent.
2) Mount front oil seal of camshaft

Fig. 1.2.014
■ Put the special tool on forehead of camshaft,
JAC-T3F003
and coat engine oil on its outside.
■ Coat the engine oil on sealing lip, and then Fig. 1.2.015
manually push the oil seal along guide sleeve
JAC-
until contacting with front oil seal housing.
Knock the oil seal to proper position with special

tool.
3) Mount relief valve assembly.
4) Mount oil filter.
■ Clean the mounting surface of oil filter on oil pump casing.
73
Mechanical Part of
■ Apply engine oil on O-ring of oil filter.
■ Tighten the oil filter until the O-ring engages with the mounting surface. Then tighten the oil filter for
another circle with a tightening torque of 12~20N.m.
Attention:
■ The oil filter must be tightened with filter spanner. If the filter is tightened by hand, oil leakage may
occur due to inadequate tightening torque.
5) Mount oil pan.
■ Clean the matching surface of cylinder body and oil pan.
■ Apply 4mm of curling beaded sealant on the Fig. 1.2.016

whole outside of oil pan flange.
6) Mount oil drain bolt of oil pan

Fig. 1.2.017
■ Mount the oil drain bolt gasket of oil pan as it is
shown in the figure.
Oil pan
Attention: side
■ After installation of oil pan, wait for at least

30min before filling engine oil .
1) Check the oil level and fill engine oil. Please refer to “Engine Oil”.
2) Start the engine and make sure there is no oil leakage.
3) Stop the engine and wait for 10min.
4) Recheck the oil level. Please refer to “Engine Oil”.
74
Mechanical Part of
Section III Cooling System of Engine
Fig. 1.3.001
I. Precautions
Precautions on sealant:
1. Removal of Sealant
After dismounting the fixed nut and bolt, separate

the matching surface with scraper and remove the
used sealant.
Attention:
■ Be careful not to damage the matching surface.
■ Insert the scraper and knock its side to make it slip, as shown in the figure..
■ Please slightly knock the spare parts with a plastic hammer for dismantlement in places where the
scraper is difficult to be used.
Attention:
■ Please be careful not to damage the matching surface when tools such as right-angled screwdriver
have to be used.
2. Application Steps of Sealant Fig. 1.3.002

Scraper
1) Clear the used sealant attached on the
application surface and matching surface of
pad with scraper.
■ Thoroughly clear the used sealant from Fig. 1.3.003

grooves, fixed bolts and bolt holes on sealant
application surface.
75
Mechanical Part of
2) Clean the application surface and matching surface of sealant with unleaded petrol, and clear the
attached water, lubricant and foreign substances.
3) Set the complete sealant with specified dimension on appointed position.
■ If there is a groove for sealant to be placed, put the sealant into the groove.
■ For a bolt hole, the sealant is generally put into Inner

Fig. 1.3.004 side
the hole and occasionally it is put outside.
Groove Bolt hole
Inner side
Please read this manual to confirm the operations.
■ Mount connecting element within 5min after sealant application.
■ If there is any dirt on sealant, please remove it as soon as possible.
■ Please do not retighten the bolt or nut after installation.
■ Fill engine oil and engine coolant 30min after the installation.
Attention:
■ The special illustration (if any) described in this manual should be complied with.
76
Mechanical Part of
II. Cooling Circuit
1. Cooling Circuit Diagram

Outlet pipe of radiator
Thermostat
Water
pump This circuit is closed during
major cycle
Engine water jacket

Radiator
Warm air
device: heat
Fan
exchanger
The water temperature

thermostat at this position will be
turned on at 82℃ to actuate
major circle and turned off below
82℃ to actuate minor cycle
Minor cycle
Coolant
Rubber
hose
Expansion
tank
Inlet pipe of radiator
Cooling circuit diagram

2. Basic Diagram of Cooling
Radiator
Expansion
tank
Thermostat
Thermostat
casing
Air throttle body
Warm air heat
exchanger
Water pump
Cylinder
Thermostat on body
Thermostat off
Cylinder
cover
Basic diagram of cooling
77
Mechanical Part of
III. Engine Coolant
1. Check
1) Level check
After the engine has cooled, check if the level of engine coolant in stock solution tank is within the range
between MIN and Max.
■ Adjust the engine coolant level when necessary.

Fig. 1.3.005
2) Leakage check
Apply pressure to cooling system with leak

Fig. 1.3.006
detector for radiator cover to check if there is any
leakage.
3) Test pressure
Caution:
■ Please do not dismount radiator cover when engine is very hot, or else, the high-pressure engine
coolant overflowing from radiator will cause severe burns.
Attention:
■ Test pressure over specified value may cause damage to radiator.
■ When it is detected that the engine coolant is decreasing, fill engine coolant into radiator. If any
spare parts are damaged, please repair or replace them.
78
Mechanical Part of
2. Replace Engine Coolant
Caution:
■ To avoid being burned, please do not replace coolant when engine temperature is extremely high.
■ Wrap up the radiator cover with thick cloth, and turn and open it carefully. Release the pressure in
radiator first, and then fully open the cover.
■ Be careful not to splash engine coolant onto the drive belt.
1) Discharge engine coolant
① Dismount the deflector on the right side of the engine. Please refer to “Engine Deflector”.
② Open the water drain plug at the bottom of radiator, and then open the radiator cover.
③ When necessary, please dismount the stock solution tank, discharge engine coolant and clean the
tank before reinstallation.
④ Check the discharged engine coolant for rust and other impurities or discoloration.
■ If it is polluted, please wash the engine cooling system. Please refer to “Wash Cooling System”.
2) Refill engine coolant
① Mount the dismounted stock solution tank and water drain plug of radiator.
Attention:
■ Be sure to clean the water drain plug and mount the new O-ring.
② Make sure all the hose clamps have been tightened firmly.
③ Dismount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
④ Cut off the outlet pipe of warm water pipe. Please lift the hose as high as possible.
⑤ Fill coolant into radiator and stock solution tank until specified level is achieved and slowly fill engine
coolant, so as to exhaust the air in system gradually.
Attention:
■ Apply the original engine coolant provided by JAC. Please refer to “Recommended Oil and
Lubricant”.
■ Cut off the connection when engine coolant overflows from warm water pipe, and then carry out
reconnection and continue to fill engine coolant.
⑥ Mount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
⑦ Mount the radiator cover.
⑧ Warm the engine until the thermostat is turned on.
Touch the lower water pipe of radiator to detect if any warm water flows out, so as to check if the
thermostat has been turned on.
79
Mechanical Part of
Attention:
■ Check the engine water temperature indicator to avoid overheating of engine.
⑨ Stop the engine to lower the temperature.
■ The cooling time can be reduced by using fan.
■ Fill the engine coolant in radiator to the filler when necessary.
⑩ Fill the engine coolant in stock solution tank to the MAX position.
○
11 Mount the radiator cover and repeat steps ③~⑨ more than twice until the engine coolant level does
not lower any more.
○
12 Run the engine to check the cooling system for leakage.
3) Wash cooling system
① Mount the dismounted radiator water drain plug and stock solution tank.
Attention:
■ Be sure to clean the water drain plug and mount the new O-ring.
② Dismount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
③ Cut off the outlet pipe of warm water pipe. Please lift the hose as high as possible.
④ Fill the engine coolant into radiator and stock solution tank, and mount radiator cover.
Cut off the connection when engine coolant overflows from warm water pipe, and then carry out
reconnection and continue to fill engine coolant.
⑤ Mount the air cleaner upper cover and air intake hose. Please refer to “Air Cleaner Assembly”.
⑥ Run the engine to warm it up to normal working temperature.
⑦ Increase the engine speed for several times when no load is applied to the engine.
⑧ Stop the engine and wait for it to cool.
⑨ Discharge the water in system. Please refer to “Discharge engine coolant”.
⑩ Repeat steps ①~⑨ until the radiator begins to discharge the cleared water.
80
Mechanical Part of
IV. Radiator
Caution:
■ Please do not dismount radiator cover when engine is very hot, or else, the high-pressure engine
coolant will cause severe burns. Wrap up the radiator cover with thick cloth and slowly turn it to
discharge the air pressure inside. Turn and open the radiator cover and take it off carefully after the
pressure is fully released.
1) Dismantlement
① Dismount the engine deflector. Please refer to “Deflector”.
② Discharge the engine coolant in radiator. Please refer to “Replace Engine Coolant”.
Attention:
■ Operate after engine is cooled.
■ Please do not make the engine coolant splash onto the drive belt.
③ Dismount the air intake pipe and take it off.

Fig. 1.3.007
④ Disconnect the harness connector of radiator fan motor and move it aside.
⑤ Dismount the inlet and outlet hoses of radiator and return hose of stock solution tank.
⑥ Dismount the mounting support of radiator and take off the radiator and radiator cooling fan
subassembly.
Attention:
■ Please do not damage or scratch the radiator core during dismantlement.
⑦ Dismount the radiator cooling fan sub-assembly from the radiator.
2) Installation
Install in the reverse order with dismantlement.
■ Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
“Leakage Check”.
81
Mechanical Part of
■ Start and warm up the engine. Visually inspect if there is any engine coolant leakage.
2. Check of Radiator Cover
1) Pull out the negative pressure valve and open it. Check if it can be fully closed after the pressure
release.
■ Make sure there is no dirt on or damage to negative pressure valve seat of radiator cover.
■ Make sure the opening and closing operations

of negative pressure valve are normal. Fig. 1.3.008
2) Check the relief pressure of radiator cover.
Standard value: 78~98KPa，

Fig. 1.3.009
Limit value: 59KPa
Connect the radiator cover to the leak detector for
radiator and apply engine coolant to sealing face of
the cover.
Replace the radiator cover when the operation of
negative pressure valve is abnormal or the relief
pressure decreases below limit value.
3. Check of Radiator
■ Check the radiator for slurry or blockage. If necessary, wash the radiator surface according to
following methods.
■ Be careful not to bend or damage the radiating fin.
■ When washing the radiator without dismantling it, please dismount all accessories such as cooling
fan, wind collection cover and horn. Then wrap up the harness connectors with adhesive tape to
prevent water from flowing in.
1) Wash the back of radiator core from top to bottom with the water hose pointing to the radiator
vertically.
2) Wash each surface of radiator core every 1min.
3) If no dirt is washed off radiator, washing must be stopped.
4) Vertically blow the back of radiator downwards with compressed air. Apply the compressed air with
pressure lower than 490KPa and keep the distance above 30cm.
5) Blow each surface of radiator core with compressed air every 1min until no water is blown out.
82
Mechanical Part of
V. Radiator Cooling Fan
1) Dismantlement
① Dismount the air intake pipe and take it off.
② Disconnect the harness connector of radiator Fig. 1.3.010

fan motor and move it aside.
③ Dismount the radiator cooling fan

sub-assembly.
Attention:
■ Do not damage or scratch radiator core during

dismantlement.
2) Installation
1) Disassembly
① Dismount the cooling fan from fan motor.
② Dismount the fan motor from wind collection cover.
2) Check after disassembly
① Cooling fan
Check the cooling fan for cracks or abnormal bend. If any, please replace the cooling fan.
② Fan motor
Check the motor for jamming.
3) Assembly
Assemble in the reverse order with disassembly.
83
Mechanical Part of
VI. Water Pump
Attention:
■ Be careful not to splash the engine coolant onto the drive belt while dismantling the water pump.
■ As the water pump can not be disassembled, it should be replaced as a whole.
■ After the installation of water pump, connect the hose, fix it with clamping band, and then check if
there is any leakage with leak detector for radiator cover.
1) Dismantlement
① Discharge the engine coolant in radiator.
Please refer to “Replace Engine Coolant”.
② Loosen the fixed bolt for belt pulley of water

Fig. 1.3.011
pump.
③ Dismount the drive belt. Please refer to “Drive

Belt”.
④ Carry out the dismantlement steps 3~9

described in “Timing Belt Mechanism”. Fig. 1.3.012
⑤ Dismount the fixed bolt for water pump.
Attention:
■ Please differentiate the positions for fixed

bolts properly.
■ Check the water pump body assembly for severe corrosion, leakage of water-seal and erosion.
■ Check for improper running due to too large end clearance.
■ Check the water pump bearing for jamming and other damages. Replace the bearing when
necessary.
84
Mechanical Part of
3) Installation
① Clear the sealant on mounting seat of water pump and inlet pipe at water pump side.
② Mount the new O-ring on groove of inlet pipe at water pump side.
Note: Apply engine coolant to O-ring.
③ Apply 3mm of curling sealant to mounting Fig. 1.3.013

surface of water pump.
④ Mount the water pump.
Attention:
■ Please do not drop the gasket during

installation.
■ Alternately tighten each fixed bolt evenly and insert them into water pump.
a. In this step, operate according to the installation steps described in “Timing Belt Mechanism”.
b. Mount the drive belt and adjust it in accordance with specified tension. Please refer to “Drive Belt”.
c. Mount the belt pulley of water pump.
d. Fill engine coolant. Please refer to “Refill engine coolant”.
VII. Thermostat Sub-assembly
1) Dismantlement
① Discharge the engine coolant through water

drain plug of radiator. Please refer to “Replace Fig. 1.3.014
Engine Coolant”.
Attention:
■ Operate after the engine has cooled.
■ Please do not splash the engine coolant

onto the drive belt.
85
Mechanical Part of
② Disconnect the inlet pipe, outlet pipe and minor

cycle pipe of radiator at thermostat casing side. Fig. 1.3.015
③ Disconnect the harness connectors of coolant
temperature sensor and water temperature alarm
switch and fixed bolts for support racks of harness
connectors of front and rear oxygen sensors, and
then remove them.
④ Dismount the fixed bolt for thermostat casing and

take off the thermostat casing. Fig. 1.3.016
⑤ Dismount the fixed bolt for thermostat upper cover

and take out the thermostat. Fig. 1.3.017

Fig. 1.3.018
① Thermostat
■ Check the opening of thermostat valve at normal
room temperature.
Temperature of thermostat (ON): 82℃ (initially open)
95℃ (fully open)
Maximum lift of valve stem: ≥8mm
Temperature of thermostat (OFF): >77℃
Please replace the thermostat when the measured
value exceeds the specified range.
② Thermostat upper cover and thermostat casing
86
Mechanical Part of
Check them for cracks and other damages.
3) Installation
Please pay attention to the following precautions and install in the reverse order with dismantlement.
① Be careful not to splash engine coolant onto the engine and wipe and dry the engine coolant with
cleaning cloth.
② Replace the O-ring of inlet pipe with a new one and apply coolant to the O-ring, so that it can be
inserted into the thermostat casing of water pump easily.
Attention:
■ Do not apply engine oil or other oils to O-ring.
■ The water pipe behind thermostat casing must be mounted stably.
③ When mounting thermostat, its poppet valve

Fig. 1.3.019
must be set at the highest position.
④ If the water temperature alarm switch needs to Fig. 1.3.020

be reused, apply specified sealant to its
thread.
⑤ If the engine coolant temperature sensor

Fig. 1.3.021
needs to be reused, apply specified sealant to
its thread.
87
Mechanical Part of
VIII. Water Piping Sub-assembly
1. Dismantlement
① Discharge the engine coolant through water drain plug at the bottom of radiator. Please refer to
“Replace Engine Coolant”.
Attention:
Fig. 1.3.022
■ Operate after the engine has cooled.
Rear end of cylinder cover
② Dismount the air cleaner assembly. Please
refer to “Air Cleaner Assembly”.
③ Dismount the upper and lower water hoses of

radiator.
④ Dismount the warm water hose and minor cycle

water piping.
⑤ Dismount the fixed bolt for intake manifold

support and take off the support. Fig. 1.3.023
⑥ Dismount the fixed bolt for inlet pipe, and then Air intake manifold
dismount the inlet pipes from rear ends of water

pump and thermostat casing.
Attention:
■ Please dismount the negative terminal of

storage battery before dismantlement.
2. Installation
Please pay attention to following precautions and install in the reverse order with dismantlement.
1) Firmly insert each hose. Mount the clamping band properly so that it will not clamp the raised
position of water piping.
2) Replace the O-ring of inlet pipe with a new one and apply coolant to the O-ring, so that it can be
inserted into the water pump and thermostat casing easily.
Attention:
■ Do not apply engine oil or other oils to O-ring.
88
Mechanical Part of
■ The water piping behind thermostat casing and water pump must be mounted firmly.
1) Check if there is any engine coolant leakage with leak detector for radiator cover. Please refer to
2) Start and warm up the engine. Visually inspect if there is any engine coolant.
IX. Trouble Analysis
Table for Overheating Cause Analysis
Symptom Check Item

Water pump Abrasion or excessive
malfunction looseness of drive belt
Jamming of thermostat
at close position
Blockage due to dust or
Improper heat radiation paper scraps —
Radiator is damaged
Mechanical damage
Excessive foreign
The radiator cooling is
substances (corrosion,
blocked
pollutants, sand, etc.)
The cooling fan fails to
work
Trouble of Spare Parts of Cooling System
The resistance for fan

Insufficient air flow rotation is too large Fan assembly —
The fan blade is
damaged
Damage of wind collection
— — —
cover
Incorrect mixture ratio of
— — —
coolant
Poor quality of engine Viscous engine coolant
—
coolant
Loose clamping band
Coolant hose
Broken hose
Water pump Improper sealing
Looseness
Radiator cover
Improper sealing
Damage, aging or incorrect
Engine coolant leaks installation of O-ring
Radiator Broken radiator water tank
Insufficient engine coolant
Broken radiator core
Breakage of stock solution
Stock solution tank
tank
Aging of cylinder cover
The stock solution tank Tail gas leakage to
is overflowing cooling system Aging of cylinder cover
gasket
Excessively high engine
speed in the case of
The engine is no-load
— Abnormal driving
overloaded
Long-term traveling
Driving at ultra high-speed
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Mechanical Part of
Drivetrain malfunction
Wheel and tyre with

Trouble of Spare Parts of Other Systems
incorrect specifications
—
mounted
Braking drag
Incorrect ignition timing
The vent of bumper is
—
blocked
Mounting cover
The radiator grill is
Blockage of slurry and
blocked
Poor ventilation paper scraps —
The radiator is
—
blocked
The condenser is Poor ventilation
blocked
X. Maintenance Parameters
Technical specification for cooling system
Temperature of thermostat (ON) 82℃ (Initially open) 95℃ (Fully open)

Temperature of thermostat (OFF) ≥77℃
Maximum lift of thermostat valve stem >8mm
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Mechanical Part of
Section IV Fuel Supply System of Engine

I. General Precautions
Caution:
The following rules should be complied with during the replacement of spare parts of fuel pipeline.
■ Set the mark “Attention: combustive” in workshop.
■ Be sure to operate in the well-ventilated area, and prepare C02 fire extinguisher in the operation
workshop.
■ Do not smoke during the fuel system servicing. No fire in working area.
■ Hold the discharged fuel in the container and cover it. Put the container in safe area.
Attention:
■ Comply with the following steps when dismounting spare parts of fuel pipeline.
- Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
- Cut off the negative pole of storage battery.
■ Replace new circlip all the time.
■ Do not distort the fuel pipe during installation.
■ Please operate on level ground.
■ Connect the fuel pipe joint and make sure the joint has been fixed. Make sure the joint and resin
pipe don’t contact with any adjacent spare parts.
■ Do not excessively tighten the hose circlip to prevent damage of hose.
■ Check each connection for fuel leakage according to following steps after installation of fuel pipe.
- Set the ignition switch at “ON” position to apply fuel pressure on fuel pipeline (do not start the
engine). Then check each connection for fuel leakage.
- Start the engine, increase its speed and check each connection for fuel leakage.
■ Only the original fuel filler cap provided by JAC can be adopted.
■ Please refer to “Fuel Evaporative Emission System” for maintenance of spare parts of the system.
91
Mechanical Part of
II. Preparation
The special tools are listed in the table below:
List of Special Tools
S.N. Tool Outline Diagram No. Illustration
Fuel pressure Measure fuel

1 JAC－T1F018
gauge pressure
III. Fuel System
1. Check Fuel Pipe
Check the fuel pipeline, fuel filler cap and fuel tank for proper installation, leakage, crack, damage, loose
connection, abrasion and aging.
2. Release Fuel Pressure
1) Dismount the fuel pump fuse in fuse box.
2) Start the engine.
3) After the engine stops, restart and actuate the engine to idle for 2~3 times to thoroughly release the
fuel pressure.
4) Set the ignition switch at OFF position.
5) Remount the fuel pump fuse after fuel system servicing.
3. Check Fuel Pressure
Attention:
■ Before cutting off the fuel pipeline, release the fuel pressure in fuel pipeline to avoid danger.
■ Always keep the joints of fuel hose sealed with O-ring.
■ Do not operate electrical system during check.
Note: prepare a container under the fuel pipe to be cut off to avoid fuel splash.
1) Fully release the fuel pressure. Please refer to “Release Fuel Pressure”.
2) Dismount the nut for fuel pressure inspection door on fuel injector guide rail.
3) Connect fuel pressure gauge.
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Mechanical Part of
4) Set the ignition switch at “ON” position and check if there is fuel leakage.
5) Start the engine and check if there is fuel leakage.
6) Obtain the reading shown in fuel pressure gauge.
■ Fuel pressure: 350KPa
Attention:
■ Do not check fuel pressure during system operation.
■ During the check of fuel pressure, please always check the fuel connecting piping for fuel leakage.
7) If the check result is not good, turn to the next step.
8) Check for the following matters.
- Blockage of fuel hose and fuel pipe.
- Blockage of fuel filter.
- Water pump and its control circuit.
IV. Fuel Injector and Guide Rail
1. Dismantlement
Caution:
■ Read the “General Precautions” before dealing with fuel system. Please refer to “General
Precautions”.
1) Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
2) Cut off the PCV hose joint at intake manifold

Fig. 1.4.001
side.
3) Cut off the harness connector of manifold absolute pressure sensor and fuel injector.
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Mechanical Part of
4) Cut off the air throttle wiredrawing and the

fixed support of wiredrawing at air throttle Fig. 1.4.002
body side.
5) Disconnect the joint of fuel hose on fuel guide

rail. Fig. 1.4.003
Attention:
■ Please prepare the container and cleaning
cloth in advance as fuel leakage may take
place.
■ Avoid the naked flame and spark.
■ Please keep the spare parts away from heat
source. Special attention must be paid when
welding around them.
■ Do not expose the spare parts to the
electrolyte of storage battery or other fluid.
■ Keep the connection clean and prevent damage and foreign substance, and properly cover the
connection with plastic bag or equivalent.
6) Dismount the fixed bolt for fuel guide rail.
7) Take out the fuel guide rail with injector from Fig. 1.4.004
intake manifold.
Attention:
■ Avoid interference with fuel injector during
removal.
■ Absorb the fuel leaked from fuel pipe with
cleaning cloth.
8) Dismount the fuel injector from fuel guide rail
according to following steps:
a. Prize up and dismount the snap-in.
b. Straightly pull out the fuel injector from fuel
pipe.
Attention:
■ Pay attention to the leakage of residual fuel in
fuel pipe.
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Mechanical Part of
■ Do not damage the nozzle of fuel injector.

■ Do not make it fall off or knock it.
■ Do not disassemble it.
1) Fuel Injector
■ Check the upper and lower seal rings of fuel injector for crack, aging and breakage. If any, please
replace them.
■ Check the injection hole of fuel injector for blockage. If any, please wash or replace it with special
instrument.
2) Fuel Guide Rail
■ Check the fuel inspection hole for damage and jamming. If any, please replace the guide rail.
■ Check if there is residuum in guide rail. If any, please replace the guide rail.
3. Installation
1) Please pay attention to the following precautions when mounting new O-ring on fuel injector.
Attention:
■ As the upper and lower O-rings are different, do not confound them.
Fuel pipe side: thick one
Nozzle side: thin one
■ Please mount the O-ring manually.
■ Lubricate the O-ring with petrol.
■ Do not wash O-ring with solvent.
■ Please make sure there is no foreign substance on O-ring and its accessories.
■ Make sure the O-ring will not be scraped by tool or fingernail, distorted or stretched during its
installation.
■ Insert new O-ring into fuel injector straightly. Fig. 1.4.005

Do not deflect or distort it.
2) Mount fuel injector ④ on fuel pipe ① in

accordance with following steps.
③ : thick one
⑤ : thin one
a. Insert the snap-in ② into the fixing groove for

snap-in on fuel injector. Insert the snap-in slice
D into raised position F of fuel injector.
95
Mechanical Part of
Attention:
■ Replace with the new snap-in every time.
■ Make sure there is no interference between the snap-in and O-ring.
b. Insert the fuel injector into fuel pipe where snap-in has been mounted.
Attention:
■ Make sure the direction of insertion aligns with the axis.
■ Insert the snap-in slice C into the raised position B of fuel pipe.
■ Make sure the flange A of fuel pipe is properly mounted in the fixing groove on snap-in flange.
c. Make sure the fuel injector will not move or fall off to complete the installation.
3) Mount fuel pipe guide rail and fuel injector assembly inside of intake manifold.
Attention:
■ Be careful not to make fuel injector nozzle contact with other spare parts.
4) For the following steps, install in the reverse order with dismantlement.
Check if there is fuel leakage according to following steps.
1) Set the ignition switch at “ON” position (when the engine stops), and then check the connection of
fuel pipe for leakage.
2) Start the engine, increase its speed and recheck the connection of fuel pipe for leakage.
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Mechanical Part of
V. Fuel Filter
1. Dismantlement
Caution:
Precautions”.
Attention:
■ The fuel filter should be periodically replaced in accordance with the maintenance instruction
specified in “User’s Manual”.
1) Release the fuel pressure in fuel pipeline. Please refer to “Release Fuel Pressure”.
6) Cut off the fuel pipe joint 1 (at fuel pump side),
joint 2 (at fuel filter side) and grounding end 3 Fig. 1.4.007
of fuel filter.
Attention:
The fuel filter should be wrapped up with towel or

equivalent, so as to avoid injection of residual fuel
pressure.
Cut off the joint according to following methods:
2) Open the fuel filler cap. Fig. 1.4.006

3) Release the pressure in fuel tank.
4) Dismount the rear seat cushion. Please refer

to “Rear Seat”.
5) Dismount the service lid for fuel tank.
■ Directly prize it up with right-angled

screwdriver.
■ Hold the side edge of joint and press the

raised position of joint to pull out the fuel pipe. Fig. 1.4.008
■ If the joint attaches to the resin pipe, push and

pull the joint for several times until it moves,
and then pull out the joint.
Attention:
■ The joint can not be cut off until the raised

position is fully pressed down. Do not
excessively distort the joint.
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Mechanical Part of
■ Do not cut off the joint with any tool.
■ Prevent the resin pipe from being heated. Special attention must be paid when welding around the
resin pipe.
■ Prevent the resin pipe from contacting with acidic fluid such as electrolyte of storage battery.
■ Do not bend or distort the resin pipe during installation and dismantlement.
■ To keep the connection clean and prevent from damage and foreign substance, please fully cover
them with plastic bag or equivalent.
7) Take off the fuel filter and fuel pipe.

Fig. 1.4.009
2. Installation
Pay attention to the following precautions and
install in the reverse order with dismantlement.
1) Fuel filter
■ Pay attention to the installation direction of

Fig. 1.4.010
fuel filter.
Face to the fuel inlet pipe side
2) Connector
Connect the connector of fuel supply hose according to following methods:
① Check the connection for foreign substance and damage.
② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.
③ Check if the connector is properly connected in accordance with following methods after connection.
■ Visually check if the 2 raised positions have been connected to the connectors.
98
Mechanical Part of
■ Stretch the resin pipe and its connector hard

Fig. 1.4.011
and make sure they have been firmly
connected.
1) Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe
for leakage.
VI. Fuel Pump Assembly
Figure of fuel pump assembly
99
Mechanical Part of
1. Dismantlement
Caution:
Precautions”.
1) Check the fuel level indicated by fuel oil meter. If the meter indicates “full” or “to be full”, discharge
the fuel in fuel tank until the meter indicates that the fuel level is lower than position “E”.
Note:
As the fuel level exceeds the mounting surface of fuel level sensor, the fuel may overflow during the
dismantlement of fuel level sensor.
2) Release the fuel pressure in fuel pipe. Please refer to “Release Fuel Pressure”.
3) Open the fuel filler cap.
4) Release the pressure in fuel tank.
5) Dismount the rear seat cushion. Please refer to “Rear Seat”.
6) Dismount the service lid for fuel tank. Fig. 1.4.012

■ Directly prize it up with right-angled
screwdriver.
7) Cut off the harness connector of fuel pump

and fuel pipe joint. Fig. 1.4.013
① Fuel pipe joint of fuel pump
② Harness connector of fuel harness
Cut off the joint according to following methods:
■ Hold the side edge of joint and press the raised position of joint to pull out the fuel pipe.
■ If the joint attaches to the resin pipe, push and pull the joint for several times until it moves, and then
pull out the joint.
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Mechanical Part of
Attention:
■ The joint can not be cut off until the raised position is fully pressed down. Do not excessively distort
the joint.
■ Do not cut off the joint with any tool.
■ Prevent the resin pipe from being heated. Special attention must be paid when welding around the
resin pipe.
■ Prevent the resin pipe from contacting with acidic fluid such as electrolyte of storage battery.
■ Do not bend or distort the resin pipe during installation and dismantlement.
■ To keep the connection clean and prevent damage and foreign substance, please fully cover them
with plastic bag or equivalent.
8) Loose and take off the locknut with special tool. Fig. 1.4.014
Note: to facilitate dismantlement, the fuel tank has

been dismounted.
9) Take off the Y-ring. Fig. 1.4.015
Attention:
■ Tilt the fuel pump when it is taking out, so as to

avoid breakage of fuel level sensor.
■ Prevent the residual fuel from being polluted

and wrap the Y-ring with cloth to pull it out
straightly.
10) Take off the fuel pump.
Fig. 1.4.016
1) Fuel pump
① Visual Inspection
■ Check if there is breakage or fuel impurity. If

any, please replace or wash it.
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Mechanical Part of
② Check of Fuel Pump Operation
■ Actuate the fuel pump with 12V regulated power supply directly and check if the operation is normal.
Attention:
■ Do not make the fuel pump operation for a long time, so as to avoid damage of pump core.
2) Y-ring
■ Check it for material loss and breakage.
3) Locknut
■ Check it for deformation, crack, material loss, breakage and damage at mounting thread.
4) Fuel Level Sensor
■ Check the fuel float for interference and oxidation of its surface.
3. Installation
Pay attention to following precautions and install in the reverse order with dismantlement.
1) Fuel pump assembly
■ The Y-ring must fully engage with fuel tank during installation.
■ Tilt the fuel pump to facilitate its installation and pay attention to its assemblage direction.
■ There should be no turnup on Y-ring during the installation.
■ Pre-tighten the locknut during its installation, and then tighten it horizontally.
2) Connector
Connect the connector of fuel supply hose according to following methods:
① Check the connection for foreign substance and damage.
② Make the connector align with the resin pipe and insert the connector straightly until “click” is heard.
③ Check if the connector is properly connected in accordance with following methods after connection.
■ Visually check if the 2 raised positions have been connected to the connectors.
■ Stretch the resin pipe and its connector hard and make sure they have been firmly connected.
1) Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel pipe
for leakage.
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Mechanical Part of
VII. Fuel Tank Assembly
Breakdown diagram of fuel tank assembly

1-Filler cap 2-Filler port 3-Fuel tank 4-Fastening band of fuel tank 5-Service lid 6-Locknut 7-Y-ring
8-Fuel pump 9-Fuel filter 10-Thermal baffle
1） Dismantlement
Caution:
Precautions”.
■ Discharge the fuel in fuel tank when necessary. Please refer to “Fuel Pump”.
■ Please operate on level ground.
① Carry out the dismantlement steps 1~7 of fuel pump. Please refer to “Fuel Pump”.
② Disconnect the fuel supply hose and vent hose.
③ Disconnect the EVAP hose.
④ Support the fuel tank bottom with special jack.
Attention:
■ The fastening band of fuel tank can not be blocked by supporting position.
103
Mechanical Part of
⑤ Dismount the clamping bands of filler port and fuel tank, and then disconnect the filler port and fuel
tank.
⑥ Dismount the fastening band of fuel tank.
■ Tightening torque: 30~40N·m Fig. 1.4.017

⑦ Manually support the tank and carefully lower
the jack to dismount fuel tank.
Attention:
■ Make sure all connections have been

disconnected.
■ Make sure there is no interference to the

vehicle.
2) Check after dismantlement
① Fuel tank
■ Check if there is impurity in fuel. If any, clean it with hot water.
② EVAP hose and circlip
■ Check the hose for blockage, corrugation, deformation and breakage.
■ Check the circlip for damage and breakage.
③ Reinforced plate and its backing pad
■ Check the surface of reinforced plate for scratch and deformation.
■ Check the backing pad of reinforced plate for crack, material loss, deformation and breakage.
3) Installation
Pay attention to following precautions and install in the reverse order with dismantlement.
■ Firmly clamp and insert the fuel supply hose.
■ Do not set the hose clamp in expansion area of fuel pipe.
■ Please refer to “Fuel Pipe Joint” for precautions of fuel pipe joint connection.
① Set ignition switch at “ON” position (when engine stops), and then check the connection of fuel
pipeline for leakage.
② Start the engine, increase its speed and recheck the connection between piping and fuel pipe of fuel
system for leakage.
104
Mechanical Part of
VIII. Acceleration Control Device
1. Element
Breakdown diagram of acceleration control device

1-Accelerator pedal 2-Support rack of accelerated wiredrawing 3-Throttle control mechanism 4-Accelerated
wiredrawing
1) Dismantlement
① Lift the accelerator pedal and disconnect the connection of pedal and wiredrawing.
② Dismount the fixed bolt for accelerator pedal Fig. 1.4.018

and take off accelerator pedal from the
internal of vehicle.
105
Mechanical Part of
③ Disconnect the connection of throttle

Fig. 1.4.019
wiredrawing and air throttle body and loose
the wiredrawing to adjust the locknut.
④ Dismount the fixed bolt for wiredrawing and

disconnect the fixation of wiredrawing. Fig. 1.4.020
⑤ Take off the throttle wiredrawing.
① Accelerator pedal
Check the pedal for crack and flexibility of movable

knot.
② Throttle wiredrawing
Check if the wiredrawing operates smoothly. If not,

please fill enough lubricating oil.
3) Installation
Pay attention to following precautions and install in Fig.
the reverse order with dismantlement.
■ Please check if the movement is smooth
during installation of throttle wiredrawing.

■ Check the adjusting nut of wiredrawing during idling and set 1~2mm of idle stroke for the pedal.
■ Check if the operation of accelerator pedal is smooth.
IX. Maintenance Parameters
Table of Maintenance Specification
Capacity of fuel tank 45L
106
Mechanical Part of
Section V Emission Control System of Engine

I. Fuel Evaporation System
1. System Illustration
Intake manifold
Air cleaner
EVAP carbon canister

solenoid valve
Fuel-burning steam
EVAP carbon Air
canister
Fuel tank
Schematic diagram of fuel evaporation system
To decrease the emission of hydrocarbon from fuel system, the fuel evaporation system is applied. The
specific method is using charcoal in EVAP carbon canister. When the engine stops or fuel is filling into
the fuel tank, the fuel-burning steam evaporated from the sealed fuel tank will be induced and stored in
the EVAP carbon canister with charcoal. During the operation of engine, the fuel-burning steam in EVAP
carbon canister will be introduced into intake manifold through clean pipeline. EVAP carbon canister is
controlled by ECM. When the engine operates, the adjustment of steam volume controlled by EVAP
carbon canister solenoid valve will be directly proportional to the increase of air flow. During deceleration
and idling, EVAP carbon canister will cut off the steam cleaning pipeline.
107
Mechanical Part of
2. Diagram of Fuel Evaporative Emission Pipeline
Diagram of fuel evaporative emission pipeline
1-Carbon canister assembly 2-Fuel inlet hose of engine 3-Pipe connecting carbon canister with solenoid valve
4-Hose connecting carbon canister with solenoid valve 5-Fuel inlet pipe of engine 6-Fuel filter
Note:
Fig. 1.5.001
Do not use soap water or any other detergent
when installing vacuum pipe or cleaning pipeline.
3. Check of Element
1) EVAP carbon canister
① Check EVAP carbon canister in accordance

with following methods:
a. Block up port 1, blow at port 3 and make sure

the air flows out from port 2 freely.
b. Block up port 3, blow at port 1 and make sure

the air flows out from port 2 freely.
② Dismount the vacuum hose
Loose the clamping band locating from carbon canister to fuel tank and carbon canister solenoid valve
and pull out the vacuum hose with slip-joint pliers.
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Mechanical Part of
③ Dismount the carbon canister
Lift the carbon canister and dismount it from the

Fig. 1.5.002
retainer of inner lining of left fender. Left front frame
2) EVAP carbon canister solenoid valve
The air flow rate is controlled by the opening variation of steam by-pass pipeline in EVAP carbon canister
solenoid valve. The solenoid valve will repeat the operations of “ON” and “OFF” according to the signal
sent by ECM to actuate the variation of valve opening, so as to optimize engine control. The optimum
value saved in ECM lies on the condition of engine. When the engine operates, the airflow rate of
fuel-burning steam coming from EVAP carbon canister will adjust along with the variation of airflow.
① Element illustration
The EVAP carbon canister controls the flow rate of fuel-burning steam flowing out from EVAP carbon
canister by duty cycle of ON/OFF. The EVAP carbon canister solenoid valve is actuated by signal of
ON/OFF duty cycle sent from ECM. The wider the pulse width in “ON” condition is, the more fuel-burning
steam will flow through the valve.
② Dismantlement
Fig. 1.5.003
a. Disconnect the vacuum hose of EVAP carbon
canister solenoid valve.
109
Mechanical Part of
b. Disconnect the harness connector of EVAP

Fig. 1.5.004
carbon canister solenoid valve.
c. Take down EVAP carbon canister solenoid

Fig. 1.5.005
valve from the retainer.
3) Filler cap
Vacuum relief valve is mounted at the filler cap. When the pressure in fuel tank is high (with much
fuel-burning steam), the vacuum relief will be closed, so as to avoid emission of fuel-burning steam to
ambient environment. When the pressure in fuel tank is low (negative pressure), the vacuum relief valve
will be opened, so as to enable the outside air to get into fuel tank.
110
Mechanical Part of
II. Forced Ventilating System of Crankcase
Diagram of forced ventilating system of crankcase
1-Air cleaner 2-Air intake hose 3-Throttle valve casing 4-Purification can 5-PCV valve 6-Vent hose 7-Air intake
manifold 8-Fuel injector
The forced ventilating system of crankcase is used to bring the cylinder blow-by gas in crankcase back
to intake manifold.
It is the forced ventilating valve (PCV) which brings the cylinder blow-by gas in crankcase back to intake
manifold. When the air throttle of engine is partially open, the intake manifold sucks blow-by gas of
crankcase through PCV valve. In normal condition, the ventilation volume of PCV valve is enough for
suction of all blow-by gas of crankcase and a little of vent air. The vent air is brought into crankshaft
through air intake pipe. During this course, the air flows through the hose connecting air intake pipe and
rocker arm chamber cover. When the air throttle is fully open, the vacuum degree can not meet the
requirement of opening of PCV valve and suction of blow-by gas of crankcase. The airflow will flow
through connecting hose in reverse direction. The PCV valve can not meet the requirements when
severe blow-by takes place in the vehicle, as part of air will get into the air intake pipe all the time.
111
Mechanical Part of
2. Check of Element
Check the PCV (forced ventilation of crankcase) valve as it is shown below:
1) Operating principle
Table for operating principle of PAV valve
No High
Valve chamber cover side Valve chamber cover side

Operating condition of Operating condition of
Out of work Idling or deceleration
engine engine
PCV valve Out of work PCV valve Fully open
Variation of vacuum degree Limited Variation of vacuum degree Slight
Moderate No
Valve chamber cover side Valve chamber cover side

Operating condition of Operating condition of Improper acceleration and
Normal operation
engine engine high speed
PCV valve Normal operation PCV valve Retardant operation
Variation of vacuum degree Large Variation of vacuum degree Extremely large
112
Mechanical Part of
2) Dismantlement and Installation
① Dismantlement
a. Disconnect the connection of PCV valve hose

Fig. 1.5.006
and valve chamber cover.
b. Dismount PCV valve from valve chamber cover.

Fig. 1.5.007
① PCV valve
Fig. 1.5.008
Fizzy noise will arise from the valve in normal
operating condition when the airflow flows by.
Strong vacuum pressure will be detected when
putting a finger at the valve inlet.
② Vent hose of PCV valve
a. Check the hose and its joint for leakage.
b. Disconnect all hoses and clean them with compressed air. If the blockage in hose can not be
cleared, replace it.
113
Maintenance Manual of Tojoy Sedan Electrical Part of Engine
Chapter 2 Electrical Part of Engine
Section 1 Ignition System

I. Ignition coil
1. Element
Fig. of Ignition coil
2. Dismantlement & Installation
1) Dismantlement
Attention:
Fig. 2.1.001
■ Confirm that the ignition switch is in the “OFF”
position.
① Dismount the trimming cover of engine. Refer

to the “Intake Manifold” section.
114
② Disconnect the harness connector from the

Fig. 2.1.002
ignition coil and the connection with the high
voltage wire.
③ Dismount the ignition coil stop bolt, and take

Fig. 2.1.003
off the ignition coil.
■ Tightening torque: 8-12 N·m
④ Dismount the high voltage wire.

Fig. 2.1.004
Attention:
■ Please do not pull the lead wire of high voltage

wire.
⑤ Dismount the ignition plug with Ignition plug

Fig. 2.1.005
sleeve.
Attention:
■ Please do not drop or shake it.
115
① Ignition coil
■ Check the primary coil resistance between the terminals.
Primary coil resistance: 0.77-0.95 Ω
■ Check the secondary coil resistances at the high voltage ends between the No.1 cylinder and No.4
cylinder, and between No.2 cylinder and No.3 cylinder.
Secondary coil resistance: 7.75-10.23 KΩ
Attention:
■ The ignition coil harness connector must be taken off when the secondary coil resistance is being
measured.
② Ignition plug
Check the ignition plug:
■ Check whether the insulator of ignition plug is damaged or fractured.
■ Check whether the ignition plug has carbon deposit. See the following table for the reasons for
carbon deposit.
Phenomenon Black charcoal Hard charcoal

Reason There are impurities in the fuel or the Impurities in the fuel; wrong ignition
mixed air content in the fuel is too high. timing, or; untight ignition plug.
■ Check whether the ignition plug electrodes are damaged.
■ Check the clearance of ignition plug.
Check the clearance of ignition plug with a clearance gauge.
Standard clearance: 1.0-1.1 mm
If the clearance is beyond the standard value, please change it.
■ Check the sparking ability of ignition plug.
a. Connect the ignition plug with the high voltage wire.
b. Keep the clearance between the edge of ignition plug and the ground metal at about 14 mm.
c. Start the engine for about 3 s, and check whether there are sparks produced between the edge of
ignition plug and the ground metal.
Attention:
■ During check, be careful not to get an electric shock.
■ If the clearance is less than 14 mm, the sparks may also be produced even though the high voltage
wire has trouble.
116
■ If there are no sparks, please change the ignition

plug. Fig. 2.1.006
③ High voltage wire
■ Check whether the high voltage wire is damaged or

cracked.
■ Check the resistance of high voltage wire.
No.1 cylinder: 5.8 KΩ
No.3 cylinder: 2.9 KΩ
If the resistance is out of the specified range, please

change it.
3) Installation
II. Diagnosis of Common Troubles

Table for Diagnosis of Common Troubles
Trouble phenomena Possible causes Solution measures

The engine can’t or is difficult Trouble of ignition coil or ignition Check or change the ignition coil or the
to start. locking switch ignition locking switch
Trouble of ignition plug Check or change the ignition plug
Unconnected high voltage wire Check the high voltage wire
Unstable idle speed Trouble of high voltage wire or Check the high voltage wire or check or
ignition plug change the ignition plug
Trouble of ignition coil Check or change the ignition coil
Engine surge or poor Trouble of high voltage wire. Check the high voltage wire
acceleration Trouble of ignition plug Check or change the ignition coil
Poor economical efficiency of Trouble of ignition plug Check or change the ignition coil
fuel.
III. Maintenance Parameters

Maintenance Specification Table for Ignition System
Ignition coil Primary coil resistance 0.77- 0.95 Ω

Secondary coil resistance 7.75-10.23 KΩ
Ignition plug Ignition plug clearance 1.0-1.1 mm
Resistance of high voltage wire 16±3.2 KΩ/m
117
Section 2 Starting and Charging System

I. Basic Diagram of Starting and Charging System
Central electric box

120 A fuse
30 A fuse link
Storage battery
link
Ignition switch
Charging
alarm light
Combined
device
Anti-theft relay
Electric generator
ETACS－low level Rectifier

Magnetic
effective field
winding
Starter
Stator
winding
Solenoid
Electric switch
motor
One-way clutch
Basic Diagram of Starting and Charging System
II. Storage Battery
1. How to use storage battery
Attention:
■ If it is necessary to use auxiliary storage battery and jumper wire to start the engine, please use a 12
V auxiliary storage battery.
■ After the connection of the jumper wires of storage battery, confirm that the jumper wires are
clamped to the terminals of storage battery and have good contact.
2. Methods of preventing excessive discharging of storage battery
The following precautions shall be particularly emphasized to prevent excessive discharging of storage
battery.
■ Always keep the surface of storage battery (esp. the top) clean and dry.
■ The connecting part of the terminals shall be clean and tightened.
118
■ If the vehicle is not used for a long time, the cathode terminal of storage battery shall be
disconnected.
■ Check the charging condition of storage battery.
3. Check
1) Visual check
■ Check whether the terminals of storage battery are damaged, and whether the electrolyte leaks. If it
is the case, please change it.
2) Voltage check (U)
① If U>13.2V, please check the electrical system.
② If 12.5V<U<12.9V, the system is normal.
③ If 11V<U<12.4V, please check the charging system.
④ If U<11V, the storage battery is damaged or the charging system has trouble. Please check the
charging system and storage battery.
3) Dismantlement and installation
Attention:
■ The ignition switch shall be turned to the “OFF”

Fig. 2.2.001
position.
① Disconnect the cathode terminal.
② Dismount the anode terminal of storage

Fig. 2.2.002
battery and the fixed bolts of storage battery
pressure plate, and then take off the pressure
plate.
③ Take off the storage battery.
④ Take off the pallet of storage battery.
119
① Pallet of storage battery
■ Check whether there is erosion. If there is, clean it with warm clean water.
② Storage battery harness
■ Check whether it is eroded or damaged. If it is, please change it.
7) Installation
Attention:
■ During connection, the anode terminal of storage battery shall be connected first.
■ After installation, each terminal may be smeared with mineral oil.
120
III. Starting System
The close of solenoid switch of starter provides a closed circuit between the storage battery and starter.
The starter is connected to the engine body for grounding. After the power supply and ground are
provided, the starter turns the crankshaft, and the engine starts.
2. Dismantlement and installation
Figure of Element of Starter
1-M port 2-S port 3-B port
1) Dismantlement Fig. 2.2.003

① Disconnect the cathode terminal of storage
battery.
Note: Before disconnecting the cathode terminal of

storage battery, pull off the vehicle key first.
121
② Lift the vehicle, and dismount the support rack

Fig. 2.2.004
of intake manifold. Please refer to the “Intake
Manifold” section.
③ Disconnect the harness connector of starter.

Fig. 2.2.005
④ Dismount the stop bolts of starter, and take off
the starter.
2) Installation
Attention:
■ Ensure to tighten the nut of “B” port.
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3. Disassembly and Assemblage
1) Disassembly
Exploded View of Starter
1-Screw 2-Front support 3-Stop ring 4-Snap ring 5-Pinion 6-Gear ring 7-Solenoid switch 8-Sun gear
9-Planetary gear 10-Ball 11-Pad 12-Stator 13-Armature 14-Electric brush retainer 15-Rear support
16-Fastening bolt
123
2) Check
① Solenoid switch check
■ Before check, disconnect the cathode terminal of storage battery.
■ Disconnect the “M” port of starter.
a. Test whether electricity is conducted between Connecting from

Fig. 2.2.006 the power
“S” port and switch body. supply
“M”
■ If not, please change the solenoid switch.
b. Test whether electricity is conducted between Fig. 2.2.007

Connecting from
the power supply
“S” port and “M” port.
“M”
■ If not, please change the solenoid switch.
② Pinion check
a. Check the teeth of meshing gear
■ If the teeth are abraded or damaged, please change the meshing gear (check the teeth of fly wheel
at the same time).
b. Check the teeth of pinion
■ If the teeth are abraded or damaged, please change the pinion (check the teeth of armature shaft
gear at the same time).
c. Check whether the pinion locks in one direction while turns smoothly in the other direction.
■ If it is able to lock or turn in both the directions, or if there is abnormal resistance, please change it.
124
③ Electric brush check

Fig. 2.2.008
■ Check the abrasion condition of electric brush.
If it is excessively abraded, please change it.
Vernier caliper
Electric brush
④ Electric brush spring check

Fig. 2.2.009
■ Remove the spring from the electric brush and
check the spring tension.
Electric brush
spring
Electric brush
⑤ Electric brush retainer

Fig. 2.2.010
a. Conduct insulation test between the electric
brush retainer (the anode side) and the support
(the cathode side). If electricity is conducted
between them, please change the electric
brush retainer.
b. Check whether the electric brush can move

smoothly.
■ If the support of electric brush bends, please

change it. If the sliding surface is dirty, please
clean it.
⑥ Stator check
Fig. 2.2.011 Magnet
■ Check whether the magnet is firmly fixed on the
stator, and check whether there are cracks.
If the spare parts have trouble, change the

assembly.
Attention:
■ Please do not clamp the stator with a bench

clamp, nor hammer it.
125
⑦ Armature check Fig. 2.2.012

a. Check whether electricity is conducted
between the adjacent rectifier cells.
■ If it is not conducted, please change it.
b. Check whether electricity is conducted

between the copper plate and the shaft of
each commutator.
■ If it is conducted, please change it.
c. Check the surface of commutator. Fig. 2.2.013

■ If it is rough, please slightly sand it with # 500
sand papers.
Sand paper
d. Check the diameter of commutator. Fig. 2.2.014

■ If it is below the standard value, please
change the commutator.
Vernier
caliper
Commutator
126
3) Assemblage
When assembling the starter, the bearing, the gear and the friction surface shall be lubricated by adding
high temperature lubricating grease. And then conduct the following operations.
① Gear clearance adjustment Fig. 2.2.015

■ Push the pinion out with the magnetic switch
powered on, and check the clearance between
the pinion and the stop block with a clearance
gauge.
Stop block
Gear clearance 0.5~1 mm
Pinion
■ If the clearance is out of the specified range,

Fig. 2.2.016
please adjust it with adjusting gaskets.
Adjusting gasket
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4. Flow of Diagnosis of Common Troubles (if there is any abnormal situation, please disconnect the
cathode of storage battery at once.)
Check Flow Chart of Common Troubles of Starting System

The engine fails to stop. Change the solenoid switch.
The engine fails to start.
Yes
Does the electric generator Does the electric generator run Yes
run after the rotation of
crankshaft? normally? Check the ignition/fuel system.
Yes
No
Check the following aspects of
Abnormal
the storage battery: 1. Charging
A Normal
situation 2. Connection of Repair the starter.
terminal 3. Erosion of terminal.
Yes Yes
Does the gear shaft run? Check the pinion clutch.
Does the starter run?
No No
Check the reduction gear, the armature and the gear shaft.
Abnormal
Check the fuse and the fusible Change.
fuse.
Normal
Check the following aspects of
the storage battery: 1. Abnormal
Charging situation 2. 1. Charge the storage battery.
Connection of terminal 3. 2. Repair the poor connection and A
Erosion of terminal. the eroded terminal of storage
battery.
Normal
Abnormal
Check the circuitry of starting
system. Repair.
Normal
Does the solenoid switch No
Repair the starter.
make noises during running?
Yes
Check the mesh condition of
If the starter is wired as follows with no
pinion and gear ring. Yes
load, does it run? Change the solenoid switch.
Abnormal
1. Adjust the displacement of
pinion. 2. Check the motion
mechanism of pinion. 3. Check
No
the gear ring. Repair the starter.
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IV. Charging System
The electric generator provides DC voltage for the vehicle electric system, and keeps the charging
condition of storage battery. The voltage output is controlled by IC adjuster.
The “B” port supplies electricity for vehicle electric system, and provides charge power supply for the
storage battery. The IC adjuster checks the input voltage at the No.4 port (“S” port) and thereby controls
the output voltage.
After the power-on and grounding, the charging alarm light will be on. When the electric generator can
provide high enough voltage, the ground circuit will be opened, and the charging alarm light will be off. If
the charging alarm light is still on when the engine is running, it has troubles.
2. Charging alarm light
If the following situations occur when the electric generator is working, the warming function of IC
adjuster will be actuated, and the charging alarm light will be turned on.
■ No or too high voltage is produced.
Exploded View of Charging System
1-Engine belt 2-Belt pulley of water pump 3-Electric generator 4-Belt pulley of crankshaft
129
1) Dismantlement
Fig. 2.2.017
① Disconnect the cathode terminal of storage
battery.
② Disconnect the harness connectors of electric

generator. Fig. 2.2.018
③ Dismount the outrigger set bolts of electric

generator and the kingpin bolts of electric Fig. 2.2.019
generator.
■ Tightening torque: set bolt: 20-25 N·m
kingpin bolt: 34-54 N·m
Fig. 2.2.020
④ Dismount the belt of electric generator. Please refer to the “Drive Belt” section.
⑤ Take off the electric generator from the vehicle.
130
2) Installation
■ Install it in the reversed order of dismantlement.
■ Before installing the electric generator, please check the belt tension of electric generator. Please
refer to the “Drive Belt” section.
Attention:
■ Tighten the nut of “B” port. Tightening torque: 10-12 N·m
Exploded View of Engine
1-Lock nut 2-Belt pulley 3-Spacer 4-Front end cover 5-Front bearing 6- Bearing cap 7-Bolt 8-Armature
9-Rear bearing 10-Stator 11-Seal gasket 12-Rectifier 13-Electric brush retainer
14-Guide sleeve of slip ring 15-Rear cover

131
1) Disassembly
Disassemble in accordance with the following order.
① Belt pulley
② Rear cover
③ Rectifier assembly
④ Separate front end cover assembly and rear cover assembly.
Attention:
■ Be careful not to damage the stator assembly.
① Armature check
Fig. 2.2.021
a. Resistance test
Resistance: about 2.0-2.5 Ω
■ If it is beyond the standard range, please

change the armature.
Slip ring
b. Insulator test
■ If electricity is conducted in the insulator, please change it.
c. Check the abrasion situation of slip ring.
■ If it is beyond the standard range, please change the slip ring.
② Carbon brush
a. Check whether the carbon brush can move The mark line of abrasion limit of
Fig. 2.2.022 electric brush
smoothly.
■ If not, please check and clean the carbon brush

support.
b. Check the abrasion situation of carbon brush.
■ If it exceeds the limit value, please change the carbon brush.

132
② Stator check
Check whether electricity is conducted between Lead

Fig. 2.2.023
the terminals.
■ If it is not conducted, please change the stator.
Ground test
Fig. 2.2.024 Lead
■ If electricity is conducted, please change the
stator.
Stator
core
3) Assemblage
① Rear bearing
Attention:
■ The rear bearing can not be reused again after being taken off. Please change it for a new one.
■ It is not allowed to lubricate the outer ring of rear bearing.
② Installation of rear cover

Fig. 2.2.025
a. Mount the carbon brushes assembly, the
adjuster assembly and the stator.
b. Push the carbon brushes with fingers, and install them on the stator.
Attention:
■ Be careful not to damage the slip surface of slip ring.
133
5. Trouble Diagnosis for Charging System
Before the electric generator test, confirm that the storage battery has been sufficiently charged. For the
test, a 30 V volt meter and a proper test probe are needed. Refer to the check table to check the electric
generator.
■ Before startup, check the fusible fuse.
■ Use a storage battery with full capacity.
Check Flow Chart of Charging System

Disconnect the Conduct the following
The ignition The alarm connector, and The alarm
check: 1. Bulb of
switch is on. light is off. ground the L-side light is off.
alarm light 2. Fuse of
harness. alarm light .
The alarm light is Conduct the following
on. check: 1. Armature 2.
The alarm light is Change the
Slip ring of armature
on. damaged IC
3. Electric brush.
regulator.
Conduct the
The engine starts
The alarm light is following check: The engine The alarm light
with a rev of 1500
on. 1. Armature runs at idle is off.
rpm.
2. Slip ring of speed.
armature 3. Normal.
Electric brush
The alarm light is
The alarm light is Normal.
on.
off.
The engine rev is Change the

More than 16.0 V.
2500 rpm. damaged IC
Measure the regulator.
voltage of B port. Less than 13.0 V.
Change the
Conduct the following
damaged IC
check: 1. Armature 2. Slip
regulator or
ring of armature 3. Electric
diode assembly.
brush 4. Stator.
Alarm light: the “charging” alarm light in the combined device.

Note:
■ If the charging system has trouble but the test results suggest normal, check the connection of “B”
port (check the tightening torque and voltage drop).
■ Check the conditions of armature coil, armature slip ring, electric brush and stator coil. If necessary,
change the spare parts out of order.
134
Electronic Control
Maintenance Manual of Tojoy Sedan System of Engine
Chapter III Electronic Control System of Engine

Section I Precautions
I. Precautions of Supplement Restraint System (SRS)

Using the SRSs like airbag and pretensioner of safety belt together with the front seat safety belt can
contribute to the reduction of the risk of injury or the hazard severity of driver and front passenger during
the crash. About the information of proper maintenance of the system, please refer to the “airbag” part of
the manual.
Caution:
■ All of the maintenance should be carried out by the franchised stores authorized by JAC in order to
avoid increasing the risk of the personal injury and death due to the SRS system failure.
■ Improper maintenances, including incorrect dismantlement and installation of SRS system, are
likely to cause the wrong action of the system resulting in the personal injury and death.
About the dismantlement methods of clock spring (hair spring) and airbag controller, please refer to the
airbag part.
■ Except for the operations illustrated in the manual, please don’t use the electrically testing
equipment to test any circuit of the airbag system. The air bag circuit harness can be identified by
the yellow or orange harness or harness connectors.
II. General Precautions
1. Only the digital electric meter is permitted to be used to check the electronic control system.
2. JAC genuine components should be used during the maintenance, otherwise it is impossible to
guarantee the normal operation of the system.
3. Only the unleaded petrol can be used during the maintenance and usage.
4. The standardized maintenance and diagnosis flow should be complied with to carry out the
maintenance.
5. The disassembly and dismantlement for the system components are prohibited during the
maintenance.
6. During the maintenance process, the electronic elements (electronic control module and sensor)
should be fetched and placed very carefully to avoid the fall of it.
7. Foster the awareness of environmental protection to effectively deal with waste of the maintenance
process.
III. Precautions in Maintenance
1. During the simulation of hot working conditions of trouble and other maintenance operations
possibly resulting in the temperature rise, never make the temperature of electronic control module
exceed 80℃.
2. The fuel pipe should not be dismantled casually during the course of maintenance. In case of the
need for maintaining the fuel system, it is necessary to carry out the pressure release for the fuel
135
Electronic Control
system before the dismantlement of fuel pipe.

3. The dismantlement of fuel pipe and the replacement of fuel filter should be carried out in the
well-ventilated place by the professional maintenance personnel.
4. The fuel injection pump is not permitted to run in dry state or water, otherwise its service life may be
shortened. In addition the positive and negative poles of the fuel injection pump can not be
reversed.
5. During the check for the ignition system, the sparking should be detected only when it is necessary
and the time should be as short as possible. The air throttle can not be opened during the check,
otherwise the copious unburned petrol may flow into the exhaust pipe, accordingly leading to the
damage of three-way catalyst.
6. The manual adjustment is unnecessary, because the idling regulation is completed solely by the
electronic fuel injection system. The throttle stop screw of air throttle body has been adjusted well by
the manufacturer before leaving the factory, and it is not permitted for the users to change its initial
position arbitrarily.
7. Do not test the input and output electric signal of components by puncturing the skin of lead wire.
IV. Precautions of On-board Diagnosis (OBD) System

The electronic control module (ECM) has an OBD system. The malfunction indicator lamp (MIL) would
light up when the OBD system is warning the driver of the malfunction caused by the aging of the
emission system.
Notes:
■ Be sure to turn the ignition switch to OFF position and disconnect the connecting wire of storage
battery cathode before carrying out the repair and check. The open circuit or short circuit of relative
switch, sensor and solenoid valve may make the MIL brighter.
■ After the operation, be sure to connect and firmly lock the connectors. Loose (unlocked) connector
may lead to the open circuit, accordingly making the MIL brighter. (confirming that there is no water,
lubricating grease and filth on the joint and port is not bent).
■ After the operation, be sure to arrange and fix the harness correctly. The interference between the
support and harness etc. may lead to the short circuit, accordingly making the MIL brighter.
■ After the operation, be sure to connect the rubber pipe well. The failed connection of the rubber pipe
may lead to the brightness of the MIL caused by the troubles of the EVAP system and fuel injection
system etc.
■ The unwanted trouble information in the ECM should be erased before delivering the vehicle to the
user (the repair is done).
■ Be sure to use the 12V storage battery as the power supply.
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Electronic Control
■ Don’t disconnect the connecting wire of storage battery when he engine is running.
■ Turn the ignition switch to OFF position and disconnect the connecting wire of storage battery
cathode before connecting or disconnecting ECM harness connectors. Otherwise the ECM may be
damaged, because even if the ignition switch is turned to OFF position, the ECM still has 12V
voltage.
■ Turn the ignition switch to OFF position and

Fig 3.1.001
disconnect the connecting wire of storage
battery cathode before dismounting the
components.
Storage
battery
■ Don’t disassemble the ECM.

■ If some storage battery cable is disconnected, the memorizer will return to the initial value of ECM.
The ECM will begin to control by itself according to the initial value. When the port of storage battery
is disconnected, the engine will operate a little differently, which doesn’t mean any trouble. Don’t
replace the components because of a little change.
■ When connecting the ECM harness
connectors, push the button pole (1) to the Fig 3.1.002
end to lock the (B) as shown in the Fig.
- ECM(2)
- Release (A)
■ Insert the contact pin connector into the ECM

Fig 3.1.003
or pull it out of the ECM and pay attention to Bent
avoid damaging the contact pin port (bent or
broken). When connecting the contact pin
connector, guarantee that the contact pin port
of ECM is not bent or broken.
■ Connect the harness connectors of ECM Broken

firmly. The poor connection will cause the
extremely high (fluctuation) voltage on the coil
and capacitor, accordingly leading to the
damage of IC.
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Electronic Control
■ The harness of the electronic control system of engine should be remained for a length of at least
10cm from the joint to avoid the trouble of the electronic control system of engine caused by
receiving the exterior noise signal and decreasing the operation of IC etc.
■ Keep the spare parts and harness of the electronic control system of engine dry.
■ Check with the ECM port and reference value to assure the normal function of ECM before
replacing the ECM.
■ Even the very little leakage in the intake system may lead to the severe trouble.
■ Don’t swing or vibrate the camshaft position sensor (phase) and the crankshaft position sensor
(position).
■ Operate the DTC validation procedures or the whole function check after running the trouble
diagnosis. If the repair process is finished, DTC should be shown in the validation procedures of
DTC. If the maintenance is finished, the whole function check should obtain a good result.
■ When measuring the ECM with the circuit tester, the contact between the two measuring devices is
not permitted. If the probes touch, the short circuit may occur and the power transistor of ECM may
be damaged.
■ When measuring the input/output voltages, don’t use the grounding port. Otherwise the transistor of
ECM may be damaged. Please use the port other than the ECM to ground.
■ When there is no fuel in the fuel pipe, don’t use the fuel pump.
■ Screw down the clamping collar of fuel hose to
the specified torque. Fig 3.1.004
■ Don’t press down the accelerator pedal when
starting the vehicle.
■ Don’t increase the rotating speed of engine
immediately after starting the vehicle.
■ Don’t speed up before shutting down the
engine.
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Electronic Control
Section II Structural Principle and Overhaul of Engine Control System

I. System Illustration
Engine Control System
1-Carbon canister 2-Carbon canister solenoid valve 3-Air throttle body assembly 4-Air throttle position
sensor 5-Stepper motor 6-Intake pressure and temperature sensor 7-Fuel injector 8-Camshaft position
sensor 9-Ignition coil 10-Front oxygen sensor 11-Three-way catalyst 12-Rear oxygen sensor 13-Engine
coolant temperature sensor 14-Crankshaft position sensor 15-Fuel filter 16-Electric fuel injection pump
17-Fuel tank 18-Diagnosis joint 19-Engine control module
II. Multiple-point Fuel Injection System
Multiple-point fuel injection (MPI) system comprises of the sensor detecting the operating conditions of
engine and the electronic control module (ECM) of engine.
The system is controlled based on the signals sent by these sensors and all of the actuators are
operating under the control of the ECM. ECM has the functions like fuel injection control, idle control and
ignition timing control etc. and some trouble diagnosis methods for simplifying the troubleshooting when
the trouble occurs.
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Electronic Control
2. Input/Output Signal
Input/Output Signal Table
Sensor Input Signal to ECM ECM Function Actuator
Crankshaft position sensor Rotation speed of
(position) engine
Camshaft position sensor (phase) Piston position
Intake pressure sensor
Intake quantity
Intake temperature sensor
Oxygen
Oxygen sensor concentration in the
Control of fuel
wasted air
injection and mix Fuel injector
Air throttle position sensor Air throttle position
proportion
Knock conditions of
Knock sensor
engine
Air conditioner
Air conditioner switch
pressure
Rotation speed sensor Vehicle speed
Engine coolant
Engine coolant temperature sensor
temperature
3. Starting Control
During the starting process, it is necessary to take the special calculation methods to control the air
quantity, fuel injection and ignition timing. In the beginning stage of the process, the air inside the intake
manifold is stagnant and the inner pressure of the air intake manifold is the atmospheric pressure. When
the air throttle is closed, the idle adjuster (idle stepper motor) is designated a fixed parameter depending
on the starting temperature. During the similar process, the specific "fuel injection timing" is designated
as the initial fuel injection pulse. Fuel injection quantity changes depending on the engine temperature to
promote the formation of the fuel film in the intake manifold and on the cylinder wall, therefore, before the
engine reaches a certain rotation speed, it is necessary to increase the concentration of the gas mixture.
Once the engine runs, the system immediately begins to reduce the starting concentration increase and
completely end the starting concentration increase when the starting operation conditions is finished
(600~700rpm). The ignition advance angle has been adjusted under the starting operation conditions
depending to the engine temperature, intake temperature and the rotation speed of engine.
4. Warm-up and Heating Control of Three-way Catalyst
After the engine is started at the low temperature, intake quantity of cylinder, fuel injection and electronic
ignition are all adjusted to compensate the higher requirement of the engine for the torque; this process
continues until the temperature is proper. During this process, the most important is the quick heating of
the three-way catalyst, because the fast transition to the three-way catalyst can markedly reduce the
emission. Under this operation condition, the “heat of the three-way catalyst” is carried out by postpone
the ignition advance angle properly and take advantage of the wasted gas.
5. Acceleration/Deceleration and Back-tow Fuel Cut Control
A part of the fuel injected into the intake manifold may fail to timely arrive in the burning process involving
the cylinder. Instead, it forms a layer of fuel film on the intake manifold wall. The fuel stored in the fuel
film may dramatically increase as the rise of load and the time extension of fuel injection. When the
opening of air throttle is increasing, part of the injected fuel is absorbed by the fuel film. Therefore, it is
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Electronic Control
necessary to inject the corresponding quantity of fuel for the complement and prevent the gas mixture
from getting thinner during the acceleration. Once the index of coincidence reduces, the additional fuel
contained in the fuel film on the intake manifold wall will re-release, and then it is necessary to reduce
the injection time accordingly during the acceleration. Back-tow or towing operation condition refers to
the situation that the power supplied by the engine at the fly wheel is negative value. At this time, the
engine friction and pumping gas loss can be used to make vehicles slow down. When the engine is in
the back-tow or towing operation condition, the fuel injection is cut off in order to reduce the fuel
consumption and the emission, but the more important is to protect the three-way catalyst. Once the
rotation speed decreases to the specific fuel supply recovery speed above the idle speed, the fuel
injection system will re-supply. In fact, ECM program has a rotation speed recovery range which
depends on the changes of such parameters as engine temperature, dynamic change of engine rotation
speed and can prevent the rotation speed from dropping to the specified minimum rotation speed by
calculation. Once the fuel injection system re-supplies the fuel, the system starts using the initial injection
pulse as the supply of fuel and re-builds the fuel film on the intake manifold wall. After the resumption of
fuel injection, torque-based control system makes the increase of engine torque slow and steady (slow
transition).
6. Idle Control
At the idle speed, the engine does not provide the torque to the fly wheel. To ensure the engine running
stably at the lowest possible idle speed, the closed-loop idle speed control system should keep the
balance between the generated torque and the "power consumption" of engine. The necessary power
should be generated during the idle time to meet the load requirements of all aspects, including the
internal friction from the engine crankshaft and valve mechanism, as well as the auxiliary components,
such as water pump. The system is based on the torque-based control strategy, that is, determining the
required output torque of engine to maintain the required idle rotation speed under any operating
conditions according to the closed-loop idle speed control. The output torque increases as the reduction
of the rotation speed of engine and decreases as the rise of the rotation speed of engine. The system
request the greater torque in response to the new "disturbance factors", such as the switching of the
air-conditioning compressor. When the engine temperature is decreasing, it is necessary to increase the
torque to compensate the greater internal friction loss and/or maintain the higher idle rotation speed. The
sum of all these required output torque is delivered to the torque coordinator to carry out the calculation
to get the corresponding intake density, gas mixture composition and ignition timing.
7. λClosed-loop Control
The post treatment of exhaust in the three-way catalyst is an effective way to decrease the concentration
of hazardous substance in the wasted gas. The three-way catalyst can decrease the HC, CO and NOX
by 98% or more and transform them into H2O, CO2 and N2. But this high efficiency can be achieved
only in a very narrow range near the excessive air factor of engine λ=1. The objective of the λ
closed-loop control is to ensure the gas mixture concentration at this range. λ closed-loop control system
functions only when equipped with the oxygen sensor. Oxygen sensor detects the oxygen content of the
wasted gas at the side of three-way catalyst. Rarefied gas mixture (λ> 1) produces a sensor voltage of
about 100mV and the concentrated gas mixture (λ <1) produces a sensor voltage of about 900mV. In
case of λ=1, the sensor voltage has a jump. λ closed-loop control responds to the input signal (λ>1= too
rarefied gas mixture, λ<1= too concentrated gas mixture) to revise the control variable and produce the
correction factor as a multiplier to correct the fuel injection duration.
8. Evaporation Exhaust Control
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Because of the transfer of the external radiation heat and oil return heat, the fuel inside the fuel tank is
heated to form the fuel vapor. Due to the limit of evaporative emission regulation, it is not permitted to
exhaust the vapor containing large quantity of HC composition directly into the atmosphere. The fuel
vapor in the system is collected in the active carbon canister through the conduit and flushed into the
engine at appropriate time to participate in the combustion process. Flushing air flow is controlled by the
control valve of control carbon canister of ECM. The control functions only when the λ closed-loop
control system is running under the closed-loop condition.
9. Fuel Injection Control
The fuel injection timing and impulse width should be controlled to provide the best mix proportion of
air/fuel to the engine corresponding to the everchanging operation condition of engine. The fuel injector
is installed at the inlet of every cylinder. The fuel is extruded from the fuel tank by the fuel pump and
delivered to each fuel injector. Normally, each cylinder injects fuel once when the crankshaft turns two
circles. The operating sequence of each cylinder is 1-3-4-2.
10. Ignition Timing Control
The primary current to the ignition coil is controlled by connecting and disconnecting the power transistor
of primary ignition circuit to regulate the ignition timing so that the best ignition timing can be provided
according to the operating conditions of engine. Ignition timing is determined by the ECM according to
the rotation speed of engine, intake quantity, engine coolant temperature and atmospheric pressure.
11. Self-diagnosis Function
When abnormal situation is detected by the sensor or actuator related to the exhaust control, the alarm
lamp of engine (inspection lamp of engine) lights up to inform the driver. The abnormal situation detected
by the sensor or actuator equals to the output of trouble diagnosis code of this kind of abnormal situation.
The RAM data inside the ECM related to the sensor and actuator can be read with the diagnosis
apparatus, and the actuator may be driven forcibly in some cases.
12. Other Control Functions
1) Fuel Injection Pump
Connect the relay of fuel injection pump to electrify the fuel injection pump when the crankshaft of engine
is beginning to rotate or rotating.
2) Fan Relay Control
The rotation speeds of the radiator fan and condenser fan is controlled according to the engine coolant
temperature, vehicle speed and air conditioner switch signal (AC).
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III. On-board Diagnosis System
1. Illustration
On-board diagnosis system (hereinafter referred to as OBD system) refers to the diagnosis system,
integrated in the engine control system, monitoring the trouble components affecting the emission as
well as the main function state of the engine. It is capable of identifying, storing and showing the trouble
information through the self-diagnosis malfunction indicator lamp (MIL).
2. Trouble Information Record
Electronic control module constantly monitors the sensor, actuator, associated circuit, malfunction
indicator lamp (MIL) and storage battery voltage etc. as well as even the electronic control module itself,
and carries out the credibility detection for the output signal of sensor, the drive signal of actuator and the
internal signal (such as λ closed-loop control, coolant temperature, idle rotation speed control and
storage battery voltage control etc.). Once a trouble is found in some link or a signal value is incredible,
the electronic control module immediately sets the trouble information record in the trouble memorizer of
the RAM. Trouble information record is stored according to the trouble code and shown based on the
order in which the troubles occurred.
The troubles can be divided into “steady-state trouble" and "sporadic trouble" according to their
occurrence frequencies (for example, because of short open circuit of harness or the poor contact of
connector).
3. Malfunction Indicator Lamp (MIL) Illustration and Its Control Strategy
1) Malfunction indicator lamp (MIL): the indicator required by the regulation for the emission-related
components or system failure. Generally, MIL is an indicator lamp can display on the console with
shape in line with the requirements of regulation and standard.
2) MIL should be activated following the principles below:
① In case of ignition switch in "ON" position (non-starting), MIL is continuously bright.
② Within the 3s after starting the engine, if there is no requirement in the trouble memory to light up the
MIL, MIL would extinguish.
③ When there is requirement to light up the MIL both in the trouble memory and the outside of the
ECM, MIL is lit.
④ When there is the requirement outside the ECM or in the trouble memory or due to the fire to blink
the MIL, MIL would blink under the frequency of 1Hz.
4. Overhaul steps
1) For the vehicles with OBD function, the overhaul in general should be carried out following the steps
below:
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OBD Overhaul Step Table
1. Connect the diagnosis test equipment to the

diagnosis connector to put through the
diagnosis test equipment.
2. Connect the “ignition switch”.
3. Read the trouble information (trouble code,

freeze frame): inquire in the maintenance
manual to confirm the trouble component and
type: draw up the maintenance plan according
to the trouble information and experiences.
4. Remove the trouble.
5. Eliminate the trouble memorizer: run the

vehicle properly following the corresponding
trouble diagnosis conditions: read the trouble
information and confirm the clearing of the
trouble.
2) Connection of Diagnosis apparatus:
The “K” line protocol and ISO9141-2 standard diagnosis joint are adopted for the system as shown in the
figure.
Standard Diagnosis Connector
This standard diagnosis joint is connected on the harness of engine steadily. The pins No 4, 7 and 16 of
the standard diagnosis joint are used for the electronic control system of engine. The pin No 4 of the
standard diagnosis joint is connected to the grounding wire: pin No 7 is connected to the pin No 15 of
ECM, that is, the data “K” line of the electronic control system of engine; pin No 16 is connected to the
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anode of the storage battery.
5. DTC Index
DTC Index Table of Trouble Diagnosis Code
Trouble Code Illustration (UAES)

P0030 Open circuit of heat control circuit of upstream oxygen sensor
P0031 Short circuit to ground of heat control circuit of upstream oxygen sensor
P0032 Short circuit to power supply of heat control circuit of upstream oxygen sensor
P0036 Open circuit of heat control circuit of downstream oxygen sensor
P0037 Short circuit to ground of heat control circuit of downstream oxygen sensor
P0038 Short circuit to power supply of heat control circuit of downstream oxygen sensor
P0053 Unreasonable heat internal resistance of upstream oxygen sensor
P0054 Unreasonable heat internal resistance of downstream oxygen sensor
P0105 Unchangeable signal of intake pressure sensor
P0106 Unreasonable signal of intake pressure sensor
P0107 Short circuit to ground of intake pressure sensor
P0108 Short circuit to power supply of intake pressure sensor
P0112 Too low signal voltage of intake temperature sensor
P0 13 Too high signal voltage of intake temperature sensor
P0 16 Unreasonable signal of engine coolant temperature sensor
P0117 Too low circuit voltage of engine coolant temperature sensor
P0118 Too high circuit voltage of engine coolant temperature sensor
P0122 Air throttle position sensor circuit voltage below minimum limit
P0123 Air throttle position sensor circuit voltage above maximum limit
P0130 Unreasonable signal of upstream oxygen sensor
P0131 Too low signal circuit voltage of upstream oxygen sensor
P0132 Too high signal circuit voltage of upstream oxygen sensor
P0133 Aging of upstream oxygen sensor
P0134 Signal trouble of upstream oxygen sensor circuit
P0136 Unreasonable signal of downstream oxygen sensor
P0137 Too low voltage of signal circuit of downstream oxygen sensor
P0138 Too high voltage of signal circuit of downstream oxygen sensor
P0140 Signal trouble of downstream oxygen sensor circuit
P0170 Unreasonable self-learning of closed-loop control of off-line detection air-fuel ratio
P0171 Too diluted self-learning of closed-loop control of off-line detection air-fuel ratio
P0172 Too concentrated self-learning of closed-loop control of off-line detection air-fuel ratio
P0201 Open circuit of fuel injector control circuit of cylinder No. 1
P0261 Short circuit to ground of fuel injector control circuit of cylinder No. 1
P0262 Short circuit to power supply fuel injector control circuit of cylinder No. 1
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P0265 Short circuit to power supply of fuel injector control circuit of cylinder No. 2
P0300 Accidental fire of multiple cylinders
P0301 Accidental fire of cylinder No. 1
P0317 Trouble of ABS signal for detecting damaged circuit
P0318 Trouble of sensor signal for detecting damaged circuit
P0321 Trouble of reference point of rotation speed
P0322 No crankshaft position sensor pulse signal (open circuit or short circuit)
P0327 Too low voltage of knock sensor signal circuit
P0328 Too high voltage of knock sensor signal circuit
P0340 Improper mounting position of camshaft position sensor
P0341 Poor contact of camshaft position sensor
P0342 Short circuit to ground of camshaft position sensor
P0343 Short circuit to power supply of camshaft position sensor
P0420 Aging of oxygen storage capability of three-way catalyst (emission exceeding limit)
P0444 Open circuit of control circuit of carbon canister solenoid valve
P0458 Too low voltage of control circuit of carbon canister solenoid valve
P0459 Too high voltage of control circuit of carbon canister solenoid valve
P0480 Open circuit of control circuit of cooling fan relay (low speed)
P0481 Open circuit of control circuit of cooling fan relay (high speed)
P0501 Unreasonable signal of speed sensor
P0506 Controlled rotation speed of idle below target idle
P0507 Controlled rotation speed of idle above target idle
P0508 Short circuit to ground of drive pin of stepper motor
P0509 Short circuit to power supply of drive pin of stepper motor
P0511 Open circuit of drive pin of stepper motor
P0532 Too low voltage of air conditioner pressure sensor circuit
P0533 Too high voltage of air conditioner pressure sensor circuit
P0537 Too low voltage of temperature sensor circuit of air conditioner evaporator
P0538 Too high voltage of temperature sensor circuit of air conditioner evaporator
P0560 Unreasonable voltage signal of system storage battery
P0562 Too low voltage of system storage battery
P0563 Too high voltage of system storage battery
P0602 Coding trouble of electronic control module
P0627 Open circuit of control circuit of fuel injection pump relay
P0628 Short circuit to ground of control circuit of fuel injection pump relay
P0629 Short circuit to power supply of control circuit of fuel injection pump relay
P0645 Open circuit of control circuit of A／C compressor relay
P0646 Short circuit to ground of control circuit of A／C compressor relay
P0647 Short circuit to power supply of control circuit of fuel injection pump relay
P0650 Trouble of drive circuit of MIL
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P0691 Short circuit to ground of control circuit of cooling fan relay

P0692 Short circuit to power supply of control circuit of cooling fan relay
P0693 Short circuit to ground of control circuit of cooling fan relay (high speed)
P0694 Short circuit to power supply of control circuit of cooling fan relay (high speed)
P 1651 Trouble of drive circuit of SVS lamp
P2177 Self-learning value of closed-loop control of air-fuel ratio above upper limit
P2178 Self-learning value of closed-loop control of air-fuel ratio below lower limit
P2195 Aging of upstream oxygen sensor (diluted)
P2196 Aging of upstream oxygen sensor (concentrated)
P2270 Aging of downstream oxygen sensor (diluted)
P2271 Aging of downstream oxygen sensor (concentrated)
IV. Engine Trouble Diagnosis

1. Trouble Overhaul General of Control System of Engine
The discontinue of fuel supply or the failure to provide the correct fuel quantity for the different operating
conditions due to the failure of sub-assemblies of electronic control system of engine (sensor, ECM and
fuel injector etc.) will lead to the following situations:
a. Starting hardship or failure of engine
b. Unstable idle
c. Poor driving performance
If any of these situations occurs, first of all, carry out the conventional detections including the basic
check of engine (ignition system trouble and correct adjustment of engine etc.). Then use the trouble
diagnosis apparatus to check the sub-assemblies of the electronic control system of engine.
Attention:
■ Before dismantling and installing any component, first of all, read the trouble code, and then
disconnect the terminal of the storage battery cathode.
■ Before disconnecting the harness from the storage battery terminal, first turn off the ignition switch.
When the engine is running or the ignition switch is turning on, disconnecting the harness of storage
battery would lead to the damage of ECM.
■ The harness between the ECM and sensor should be shielded by the grounding wire connected to
the vehicle body in order to prevent the interference from the ignition system and radio. If the
shielded harness fails, the harness should be replaced.
■ When checking the charging state of engine, don’t disconnect the anode of the storage battery to
prevent the damage of ECM.
■ When using the outside charger to charge the storage battery, it is necessary to disconnect the
connecting wire of storage battery to prevent the damage of ECM.
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2. Trouble Diagnosis Flow Chart
The check starts
1. Acquire the symptom information

Ask the user for more information associated with symptom
1. Check the DTC

Check DTC and print DTC and freeze frame User described the
User described the
data, and check the related maintenance record symptom and
symptom and the
apparatus did not
apparatus displayed the
User did not show the DTC
DTC
describe the
2. Recognize the symptom symptom, but 4. Recognize the symptom
Attempt to diagnose the apparatus Attempt to diagnose the symptom
symptom described by the user. displayed the described by the user.
DTC.
5. Implement the confirmation steps of DTC. 6. Implement the basic check.
Do not use the trouble diagnosis apparatus Use the trouble

diagnosis apparatus
Within the scope
of technical 7. Run the trouble diagnosis &
9. Use the trouble parameters
check mode
symptom table to check
the troubled system Beyond the scope of
the technical
No troubled parameters
component found
8. Check the troubled
10. Check the troubled component through the component
diagnosis steps
Troubled component
found
Abnormal (DTC detected)
11. Repair or replace the troubled components
12. Final check Abnormal (symptom

Confirm no symptom found still exists)
Implement the “DTC confirmation steps” again,
and be sure to maintain the trouble properly.
Normal
The check ends
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3. Trouble Symptom Check Table
Trouble Symptom Check Table
Trouble Symptom Check Order No.

Unable to communicate with Unable to communicate with all the systems 1
diagnosis apparatus Only unable to communicate with ECM 2
Engine alarm lamp failed to light up immediately after the
Engine alarm lamp and 3
ignition switch is turned to ON.
corresponding element
Engine alarm lamp keeps bright 4
No initial ignition (unable to start) 5
There is initial ignition but it burns incompletely (unable to
Start 6
start)
Too long starting duration (unable to start normally) 7
Unstable idle (fluctuant idle speed and hunting) 8
Idling Stability (abnormal idle speed) High idle speed (abnormal idle speed) 9
Low idle speed (abnormal idle speed) 10
The engine extinguishes at the idle when it is cold.
11
(extinguishing at the deceleration)
The engine extinguishes at the idle when it is hot.
Idle Stability (extinguishment of 12
(extinguishing at the deceleration)
engine)
The engine extinguishes at the start. (extinguishing at the
13
acceleration)
The engine extinguishes during the deceleration 14
Vehicle surge, drop or instability of vehicle speed 15
Shock or vibration during the acceleration 16
Shock or vibration during the deceleration 17
Drive
Poor acceleration 18
Surge 19
Knock 20
Failure of extinguishment 21
Too high concentration of CO and HC at the idle operation 22
Low voltage of AC generator 23
Abnormal idle when starting the air conditioner 24
Abnormal operation of fan 25
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4. Trouble Symptom Table
Trouble Symptom Table
Items Symptom
Starter drags the engine, but there is no combustion inside the cylinder and the
Failure of starting
engine does not start.
Start Extinguishment after
There is combustion inside the cylinder, but the engine extinguishes immediately.
combustion
Hardship of starting Engine starts after the crankshaft rotates a while.
Engine does not maintain a constant speed and the speed changes within the
Hunting
range of idle speed.
Usually, it can be determined with the swing of tachometer pointer and the
Fluctuation of idle
vibration passed to the steering wheel, selector rod and body etc.
Stability Incorrect idle Engine is running idly at the incorrect rotation speed.
of idle Extinguishment of engine
When releasing the accelerator pedal, no matter whether the vehicle is moving,
speed (extinguishment during
the engine extinguishes.
deceleration)
Extinguishment of engine
When the accelerator pedal is depressed or being depressed, the engine
(extinguishment during
extinguishes.
acceleration)
The phenomenon of “vehicle breath” refers to that the vehicle speed (rotation
Vehicle surge, drop of speed of engine) is corresponding slow when there is a need to accelerate and
vehicle speed depress down the accelerator pedal at the current vehicle speed or the temporary
decline of vehicle speed (rotation speed of engine) during the acceleration.
Poor acceleration refers to that the vehicle is unable to acquire the acceleration
capability changing with the opening of air throttle, even if it remains a stable
Poor acceleration
acceleration, it is still the trouble; or refers to the disability to reach the maximum
Driving
vehicle speed.
When firstly depressing down the accelerator pedal to speed up, the rotation
Instability
speed of engine increases slowly.
Shock There is huge shock or vibration when the engine is accelerating or decelerating.
Surge There is repeatedly forward surge when traveling at a constant or variable speed.
There is a strong voice like the hammer against the cylinder wall during the driving
Knock
which is harmful to the moving.
Keep running(failure of
Parking
extinguishment)
5. Basic Trouble Check
When checking the engine trouble, first of all, it should begin from the basic system. If the starting failure
of engine, unstable idle or insufficient fuel supply occurs, it is necessary to start checking the following
basic systems:
a. power supply: storage battery, fusible link and fuse wire
b. Grounding wire
c. Fuel supply: fuel pipe, fuel filter and fuel pump
d. Ignition system: ignition plug, high tension line and ignition coil.
e. Emission control system: PCV system and vacuum leakage.
f. Others: ignition timing and idle.

The trouble of electronic control system of engine is generally caused by the poor contact of the harness
connector. All the harness connectors should be checked to verify whether they are connected correctly.
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6. Check of Idling Rotation Speed
1) Check Conditions
Attention:
■ Check the conventional items like ignition plug, fuel injector and compression pressure of the
cylinder before carrying out the check.
① The engine coolant temperature is 80~95℃.
② Lamps, electronic fan and all the accessories are turned off.
③ Gearbox is at neutral position.
④ The steering wheel is at the medial position (equipped with power steering system).
2) Connect the diagnosis apparatus.
3) Start the engine and run it at the lowest idle speed.
4) Run the engine for over 5s when the rotation speed is 2000~3000r/min and then make the engine
operate for 2min at the idle speed.
5) Read the idle rotation speed (1.3L:750±50r/min; 1.5L: 750±100r/min).
7. Fuel Pressure Test
Attention:
■ Before disconnecting the fuel pipeline, it is necessary to release the fuel pressure inside the fuel
pipeline to eliminate the danger.
■ It is necessary to consistently use the O-ring to keep the seal of the connecting joint of fuel hose.
■ Don’t operate the electrical system when carrying out the check.
Note: Prepare a container under the fuel pipe which is about to be disconnected to avoid the fuel
spillage.
1) Release the fuel pressure to zero. Please refer to “Release of Fuel Pressure”.
2) Dismount the nut at fuel pressure inspection port on the guide rail of fuel injector.
3) Connect the fuel pressure gauge.
4) Turn the ignition switch to the “ON” position to check for the fuel leakage.
5) Start the engine and make it run at the idle speed to check for the fuel leakage.
6) Read the value on the fuel pressure gauge.
■ Fuel pressure: 350KPa
Attention:
■ Don’t check the fuel pressure when the system is operating.
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■ When checking the fuel pressure, it is necessary to confirm whether there is fuel leakage in the fuel
pipeline.
7) If the measured fuel pressure is more than the standard value, analyze the possible reasons based
on the following table and carry out the necessary repairs.
Fuel System Trouble Diagnosis Table 1
Phenomenon Possible Cause Troubleshooting

Blockage of fuel filter Replace the fuel filter
Too low fuel pressure Poor seal of fuel pressure adjuster leading to the fuel Replace the fuel
leakage at the fuel return side injection pump
Replace the fuel
Cementation of fuel pressure
injection pump
Too high fuel pressure
Repair or replace the
Blockage or bend of fuel return pipe
fuel pipe
8) Shut down the engine and check the changes of fuel pressure gauge reading for 5min. If the reading
of fuel pressure gauge drops, observe the reduction rate. Press down the gauge to analyze and
eliminate the trouble.
Fuel System Trouble Diagnosis Table 2
Phenomenon Possible Cause Troubleshooting

Slow drop of fuel pressure after the
Leakage of fuel injector Replace the fuel injector
extinguishment of engine
Complete drop of fuel pressure after the Replace the fuel injection
Trouble of fuel injection pump
extinguishment of engine pump
9) Reduce the pressure inside the fuel pipeline.
10) Disconnect the fuel pressure gauge and install the inspection port nut.
11) Check for the leakage of fuel through the following steps.
① Turn the ignition switch to the "ON" position (extinguishment of engine), and then check for leakage
at the joint of the fuel pipeline.
② Start the engine and increase the rotation speed, and confirm whether there is the leakage at the
joint of fuel system.
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Section III Structural Principle and Overhaul of Engine Electronic Elements

I. Intake Manifold Absolute Pressure (MAP) Sensor
1. Element Illustration
1) The sensor is composed of the intake manifold absolute pressure and intake temperature sensors.
2) The intake manifold absolute pressure (MAP) sensor is a voltage-dependent variable resistance
which measures the pressure change in the intake manifold leading to the changes of engine load
and speed, and transforms it into a voltage output. MAP sensor is also used to measure the
atmospheric pressure when starting the vehicle, and under certain conditions, permit the ECM to
adjust automatically at different altitudes. ECM provides the voltage of 5V to the MAP sensor and
receives the voltage through the signal wire. The sensor provides a grounding wire through its
variable resistance. The input signal of MAP sensor affects the control of fuel output and ignition
timing by the ECM.
3) The intake temperature sensor is a thermal resistance with the negative temperature coefficient
(NTC), and the resistance value decreases with the rise of intake temperature. The sensor conveys
to the controller a voltage representing the changes of intake temperature.
2. Installation Position of Element

Fig. 3.3.001
It is installed on the intake manifold
3. Circuit Diagram of Element

Fig. 3.3.002
Pin 1: grounding
Pin 2: output the temperature signal
Pin 3: power supply 5V
Pin 4: output the pressure signal
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4. Element Check
1) Disconnect the connector of wire harness to check the resistances of pin 1 and pin 2 of element.
■ Rated resistance at 20 ℃: 2.5kΩ±5%
2) Check the voltage of pin 4 of element.
■ Voltage is about 1.3V at idle speed.
■ In case of no load, there is a little change in voltage after slowly opening the air throttle; voltage
instantaneously climbs up to about 4.0V after quickly opening the air throttle and drops down to
around 0.8V after quickly closing the air throttle and finally maintains at about 1.3V.
■ If the voltage is not within the range, please check whether the system leaks or is blocked; replace
the sensor if necessary.
1) Dismantlement
① Disconnect the wire harness connectors of intake

Fig. 3.3.003
manifold pressure & temperature sensors.
Attention:
■ confirm the ignition switch is at the “Off” position.
② Dismantle the fastening bolts of intake manifold

Fig. 3.3.004
pressure & temperature sensors and take off the
intake pressure & temperature sensors.
■ Tightening torque: 4～6N·m
Attention:
■ Pay attention to the position of seal ring during

the dismantlement, and don’t damage or miss the
seal ring.
2) Installation
Pay attention to the following items and install in the reverse order with dismantlement.
■ Apply a small amount of engine oil to the seal ring of sensor in order to facilitate the installation.
■ Confirm the complete joint of sensor and intake manifold.
■ Confirm the reliable installation of wire harness connector.
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II. Engine Coolant Temperature (ECT) Sensor
The engine coolant temperature sensor is used to detect the engine coolant temperature and send the
signal to the ECM. The engine coolant temperature sensor uses a thermal resistance with the negative
temperature coefficient, the resistance value of which decreases with the rise of temperature. ECM
determines the coolant temperature through the output voltage of sensor and provides the gas mixture
with the best air-fuel ratio to the engine.

Fig. 3.3.005
It is installed on the casing of the thermostat.
Pin 1: Grounding
Fig. 3.3.006
Pin 2: Output the temperature signal
4. Element Check
Make the temperature induction part of the engine coolant temperature sensor immersed into the hot
water and check the resistance value between pin 1 and pin 2.
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Resistance Value Specification Table of Coolant Temperature Sensor
Resistance Value (kΩ)

Temperature
No. Temperature Tolerance ±1℃ Temperature Tolerance ±0℃
(℃)
Minimum Maximum Minimum Maximum
1 8.16 10.74 8.62 10.28 -10
2 2.27 2.73 2.37 2.63 +20
3 0.290 0.354 0.299 0.345 +80
■ If the resistance value is not within the range, please replace the sensor.
1) Dismantlement
Fig. 3.3.007
① Discharge the engine coolant in the radiator. Please
refer to "Replacement of Engine Coolant".
② Disconnect the wire harness connector of the engine

coolant temperature sensor.
③ Dismantle the engine coolant temperature sensor. Fig. 3.3.008

2) Installation
Pay attention to the following steps and install in the reverse order with dismantlement.
■ Apply LT648 or equivalent product to the thread part of sensor and screw it down according to the
specified torque.
■ Start the engine and make it run at idle speed and check for the leakage of engine coolant visually.
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III. Air Throttle Position Sensor (TPS)
The air throttle position sensor is a rotationally variable resistance which rotates with the air throttle shaft
to sense the angle of air throttle. When the shaft of air throttle rotates, the angle of air throttle of TPS is
changing. ECM detects the opening of air throttle according to the output signal of TPS.

Fig. 3.3.009
It is installed on the air throttle body

Fig. 3.3.010
Pin 1: grounding
Pin 2: 5V power supply
Pin 3: output signal
4. Element Check
Note: when checking the resistance value, it is necessary to disconnect the wire harness connector of
sensor.
1) Check the resistance value between pin 1 and pin 2.
■ Resistance value: 2kΩ~20％ (at room temperature)
2) Check the resistance value between pin 1 and pin 3. When rotating the air throttle, the resistance
value should vary linearly with the opening of the air throttle.
3) Check the resistance value between the pin 2 and pin 3. The resistance value is the opposite.
Note: when observing the changes of resistance value, notice whether there is a huge jump of resistance
value.
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4) Check the voltage of pin 2.
Note: At this point, ignition switch is turned to the "ON" position but the engine is not started.
■ Reference voltage is 5.0V.
5) Check the voltage of pin 3.
Note: At this point, ignition switch is turned to the "ON" position but the engine is not started.
① when the air throttle is fully closed, its voltage is about 0.4V.
② when the air throttle is fully opened, its voltage is about 4.0V.
1) Dismantlement
① Disconnect the wire harness connector of air throttle position sensor.
Note: Make sure that the ignition switch is at the “Off” position.
② Dismantle the air throttle body assembly.

Fig. 3.3.011
③ Dismantle the fastening bolts of the air throttle

position sensor to take off the sensor.
2) Installation
■ Tightening torque: 1.5～2.5N·m
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IV. Camshaft Position Sensor (CMP)
The camshaft position (phase) sensor is Hall type, which is used to sense the stop point position of first
cylinder at the compression stroke. ECM determines the sequence of fuel injection according to the CMP
signal.
2. Installation Position of Element Fig. 3.3.013

It is installed at the rear end of the cylinder cover
and on the end cap of camshaft.
3. Circuit Diagram of Element Fig. 3.3.014

Pin 1: grounding
Pin 2: signal output
Pin 3: 5V reference voltage
4. Element Check
1) Check the output voltage of camshaft position

sensor.
Output Signal Table of Camshaft Position Sensor
Operating Conditions of Engine Idle Speed 3000r/min

Output Signal 0~B+(5~8Hz) 0~B+(24~26Hz)
2) Use the voltage range of multimeter to check the voltage between the pin 3 and pin 1.
Note: At this point, ignition switch is turned to the “ON” position but the engine is not started.
■ The reference voltage is 12V or 5V (depending on the vehicle model).
3) Use the vehicle oscilloscope to check whether the signal of pin 2 is normal, which should be the
square-wave signal.
Note: Start the engine to check.
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Electronic Control

Fig. 3.3.015
1) Dismantlement
① Disconnect the PCV pipe and CMP wire

harness connector.
② Dismantle the fastening bolt of CMP sensor to

take off the CMP sensor.
2) Installation
■ Pay attention to the Installation gap.
Standard value: 0.8～1.2mm
■ Tightening torque:7.8～9.8N·m
V. Crankshaft Position Sensor (CKP)
Crankshaft position (rotating speed of engine) sensor is magnetic-electric type and composed of the
magnet and coil. The voltage signal of the crankshaft position sensor is sent to ECM and used to
determine the rotating speed of engine and the location of crankshaft.
It is installed on the plane of the fly wheel at the

Fig. 3.3.016
rear of engine.
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Electronic Control
Fig. 3.3.017
Pin 1: Signal wire A
Pin 2:Signal wire B
Pin 3: Shielded wire
4. Element Check
1) Disconnect the wire harness connector to

check the resistance value between pin 2 and
pin 3.
Resistance value:731～989Ω
2) Check the gap between the crankshaft position sensor and the tooth tip of signal disk.
Standard gap: 0.8～1.2mm
3) Check the signal of crankshaft position sensor.
Note: use the vehicle oscilloscope to check when the engine is starting.
Test waveform (AC signal) figure is as follows:
Waveform Figure of Crankshaft Position Sensor

Fig. 3.3.018
1) Dismantlement
① Disconnect the CKP sensor wire harness

connector.
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② Dismantle the fastening bolts of CKP sensor Fig. 3.3.019

to take off the CKP sensor.
2) Installation
■ Pay attention to the installation gap of CKP sensor.
■ It is necessary to first press in the CKP sensor, and then screw it down according to the specified
torque.
VI. Heated Oxygen Sensor (HO2S)
Heated oxygen sensor oxygen senses the oxygen 图 3.3.020
Fig. 3.3.020
concentration in the exhaust and then transforms it into
the voltage signal and sends such signal to the ECM.
When the air-fuel ratio is higher than the theoretical
value, the output voltage of heated oxygen sensor is
about 900mV; when the air-fuel ratio is lower than the
theoretical value (the oxygen concentration in the
exhaust is too high), the output voltage of oxygen
sensor is approximately 100mV. ECM controls the fuel
injection based on these signals in order to maintain an
appropriate air-fuel ratio.

Fig. 3.3.021
The front (upstream) oxygen sensor is installed on the
exhaust manifold before the three-way catalyst and the
rear (downstream) oxygen sensor installed behind the
three-way catalyst.
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Pin 1: anode of heated power supply
Pin 2: cathode of heated power supply
Pin 3: signal grounding
Pin 4: signal
Downstream oxygen sensor and upstream oxygen

sensor
4. Element Check
1) Check the voltage between the pin 3 and pin 4.
At the idle speed, when the oxygen sensor reaches its normal operating temperature of 350 ℃, carry out
the check. At this time, the voltage should be fluctuating quickly within 0.1~0.9V.
2) Check the resistance value of pin 1 and pin 2.
Note: it is necessary to disconnect the wire harness connector of the sensor when carrying out the
check.
■ Resistance value: 2.5～4.5Ω

Fig. 3.3.023
1) Dismantlement
① Disconnect the oxygen sensor wire harness
connector.
② Dismantle the oxygen sensor with the special socket.

Attention:
■ Use the hairless cotton to block the mounting hole of the oxygen sensor to keep the debris or oil &
water away from the exhaust manifold.
■ Check the appearance of oxygen sensor.
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Reddish brown: lead poisoning
Off-white: normal
Black: carbon deposition
2) Installation
■ Pay attention to the trend of wire harness of oxygen sensor.
VII. Fuel Injector (INJ)
The fuel injector injects the fuel according to the signal sent by the ECM and determines the fuel
injection volume through the opening time of the fuel injector solenoid valve.

Fig. 3.3.024
It is installed on the fuel guide rail.
Fig. 3.3.025
Pin 1: power supply (anode)
Pin 2: control (cathode)
1st cylinder 2nd cylinder 3rd cylinder 4th cylinder
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4. Element Check
Attention:
■ Please use the special cleaning and analysis instruments for fuel injector under a certain cycle to
clean and analyze the fuel injector.
1) Check the resistance.
Note: check after disconnecting the wire harness connector.
■ Standard resistance value: 11-16Ω
2) Use the trouble diagnosis apparatus to check the operating time of the fuel injector.
■ Standard operation time: 2.O～3.0ms at the idle speed and more during the acceleration.
3) Check the operating sound of fuel injector.
Note: Use a stethoscope to check the click sound of the fuel injector at the idle speed or use the fingers
to check the vibration situation of the fuel injector.
If the vibration can not be felt, check the wire harness connector, fuel injector or the control signal about
fuel injector by ECM.
Please refer to the “Fuel System”.
VIII. Stepper Motor (IAC)
ECM controls the number of moving steps of stepper motor by controlling the times of changing the coil
current direction in order, so as to adjust the cross-sectional area of bypass channel and the air flow.

Fig. 3.3.026
It is installed on the air throttle body
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Pin A:ECM pin 22
Pin B:ECM pin 21
Pin C:ECM pin 35
Pin D:ECM pin 36
4. Element Check
1) Resistance Check
Note: disconnect the wire harness connector to carry out the check.
■ Rated resistance: 53±5.3Ω
■ Self-learning method: turn on the ignition switch, but don’t start the engine immediately, wait for 5s
to start the engine.
If it is found at this time that the idle of engine is poor, it is necessary to repeat the above steps.

Fig. 3.3.028
1) Dismantlement
① Disconnect the wire harness connector and dismantle
the fastening bolts of stepper motor.
② Take off the stepper motor
Attention:
■ It is not permitted to impose any form of the axial force
for trying to push in or pull out the shaft.
2) Installation
■ Before installing the idle adjuster of the stepper motor into the air throttle body, the shaft should be in
the fully retracted position.
■ Pay attention to the cleaning and maintenance of the by-pass air passage.
■ After dismantling the storage battery or ECM, pay attention to the self-learning of the stepper motor.
■ Tightening torque: 4.0±0.4Nm
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IX. Knock Sensor (KS)
The knock sensor is installed on the side surface of cylinder body to sense the deflagration of engine.
The deflagration is provided to the piezoelectric element in the form of vibration and pressure. And then
the vibration and pressure are transformed into the voltage signals and sent to the ECM. If the engine
deflagration occurs, it is necessary to prevent the deflagration by delaying the ignition time.

Fig. 3.3.029
It is installed on the side surface of cylinder body.
3. Element Check
1) Circuit Diagram of Element。
Pin 1: signal A terminal
Pin 2: signal B terminal
Pin 3: shielded wire
2) Check the resistance.

Fig 3.3.030
resistance value: 5MΩ
4.Dismantlement and Installation
1) Dismantlement
① Disconnect the wire harness connector of knock

sensor.
② Dismantle the fastening nuts of knock sensor to

take off the knock sensor, as shown in Fig. 3.3.029. Fig. 3.3.031
Attention:
■ Don’t drop or damage the sensor.
2) Installation
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X. Air Conditioner Switch and Relay
When the air conditioner is turned on, the switch of air conditioner delivers the voltage signal of storage
battery to the ECM. When the signal representing that the air conditioner is turned on is input, ECM
drives the stepper motor to enhance the idle speed of engine and correct the advance angle of ignition.
ECM simultaneously controls the action of the relay of air conditioner so that the electromagnetic clutch
of compressor is operating.
2. Element Check
When the engine is running at the idle speed, the trouble diagnosis apparatus should be used to check
whether the switch of air conditioner is normal.
Check Table of Air Conditioner Switch
Check Items Switch of Air Conditioner Normal Indications

Off Off
Switch of Air Conditioner
On On
Compressor of Air Off Off (Compressor clutch doesn’t operate)
Conditioner On On (Compressor clutch operates)
XI. Carbon Canister Solenoid Valve
The carbon canister solenoid valve is used to control the flow of fuel steam in the carbon canister.
Operating principle: refer to “Fuel Evaporation System”.

It is installed at the side of intake manifold.
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Fig. 3.3.033
Pin 1: output end of main relay
Pin 2: control signal of ECM
4. Element Check
Fig. 3.3.034
1) Check the resistance between pin 1 and pin 2.
■ Rated resistance: 22～30Ω
1) Dismantlement
① Disconnect the hose at the side of carbon canister

solenoid valve.
② Disconnect the wire harness connector of carbon

canister solenoid valve. Fig. 3.3.035
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③ Disconnect the hose at the side of carbon

Fig. 3.3.036
canister.
④ Take off the carbon canister solenoid valve

Fig. 3.3.037
from the retainer.
2) Installation
■ The airflow direction should meet the requirement during the installation.
■ It is necessary to try to keep the water and oil away from the valve during the dismantlement and
installation.
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XII. Ignition Coil
When the ignition power transistor is turned on through the signal from the ECM, ECM delivers the signal
to the ignition coil, and then the current of the primary coil is cut off and a high voltage is generated in the
secondary coil.

It is installed at the upper end of valve chamber
cover.

Fig. 3.3.039
1) Ignition coil No. 1 (cylinders 1 to 4)
Primary winding pin +: main relay
Primary winding pin -:
Pin No.3 of ECM
2) Ignition coil No. 2 (cylinders 2 to 3)
Primary winding pin +: main relay
Primary winding pin -:
Pin No.7 of ECM
4. Element Check
1) Check the resistance value of winding with the

ammeter.
Note: Check after disconnecting the wire harness connector of element.
■ Resistance value of primary winding: 0.77～0.95Ω
■ Resistance value of secondary winding: 7.57～10.23kΩ。
Dismantlement and Installation: refer to “Ignition System”.
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XIII. Electric Fuel Pump
It is used to deliver the fuel to the main fuel supply pipe from the fuel tank at a certain fuel pressure and
flow, and maintain the stable fuel pressure (through the fuel pressure adjuster).
It is installed inside the fuel tank
Pin illustration: the electric fuel pump has two pins, and the fuel pump casings next to the two pins are
marked with "+" and "-" signs, which represent respectively the connections to the anode (fuel pump
relay) and ground.
Fig. 3.3.040
4. Element Check
1) Check the internal resistance of fuel pump.
Its internal resistance is not zero or infinity.
2) Check the fuel pressure
Refer to “Fuel System”.
Refer to “Fuel Pump Assembly”.
Attention:
■ In order to prevent the accidental damage of fuel pump, please do not run the fuel pump at the
fuel-free state.
■ When there is a need to replace the fuel pump, please pay attention to the cleaning of fuel tank and
pipeline, and the replacement of fuel filter.
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XIV. Electronic Control Module (ECM) of Engine
1) Function
■ Multi-point fuel sequence injection control
■ Ignition control
■ Idle control
■ Provide the power supply of sensor: 5V/100mA
■ λ closed-loop control with self-adaptation
■ Carbon canister solenoid valve control
■ Switch of air conditioner
■ Malfunction indicator lamp of engine
■ Fuel ration correction
■ Output of rotating speed signal of engine (TN signal)
■ Input of speed signal
■ Self-diagnosis of trouble
■ Receipt of load signal of engine,
And so on.
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2) Definitions of ECM Pins:
Definition Table of ECM Pins
Pin Function Code Pin Function Code

1 Reserved Q1 33 Reserved D2
2 Heating of upstream oxygen sensor P1 34 Reserved C2
3 Ignition coil 1 Q2 35 Terminal C of stepper motor B2
4 Heating of downstream oxygen sensor P2 36 Terminal D of stepper motor A2
5 Ignition grounding Q3 37 Carbon canister solenoid valve O3
6 Reserved P3 38 Reserved N3
7 Ignition coil 2 Q4 39 Sensor grounding 1 M3
8 Non-durative power supply P4 40 Sensor grounding 2 L3
9 Output of rotating speed of engine O1 41 Engine coolant temperature K3
10 Pressure switch of air conditioner N1 42 Camshaft position (phase) sensor J3
11 Reserved M1 43 Electronic grounding 1 H3
12 Switch of headlight L1 44 Switch of air conditioner G3
13 Reserved K1 45 Upstream oxygen sensor F3
Terminal B of engine rotating speed
14 Reserved J1 46 E3
(crankshaft position) sensor
Terminal A of engine rotating speed
15 Diagnosis wire K H1 47 D3
(crankshaft position) sensor
16 Durative power supply G1 48 Power grounding 1 C3
17 Ignition switch F1 49 Fuel injector - cylinder 3 B3
18 5V power supply 2 E1 50 Fuel injector - cylinder 1 A3
19 5V power supply 1 D1 51 Non-durative power supply 04
20 Malfunction indicator lamp (MIL) C1 52 Relay of high-speed fan N4
21 Terminal B of stepper motor B1 53 Reserved M4
22 Terminal A of stepper motor A1 54 Reserved L4
23 Services indicator lamp (SVS) O2 55 Reserved K4
24 Switch of blower N2 56 Reserved J4
25 Intake temperature sensor M2 57 Speed signal sensor H4
26 Air throttle position sensor L2 58 Reserved G4
27 Reserved K2 59 Intake pressure sensor F4
28 Reserved J2 60 Fuel pump relay E4
29 Downstream oxygen sensor H2 61 Relay of A/C compressor D4
30 Terminal A of knock sensor G2 62 Relay of low-speed fan C4
31 Terminal B of knock sensor F2 63 Fuel injector - cylinder 2 B4
32 Main relay E2 64 Fuel injector - cylinder 4 A4
* The specific pin numbers are subject to the wire harness principle diagram (the reserved mean the
empty pins).
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3) Electrical Principle Diagram
Power supply
Ignition Fuel injector 1
5V output 1 Fuel injector 2
5V output 1 Fuel injector 3
Main relay Fuel injector 4
Self-diagnosis wire K Trouble indication signal
CAN 1H
CAN 1L Fuel pump relay
Crankshaft sensor + Air conditioner relay
Crankshaft sensor - Fan 1
Knock sensor A Stepper motor A

Knock sensor B Stepper motor B
Stepper motor C
Stepper motor D
Intake pressure sensor
Upstream oxygen sensor
Air throttle position Heating of oxygen sensor
Coolant temperature sensor Heating of oxygen sensor
Intake temperature sensor Carbon canister control valve
Downstream oxygen sensor Wasted gas recycle control valve
Pressure and temperature of air
conditioner
Acceleration sensor
Recycle position of wasted gas
Reserved input Output of fuel consumption

Reserved input Output of rotating speed
Battery
Fan 2
Camshaft signal Reserved
Speed Reserved
Electronic load 1 Reserved
Switch of air conditioner Reserved
ABS
Electronic load 2
Anti-theft password Ignition control 1
Ignition control 2
Heating of oxygen sensor
Heating of oxygen sensor
Electrical Principle Diagram
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It is installed at the side of “A pillar”
3. Element Check
1) Read the engine trouble record with the data wire K.
2) Check whether the connecting wire of ECM is intact and put the focus on the ECM power supply
and grounding line.
3) Check whether the external sensor is normal, whether the output signal is credible and whether its
line is intact.
4) Check whether the actuator is normal and whether its line is intact.
5) Finally, replace the ECM to carry out the test.
1) Dismantlement
① Turn the ignition switch to “OFF” position to dismantle the negative terminal of storage battery.
② Dismantle the lower part of the console referring to “console”.
③ Disconnect the wire harness connector of ECM port. Refer to “Precautions”.
④ Dismantle the fastening bolts of ECM to take off the ECM.
2) Installation
■ Install in the reverse order with dismantlement.
■ For the precautions about the installation, please refer to “Precautions”.
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Section IV Trouble Diagnosis Procedures for Engine Control System

I. Diagnosis by Trouble Code
1. Illustration
1) The following overhaul can be carried out only after the current stable trouble has been identified,
otherwise the diagnosis will be wrong.
2) The "multimeter" referred to hereinafter means the digital multimeter and it is not permitted to use
the analog multimeter to check the electric control system lines.
3) When carrying out the overhaul for the vehicle with the anti-theft system, if the requirement of
replacing the ECM is included in the "Next Steps" column, it is necessary to program the ECM after
the replacement.
4) If the trouble code points to a low voltage of a specific circuit, it indicates that the circuit is likely to
have short circuit to ground or open circuit; if the trouble code points to a high voltage of a specific
circuit, it indicates that the circuit is likely to have short circuit to the power supply; if the trouble code
points to a circuit trouble, it indicates that the circuit is likely to have broken circuit or a variety of line
troubles.
2. Diagnosis Help
1) If the trouble code can not be erased, it means the trouble is stable; in case of the sporadic trouble,
it is necessary to check whether the connector of wire harness is loosened.
2) The check has been accomplished according to the above steps and nothing unusual has been
found.
3) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure and
mechanical ignition timing etc. on the system during the overhaul process.
4) Replace the ECM to carry out the test.
■ If the trouble code can be cleared at this time, it means the trouble site is at ECM; if the trouble code
still can not be erased at this point, then remount the original ECM and repeat the procedures again
to carry out the overhaul.
3. Illustration of Scan Tool or Diagnosis Apparatus Mode
OBD system can provide a great deal of the information related with the trouble diagnosis, which is the
useful reference for the overhaul of the electronic control system of engine. According to the definition in
the automotive industry international standard ISO/DIS15031-5, the information about the OBD system
based on 9 different services/modes can be obtained through the diagnosis instrument in line with the
requirements of ISO/DIS15031-4. The primary functions of each mode are as follows:
- 01 Read the current data of the diagnosis about power system;
- 02 Read the data of freeze frame;
- 03 Read the diagnosis trouble code of the system about the emission;
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- 04 Clear and reset the diagnosis information about the emission;
- 05 Read the monitoring test results of oxygen sensor;
- 06 Read the OBD test results of the specific monitoring system;
- 07 Read the monitoring trouble code of OBD system about the current or last driving cycle;
- 08 Component test, where no mandatory requirement is specified;
- 09 Read the identification numbers of vehicle and software
It is worth while to point that the various scan tools or diagnosis apparatus may be different in the design
and use, but the read content must belong to one of the above-mentioned modes. The trouble code will
be displayed and output at mode 3 after the confirmation of the trouble; the trouble codes in the current
drive cycle or in the last drive cycle will be displayed and output at mode 7.
4. Trouble Code Diagnosis
■ Various ECM pins referred to below should be subject to the actual wire harness diagrams.
1) Trouble code: P0030 open circuit in the heating control circuit of upstream oxygen sensor
Step 1: Use the diagnosis apparatus to read the “ mode 3” and “ mode 7”
Read Result 1 Read Result 2
Mode 3 Mode 7 Mode 3 Mode 7
With trouble information No trouble information No trouble information With trouble information
P0030 P0030
Maintenance hints: Maintenance hints:

The trouble has been identified and there may be the The trouble has not been finally identified and may be the
following problems: intermittent one, and the following items should be
1) Open circuit between the circuit connected to ECM checked:
pin and the pin 2 of upstream oxygen sensor 1) Measure the resistance between the pin of ECM
2) Open circuit between the pin 1 of upstream oxygen connector and the pin 2 of upstream oxygen sensor
sensor and the main relay and determine whether it is normal.
3) Open circuit between the pin 1 and pin 2 of upstream 2) Measure the resistance of pin 1 of upstream oxygen
oxygen sensor sensor and the main relay and determine whether it is
normal.
3) Measure the resistance between the pin 1 and pin 2 of
upstream oxygen sensor and determine whether it is
normal.
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2) Trouble code: P0031 short circuit to ground in the heating circuit of upstream oxygen sensor
Step 1: Use the diagnosis apparatus to read “mode 3” and “mode 7”
P0031 P0031

1) Short circuit to ground in the circuit connected to the checked:
ECM pin 1) Measure whether the resistance to ground of ECM pin
is normal.
3) Trouble code: P0032 short circuit to power supply in the heating circuit of upstream oxygen sensor
P0032 P0032

1) Short circuit between the circuit connected to ECM pin checked:
and the circuit of pin1 of upstream oxygen sensor 1) Measure whether the ECM voltage is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between the ECM pin and the
and other power supply circuits pin 1 of upstream oxygen sensor.
4) Trouble code: P0036 open circuit in the heating circuit of downstream oxygen sensor
P0036 P0036

1) Open circuit between the circuit connected to ECM checked:
pin and the pin 2 of downstream oxygen sensor 1) Measure the resistance between the ECM connector
2) Open circuit in the circuit from the pin 1 of and pin 2 of downstream oxygen sensor.
downstream oxygen sensor to the main relay 2) Measure the resistance between the pin 1 of
3) Open circuit between the pin 1 and pin 2 of downstream oxygen sensor and the main relay.
downstream oxygen sensor 3) Measure the resistance between the pin 1 and pin 2 of
downstream oxygen sensor.
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5) Trouble code: P0037 short circuit to ground in the heating circuit of downstream oxygen sensor
P0037 P0037

1) Short circuit to ground in the circuit connected to ECM checked:
pin 1) Measure whether the resistance to ground of ECM pin
is normal.
6) Trouble code: P0038 short circuit to power supply in the heating circuit of downstream oxygen
sensor
P0038 P0038

and the circuit of pin 1 of downstream oxygen sensor 1) Measure whether the resistance of ECM pin is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between ECM pin and the
and other power supply circuits circuit of pin 1 of downstream oxygen sensor.
7) Trouble code: P0053 unreasonable heating internal resistance of upstream oxygen sensor
Diagnosis illustration of oxygen sensor heater: The system identifies whether the heating output is
correct by measuring the heating resistance of sensor. The oxygen sensor will be damaged by the
condensate under some certain adverse conditions, especially at cold start-up stage.
Upstream oxygen sensor is heated directly after the engine is started. The downstream oxygen sensor
will be heated only when the theoretic temperature inside the catalytic converter device is higher than
308 ℃.
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P0053 P0053

The trouble has been identified and there may be the Trouble has not been finally identified and it is necessary to
following problems: wait for the system to finish the diagnosis.
1) The heating function of upstream oxygen sensor fails
and it is necessary to replace the oxygen sensor.
8) Trouble code: P0054 unreasonable heating internal resistance of downstream oxygen sensor
Diagnosis illustration of oxygen sensor heater: The system identifies whether the heating output is
correct by measuring the heating resistance value of sensor. The oxygen sensor will be damaged by the
condensate under some certain adverse conditions, especially at cold start-up stage.
Upstream oxygen sensor is heated directly after the engine is started. The downstream oxygen sensor
will be heated only when the theoretic temperature inside the catalytic converter device is higher than
308 ℃.
P0054 P0054

1) The heating function of downstream oxygen sensor
fails and it is necessary to replace the oxygen sensor.
9) Trouble code: P0105 No change of intake pressure sensor signal
P0105 P0105

following problems: check the following items:
1) Vacuum leakage or blockage of intake pressure 1) Check or clean the vacuum pipe of sensor and then
sensor reinstall it. Use the “mode 1” of diagnosis apparatus to
2) Seriously aging of intake pressure sensor read the pressure after the start-up.
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10) Trouble code: P0106 unreasonable signal of intake pressure sensor
P0106 P0106

1) Air leakage of induction element inside the pressure checked:
sensor 1) The pressure sensor is a free voltage sensor, so it can
2) Damage of pressure sensor not carry out the diagnosis by reading the pressure
3) Air leakage at the installation position of pressure parameters in the diagnosis apparatus. Therefore it is
sensor necessary to wait for the system to give the final
4) Excursion of pressure sensor characteristics diagnosis result.
11) Trouble code: P0107 too low voltage in the intake pressure sensor circuit
P0107 P0107

1) Short circuit to ground in the sensor signal circuit checked:
detected by ECM 1) Resistance between the ECM pin and ground
12) Trouble code: P0108 too high voltage in the intake pressure sensor circuit
P0108 P0108

1) Short circuit to power supply of sensor signal circuit checked:
detected by ECM 1) Voltage of ECM pin
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13) Trouble code: P0112 too low signal voltage in the intake temperature sensor
P0112 P0112

1) Short circuit to ground in the sensor signal circuit checked:
connected to ECM pin 1) Measure the resistance between the sensor signal
circuit of ECM pin and ground.
14) Trouble code: P0113 too high signal voltage in the intake temperature sensor
P0113 P0113

1) Short circuit to power supply in the sensor signal checked:
circuit connected to ECM pin 1) Measure whether the voltage of sensor signal circuit
of ECM pin is normal.
15) Trouble code: P0116 unreasonable indicating temperature of engine coolant temperature sensor
P0116 P0116

1) The coolant temperature sensor is damaged and
needs replacing.
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16) Trouble code: P0117 too low voltage of engine coolant temperature sensor circuit
P0117 P0117

and the ground 1) Measure the resistance between the ECM pin and the
ground.
17) Trouble code: P0118 too high voltage of engine coolant temperature sensor circuit
P0118 P0118

and other power supply circuits 1) Measure whether the voltage of ECM pin is normal.
18) Trouble code: P0122 the voltage of air throttle position sensor circuit less than the minimum limit
P0122 P0122

1) Short circuit to ground of ECM pin checked:
1) Measure the resistance between the ECM pin and the
ground.
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19) Trouble code: P0123 the voltage of air throttle position sensor circuit more than the maximum limit
P0123 P0123

and other power supply circuits 1) Measure whether the voltage of ECM pin is normal.
20) Trouble code: P0130 unreasonable signal of upstream oxygen sensor

Introduction of trouble causes: when the signal of upstream oxygen sensor is of the following conditions,
the system will determine that the signal of upstream oxygen sensor is unreasonable.
a. Upstream oxygen sensor signal maintains within the lower voltage range (0.1～0. 4V) for a long
time, but the downstream oxygen sensor signal constantly keeps above 0.5V.
b. Upstream oxygen sensor signal maintains within the higher voltage range (0.6～1.5V), but the
downstream oxygen sensor signal constantly keeps 0.1V below.
c. Upstream oxygen sensor signal circuit couples with the heating circuit.
P0130 P0130

following problems: wait for the ECM to finish the final detection.
1) Check whether the connector of oxygen sensor is
correct and normal.
2) Check whether the upstream oxygen sensor signal
circuit couples with the heating circuit.
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21) Trouble code: P0131 too low voltage of upstream oxygen sensor circuit
P0131 P0131

1) Short circuit to ground in the signal circuit connected checked:
to ECM pin 1) Measure the resistance between the signal circuit
connected to ECM pin and the ground.
22) Trouble code: P0132 too high voltage of upstream oxygen sensor circuit
Introduction of trouble causes: ECM will measure the voltage of upstream oxygen sensor circuit after the
engine is started, and if the signal voltage is more than 1.5V for a long time, such situation will be
determined as the short circuit to power supply in the upstream oxygen sensor signal circuit.
P0132 P0132

1) Short circuit between the signal circuit connected to checked:
ECM pin and the circuit of pin 1 of oxygen sensor 1) Measure the resistance between the signal circuit
2) Short circuit between the signal circuit connected to connected to ECM pin and the pin 1 of oxygen sensor
ECM pin and other power supply circuits 2) Measure the voltage of signal circuit connected to
ECM pin.
23) Trouble code: P0133 aging of upstream oxygen sensor
Introduction of trouble causes: Under the normal circumstances, the air-fuel ratio of gas mixture is
switched between the diluted and the concentrated, and the corresponding oxygen sensor signal will be
reflected in the continuous jump of signal amplitude. When the oxygen sensor is aged, its perceptual
sensitivity to gas mixture will drop, which will be reflected in the lengthening of cycle of signal fluctuation.
ECM will calculate the average signal cycle in accordance with the corresponding algorithm. If the
calculated cycle is slower than the pre-set critical value, the sensor will be determined as aged.
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P0133 P0133

The trouble has been identified and there may be the The trouble has not been finally identified and it is
following problems: necessary to wait for the ECM to finish the detection.
1) The sensor is aged and should be replaced.
24) Trouble code: P0134 trouble of signal of upstream oxygen sensor

Introduction of trouble causes: ECM will measure the voltage of the upstream oxygen sensor circuit after
starting the engine. When the signal voltage is always changing within 0.4~0.6V, system determines that
the trouble is the open circuit of the upstream oxygen sensor signal circuit.
P0134 P0134

1) Open circuit in the circuit from the oxygen sensor to checked:
the ECM pin 1) Measure the resistance between the ECM connector
2) Poor connector of oxygen sensor (oxidation of pin) and the pin 4 of oxygen sensor.
25) Trouble code: P0136 unreasonable signal of downstream oxygen sensor

Introduction of trouble causes: the upstream oxygen sensor signal circuit couples with the heating circuit.
P0136 P0136

1) Check whether the connector of oxygen sensor is
correct and normal.
2) Check whether the upstream oxygen sensor signal
circuit couples with the heating circuit.
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26) Trouble code: P0137 too low voltage of downstream oxygen sensor signal circuit
P0137 P0137

1) Short circuit to ground in the signal circuit connected checked:
to ECM pin 1) Measure the resistance between the signal circuit
connected to ECM pin and the ground.
27) Trouble code: P0138 too high voltage of downstream oxygen sensor signal circuit
Introduction of trouble causes: ECM will measure the voltage of the downstream oxygen sensor circuit
after starting the engine. When the signal voltage is above 1.5V for a long time, such situation is
determined as the short circuit to power supply in the downstream oxygen sensor signal circuit.
P0138 P0138

1) Short circuit between the signal circuit connected to checked:
ECM pin and the pin 1 of oxygen sensor 1) Measure the resistance between the signal circuit
2) Short circuit between the signal circuit connected to connected to ECM pin and the pin 1 of oxygen sensor
ECM pin and other power supply circuits 2) Measure the voltage of signal circuit connected to
ECM pin.
28) Trouble code: P0140 signal trouble of downstream oxygen sensor circuit
Introduction of trouble causes: ECM will measure the voltage of the downstream oxygen sensor circuit
after starting the engine. When the signal voltage is constantly changing within 0.4～0.6V, the system
determine that the trouble is the open circuit in downstream oxygen sensor signal circuit.
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Electronic Control
P0140 P0140

1) Open circuit in the circuit from the oxygen sensor to checked:
the ECM pin 1) Measure the resistance between the ECM connector
2) Poor connector of oxygen sensor (oxidation of pin) and the pin 4 of oxygen sensor.
29) Trouble code: P0170 unreasonable self-learning of closed-loop control of air-fuel ratio in the off-line
detection
30) Trouble code: P0171 too diluted self-learning of closed-loop control of air-fuel ratio in the off-line
detection
31) Trouble code: P0172 too concentrated self-learning of closed-loop control of air-fuel ratio in the
off-line detection
Note: Overhaul procedure is applicable to such situation where trouble codes of intake pressure sensor,
carbon canister solenoid valve and oxygen sensor etc. do not appear at the same time. If the related
trouble codes coexist at the same time, deal with other troubles first and then overhaul the fuel pipeline.
32) Trouble code: P0201 open circuit of control circuit of fuel injector of cylinder 1
P0201 P0201

1) Whether there is the open circuit in the coil of fuel checked:
injector. 1) Whether there is the open circuit in the coil of fuel
2) Whether the pin of fuel injector connector is injector
connected well to the ECM pin. 2) Whether the pin of fuel injector connector is
3) Whether the pin of fuel injector connector is connected well to the ECM pin
connected well to the main relay. 3) Whether the pin of fuel injector connector is
connected well to the main relay
36) Trouble code: P0261 short circuit to ground in the control circuit of fuel injector of cylinder 1
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Electronic Control
P0261 P0261

1) Short circuit to ground in every drive circuit connected checked:
to ECM pin 1) Measure the resistance to ground in the circuit
connected to ECM pin.
40) Trouble code: P0262 short circuit to power supply of control circuit of fuel injector of cylinder 1
P0262 P0262

and other power supply circuits 2) Measure the voltage of circuit connected to ECM pin.
44) Trouble code: P0300 miss-fire in multiple cylinders

45) Trouble code: P0301 miss-fire in cylinder 1
Introduction of trouble causes: The miss-fire means that because of the failure of engine ignition system
to effectively release the ignition energy (ignition failure), the deviation of fuel injection volume (deviation
of the concentration of the gas mixture), too low cylinder compression pressure or any other cause, the
combustion process inside a cylinder is interrupted or failed, which will result in the excessive emissions
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Electronic Control
or the damage of the catalytic converter due to the overheating. As for the OBD system, it refers to the
trouble where the times of miss-fire are more than the set value.
P030x P030x

following problems: necessary to wait for the system to determine.
1) Fuel injector should be cleaned.
2) Intake passage should be cleaned.
3) Air leakage of valve
4) Trouble of ignition system (check and replace the
ignition plug and high-voltage wire).
5) Serious abrasion of cylinder
49) Trouble code: P0317 trouble of ABS poor road detection signal
Introduction of trouble causes: The signal from the ABS wheel speed sensor is abnormal, which makes
the signal can not be used to detect the road bumps.
P0317 P0317

1) Check the ABS wheel speed signal. checked.
50) Trouble code: P0318 trouble of poor road detection sensor signal
Introduction of trouble causes: When the acceleration measured by the acceleration sensor is beyond
the set reasonable range, such situation will be determined as the trouble of sensor. A period of time, for
example 10s after the vehicle stops, the acceleration sensor should not detect the bumpy road. If there is
bumping road detected at this time, the system will determine that the trouble of acceleration sensor
occurs.
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Electronic Control
P0318 P0318

pin 1) Check the resistance to ground in the circuit
2) Short circuit to power supply or open circuit in the connected to ECM pin.
circuit connected to ECM pin 2) Check the voltage of circuit connected to ECM pin.
3) Looseness at the installation position or support of the 3) Check whether the installation position and support
acceleration sensor are normal.
4) Damaged acceleration sensor
51) Trouble code: P0321 trouble of reference point of crankshaft position sensor
Introduction of trouble causes: The 60-2 teeth speed measurement system is adopted for the System.
The 60-2 induction ring gear is installed on the fly wheel and will generate the magnetic changes in the
sensor with the rotation of fly wheel (rotating speed in line with the crankshaft), which will result in the
induced AC voltage the frequency of which depends on the rotating speed. ECM signal circuit converts
the input sine wave to the square wave. When the ECM detects that the distance between two falling
edges of two square waves is greater than two times of tooth space, the reference location is found.
Physically, the reference pitch corresponds to the specific location of cylinder 1, and the second falling
edge in the system after the reference pitch is defined as the signal of software reference point (BM) and
the distance from the software reference point signal to the crankshaft corner at the upper stop point of
cylinder 1 is the fixed value of 108° CA. Therefore, crankshaft rotates a circle each and the system will
receive a software reference point signal and the signal system will maintain “synchronized" with the
crankshaft position in accordance with the software reference point signal to ensure the correct control of
fuel injection, intake and ignition timing.
If one of the following circumstances is found, then the crankshaft software reference point signal (BM)
trouble is determined:
① It is frequently found that the crankshaft software reference point signal (BM) precedes or lags the
expected position;
② The rotating speed signal can be detected but the crankshaft software reference point signal (BM)
can not be detected;
③ The crankshaft software reference point signal (BM) is lost frequently;
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P0321 P0321

The trouble has been identified and there may be the As the trouble is caused by the intermittent short circuit or
following problems: open circuit, it is necessary to wait for the system to confirm
1) Intermittent short circuit or open circuit in the circuit itself before the trouble is finally identified.
connection
2) Deviation of installation position of signal gear of
crankshaft
3) Deviation of installation position of crankshaft position
sensor
52) Trouble code: P0322 no pulse signal of crankshaft position sensor (open circuit or short circuit)
Introduction of trouble causes: After the engine is started, ECM will monitor the signals of crankshaft
position sensor and camshaft position sensor at the same time. If it is able to receive the continuous
camshaft position sensor signal but not the crankshaft position sensor signal, the system will determine
that the signal of crankshaft position sensor signal is lost.
P0322 P0322

1) Open circuit in the circuit from the crankshaft position checked:
sensor to the ECM 1) Circuit resistance from the crankshaft position sensor
1) Short circuit in the circuit from the crankshaft position to the ECM
sensor to the ECM 2) Circuit voltage from the crankshaft position sensor to
3) Open circuit of coil of crankshaft position sensor the ECM
3) Crankshaft position sensor coil resistance
53) Trouble code: P0327 too low voltage of knock sensor signal circuit
Introduction of trouble causes: The knock sensor is installed on the engine body and vibrates according
to different vibration frequencies under various operating conditions of engine to produce voltage signals
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containing a variety of frequencies. Voltage signal is able to reflect not only the occurrence of knock of
engine body but also the value of engine background noise (noise of mechanical component) objectively.
When the engine and knock sensor are operating normally, the background noise value will fluctuate
within the specified range, and once the background noise is lower than the set value, the system will
consider that the trouble exists in the knock sensor signal circuit.
P0327 P0327

following problems: check the following items:
1) Open circuit or short circuit to ground from ECM pin to 1) Check the resistance in the circuit from the ECM to pin
pin 1 of knock sensor 1 of knock sensor.
2) Open circuit or short circuit to ground from ECM pin to 2) Check the resistance in the circuit from the ECM to pin
pin 2 of knock sensor 2 of knock sensor.
54) Trouble code: P0328 too high voltage of knock sensor signal circuit
Introduction of trouble causes: The knock sensor is installed on the engine body and vibrates according
to different vibration frequencies under various operating conditions of engine to produce voltage signals
containing a variety of frequencies. Voltage signal is able to reflect not only the occurrence of knock of
engine body but also the value of engine background noise (noise of mechanical component) objectively.
When the engine and knock sensor are operating normally, the background noise value will fluctuate
within the specified range, and once the background noise is higher than the set value, the system will
consider that the trouble exists in the mechanical component of engine.
P0328 P0328

following problems: wait for the system to finish the diagnosis itself.
1) Some components of engine are worn out seriously
and it is necessary to check the mechanical parts of
engine (piston ring, piston pin, bearing and spare part
gap etc.).
55) Trouble code: P0340 improper installation position of camshaft position sensor
56) Trouble code: P0341 poor contact of camshaft position sensor
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Electronic Control
Introduction of trouble causes: The camshaft position sensor works in such a way to monitor the location
of camshaft by using the Hall element to induce a trigger wheel rotating together with the camshaft. The
phase signals received by ECM should change alternatively and regularly between high and low levels.
If the ECM only detects the slow changes between high and low levels or irregular changes, it is
considered that the trouble exists in the phase signal.
P0340 P0340

1) Improper installation position of camshaft position checked:
sensor 1) Installation position of camshaft position sensor
2) Poor connection of connector of camshaft position (angle, gap with phase trigger wheel)
sensor wire harness 2) Connection of connector of camshaft position sensor
wire harness (tightness of pin, oxidation of pin)
57) Trouble code: P0342 short circuit to ground of camshaft position sensor
If the ECM continuously detects the phase signal at the low level, it is considered that the short circuit to
ground exists in the phase signal circuit.
P0342 P0342

1) Short circuit between the circuit connected to ECM checked:
and the circuit of pin 3 of camshaft position sensor 1) Check the resistance to ground of the circuit
2) Short circuit to ground in the circuit connected to ECM connected to ECM pin.
2) Check the resistances of the circuit connected to ECM
pin and the circuit of pin 3 of camshaft position sensor.
58) Trouble code: P0343 short circuit to power supply of camshaft position sensor
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If the ECM continuously detects the phase signal at the high level, it is considered that the short circuit to
power supply exists in the phase signal circuit.
P0343 P0343

and the circuit of pin 1 of camshaft position sensor 1) Check the voltage of ECM pin circuit
2) Short circuit between the circuit connected to ECM 2) Check the resistance between the circuit of ECM pin
and other power supply circuits and the circuit of pin 1 of camshaft position sensor
59) Trouble code: P0420 aging of oxygen storage capability of three-way catalyst (emission exceeding
the limit)
Introduction of trouble causes: There is a corresponding relationship between the three-way catalyst
conversion efficiency and its oxygen storage capacity. The amplitude of downstream oxygen sensor can
indirectly reflect the oxygen storage capacity of catalyst. The greater the amplitude is, the poorer the
oxygen storage capacity of catalyst is and the worse the conversion efficiency of corresponding catalyst
is. The main principle of catalyst diagnosis is to monitor the voltage fluctuation amplitude of downstream
oxygen sensor by the system, and if the measured amplitude is greater than the set limit, the system will
determine the failure of three-way catalyst.
P0402 P0402

following problems. necessary to wait for the system to determine.
1) Too low efficiency of the three-way catalyst will lead to
the excessive emission.
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60) Trouble code: P0444 open circuit in the control circuit of carbon canister solenoid valve
P0444 P0444

1) Open circuit between the circuit connected to the checked:
ECM and the pin 2 of carbon canister solenoid valve 1) Measure the resistance between the ECM connector
2) Open circuit from the pin 1 of canister solenoid valve and pin 2 of carbon canister solenoid valve
to the main relay 2) Resistance between the pin 1 of carbon canister
3) Open circuit in the electromagnetic coil between the solenoid valve and the main relay
pin 1 and pin 2 of carbon canister solenoid valve 3) Resistance between the pin 1 and pin 2 of carbon
canister solenoid valve
61) Trouble code: P0458 too low voltage of control circuit of carbon canister solenoid valve
P0458 P0458

1) Measure whether the resistance to ground of ECM pin
is normal.
62) Trouble code: P0459 too high voltage of control circuit of carbon canister solenoid valve
P0459 P0459

and the pin 1 of carbon canister solenoid valve 1) Measure whether the voltage of ECM pin is normal.
2) Short circuit between the circuit connected to ECM pin 2) Measure the resistance between the ECM pin and pin
and other power supply circuits 1 of carbon canister solenoid valve
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63) Trouble code: P0480 open circuit in control circuit of cooling fan relay (low speed)
64) Trouble code: P0481 open circuit in control circuit of cooling fan relay (high speed)
65) Trouble code: P0691 short circuit to ground in control circuit of cooling fan relay (low speed)
66) Trouble code: P0692 short circuit to power supply in control circuit of cooling fan relay (low speed)
67) Trouble code: P0693 short circuit to ground in control circuit of cooling fan relay (high speed)
68) Trouble code: P0694 short circuit to power supply in control circuit of cooling fan relay (high speed)
Introduction of trouble causes: The circuit control module inside the ECM will detect the fan relay circuit
voltage after the engine is started. When the voltage or current under the trouble mode is met, the
determination is the trouble of relay circuit.
P0480 P0480

1) Open circuit/short circuit to ground/short circuit to checked:
power supply between the circuit connected to ECM 1) Measure the resistance or voltage of the circuit
and fan relay between the ECM connector and relay pin.
2) Open circuit between the relay and main relay 2) Resistance between the relay and main relay
3) Open circuit in the electromagnetic coil of relay 3) Resistance between the two pins of relay
69) Trouble code: P0501 unreasonable signal of vehicle speed sensor
Introduction of trouble causes: When the vehicle is sliding with the released accelerator pedal under a
selected gear, ECM will monitor the rotating speed of engine and the vehicle speed at the same time. If
the engine maintains the high rotating speed but the vehicle speed shown is “zero” or obviously too low,
the system will determine the trouble of vehicle speed signal.
P0501 P0501

1) Short circuit to ground or open circuit in the signal checked:
circuit from ECM to vehicle speed sensor 1) Check the resistance in circuit from ECM connector to
the vehicle speed signal sensor.
2) Check the resistance to ground in the circuit of ECM
pin.
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Electronic Control
70) Trouble code: P0506 rotating speed under idle control lower than target idle speed
Introduction of trouble causes: The idle rotating speed of engine is fulfilled through closed-loop control. If
the actual rotating speed of engine is still below the target idle rotating speed after the ECM enters the
idle control for a certain period of time, this trouble is determined.
P0506 P0506

following problems: intermittent one.
1) Stepper motor is blocked in a smaller opening.
2) Check the adjusting screw of air throttle, throttle
wiredrawing and operating conditions of air throttle
and etc.
3) The inside of air throttle body is too dirty.
71) Trouble code: P0507 rotating speed under idle control higher than target idle speed
Introduction of trouble causes: The idle rotating speed of engine is fulfilled through closed-loop control. If
the actual rotating speed of engine is still above the target idle rotating speed after the ECM enters the
idle control for a certain period of time, this trouble is determined.
P0507 P0507
Maintenance hints:
The trouble has been identified and there may be the
following problems:
1) Check the adjusting screw of air throttle, throttle
Maintenance hints:
wiredrawing and operating conditions of air throttle
The trouble has not been finally identified and may be the
and etc.
intermittent one.
2) The inside of air throttle body is too dirty.
3) Stepper motor is blocked in a bigger opening.
4) Check the forced ventilation pipe of crankcase for the
shedding or gas leakage.
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Electronic Control
72) Trouble code: P0508 short circuit to ground of drive pin of stepper motor
73) Trouble code: P0509 short circuit to power supply of drive pin of stepper motor
74) Trouble code: P0511 open circuit of drive pin of stepper motor
Introduction of trouble causes: After the engine is started, the circuit control module inside the ECM will
continuously monitor the voltage of drive circuit of idle stepper motor. When the short circuit to
ground/power supply/open circuit occurs in one of four circuits, the system will determine the
corresponding trouble of stepper motor circuit.
P0508 P0508

1) Short circuit to ground/short circuit to power checked:
supply/open circuit in any of drive circuits of stepper 1) Measure the resistance or voltage between the drive
motor connected to ECM circuit of each stepper motor connected to ECM and
the ground
75) Trouble code: P0560 unreasonable voltage signal of system storage battery
76) Trouble code: P0562 too low voltage of system storage battery
77) Trouble code: P0563 too high voltage of system storage battery
P0560 P0560

1) Damaged generator or leakage of storage battery checked:
2) Open circuit in the excitation circuit of generator 1) Check the generating capacity of generator (measure
3) Damaged adjustor of generator leads to the failure of the generator voltage after the start-up).
generated energy control, making too high generated
voltage.
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78) Trouble code: P0627 open circle in control circuit of fuel injection pump relay
79) Trouble code: P0628 short circuit to ground in control circuit of fuel injection pump relay
80) Trouble code: P0629 short circuit to power supply in control circuit of fuel injection pump relay
P0062X P0062X

power supply between the control circuit of fuel 1) Measure the resistance or voltage in the control circuit
injection pump connected to ECM and the fuel of fuel injection pump relay connected to ECM.
injection pump relay 2) Resistance between the relay and main relay
2) Open circuit between the relay and main relay 3) Resistance between the two pins of relay
3) Open circuit in the electromagnetic coil of relay
81) Trouble code: P0645 open circuit in control circuit of A/C compressor relay
82) Trouble code: P0646 short circuit to ground in control circuit of A/C compressor relay
83) Trouble code: P0647 short circuit to power supply in control circuit of A/C compressor relay
P064X P064X

power supply between the control circuit connected to 1) Measure the resistance or voltage in the control circuit
the A/C compressor relay connected to ECM and the of A/C compressor relay connected to ECM.
relay 2) Resistance between the relay and main relay
2) Open circuit between the relay and main relay 3) Resistance between the two pins of relay
3) Open circuit in the electromagnetic coil of relay
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Electronic Control
84) Trouble code: P0650 trouble of drive circuit of malfunction indicator lamp (MIL)
P0650 P0650

power supply in the drive circuit of malfunction 1) Measure the resistance or voltage in the drive circuit
indicator lamp (MIL) connected to ECM of MIL connected to ECM.
2) Open circuit between the MIL and main relay
3) Burnout of MIL
85) Trouble code: P1651 trouble of drive circuit of services indicator lamp (SVS)
P0650 P0650

power supply in the drive circuit of SVS connected to 1) Measure the resistance or voltage in the drive circuit
ECM of the SVS connected to ECM.
2) Open circuit between SVS and main relay
3) Burnout of SVS
86) Trouble code: P2177 self-learning value of air-fuel ratio closed-loop control exceeding the upper limit
87) Trouble code: P2178 self-learning value of air-fuel ratio closed-loop control exceeding the lower limit
Principle and introduction of trouble causes: In order to optimize the general conversion efficiency of the
catalytic converters for the HC, CO and NOx, the air-fuel ratio of the gas mixture should be kept at 14.7:1.
In case of the manufacturing deviation of spare part of engine, the deposition of colloid in the petrol at
the back of fuel injector, intake passage or valve and the air leakage of intake and exhaust system, the
air-fuel ratio will deviate from the 14.7:1 (diluted or concentrated), which will lead to the deterioration of
emission and the degradation of engine performance. Engine control system will correct fuel injection
volume and self learn according to the deviation degree of air-fuel ratio and characteristics. When the
value of self-learning reaches the set upper limit of system (if the gas mixture is diluted or concentrated,
the system will continuously correct the fuel injection volume until the maximum value), the system will
determine the trouble that the self-learning value exceeds the upper limit.
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Electronic Control
P2177 or P2178 P2177 or P2178
Maintenance hints:
The trouble has been identified and there may be the
following problems:
1) Fuel injector is blocked and needs to be cleaned.
Maintenance hints:
2) Air leakage in the intake and exhaust systems
Trouble has not been finally identified and it is necessary to
3) Too much deposition of colloid at the back of intake
wait for the system to finish the diagnosis.
passage or intake valve should be wiped out.
4) Deviation of spare part of engine
5) Deviation of valve gap
6) Deviation of fuel system pressure
88) Trouble code: P2195 aging of upstream oxygen sensor (diluted)
Introduction of trouble causes: The offset of upstream oxygen sensor signal will lead to the deviation of
air-fuel ratio, and the rear oxygen closed-loop adjustment will rectify this deviation. The system set a
certain range for the correction of rear oxygen closed-loop, and when the correction exceeds the upper
limit of the range set by the system, the system will determine that the characteristics of the upstream
oxygen sensor has deviated.
P2195 P2195

1) The deviation of characteristics of the upstream
oxygen sensor may lead to the excessive emission.
89) Trouble code: P2196 aging of upstream oxygen sensor (concentrated)
Introduction of trouble causes: The offset of upstream oxygen sensor signal will lead to the deviation of
air-fuel ratio and the rear oxygen closed-loop adjustment will rectify this deviation. The system set a
certain range for the correction of rear oxygen closed-loop, and when the correction exceeds the lower
limit of the range set by the system, the system will determine that the characteristics of the upstream
oxygen sensor has deviated.
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Electronic Control
P2196 P2196

1) The deviation of characteristics of the upstream
oxygen sensor may lead to the excessive emission.
90) Trouble code: P2270 aging of downstream oxygen sensor (diluted)
Introduction of trouble causes: Under the normal circumstances, the oxygen sensor signal should
fluctuate around the control target value. If it is found that the sensor voltage is continuously diluted at a
certain period of time, the system will enrich the gas mixture. If the sensor voltage signal is not getting
concentrated in the expected direction, it is determined that the trouble is the diluted aging of oxygen
sensor.
91) Trouble code: P2271 aging of downstream oxygen sensor (concentrated)
Introduction of trouble causes: Under the normal circumstances, the oxygen sensor signal should fluctuate
around the control target value. If it is found that the sensor voltage is continuously concentrated at a certain
period of time, the system will attenuate the gas mixture. If the sensor voltage signal is not getting diluted in the
expected direction, it is determined that the trouble is the concentrated aging of oxygen sensor.
P2270 or P2271 P2270 or P2271

1) Drop of performance of downstream oxygen sensor
may lead to the excessive emission.
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Electronic Control
II. Diagnosis by Trouble Phenomena

1. Illustration
Before carrying out the trouble diagnosis steps in accordance with the engine trouble phenomenon, it is
necessary to first conduct the preliminary check:
1) Confirm that the malfunction indicator lamp of engine is operating normally.
2) Use the trouble diagnosis apparatus to check and confirm there is no record of trouble information.
3) Confirm the existence of the trouble complained about by the owner and the conditions about the
occurrence of the trouble.
And then check the appearance:
1) Check whether there is the fuel leakage in the fuel pipeline.
2) Check whether there is breakage or kink in the vacuum pipeline and whether the connection is
normal.
3) Check whether the intake pipeline is blocked, leaked, flattened or damaged.
4) Check whether the high-voltage wire of ignition system is broken, aged and whether the ignition
sequence is correct.
5) Check whether the grounding position of wire harness is clean and firm.
6) Check the connector of each sensor and actuator for the looseness or poor contact.
Note: If any of the above-mentioned phenomena exists, it is necessary to first take the maintenance
operation against it; otherwise the following trouble diagnosis and maintenance will be affected.
2. Diagnosis Help
1) Confirm there is no trouble record in the engine.
2) Confirm the existence of the trouble complained by the owner.
3) The check has been done according to the above steps, and there is nothing unusual found.
4) It is not permitted to neglect the effects of the maintenance of vehicle, cylinder pressure, mechanical
ignition timing and fuel etc. on the system during the overhaul process.
5) Replace the ECM for the test.
If the trouble phenomenon can be cleared at this time, it means the trouble site is at ECM; if the trouble
phenomenon still exists at this point, remount the original ECM and repeat the procedures again to carry
out the overhaul.
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Electronic Control
Trouble phenomenon 1: during the start-up, the engine does not run or runs slowly
General trouble position:
1. Storage battery; 2. Starter; 3.Wire harness or ignition switch; 4.Mechanical part of engine
General diagnosis procedure:
No. Operating Steps Detection Results Subsequent Steps
Use the multimeter to check the voltage between the two Yes Next step
1 terminals of storage battery to see whether it is about 8-12V
Replace the
during the start-up of engine. No
storage battery
Maintain the ignition switch at the starting position and use the Yes Next step
2 multimeter to check whether there is a voltage above 8V at the
Repair or replace
cathode terminal of starter. No
wire harness
Dismantle the starter to check its operating state. Mainly Repair or replace the
Yes
3 check whether there is a broken circuit in the starter or starter
whether it is blocked due to the poor lubrication.
No Next step
Replace with the

If the trouble only happens in the winter, then check whether
Yes lubricating oil of the
4 too large resistance of starter is caused due to the improper
proper grade
selection of the lubricating oil for engine or the gearbox oil.
No Next step
Overhaul the internal

Check whether the internal mechanical resistance of engine is Yes
resistance of engine
5 too large; if so, the failure of rotation or the slow rotation of
starter may occur. Repeat the above
No
steps
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Electronic Control
Trouble phenomenon 2: Engine can be drive to run but can not be started successfully during the
start-up
1. No fuel in the fuel tank; 2. Fuel injection pump; 3.Crankshaft position sensor; 4.Ignition coil;
5.Mechanical part of engine
Detection
No. Operating Steps Subsequent Steps
Results
Connect the fuel pressure gauge (the access point is at the front Yes Next step
end of the induction manifold of the fuel distribution pipe
1 assembly) to the engine, and start the engine to check whether Overhaul the fuel supply
the reading of fuel pressure gauge at idle condition is at about No
system
350kPa.
Yes Next step

Connect the electric control system diagnosis apparatus to the
2 engine to observe the data of "rotating speed of engine" and start Overhaul the line of
the engine to observe whether there is the speed signal output. No crankshaft position
sensor
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
the ignition plug to make the ignition plug electrodes around
3
5mm away from the engine body, and start the engine to check Overhaul the ignition
No
whether there is the blue and white high-voltage fire. system
Eliminate the mechanical

Check the pressure states of all the cylinders of engine and Yes
4 trouble of engine
observe whether the pressure of engine cylinder is insufficient.
No Next step
Connect the adapter of electric control system and turn on the Yes Diagnosis help
ignition switch to check whether the power supplies of the pins
5
#16, #17, #8 and #51 are normal; check whether the groundings Overhaul the
No
of pins #5, #43 and #48 are normal. corresponding line
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Electronic Control
Trouble phenomenon 3: Difficulty in warm start

1. Poor quality of fuel; 2.Fuel injection pump; 3.Coolant temperature sensor; 4.Ignition coil
Detection
Results
Connect the fuel pressure gauge (the access point is at the front end Yes Next step
of the induction manifold of the fuel distribution pipe assembly) to the
1
Overhaul the fuel
engine and start the engine to check whether the reading of fuel No
supply system
pressure gauge at idle condition is at about 350kPa.
Pull out the high-voltage wire of one of the cylinders and connect the Yes Next step
ignition plug to make the ignition plug electrodes around 5mm away
2
from the engine body, and start the engine to check whether there is Overhaul the ignition
No
the blue and white high-voltage fire. system
Pull out the connector of coolant temperature sensor and start the Overhaul the line or
Yes
engine to observe whether the engine is successfully started at this replace the sensor
3 time. (Alternatively, connect a 300 ohm resistance in series at the
connector of coolant temperature sensor in place of it to observe No Next step
whether the engine is successfully started at this time.)
Check the vacuum pipe of fuel pressure regulator for the shedding or Yes Overhaul or replace
4
air leakage.
No Next step
Check the fuel state and observe whether the trouble phenomenon Yes Replace the fuel
5
occurs just after adding the fuel.
No Next step
ignition switch to check whether the power supplies of the pins #16,
6
#17, #8 and #51 are normal; check whether the groundings of pins Overhaul the
No
#5, #43 and #48 are normal. corresponding line
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Electronic Control
Trouble phenomenon 4: Difficulty in cold start

1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Air throttle body and idle bypass air passage; 7.Mechanical part of engine

Connect the fuel pressure gauge (the access point is at the Yes Next step
1 front end of the induction manifold of the fuel distribution pipe
assembly) and start the engine to check whether the reading Overhaul the fuel
No
of fuel pressure gauge at idle condition is at about 350kPa. supply system
Pull out the high-voltage wire of one of the cylinders and Yes Next step
2 connect the ignition plug to make the ignition plug electrodes
around 5mm away from the engine body, and start the engine Overhaul the ignition
No
to check whether there is the blue and white high-voltage fire. system
Pull out the connector of coolant temperature sensor and start Overhaul the line or
Yes
the engine to observe whether the engine is successfully replace the sensor
3 started at this time. (Alternatively, connect a 2500 ohm
resistance in series at the connector of coolant temperature
sensor in place of it to observe whether the engine is No Next step
successfully started at this time.)
Wash the air throttle
Gently step down the accelerator pedal to observe whether it Yes
4 and idle air passage
is easy to start.
No Next step
Dismantle the fuel injector and use the cleaning analyzer Replacement of
Yes
5 special for fuel injector to check whether there is leakage or trouble
blockage in the fuel injector.
No Next step
Check the fuel state and observe whether the trouble Yes Replace the fuel
6
phenomenon occurs just after adding the fuel.
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and Yes mechanical trouble of
7 observe whether the pressure of engine cylinder is engine
insufficient.
No Next step
8 ignition switch to check whether the power supplies of the
pins #16, #17, #8 and #51 are normal; check whether the Overhaul the
No
groundings of pins #5, #43 and #48 are normal. corresponding line
209
Electronic Control
Trouble phenomenon 5: Difficulty in starting at any time but with normal rotating speed
1. Poor quality of fuel; 2. Fuel injection pump; 3.Coolant temperature sensor; 4.Fuel injector; 5.Ignition
coil; 6.Air throttle body and idle bypass air passage; 7.Intake passage; 8.Ignition timing; 9.Ignition
plug; 10.Mechanical part of engine
Overhaul the intake

Check whether the air filter is blocked and whether the intake Yes
1 system
passage is leaked.
No Next step
Connect the fuel pressure gauge (the access point is at the front Yes Next step
2 end of the induction manifold of the fuel distribution pipe assembly)
and start the engine to check whether the reading of fuel pressure Overhaul the fuel
No
gauge at idle condition is at about 350kPa. supply system
Pull out the high-voltage wire of one of the cylinders and connect Yes Next step
3 the ignition plug to make the ignition plug electrodes around 5mm
away from the engine body, and start the engine to check whether Overhaul the ignition
No
there is the blue and white high-voltage fire. system
Check the ignition plug of each cylinder to observe whether its Yes Next step
4
model and gap are in compliance with the specification.
No Adjust or replace
Pull out the connector of coolant temperature sensor and start the Overhaul the lien or
Yes
5 engine to observe whether the engine is successfully started at this replace the sensor
time.
No Next step
Wash the air throttle

Yes
6 Gently step down the throttle to observe whether it is easy to start. and idle air passage
No Next step
Dismantle the fuel injector and use the cleaning analyzer special Replacement of
Yes
7 for fuel injector to check whether there is leakage or blockage in trouble
the fuel injector.
No Next step
8
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and Yes mechanical trouble of
9
observe whether the pressure of engine cylinder is insufficient. engine
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition timing
10
is in line with the specification. Overhaul the ignition
No
timing
11 ignition switch to check whether the power supplies of the pins #16,
No
210
Electronic Control
Trouble phenomenon 6: Normal start-up but unstable idle at any time

1. Poor quality of fuel; 2.Fuel injector ; 3.Ignition plug; 4.Air throttle body and idle bypass air passage;
5.Intake passage; 6.Idle adjustor (stepper motor ); 7.Ignition timing; 8.Ignition plug; 9.Mechanical
part of engine.
Detection
Results
Overhaul the intake

1 system
passage is leaked.
No Next step
Yes Wash or replace

2 Check whether the idle adjustor is jammed.
No Next step
Check the ignition plug of each cylinder to observe whether its model Yes Next step
3
and gap are in compliance with the specification.
Check whether there is carbon deposit in the air throttle body and Yes Wash
4
idle bypass air passage.
No Next step
Dismantle the fuel injector and use the cleaning analyzer special for Replacement of
Yes
5 fuel injector to check whether there is leakage, blockage or too poor trouble
flow in the fuel injector.
No Next step
6
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and observe Yes mechanical trouble of
7
whether the pressure difference of each engine cylinders is large. engine
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition timing is
8
in line with the specification. Overhaul ignition
No
timing
9
Overhaul the
#17, #8 and #51 are normal; check whether the groundings of pins No
corresponding line
#5, #43 and #48 are normal.
211
Electronic Control
Trouble phenomenon 7: Normal start-up but unstable idle speed during the warm-up process
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Ignition plug; 4.Air throttle body and idle
bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Overhaul the intake

1 system
passage is leaked.
No Next step
Check the ignition plug of each cylinder to observe whether its model Yes Next step
2
and gap are in compliance with the specification.
Wash the related

Dismantle the idle adjustor to check whether there is carbon deposit Yes
3 components
in the air throttle body, idle adjustor and idle bypass air passage.
No Next step
Pull out the connector of coolant temperature sensor and start the Overhaul the lien or
Yes
4 engine to observe whether the idle speed of engine is unstable replace the sensor
during warm-up process.
No Next step
Yes
No Next step
6
No Next step
Eliminate the
Check the pressure states of all the cylinders of engine and observe
Yes mechanical trouble of
7 whether the pressure difference of each engine cylinders is large.
engine
No Next step
8
No
212
Electronic Control
Trouble phenomenon 8: Normal start-up but unstable idle speed after the warm-up process
1. Poor quality of fuel; 2. Coolant temperature sensor; 3.Ignition plug; 4.Air throttle body and idle
bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Mechanical part of engine.
Detection
Results
Check whether the air filter is blocked and whether the Yes Overhaul the intake system
1
intake passage is leaked.
No Next step
Check the ignition plug of each cylinder to observe Yes Next step
2 whether its model and gap are in compliance with the
specification. No Adjust or replace
Dismantle the idle adjustor to check whether there is Yes Wash the related components
3 carbon deposit in the air throttle body, idle adjustor and
idle bypass air passage. No Next step
Pull out the connector of coolant temperature sensor and Overhaul the lien or replace
Yes
4 start the engine to observe whether the idle speed of the sensor
engine is unstable during warm-up process.
No Next step
Dismantle the fuel injector and use the cleaning analyzer Yes Replacement of trouble
5 special for fuel injector to check whether there is
leakage, blockage or too poor flow in the fuel injector. No Next step
6
No Next step
Check the pressure states of all the cylinders of engine Eliminate the mechanical
Yes
7 and observe whether the pressure difference of each trouble of engine
engine cylinders is large.
No Next step
Connect the adapter of electric control system and turn Yes Diagnosis help
on the ignition switch to check whether the power
8 supplies of the pins #16, #17, #8 and #51 are normal; Overhaul the corresponding
check whether the groundings of pins #5, #43 and #48 No
line
are normal.
213
Electronic Control
Trouble phenomenon 9: Normal start-up but unstable idle speed or flameout under some certain loads
(for example, when the air conditioner is on)
1. Air conditioning system; 2. Idle adjustor; 3.Fuel injector
Detection
Results
Wash the related

Dismantle the idle adjustor to check whether there is carbon deposit Yes
1 components
No Next step
Observe whether the output power of engine is increasing when Yes To step 4
turning on the air conditioner, namely, use the electric control system
2
diagnosis apparatus to observe the changes of ignition advance
No Next step
angle, fuel injector pulse width and intake volume.
Connect the adapter of electric control system and disconnect the Yes Next step
connecting wire of the pin #75 of electronic control module to check
3
whether there is high level signal at the wire harness end when Overhaul the air
No
turning on the air conditioner. conditioning system
Check whether the pressure of air conditioning system, Yes Next step
4 electromagnetic clutch of compressor and the compression pump of
Overhaul the air
air conditioner are normal. No
conditioning system
Yes

No Next step
6
No
214
Electronic Control
Trouble phenomenon 10: Normal start-up but too high idle speed
1. Air throttle body and idle bypass air passage; 2.Vacuum pipe; 3.Idle adjustor; 4.Coolant temperature
sensor; 5.Ignition timing
Detection
Results
Yes Adjust
1 Check whether the throttle wiredrawing is jammed or too tight.
No Next step
Overhaul the intake

Yes
Check whether there is air leakage in the intake system and vacuum system
2
pipeline.
No Next step
Wash the related

Yes
Dismantle the idle adjustor to check whether there is carbon deposit components
3
No Next step
Overhaul the lien or

Pull out the connector of coolant temperature sensor and start the Yes
replace the sensor
4 engine to observe whether the idle speed of engine is too high at this
time.
No Next step
Yes Next step

Check whether the ignition timing of engine is in line with the
5
specification.
Overhaul ignition
No
timing
Connect the adapter of electric control system and turn on the

Yes Diagnosis help
6
#17, #8 and #51 are normal; check whether the groundings of pins
Overhaul the
#5, #43 and #48 are normal. No
corresponding line
215
Electronic Control
Trouble phenomenon 11: Rotating speed fails to increase or flameout occurs during the acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Ignition plug; 4. Air
throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9.Exhaust pipe.

Overhaul the intake
Yes
1 Check whether the air filter is blocked. system
No Next step
front end of the induction manifold of the fuel distribution pipe
2 assembly) to the engine and start the engine to check whether Overhaul the fuel
supply system
350kPa.
3
Dismantle the idle adjustor to check whether there is carbon Wash the related
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass components
air passage.
No Next step
Yes Next step
Check whether the intake pressure sensor, air throttle position
5
sensor and its line are normal. Overhaul the lien or
No
replace the sensor
Yes
No Next step
7
No Next step
Yes Next step
Check whether the ignition sequence of engine and ignition
8
timing is in line with the specification. Overhaul ignition
No
timing
Yes Next step
9 Check whether the operation of the exhaust pipe is smooth.
No
exhaust pipe
10 ignition switch to check whether the power supplies of the pins
#16, #17, #8 and #51 are normal; check whether the Overhaul the
No
216
Electronic Control
Trouble phenomenon 12: Slow reaction during the acceleration
1. Poor quality of fuel; 2. Intake pressure sensor and air throttle position sensor; 3.Ignition plug; 4.Air
throttle body and idle bypass air passage; 5.Intake passage; 6.Idle adjustor; 7.Fuel injector;
8.Ignition timing; 9. Exhaust pipe.
Overhaul the intake

Yes
1 Check whether the air filter is blocked. system
No Next step
2 assembly) to the engine and start the engine to check whether Overhaul the fuel
supply system
350kPa.
3
Yes
4 deposit in the air throttle body, idle adjustor and idle bypass air components
passage.
No Next step
Yes Next step

5
sensor and its line are normal. Overhaul the lien or
No
replace the sensor
Yes
No Next step
7
No Next step
Yes Next step

Check whether the ignition sequence of engine and ignition
8
timing is in line with the specification. Overhaul ignition
No
timing

9 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
ignition switch to check whether the power supplies of the pins
10
No
217
Electronic Control
Trouble phenomenon 13: Powerlessness and poor performance during the acceleration
1. Poor quality of fuel; 2.Intake pressure sensor and air throttle position sensor; 3.Ignition plug;
4.Ignition coil; 5.Air throttle body and idle bypass air passage; 6.Intake passage; 7.Idle adjustor;
8.Fuel injector ; 9.Ignition timing ; 10.Exhaust pipe.
Check whether there are such troubles as the clutch slipping, Yes Repair
1 low tire pressure, brake drag, wrong size of tire and incorrect
alignment of four wheels etc. No Next step
Yes Overhaul the intake system

2 Check whether the air filter is blocked.
No Next step
3 assembly) to the engine and start the engine to check whether Overhaul the fuel supply
system
350kPa.
Pull out the high-voltage wire of one of the cylinders and Yes Next step
connect the ignition plug to make the ignition plug electrodes
4 Overhaul the ignition
around 5mm away from the engine body, and start the engine No
system
to check whether the strength of high-voltage fire is normal.
5
model and gap is in compliance with the specification.
Yes
6 deposit in the air throttle body, idle adjustor and idle bypass air components
passage.
No Next step
Yes Next step
7
sensor and its line are normal. Overhaul the lien or replace
No
the sensor
Dismantle the fuel injector and use the cleaning analyzer Yes Replacement of trouble
8 special for fuel injector to check whether there is leakage or
blockage in the fuel injector. No Next step
9
No Next step
Check whether the ignition sequence of engine and ignition Yes Next step
10
timing is in line with the specification.
No Overhaul ignition timing
11 Check whether the operation of the exhaust pipe is smooth. No
exhaust pipe
12 ignition switch to check whether the power supplies of the pins
No
218
Contents of Overview and Maintenance
Chapter I Overview..........................................................................................................1
Section I General Instructions.....................................................................................................1
I. Summary.............................................................................................................................1
II. How to Use This Manual .....................................................................................................1
Section II Vehicle Information....................................................................................................2
I. Identification Information Position .......................................................................................2
II. Nameplate...........................................................................................................................2
III. Vehicle Identification Number (VIN) ....................................................................................3
IV. Engine Number ...................................................................................................................3
Section III Lifting, Protection and Traction of Vehicle ...............................................................5
I. Lifting of Vehicle..................................................................................................................5
II. Protection of Vehicle ...........................................................................................................5
III. Traction of Vehicle ..............................................................................................................6
Chapter II Maintenance ...................................................................................................8

Section I Maintenance ....................................................................................................................8
I. Preparation .........................................................................................................................8
II. General Maintenance..........................................................................................................8
III. Regular Maintenance ..........................................................................................................9
IV. Recommended Oil and Lubricant......................................................................................11
V. Maintenance of Engine .....................................................................................................12
VI. Maintenance of Chassis and Body....................................................................................20
VII. Maintenance Data.............................................................................................................28
1
Maintenance Manual of Tojoy Sedan Overview
Chapter I Overview
Section I General Instructions
I. Summary
This Manual provides the procedures required by service operations, including:
1. Structure and composition
2. Principles
3. Dismantlement and installation steps
4. Inspection methods
5. Adjustment & commissioning methods
6. Common trouble diagnosis procedures
7. Technical parameters
The simple operations that can be conducted through the observation of vehicle are left out in this
Manual. No description is given for the necessary basic skills of maintenance technicians in this Manual.
II. How to Use This Manual

This Manual covers four parts, i.e. engine volume, chassis volume, electrical appliance & structure
volume of vehicle body, and circuit overhaul volume. In the front of each part is given a detailed content
index, in which you can find the section you want quickly.
The content provided in this Manual includes the following information:
1. Working principles;
2. Element position
3. Overhaul specifications
4. Component dismantlement & installation steps
5. Common troubles and overhaul procedures
Such information accords with the current model when this Manual is published.
1
Section II Vehicle Information

I. Identification Information Position
II. Nameplate
1. Position of nameplate: it is located at the firewall of engine compartment.
2. Instructions of nameplate
Made
Madebyby China
China Anhui
Anhui Jianghuai
Jianghuai Automobile
Automobile Co.,
Co., Ltd.
Ltd.
Brand Jianghuai VIN LJ12FKR1584200046
Model HFC7130AG Engine displacement 1.30L
Engine Model 4G13S1 Rated power 68.5 Kw
Max. gross weight 1475 Kg Fixed number 5 persons
Ex-factory no. 8420046 Ex-factory date Sep. 2008
Example of Nameplate
2
III. Vehicle Identification Number (VIN)

1) VIN position: it is located on the nameplate or at the bottom left corner of windshield.
2) Illustration of VIN
Production SN
Assembly factory
4: General Assembly Workshop of Passenger Car
Manufacture Company
7: General Assembly Workshop of Passenger Car
Inspection
digit
Year code
8: 2008
9: 2009
A: 2010
Vehicle type
2: passenger car
Code of engine type and rated

Wheelbase power
R: >2390~2600 1: gasoline ≤70Kw
2: gasoline >70~90Kw
3: gasoline >70~110Kw
Manufacturer Body type Max. gross weight
LJ1: Anhui Jianghuai F: 3 boxes & 4 doors K: >1000~2000
Automobile Co., Ltd. G: 2 boxes & 5 doors
IV. Engine Number

1. Position of engine number
It is printed on the rear left of cylinder body.
Fig. 1.2.001
3
2. Meaning of Engine Number

Fig. 1.2.002
4G13S1 – Engine model
☆D284S0027☆:
D284S0027 – Production Code
D2 – Division symbol of engine model
8 – 2008
4 – April
S0027 – Production SN
4
Section III Lifting, Protection and Traction of Vehicle

I. Lifting of Vehicle
1. Vehicle’s Supporting Points
The positions of vehicle’s supporting points are shown in the figure below.
Attention:
Don’t lift the vehicle by using the point out of the designated positions; or else, the body may be
damaged.
Supporting point
Positions of Vehicle’s Supporting Points
2. Operation of Lifter
The lifter shall be operated strictly in accordance with the specifications of manufacturer.
Caution:
The operation against the specifications may cause the damage or injury to vehicle or personnel.
II. Protection of Vehicle

1. Appearance Protection
Before working, make sure that the vehicle is fitted with four appliances, i.e. seat cover, steering
wheel cover, gearshift lever cover, and foot mat. A protective pad must be applied on the fenders
when opening the engine hood for overhaul.
2. Preventive Measures Before Welding
Since electrical components are installed on the vehicle, the following procedures must be carried
out in order to avoid too large current through such components in welding.
1) Turn the ignition switch to “OFF” position;
2) Cut off the negative wiring of storage battery;
3) Ground the welding equipment carefully at a point nearby the welding area;
4) Cover other equipment around the welding area to prevent solders from splashing on them.
5
III. Traction of Vehicle

If the traction of vehicle is required, please contact the local authorized after-sales service center or
a special vehicle towing service company.
1. Traction by towing vehicle
Caution:
No passenger allowed in the vehicle being towed;
Don’t allow the traction speed over the safety speed or the stated speed limit;
Make sure the vehicle being towed are fixed firmly;
Operation against above-mentioned precautions may cause physical injury.
2. Traction by wheel lifter
1) Turn the ignition switch to “ACC (accessory)” position;
2) Turn on the hazard warning flash lamp;
3) Shift to neutral gear;
4) Release the parking brake;
5) Make sure the front wheels are away from ground.
Attention:
If it is necessary to tow the vehicle from the back, the supporting wheel of traction device should be
applied under front wheels. Don’t allow front wheels in contact with ground in towing; or else, the
transmission may be seriously damaged.
3. Emergency towing
If no towing vehicle is available under emergency, a rope may be fixed to the emergency towing
hole under the vehicle for temporary traction.
1) Front towing hole: It is under the front bumper. A Fig. 1.3.001
driver is required in the vehicle for steering and
braking purposes in towing. Such traction method
is applicable only on hard pavement with towing
distance and speed limited to certain extent. In
addition, such parts as wheels, axles, drive
system, steering system, and brakes must be in
good conditions.
Towing hole
6
Caution:
The vehicle may be damaged when towed by rope.
In order to minimize such damage,
① If no other towing equipment is available, the towing hole must be used;
② Always tow the vehicle from its forehead;
③ Keep the towing rope away from the bumper;
④ Check the towing rope by pulling it to make sure

both ends of it are fixed firmly on the towing hole.
Fig. 1.3.002
2) Rear towing hook: It can used to tow another
vehicle only under emergency (when a vehicle is
trapped in a ditch, heavy snow or mud pit). When
using the rear towing hook, always keep the rope or
chain perpendicular to the towing hook. Don’t apply
force to the towing hook from any side. Don’t start the
towing sharply to avoid any damage.
Towing hook
7
Maintenance Manual of Tojoy Sedan Maintenance
Chapter II Maintenance
Section I Maintenance
I. Preparation
1. Maintenance Tools
List of Maintenance Tools
No. Tools Outside View Description
For dismantlement and

1 Power tool installation of bolts and
nuts
For dismantlement and

Ignition plug
2 installation of ignition
socket
plug
II. General Maintenance

General maintenance means the inspection and maintenance items which shall be performed everyday
during the normal use of vehicles. These maintenance items are very important, for they can keep the
vehicle under normal service performance. Vehicle owners can perform these inspections by
themselves, or go to a JAC franchised store for assistance. As follows is content of general
maintenance:
1. Exterior of Vehicle
The following inspection and maintenance items shall be frequently conducted.
List of Items to be Frequently Inspected for the Exterior of Vehicle
Item Inspection
Tyre Use an air gauge to inspect the pressure of tyres (including spare tyre) in the service
station regularly, and adjust the pressure in accordance with technical data if necessary.
Check whether there’s any damage, crack or excessive wear and tear carefully.
Windshield Clean the windshield regularly. Check whether there’s any crack or other damage in/to
the windshield every six months or more frequently. And repair it, if necessary.
Windshield If the wiper doesn’t work efficiently, please check whether it is free from tear or wear.
wiper blade
Door and Check whether all of the doors, engine hood, boot cover and tail door can be normally
engine hood opened and closed, and whether all the door locks are locked close. Lubricate any of
them, if necessary. Moreover, If the vehicle often travels on the salt-spread roads or in the
areas with corrosive substances, inspect the lubricating state frequently.
Tyre rotation The tyre rotation shall be conducted after each 8000 km traveling.
Vehicle lamps Check whether the headlamp, stop lamp, tail lamp, turning signal light and other lighting
units are working normally, and have been stably fixed. Meanwhile, inspect the focusing
function of headlamp.
8
2. Interior of Vehicle
The following inspection and maintenance items shall be regularly performed.
List of Items to be Regularly Inspected for the Interior of Vehicle
Item Inspection
Alarm light and Make sure all the alarm lights and buzzers are working normally.
buzzer
Windshield wiper Check whether the wiper and cleaner are working normally; check whether there
and cleaner is any crack in the wiper.
Windshield defroster Check whether the air can be correctly bled from the air outlet hole of defroster,
and if the heater or air conditioner can breathe enough air during the operation of
heater or air conditioner.
Steering wheel Check whether the free travel of steering wheel is in the standard range. And
inspect the changes of steering performance, such as the free travel beyond the
range, hard steering and abnormal noise etc.
Safety Belt Check whether all the components of safety belt system are flexible and working
normally, and fixed firmly and stably. Inspect whether the safety belt is cracking,
worn out or damaged in other ways.
Accelerator pedal Check if the pedal can be operated smoothly, and ensure that the pedal would not
be seized or loaded unevenly. And also make sure that the bottom plate pad is far
from the pedal.
Brake pedal and Check if the pedal can be operated smoothly, and make sure the pedal still keeps
booster an appropriate distance from the bottom plate when it is completely pressed
down. Inspect the function of brake vacuum booster. And make sure that the
bottom plate pad is far from the pedal.
Parking brake Check the travel of handle.
3. Engine and Vehicle Chassis
The following inspection and maintenance items shall be regularly performed.
List of Items to be Regularly Inspected for the Engine and Vehicle Chassis
Item Inspection
Cleaning liquid for windshield Check whether there is adequate cleaning liquid within the
stock solution tank.
Level of engine coolant Check the coolant level when the engine is cold.
Engine oil level Stop the vehicle on a level ground, then switch off the engine,
and check the engine oil level.
Levels of brake fluid and clutch fluid Make sure that the levels of brake fluid and clutch fluid are
between the “MAX” line and “MIN” line of stock solution tank.
Storage battery Check the state of voltage and electric pole terminal posts of
storage battery.
Liquid leakage After the vehicle has been stopped for a while, check if there is
any leakage of fuel, engine oil, water or other liquid under the
vehicle. The dripping from the air conditioner which has just
been used is normal; however, in case of obvious leakage or
petrol fume, we shall find out the cause, and immediately
perform relative maintenance.
III. Regular Maintenance
The regular maintenance intervals and items for vehicle in general traveling conditions are shown in the
following table. These maintenances shall be preformed by a JAC franchised store.
9
Maintenance List of Vehicle in General Driving Conditions
Illustration of symbols: ● = inspection, adjustment or cleaning, replacement, if necessary; ▲ =

replacement; T = tightening to specified torque. (Note: mileage or months, whichever comes first.)
Interval Mileage (km) × 1000 5 10 20 30 40 50 60 70 80 90 100
Item months 3 6 12 18 24 30 36 42 48 54 60
Engine oil, engine oil Replaced after every 5,000 km or six months
filter
Filter element of air Cleaned after every 5,000 km, and replaced after every 15,000
filter km
A/C warm air system ● ● ● ● ● ●
Coolant ● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
Cooling system hose
● ●
and clamping band
Vent hose and
Engine ● ● ● ● ● ●
connector
Positive crankcase
● ●
ventilation system
Fuel filter ▲ ▲ ▲ ▲ ▲
Exhaust pipe and
● ● ● ● ● ●
installation seat
Ignition plug ▲ ▲ ▲
Ignition timing ● ●
Timing belt ● ● ● ● ● ● ● ▲ ● ● ●
Maintenance List of Vehicle in General Driving Conditions (Continued)

replacement; T = tightening to specified torque. (Note: mileage or months, whichever comes first.)
Interval 5 10 20 30 40 50 60 70 80 90 100
Mileage (km) × 1000
Item
months 3 6 12 18 24 30 36 42 48 54 60
Clutch pedal free
● ● ● ● ● ● ● ● ● ● ●
travel
Clutch pedal free
● ● ● ● ● ● ●
travel and brake
Brake pad and
● ● ● ● ● ● ● ● ● ● ●
brake disc
Brake fluid and hose ● ● ● ● ▲ ● ● ● ▲ ● ●
Steering wheel and
● ● ● ● ● ●
transmission
Four-wheel
● ● ● ● ● ● ● ● ● ● ●
alignment
Chassis and
Ball pin and dust
Body ● ● ● ● ● ● ● ● ● ● ●
boot
Transmission gear
▲ ▲ ▲ ▲ ▲ ▲
oil
Front and rear
● ● ● ● ● ●
suspensions
Bolt and nut T T T T T T T
Tyre and inflation
● ● ● ● ● ● ●
pressure
Power steering fluid ● ● ● ● ▲ ● ● ● ▲ ● ●
Air conditioner / cool
● ● ● ● ● ● ●
air
10
While the vehicle is operating under the following particular or severe conditions, the supplementary
maintenance shall be performed or the maintenance interval shall be shortened.
1. Repeated short-distance traveling;

2. Continuous idle running or long-time intermittent driving;
3. Traveling on the sand ground or in dusty conditions;
4. Frequently travels in traffic congestion condition;
5. Frequent high-speed driving.
Maintenance List of Vehicle in Particular or Severe Driving Conditions

replacement; T = item needs to be tightened to specified torque. (Note: mileage or months, whichever
comes first.)
Interval Mileage (km) × 1000 5 10 20 30 40 50 60 70 80 90 100
Item months 3 6 12 18 24 30 36 42 48 54 60
Drive belt Check and adjust it every 10,000 km, replace it when
necessary.
Engine oil, engine oil Replaced after every 5,000 km or three months
filter
Filter element of air Cleaned after every 3,000 km, and replaced after every 10,000
Engine
filter km
Vent hose and
● ● ● ● ●
connector
Ignition plug ▲ ▲ ▲ ▲ ▲
Idle speed ● ● ▲ ● ▲ ●
Clutch pedal free It shall be adjusted every 5，000 km.
travel
Tyre and inflation
● ● ● ● ● ● ● ● ● ● ●
pressure
Chassis and
Dust filtering screen ● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
Body
Front wheel
● ● ▲ ● ▲ ● ▲ ● ▲ ● ▲
alignment
Transmission gear
● ● ● ▲ ● ● ▲ ● ● ▲ ●
oil
IV. Recommended Oil and Lubricant
As shown in the following list are the types of oil and lubricant recommended by JAC:
List of Recommended Oil and Lubricant
Item Capacity (L) Recommended oil / lubricant

Engine oil 3 SAE5W-30 (winter in the north), SAE15W-40 (full year
in the south or summer in the north) grade SJ or above
Cooling system 5.5 High-quality HF-C anti-freezing solution
Manual transmission gear oil 2.0 API GL-4, SAE75W/90
Power steering fluid 0.9 PSF-3
Brake fluid and clutch fluid 0.56±0.05 DOT4 (Great Wall)
A/C refrigerant 480g R134a
Wiper cleaning liquid 3 JAC—A10010
A/C compressor lubricating oil 0.12 PAG56
11
V. Maintenance of Engine
1. Inspection for the Driving Belt

1) The inspection shall be performed only when the engine is cold or after the engine has been
stopped for 30 min.
2) Check visually whether there is any damage, wear or crack on the inside or edges of belt.
3) Rotate the crank pulley clockwise for two times, and then check whether the tension values of all
belts are same through testing.
4) During the measurement of deflection, a force of 98 N shall be applied.
5) If the deflection exceeds the limited value, corresponding adjustment shall be performed.
■ Belt deflection: 7~10 mm.
Attention:
■ After installation, the belt deflection shall be immediately inspected in this way: adjust the deflection
to the specified value at first, and then rotate the crankshaft for more than two circles, after that, in
order to avoid the variation of deflection between belt pulleys, adjust it to the specified value again.
2. Adjustment of Tension Degree
List of Adjustment of Tension Degree
Part Adjusting Method
Generator belt Adjust the adjusting bolt on the generator
Belts of power steering pump and A/C Adjust the adjusting bolt on the power steering pump
compressor
Attention:
■ Upon the old belt is replaced by a new one, the deflection of new belt shall be adjusted, such as to
make it fit in with the pulley groove.
■ After installation, the belt deflection shall be immediately inspected in this way: adjust the deflection
to the specified value at first, and then rotate the crankshaft for more than two circles, after that, in
order to avoid the variation of deflection between belt pulleys, adjust it to the specified value again.
■ During the installation of belt, please make sure that the belt is in correct mesh with the pulley
groove.
■ Don’t spill the engine oil or engine coolant on the belt.
■ Don’t excessively wind or twist the belt.
3. Replacement of Engine Coolant
Caution:
■ In order to avoid scald, please do not replace the coolant when the engine temperature is still very
high.
■ Use thick cloth to wrap the radiator cap, and unscrew it carefully. Release the pressure inside the
radiator at first, and then completely unscrew it to open the radiator.
■ Be careful, so as not to spill the engine coolant on the driving belt.
1) Draining the engine coolant
12
① Dismount the right deflector of engine. See “Engine Deflector” please.

② Open the water drain plug at the bottom of radiator, and then open the cap of radiator.
③ If necessary, please dismount the stock solution tank, drain the engine coolant, and clean the stock
solution tank prior to the reinstallation.
④ Check if there’s any foreign matter such as rust or any color change in the discharged engine
coolant.
■ In case it is polluted, please wash the engine cooling system. See “Washing the Cooling System”
please.
2) Refilling the engine coolant
① Install the dismantled stock solution tank and the water drain plug of radiator.
Attention:
■ The water drain plug must be cleaned, and a new O-ring must be installed.
② Please make sure that all the hose clamps have been stably tightened.
③ Dismount the upper cover of air filter and the intake hose. Please refer to the “Air Filter Assembly”.
④ Cut off the outlet tube of warm water pipe. Please lift the hose as high as possible.
⑤ Fill coolant into the radiator and stock solution tank to the specified level; the engine coolant must be
filled in a slowly way, such as to gradually remove the air from the system.
Attention:
■ Please mix the original JAC engine coolant or equivalent product with water. See “Recommended
Oil and Lubricant” please.
■ When the engine coolant overflows from the warm air outlet pipe, cut off the connection, and then
reconnect them and continue the filling of engine coolant.
⑥ Install the upper cover of air filter and intake hose. Please refer to “Air Filter Assembly”.
⑦ Install the radiator cap.
⑧ Warm up the engine until the thermostat is switched on.
■ Examine if there’s warm water flowing out by touching the lower hose of radiator, such as to check
whether the thermostat has been switched on.
Attention:
■ Observe the water temperature gauge of engine frequently, such as to avoid the overheating of
engine.
⑨ Stop the engine, such as to lower the temperature.
■ The cooling time can be reduced through the use of fan.
⑩ Fill the engine coolant in the stock solution tank to the MAX level.
⑪. Install the radiator cap, and repeat steps ③~⑨ for more than two times until the level of engine
coolant doesn’t go down any more.
13
○
12 Start the engine, and check if there’s any leakage in the cooling system.
3) Washing the cooling system

① Install the water drain plug of radiator and the stock solution tank which have been dismantled.
Attention:
■ The water drain plug must be cleaned, and a new O-ring must be installed.
② Dismount the upper cover of air filter and the intake hose. Please refer to the “Air Filter Assembly”.
③ Cut off the outlet tube of warm water pipe. Please lift the hose as high as possible.
④ Fill engine coolant into the radiator and stock solution tank, and install the cap of radiator.
When the engine coolant overflows from the warm air outlet pipe, cut off the connection, then reconnect
them and continue the filling of engine coolant.
⑤ Install the upper cover of air filter and intake hose. Please refer to “Air Filter Assembly”.
⑥ Start the engine, warm up it to the normal working temperature.
⑦ Speed up the engine for several times with it unloaded.
⑧ Stop the engine, and wait for the engine to cool down.
⑨ Discharge the water inside the system. Please refer to “Draining the engine coolant”.
⑩ Repeat steps ③~⑨ until the radiator starts to discharge the cleared water.
4. Inspection for the Cooling System
Caution:
■ Never open the radiator cap when the temperature of engine is still very high. The high temperature
and high pressure liquid overflowing from the radiator may cause severe scald.
■ Use thick cloth to wrap the radiator cap, firstly unscrew it for 1/4 circle to release the pressure inside
the radiator, and then completely unscrew it to open the radiator.
1) Inspection for the hose of cooling system
■ Check the hose for incorrect installation, crack, damage, loose connection, wear or ageing.
■ Please repair or replace the damaged components if necessary.
2) Inspection for radiator cap
① Check the valve seat of radiator cap.
■ Check whether the valve seat expands outward, i.e. when the plunger is vertically lifted from the top,
the end of plunger is out of view.
■ Check if there’s any dust or damage on/to the valve seat.
14
② Withdraw the negative pressure valve and

Fig. 2.1.001
open it, and upon the pressure is released,
check whether it can be completely closed.
■ Please make sure that there isn’t any smudge
or damage on/to the valve seat.
■ Make sure that the valve seat can be normally
opened and closed.
③ Check the pressure released by radiator cap.
Standard: 78~98 KPa
Limit: 59 KPa Fig. 2.1.002
— Connect the radiator cap to the radiator leak
detector, and please apply engine coolant
onto the sealing face of cap.
■ In case abnormal situation is found in the
above-mentioned three inspection items,
please replace the radiator cap.
Attention:
■ During the installation of radiator cap, please wipe the radiator filler carefully to clear away all the
paraffin residue or foreign substance.
3) Inspection for radiator
Check whether there’s any mud or clogging situation inside the radiator. If necessary, please clean the
radiator surface according to the following method.
■ Don’t twist or damage the radiation fins.
■ In case the cleaning work is performed without dismounting the radiator, all the accessories such as
cooling fan, wind collection hood and horn shall be dismounted. Then, use adhesive tape to wrap up
the connectors of wire harness for water proofing.
① Use a water hose to wash the back of radiator core from the top to the bottom vertically.
② Wash each surface of the radiator core every other minute.
③ In case no dirt is washed away from the radiator, the washing work shall be stopped.
④ Blow the back of radiation core with compressed air vertically and downwards. The pressure of
compressed air shall be less than 490 KPa, and a distance of more than 30 cm shall be kept.
⑤ Wash each surface of the radiator core with compressed air every other minute until no water can
be blown away.
4) Inspect whether there’s leakage in the system
① The leakage situation shall be inspected through applying a pressure to the cooling system with a
leak detector of radiator cap.
15
■ Test pressure: 157 KPa

Fig. 2.1.003
Caution:
■ Never open the radiator cap when the temperature
of engine is still very high; or else the high
temperature and high pressure liquid overflowing
from the radiator may cause severe scald.
Attention:
■ A pressure exceeds the specified test pressure
may cause damage to the radiator.
Note: In case the engine coolant is found decreased, please refill engine coolant into the radiator.
(1) If any component is found damaged, please repair
or replace it.
5. Inspection for Fuel Pipeline Fig. 2.1.004
Check the fuel pipeline, fuel filler cap and fuel tank for
incorrect installation, leakage, crack, damage, loose
connection, wear or ageing. Fuel pipeline
Engine
Fuel tank
■ Please repair or replace the damaged component
if necessary.
6. Replacement of Air Filter

Fig. 2.1.005
1) Dismantlement
① Unscrew the lock bolt of upper cover of air filter,
and lift up the upper cover.
② Dismount the filter element of air filter. Fig. 2.1.006
2) Inspection After the Dismantlement
■ The air filter must be regularly cleaned or replaced

according to the recommended schedule. Please
refer to “Regular Maintenance”.
16
■ Use compressed air to blow the back of filter element of air filter until nothing can be blown away.
3) Installation
7. Replacement of Engine Oil
Attention:
■ The temperature of engine oil is very high, so you should be careful not to be scalded.
■ Long-time direct contact between skin and the used oil shall be avoided. In that case, the skin shall
be thoroughly washed with soap or detergent as soon as possible.
1) Warm up the engine, and check whether there’s engine oil leakage in the engine hatch. Please refer
to “Leakage of engine oil”.
2) Switch off the engine, and wait for ten minutes.
3) Loosen the engine oil filler cap, and then dismount the oil drain bolt.
4) Discharge the engine oil.
5) Install the oil drain bolt with new gasket.
Attention:
■ The foreign matters such as iron dust on the oil drain bolt must be cleaned, and new gaskets shall
be installed.
■ The tightening torque of oil drain bolt is 34~44 N·m.
6) Refill the new engine oil.
Concerning the specification and viscosity of engine oil, please refer to “Recommended Oil and
Lubricant”.
■ Engine oil quantity: 2.5~3.5 L
Attention:
■ During the filling of engine oil, please do not withdraw the oil rule.
■ The filling amount of engine oil shall vary with engine oil temperature and oil drain time. The content
above is only for reference.
■ Oil rule shall be used all the way to check whether the filling amount of engine oil is proper.
7) Warm up the engine, and check whether there’s any engine oil leakage around the oil drain bolt and
engine oil filter.
8) Switch off the engine, and wait for ten minutes.
9) Check the level of engine oil. See also “Engine oil level”.
8. Replacement of Engine Oil Filter
1) Dismantlement
① Use engine oil filter wrench to dismount the engine oil filter.
17
Attention:
■ Original JAC engine oil or equivalent product shall be used.
■ Both the temperatures of engine and engine oil are very high, so you should be careful not to be
scalded.
■ For the dismantlement, a cloth shall be prepared to wipe up the leaked or splashing engine oil.
■ Please keep the driving belt free from engine oil.
■ Wipe up the engine oil splashing on the engine and vehicle thoroughly.
2) Installation Fig. 2.1.007

① Clear the foreign substance on the mounting
surface of engine oil filter.
② Apply a proper layer of engine oil onto the oil
seal surface of new engine oil filter.
③ Tighten the engine oil filter.
■ Tightening torque: 1 2~20N·m
Attention:
■ The engine oil filter must be tightened with a filter wrench.
■ Manual tightening may cause oil leakage due to the inadequate tightening torque.
3) Post-installation inspection
① Check the engine oil level, and fill engine oil when it is inadequate. See also “Engine Oil”.
② Start the engine, and check if there’s any engine oil leak.
③ Switch off the engine, and wait for ten minutes.
④ Check the engine oil level, and fill engine oil. See also “Engine Oil”.
9. Replacement of Ignition Plug
1) Dismantlement
① Dismount the engine hood. See also “Intake manifold”.
② Dismount the ignition coil and high-voltage wire. See also “Ignition coil”.
③ Use ignition plug socket wrench to dismount the ignition plug.
Attention:
■ Please do not drop or shock the ignition plug.
18
2) Inspection after the dismantlement
In general conditions, the standard ignition plug shall be used.
In the following conditions, if carbon deposition frequently occurs during the use of standard ignition plug,
the hot ignition plug shall be used:
■ The engine is frequently started.
■ The ambient temperature is too low.
In the following conditions, in case ignition knock frequently occurs during the use of standard ignition
plug, the cold ignition plug shall be used:
■ Long-time traveling on the expressway;
■ The engine is frequently running under a high speed.
Attention:
■ Please do not drop or shock the ignition plug.
■ Please do not use the steel brush for washing.
■ If there’s carbon deposition in the end of ignition plug, please use ignition plug cleaner to clean it.
■ During the replacement interval, the ignition plug gap shall be checked when it is necessary.
Ignition plug gap: 1.0~1.1 mm
3) Installation
Install in the reverse order with dismantlement. The tightening torque of ignition plug is: 20~30 N·m.
10. Replacement of Fuel Filter
1) Dismantlement
Caution:
■ Prior to the treatment of fuel system, one must read the “General Precautions”. See also “General
Precautions”.
① Release the fuel pressure inside the fuel pipeline. See also “Releasing the fuel pressure”.
② Open the fuel filler cap.
③ Release the pressure inside the fuel tank.
④ Dismount the rear seat cushion. See also “Rear Seat”.
⑤ Dismount the fuel tank service cap.
⑥ Dismount the fuel filter and fuel pipe.
For detailed description, please refer to “Fuel Filter”.
19
2) Installation
Please pay attention to the following precautions and install in the reverse order with dismantlement.
① Installation direction of fuel filter Fig. 2.1.008
■ Pay attention to the installation direction of

fuel filter.
Towards the side of inlet tube.
② Installation of pipe connectors.
3) Post-installation inspection
Check whether there’s any fuel leakage according to the following steps.
① Turn the ignition switch to “ON” (while the engine is shut-off), and then check if there’s leakage at
the joints of fuel pipeline.
② Start the engine and enhance the rotating speed, then double check if there’s fuel leakage at the
joints of fuel pipeline.
11. Inspection for the Evaporator Pipeline of Fuel Evaporative Emission System (EVAP)
1) Visually check whether the installation position of EVAP evaporator pipeline is correct, and if it is
free from leakage, crack, damage, loose connection, scratching or ageing etc.
2) Check if the vacuum release valve of fuel tank cap is free from blocking, or jamming etc. See also
“Fuel Evaporative Emission System”.
VI. Maintenance of Chassis and Body
1. Inspection for Exhaust System
Check whether the positions of exhaust pipe, muffler and fixed support are correct, and if they are free
from leakage, crack, damage, loose connection, wear and ageing.
■ In case the component is found damaged,

Fig. 2.1.009
please repair or replace it.
20
2. Inspection for Clutch Fluid Level and Leakage
If the fluid level is too low, please check whether the clutch system is free from leakage.
3. Inspection for Clutch System
Check whether the installation positions of liquid pipelines and working cylinders are correct, and if they
are free from crack, damage, loose connection, wear or ageing.
4. Inspection for Manual Transmission Gear Oil
Check the oil level and if it is free from leakage. For detailed information, please refer to “Inspection for
Manual Transmission Oil”.
5. Replacement of Manual Transmission Gear Oil
1) Fully drain the oil from the oil drain plug, and then refill it with new gear oil. For detailed information,
please refer to “Replacement of Manual Transmission Oil”.
2) Check the fluid level of gear oil. For detailed information, please refer to “Inspection for Manual
Transmission Oil Level”.
6. Wheel Balance
1) Dismantlement
① Dismount the wheels and tyres which need to be adjusted.
② Dismount the used balance blocks from both sides of the wheel, and clear the foreign matters on the
treads of tyre.
Note: for new tyres, the tape on the tyre shall be removed.
Attention:
■ During the dismantlement, be careful not to scratch the tyre.
2) Adjustment for wheel balance
① Take the center hole as the guidance, and install the wheel to the wheel balancer. Start the wheel
balancer.
② When the unbalance values for both inside and outside have been displayed on the display of wheel
balancer, multiply the unbalance value of outside with 5/3, such as to define the weight of balance
blocks which will be actually applied. Then, select the outside balance block which is nearest to the
calculated value, and install it to the specified outside position, or at the specified angle in relation to
the wheel.
Attention:
■ The outside balance block shall be installed first, and followed by the inside one.
■ Prior to the installation of balance block, the fitting surface of wheel must be thoroughly cleaned.
a. Install the balance block to the position indicated in the figure.
21
b. As shown in the figure, during the installation

Fig. 2.1.010
of balance block on the wheel, the balance
block shall be placed in the groove area on the
wheel inner wall, and fix its center toward the Adhesive weight
Center of gravity
position (or angle) indicated by the wheel
balancer.
Aim toward
the groove
Position (or angle) indicated

by the wheel balancer
Attention:
■ The balance block can not be repeatedly used; it shall be replaced every time.
■ At most three balance blocks are allowed to be installed.
■ The original balance blocks shall be applied all along.
c. In case the calculated weight of balance block Fig. 2.1.011
is more than 50 g, the two balance blocks
shall be installed in a line.
Attention:
■ Please do not place a balance block on
another one.
③ Restart the wheel balancer.
Position (or angle) indicated
④ According to the position (or angle) indicated by the wheel balancer
by the wheel balancer, knock in the balance

block at the inside of wheel.
Attention:
■ At most two balance blocks are allowed to be installed.
⑤ Start the balancer. Make sure the residual unbalance value of both the inside and outside is only 5 g
or less.
■ In case the residual unbalance value of either side is more than 5 g, please repeat the installation
steps for balance block.
7. Tyre Rotation Fig. 2.1.012
■ Tyre rotation shall be performed every 8000
km.
Tyre rotation also shall be performed when the
new tyre is put on.
Note: As shown in the figure is the recommend
method for tyre rotation.
22
8. Inspection for Brake Fluid Level and Leakage Fig. 2.1.013

Highest line
If the fluid level is too low, please check whether
the brake system is free from leakage. Lowest line
Normal
9. Inspection for Brake Pipeline and Wiredrawing Fig. 2.1.014
Check whether the positions of brake pipeline and

parking brake wiredrawing are correct, and if they
are free from leakage, wear, scratching or ageing
etc.
10. Replacement of Brake Fluid
Attention:
■ Refill brake fluid “DOT4” (Great Wall).
■ Please do not reuse the discharged brake fluid.
■ In order to keep the paintwork free from damage, please do not splash the brake fluid onto the
paintwork. If the fluid is splashed onto the paintwork, please use water to clean it immediately.
1) Insert the ethylene tube into the release valve. Fig. 2.1.015
2) Press on the brake pedal, loosen the release

valve, and then discharge the brake fluid
slowly.
3) Wash the inner side of stock solution tank, and refill it with new brake fluid.
4) Loosen the release valve, press down the brake pedal slowly, and then release it. Repeat this
23
process every other 2 or 3 s until there’s outflow of Fig. 2.1.016

new brake fluid, and then press on the brake pedal
and close the release valve. Repeat this operation
process for all the wheels.
5) Release the air. See also “Air Release from the Brake Pipeline”.
11. Inspection for Brake
1) Brake disc
Check whether it is free from wear and damage.
Standard Specification Table of Brake Disc
Type Floating caliper type / with ventilated disc

Brake disc diameter 241 mm
Brake disc Brake disc thickness 19 mm
Friction block thickness 9 mm
Cylinder bore 51 mm
2) Brake drum
Check whether the inner diameter and circular runout of brake drum are in the scope of standard values.
If not, corresponding processing or replacement shall be performed.
Standard Specification Table of Brake Drum
Type Leading trailing shoe brake

Brake drum diameter 204 mm
Brake drum Cylinder bore of brake slave cylinder 17.46 mm
Clearance adjustment Automatically
Circular runout < 0.05 mm
3) Brake caliper Fig. 2.1.017
Check if there’s any oil leak.
24
4) Rear brake wheel cylinder Fig. 2.1.018
Check if there’s any oil leak.
5) Front brake shoe Fig. 2.1.019
Check the situation of wearing or damage.
■ Standard thickness: -9 mm
■ Wearing limit thickness: 2 mm
6) Rear brake shoe Fig. 2.1.020
Check the brake shoe thickness and its contact

state with the brake drum. If it fails to meet the
requirement, please replace it.
■ Standard thickness of brake shoe (A): 5 mm
■ Allowable limiting thickness (A): 1 mm
12. Inspection for Steering Gear and Pull-rod Fig. 2.1.021
1) Steering gear
■ Check whether the steering gear housing and

dust boot are free from looseness, damage
Check the leakage of
and lubricating grease leak. lubricating grease
Check the tightening torque
■ Check whether its connection with the
steering column is loose.
25
2) Steering pull-rod
Check whether the ball joint, dust boot and other components are free from looseness, wear, damage or
lubricating grease leak.
13. Inspection for Power Steering Fluid and Pipeline
Shut off the engine, and check the fluid level in the stock solution tank.
Attention: Fig. 2.1.022

■ Please do not fill excessive oil.
■ Check whether the installation position of pipeline is

correct, and if it is free from leakage, crack, damage,
loose connection, wear or ageing.
■ Check if there’s power steering fluid accumulation on

the dust boot of rack.
14. Axle and Suspension Components
Check whether the clearance between front/rear axles and suspension components is excessive, and if
they are free from crack, damage, wear or other damages.
■ Rock each wheel to check if the clearance is Fig. 2.1.023

excessive.
■ Check the working situation of wheel bearing.
■ Check whether the axle, suspension nut and bolt are

loose.
■ Check whether the shock absorber is free from oil

leak or other damages.
■ Check whether the suspension ball joint is free from

lubricating grease leak, check if the ball joint dust boot
is free from crack or other damages.
Fig. 2.1.024
26
15. Inspection for Front Drive Shaft Fig. 2.1.025
Check whether the dust boot and drive shaft are

free from crack, wear, damage and lubricating
grease leak.
16. Lubrication of Door Lock, Hinge and Engine Hood Lock Pin
Diagram of Lubricating Sites of Door Lock, Hinge and Engine Hood Lock Pin
17. Inspection for Safety Belt, Fastener and Pre-tensioner
Attention:
■ After any kind of impact, all the safety belt assemblies including the retractor and other accessories
(such as fixing bolt, guide rail device) shall be checked.
We suggest that you should replace the used safety belt assembly after an impact, unless it is still free
from any damage after slight impact.
And the safety belt assembly which is not used during the impact shall also be checked, please replace
any damaged safety belt assembly.
27
In case a front impact which activates both driver’s and passenger’s airbags happens, the safety belt
pre-tensioner shall be replaced, even though the safety belt is not used at all.
■ If any component of safety belt assembly has problems, please do not repair it, but replace the
safety belt assembly.
■ In case the safety belt is broken, worn or damaged, please replace the safety belt assembly.
■ Please do not lubricate the lock tongue and snap ring.
■ Use original safety belt assembly of JAC.
■ Check whether the anchorage is loose.
■ Check whether the safety belt is damaged.
■ Check whether the motion of retractor is flexible.
■ While the snap ring is open, check whether the snap ring and lock tongue function normally.
VII. Maintenance Data
1. Tightening Torque of Standard Components
Tightening Torque List of Standard Components
Nominal Diameter of Torque (N·m)

Thread Pitch
Thread Head mark 4 Head mark 7
M5 0.8 3~4 5~6
M6 1.0 5~6 9~11
M8 1.25 12~15 20~25
M10 1.25 25~30 30~50
M12 1.25 35~45 60~80
M14 1.5 75~85 120~140
M16 1.5 110~130 180~210
M18 1.5 160~180 260~300
M20 1.5 220~250 360~420
M22 1.5 290~330 480~550
M24 1.5 370~420 610~700
Attention:
■ The torques listed above are the standard values which are applied to the following conditions:
a. Steel, plating nuts and bolts.
b. Plated steel plain washers.
28
c. All the dry nuts, bolts and gaskets.
■ The torques listed above are not applied to the following conditions:
a. When the component is to be tightened with spring gasket and tooth washer;
b. During tightening of the plastic parts.
c. When self-tapping screw or locknut is used.
d. In case of oiled thread and surface.
■ In the following conditions, the torques listed above shall be correspondingly reduced:
a. if a spring gasket is used, the torque shall be reduced by 15%.
b. If the bolt surface is coated with engine oil, the torque shall be reduced by 15%.
29
Maintenance Manual of Tojoy Sedan Clutch and Manual Transmission
Chassis Volume
Chapter I Clutch and Manual Transmission ......................................................................................1
Section I Clutch ..............................................................................................................................1
I. Precautions .........................................................................................................................1
II. Preparation .........................................................................................................................1
III. Common Trouble Diagnosis................................................................................................1
IV. Clutch Hydraulic Oil ............................................................................................................3
V. Master Cylinder of Clutch....................................................................................................4
VI. Clutch Pedal........................................................................................................................6
VII. Clutch Plate, Clutch Friction Wafer and Fly Wheel..............................................................8
VIII. Hydraulic Pipeline .............................................................................................................11
IX. Maintenance Parameters ..................................................................................................12
Section II Manual Transmission....................................................................................................13
I. Precautions .......................................................................................................................13
II. Preparation .......................................................................................................................13
III. Common Trouble Diagnosis..............................................................................................15
IV. System Illustration.............................................................................................................16
V. Gear Oil of Manual Transmission......................................................................................18
VI. Oil Seal .............................................................................................................................19
VII. Gear Shift Control Device .................................................................................................20
VIII. Manual Transmission Assembly........................................................................................23
IX. Gearbox Casing (Left Case) .............................................................................................38
X. Clutch Casing (Right Case)...............................................................................................40
XI. Input Shaft and Gear.........................................................................................................43
XII. Intermediate Shaft.............................................................................................................51
XIII. Differential.........................................................................................................................60
XIV. Shift Control Sub-assembly...............................................................................................63
XV. Gear Shifting Control Sub-assembly .................................................................................65
XVI. Reversing Lamp Switch ....................................................................................................66
1
XVII. Maintenance Parameters.............................................................................................66
Chapter II Traveling System..............................................................................................................68
Section I Power Steering System .................................................................................................68
I. Precautions .......................................................................................................................68
II. Preparation .......................................................................................................................69
IV. Power Steering Fluid.........................................................................................................70
V. Steering Wheel..................................................................................................................72
VI. Steering Column ...............................................................................................................76
VII. Steering Gear....................................................................................................................79
VIII. Power Steering Pump .......................................................................................................85
IX. Hydraulic Pipeline .............................................................................................................89
X. Maintenance Data and Specifications ...............................................................................90
Section II Front Axle......................................................................................................................91
I. Precautions .......................................................................................................................91
II. Preparation .......................................................................................................................91
IV. Front Wheel Hub and Steering Knuckle ............................................................................92
V. Front Drive Shaft...............................................................................................................97
VI. Maintenance Parameters ................................................................................................107
Section III Rear Axle ...................................................................................................................108
I. Preparation .....................................................................................................................108
II. Wheel hub.......................................................................................................................108
III Maintenance Parameters ................................................................................................112
Section IV Front Suspension ......................................................................................................113
I. Precautions .....................................................................................................................113
II. Preparation .....................................................................................................................113
III. Front Suspension Assembly............................................................................................114
IV. Front Damper..................................................................................................................116
2
V. Lower Suspension Arm ...................................................................................................119
VI. Stabilizer Bar...................................................................................................................122
VII. Connecting Ball Joint of Stabilizer Bar ............................................................................123
VIII. Support Beam of Engine .................................................................................................124
IX. Common Trouble Diagnosis............................................................................................127
X. Maintenance Parameters ................................................................................................128
Section V Rear Suspension........................................................................................................129
I. Precautions .....................................................................................................................129
II. Preparation .....................................................................................................................129
III. Rear Suspension Assembly ............................................................................................130
IV. Rear Damper ..................................................................................................................132
V. Rear Suspension Arm (A) ...............................................................................................136
VI. Rear Suspension Arm (B) ...............................................................................................137
VII. Thrusting Rod .................................................................................................................138
VIII. Rear Stabilizer Bar ..........................................................................................................139
IX. Support Bar of Stabilizer Bar...........................................................................................140
X. Common Trouble Diagnosis............................................................................................141
XI. Maintenance Parameters ................................................................................................141
Section VI Wheel and Tire ..........................................................................................................142
I. Wheel..............................................................................................................................142
II. Tire..................................................................................................................................142
III. Tire Assembly of the Wheel ............................................................................................144
IV. Common Trouble Diagnosis for Tire Assembly of the Wheel ..........................................146
V. Maintenance Parameters ................................................................................................147
Chapter III Braking System .............................................................................................................148
Section I Parking Braking System...............................................................................................148
I. Precautions .....................................................................................................................148
II. Parking Braking System..................................................................................................148
Section II Braking System...........................................................................................................153
3
I. Precautions .....................................................................................................................153
II. Preparation .....................................................................................................................153
III. Brake Pedal ....................................................................................................................154
IV. Brake Master Cylinder ....................................................................................................156
V. Brake Fluid......................................................................................................................157
VI. Brake Pipeline.................................................................................................................159
VII. Brake Vacuum Booster ...................................................................................................162
VIII. Front Disc Brake Tongs ..................................................................................................165
IX. Rear Brake......................................................................................................................172
X. Troubleshooting ..............................................................................................................177
XI. Maintenance Parameter..................................................................................................179
Section III Anti-lock Braking System ...........................................................................................181
I. Precautions .....................................................................................................................181
II. Preparation .....................................................................................................................182
III. System Illustration...........................................................................................................182
IV. Anti-lock Braking Mode ...................................................................................................184
V. Speed Sensor .................................................................................................................185
VI. ABS Hydraulic Assembly ................................................................................................187
VII. ABS Control Module .......................................................................................................188
VIII. Exhaust of ABS ...............................................................................................................191
IX. Trouble Diagnosis ...........................................................................................................199
4
Chapter I Clutch and Manual Transmission
Section I Clutch
I. Precautions
■ The hydraulic oil recommended for the clutch is brake fluid “DOT 4”.
■ Please do not reuse the discharged clutch hydraulic oil.
■ Take care not to spill the clutch hydraulic oil onto the painted surface of the body.
■ Please do not use mineral oil such as petrol and kerosene, or it will corrode the rubber spare parts
of the hydraulic system.
■ Please do not disassemble the master cylinder and the hydraulic release bearing.
Caution:
■ Use the dust collector, never the compressed air to clean the clutch friction wafer.
II. Preparation
Special tools used are as follows:
Table of Special Tools
No. Tool Outline Diagram Code Illustration
Fly wheel
1 JAC-T1F011 For Fixing fly wheel
retainer
III. Common Trouble Diagnosis
The performance diagnosis of the clutch assembly and the clutch control system shall be carried out by
experienced drivers or skilled vehicle maintenance technicians.
The following (trouble) diagnosis covers common troubles and possible causes. After proper diagnosis is
performed, adjust it according to the corresponding solutions in the diagnosis table and to the right
chapter or section of the maintenance manual for each specific program or replace the spare part as
required.
The clutch friction wafer and the clutch plate cannot be repaired during the vehicle maintenance, so if
any spare part of them is broken, the whole assembly has to be replaced.
If the rivet of clutch friction wafer is worn or the clutch friction wafer is contaminated by oil or grease, it is
improper to use the clutch friction wafer again.
1
If any spare part needs to be replaced, then a new spare part with quality assurance shall be used for
replacement.
The present diagnosis table is helpful in diagnosing troubles of clutch system caused by conditions as
follows: unable to disengage, incomplete disengagement, incomplete engagement, slipping, noise and
whipping.
The numbers in the diagnosis table are not for the check sequence, and there is no precedence
relationship between two possible causes.
Diagnosis Table for Clutch System
Check Possible Cause Troubleshooting
Unable to The clutch is unable to disengage means that it cannot Replace distorted, wearing and broken spare
disengage function and cut off the power transferred from the parts.
engine. Adjust the clutch system.
Check the following conditions:
1. The release lever of clutch is distorted.
2. The diaphragm spring is distorted.
3. The retaining ring of diaphragm spring is broken.
4. Improper adjustment of the control system of clutch
pedal and the clutch wiredrawing.
5. The clutch friction wafer is engaged with the fly wheel
or clutch plate.
Incomplete The incomplete disengagement will cause the clutch Replace the distorted, wearing, broken spare
disengagement unable to cut off the power transferred from the engine parts or the one that exceeds the specified
normally, and it also becomes difficult to control the size. If the friction wafer cannot fit the
shifting lever because of the continuing rotation of the operation of the spline of gearbox input shaft
clutch friction wafer and the input shaft of gearbox. properly, then the replacement of clutch
Check the following conditions: friction wafer is needed. Replace the gearbox
1. The clutch friction wafer is distorted and swings while input shaft if necessary. If the clutch friction
rotating. wafer exceeds the specified size or is
2. The clutch friction wafer is damaged. damaged, the replacement is needed.
3. The spline of clutch friction wafer does not match with Replace the inapplicable thrust bearing of
the one of gearbox input shaft, or the spline facing is clutch.
damaged. Adjust the clutch system to remove
4. The clutch friction wafer is engaged with the fly wheel unnecessary clearance and solve the
or seizes the clutch plate. mechanical trouble.
5. The thickness of fly wheel/clutch plate/clutch friction Mount the improperly assembled spare part
wafer exceeds the specified size. again.
6. Mechanical troubles with the control system of clutch
pedal and the clutch wiredrawing or improper
adjustment.
Incomplete Incomplete engagement may cause the clutch unable Replace the distorted, wearing and broken
engagement to transfer the engine power to the gearbox input shaft spare parts.
normally and also leads to the slipping of the clutch Replace the clutch friction wafer or defective
friction wafer. Check the following conditions: clutch assembly.
1. The clutch friction wafer is contaminated by oil or Adjust the free play of the clutch pedal in a
grease. correct way.
2. The clutch friction wafer is damaged. Adjust the clutch system to remove
3. The clutch pedal is of no free play. unnecessary clearance and solve the
4. The diaphragm spring/clutch plate/release lever of mechanical trouble.
clutch/spline of clutch friction wafer is distorted or Mount the improperly assembled spare part
damaged. again.
5. Mechanical troubles with the control system of clutch
pedal and the clutch wiredrawing or improper
2
adjustment.
The slipping of clutch friction wafer may cause the Replace the distorted, wearing, broken spare
clutch unable to transfer the engine power normally. parts or the one that exceeds the specified
size and specification.
Check the following conditions: The solutions are the same as those in the
1. The clutch friction wafer is worn. “Unable to disengage” and “Incomplete
2. The clutch friction wafer is contaminated by oil or engagement”.
grease. Stop the engine, cool the clutch casing (if the
3. Incomplete engagement of the clutch. temperature is excessively high), and then
4. The thickness of fly wheel/clutch plate/clutch friction make further diagnosis.
wafer exceeds the specified size, and the friction Mount the given clutch in a correct way.
Slipping
surface is larger than the given specification. Adjust the clutch system in order to remove
5. Excessively high temperature inside the clutch unnecessary clearance and solve the
casing caused by driver’s improper operation. mechanical trouble.
6. The improper clutch is mounted. Mount improperly assembled spare part
again.
The driver shall not put the feet on the clutch
pedal all the time.
Check the following conditions: Mount improperly assembled spare part
1. Improper clutch friction wafer. again.
2. Poor balance.
Noise
3. Troubles with the thrust bearing of clutch.
4. The torsion damp spring of clutch friction wafer is
damaged.
When the clutch friction wafer cannot engage with the Replace the clutch assembly.
fly wheel gently, the following conditions may appear.
Check the following conditions:
1. The damp spring of clutch friction wafer does not
Whipping meet the specification.
2. The clutch friction wafer does not meet the
specification.
3. The clutch friction wafer is contaminated by oil or
grease.
IV. Clutch Hydraulic Oil
1. Check gists
Attention:
■ Please do not use vacuum pump or any other kind of power emptying device to operate on this
system.
■ Check the liquid level of the hydraulic oil for clutch, and make sure that it is at the normal level.
■ Do not let the clutch hydraulic oil drip on the painted surface of the body or other components. If the
hydraulic oil is spilled on it, wipe the surface or the component with a dry cloth immediately.
2. Exhaust air in pipeline
Note: If it becomes spongy while dismantling the clutch pipeline, master cylinder of the clutch, hydraulic
release bearing and the clutch pedal, the air in the system shall be exhausted.
1) Loosen the exhaust bolt of the slave cylinder of clutch.
3
2) Step down the clutch pedal slowly until the air is exhausted completely.
3) Step down the clutch pedal completely, and keep it. Screw down the exhaust bolt.
4) Add hydraulic oil to the clutch hydraulic system.
Attention:
■ Keep the height of fluid level in the stock solution tank between MIN and MAX all along.
5) Repeat the steps above until the discharged clutch hydraulic oil is clean and with no bubbles.
6) Make sure of the normal operation of the clutch.
① Start the engine, step down the clutch pedal, and engage the reverse gear carefully after about 2s. If
there is big noise while engaging, step down the clutch pedal completely for five times to exhaust air
in the system.
② Check the operation condition of the clutch after about 30s. If there is still big noise, please repeat
exhausting.
V. Master Cylinder of Clutch
1. Elements
Disassembly Diagram for Master Cylinder of Clutch
1- Stock solution tank 2- Clamping band 3- Piston 4- Snap ring 5- Push rod 6- Master cylinder body 7-
Lock pin
4
1) Dismantlement
① Discharge the clutch hydraulic oil from the exhaust bolt of clutch.
② Cut off the lock pin between the push rod of clutch master cylinder and the clutch pedal.
Fig. 1.1 001
③ Cut off the connecting hose between the

Fig. 1.1 002
master cylinder of clutch and the brake master
cylinder.
④ Dismantle the oil pipe and the fixing bolt of

Fig. 1.1 003
clutch master cylinder.
⑤ Take out the clutch master cylinder.
■ Check whether the clutch pipeline is blocked.
■ Check whether the clutch hose and hard pipe have damages such as breakage and rust.
3) Installation
Pay attention to the following precautions, and install in the reverse order with the dismantlement.
5
■ Apply specified hydraulic oil on the inwall of the pump body and the exterior surface of the piston
assembly. (Brake hydraulic oil D0T 4)
■ Exhaust air in the system. Please refer to the “Clutch Hydraulic Oil”.
■ Adjust the free play of clutch. Please refer to the “On-vehicle Check and Adjustment”.
■ Refer to the “Tightening Torque Table” for the tightening torque.
VI. Clutch Pedal
1. On-vehicle check and adjustment
Check for free play:
■ Press down the clutch pedal by hands until Fig. 1.1 004
you feel certain resistance, and then use the
dividing ruler to check whether the free play is
within the specified range.
The free play of the pedal: 6~13 mm
1) Elements
Clutch Pedal Diagram
6
2) Dismantlement
① Dismantle the lock pin of the clutch pedal to

Fig. 1.1 005
cut off its connecting with the push rod of
clutch master cylinder.
② Dismantle the fixing bolt of clutch pedal, and

Fig. 1.1 006
then take it out.

Fig. 1.1 007
Check whether the clutch pedal is twisted,
damaged or there are any cracks on the welded
junction. If any mentioned condition appears,
please replace the clutch pedal assembly.
4) Installation
Install in the reverse order with the dismantlement.
■ Tightening torque: 20~30Nym
Attention:
■ Do not push the push rod to the clutch master cylinder while adjusting the height of the clutch pedal.
■ Check whether the stroke and free play of the clutch pedal is within the specified range after
adjustment.
■ If the free play of the clutch pedal is not within the specified range, there must be air in the clutch
hydraulic pipeline or troubles with the clutch master cylinder. Exhaust air in the system, and
disassemble the master cylinder or clutch for check.
7
VII. Clutch Plate, Clutch Friction Wafer and Fly Wheel
1) Elements
Disassembly Diagram for Clutch
1-Fly wheel 2-Clutch friction wafer 3-Clutch plate 4-Fixing bolt
Attention:
■ Do not let any grease contaminate the surface of clutch friction wafer, plate and fly wheel.
2) Dismantlement
① Dismantle the manual transmission assembly from the vehicle. Please refer to the “Manual
Transmission Assembly”.
② Loosen the fixing bolt of clutch plate evenly. Then dismantle the clutch plate and friction wafer.
Attention:
■ Only loosen one bolt by one to two circles every time in order to prevent damaging the flange of the
clutch casing.
③ Dismantle the fixing bolt of fly wheel from rear end of the cylinder body, and take off the fly wheel.
④ Dismantle the hydraulic release bearing from the clutch casing.
8

① Clutch friction wafer
■ Check whether the surface is contaminated by grease or deteriorated because of the looseness of
rivet, single-side contact, or burn. If so, replace the clutch friction wafer.
■ Measure the immersion depth of rivet. If it exceeds the limit, please replace the clutch friction wafer.
Limit: 0.3 mm
Fig. 1.1 008
■ Check whether the return spring is loose or damaged. If
so, please replace the clutch friction wafer.
■ Mount the clutch friction wafer onto the input shaft, and
then check the sliding status and the looseness of the
rotation direction. If the sliding is poor, it shall be cleaned
or replaced on condition that the sliding is still poor after
cleaning. If the looseness is obvious, the clutch friction
wafer or input shaft or both shall be replaced.
② Clutch plate
■ Check whether the end of the diaphragm spring is worn or there is any difference in height. If the
wearing place is obvious or the difference in height is beyond the limit, the clutch friction wafer shall
be replaced.
Limit: 0.5 mm.
■ Check whether the surface of plate is worn, discolored or with cracks.
■ Check whether the rivet of the plate is loose. If so, replace the clutch plate.
③ Hydraulic release bearing
■ Check whether the bearing is burnt, damaged or accompanied with abnormal sound and rough
rotation while working.
■ Check whether the diaphragm spring of hydraulic bearing is worn. If so, please replace it.
④ Fly wheel
Micrometer gauge
■ Use the micrometer gauge to measure the flatness of
Fig. 1.1 009
contact surface between the fly wheel and clutch
friction wafer. If it does not meet the requirement,
please replace the fly wheel.
■ If there is ablative or discolored places on the contact
surface between the clutch plate and friction wafer,
please apply sanding treatment with the abrasive
paper.
Attention:
■ Please measure the flatness on the exterior surface of fly wheel. (Not measure on the anchor pin)
9
4) Installation
① Clean the clutch friction wafer and the key slot of input shaft, and remove the grease and worn
sweepings.
② Apply the grease on the key slot of input shaft.
Attention:
■ Recommended grease: SAE J310 or similar products.
■ Make sure that the grease is applied on the specified position, or it may cause noise from the clutch,
poor release or damage. Too much grease also may lead to slipping or whipping.
③ Mount the fly wheel, and tighten it up as specified tightening torque; Use special tools to mount the
clutch friction wafer and clutch plate.
④ Perform step by step as the sequence shown Fig. 1.1 010

in the figure to tighten up the clutch fixing bolt
in turn and evenly.
Attention:
■ Tighten up each bolt by 1~2 circles

sequentially.
Tightening torque: 15~22 Nym
⑤ Mount the hydraulic release bearing.
⑥ Mount the manual transmission on the vehicle. Refer to the “Manual Transmission” for the
installation process.
10
VIII. Hydraulic Pipeline
Hydraulic Pipeline Diagram
1-Quick joint 2-Clutch plate and driven disk 3-Oil pipe 4- Hose 5- Left mounting of gearbox 6- Induction
manifold 7-Master cylinder of clutch 8-Clutch pedal
Please pay attention to the following precautions while dismantling and mounting the clutch hydraulic
pipeline.
Attention:
■ Do not let the hydraulic oil for clutch drip on the painted surface of the body or other components. If
the hydraulic oil is spilled on them, wipe the surface or the component with a piece of dry cloth
immediately, and then wash it with water.
■ While mounting the clutch pipeline on the hydraulic release bearing, three-way valve and clutch pipe,
insert it to the end, and check whether the clip is in position.
■ Please use the oil pipe wrench to screw down the oil pipe joint.
■ After installation, please exhaust air in the clutch hydraulic system, and refer to the “Air Exhaust”.
11
IX. Maintenance Parameters
1. Technical Parameters
Table of Technical Parameters
Free play of clutch 6~13 mm
2. Lubricating Grease
Lubricating Grease Table
Kingpin of master cylinder SAE J310, NLGI NO. 2
3. Tightening Torque
Tightening Torque Table
Items Torque (Nym)
Fixed nut for the master cylinder of clutch 20~30
Fixed support for oil pipe of hydraulic release

8~12
bearing
Exhaust bolt 7~13
Installation bolt for clutch plate 20~30
Fixing bolt for fly wheel 127~137
12
Maintenance Manual of Tojoy Sedan Traveling System
Section II Manual Transmission

I. Precautions
■ Don’t reuse the discharged gear oil of manual transmission.
■ When checking or replacing the gear oil of manual transmission, keep the vehicle level.
■ When dismantling and installing gearbox, keep its interior free of dust and foreign substances.
■ Check and confirm that the installation position is correct before dismantlement or disassembly. If
necessary, make an installation mark and ensure that the mark will not affect the function of the
marked component.
■ Tighten the bolts and nuts by multiple steps and in diagonal direction, namely, tighten the middle
bolts and nuts at first, and then tighten the outer bolts and nuts, according to the regulations. If the
tightening order is specified, do as required.
■ Be careful not to damage the sliding surfaces and matching surfaces of elements.
II. Preparation
See the table below for the adopted special tools.
For installation and

Withdrawal dismantlement of
1 tool for JAC-T1B001 various gears,
bearing bearings and shaft
sleeves

Withdrawal dismantlement of
2 tool for JAC-T1B002 various gears,
bearing bearings and shaft
sleeves
13
Used together with

3 Erector cover JAC-T1B005
erector and erection joint
Used together with

4 Erector-100 JAC-T1B006 erector cover and
erection joint
Used together with

5 Erector-200 JAC-T1B007 erector cover and
erection joint
Used together with

JAC-T1B008 erector, for installation of
JAC-T1B009 bearings of intermediate
6 Erection joint
JAC-T1B011 shaft and input shaft as
JAC-T1B012 well as the shaft sleeves
for gear 1, 2 and 4
Used together with

Installation
7 JAC-T1B016 erector, for installation of
handle
bearing
Erector for
For installation of shift
8 shift shaft oil JAC-T3B001
shaft oil seal of gearbox
seal
Erector for
For installation of
9 differential oil JAC-T3B002
differential oil seal
seal
14
For dismantlement
Detacher for
of spring pin of gear
10 spring pin of JAC-T3B003
shifting fork of
gearbox
gearbox
Erector for
For installation of
right bearing
right bearing of
11 of JAC-T3B005
intermediate shaft
intermediate
of gearbox casing
shaft
Table of Common Trouble Diagnosis
Trouble Cause Troubleshooting

Wear of gear shifting fork shaft Replacement
Skid and Wear of gear shifting fork or synchronizer sleeve Replacement
throw-out of Too soft or damaged retaining spring of shift shaft Replacement
gear Wear of toothed sleeve and gear’s chamfered teeth Replacement of toothed sleeve
of synchronizer and gear of synchronizer
Insufficient gear oil of gearbox Addition
Incorrect free play of clutch pedal Adjustment
Deformation or damage of clutch plate lining Replacement
Damage of clutch plate Replacement of plate
Difficult gear
Wear of synchronizer ring gear Replacement
shifting Wear of toothed sleeve and gear’s chamfered teeth Replacement of toothed sleeve or
of synchronizer gear of synchronizer
Deformation of shift shaft Replacement
Failure of wiredrawing adjustment to proper
Adjustment of wiredrawing
position
Insufficient gear oil of gearbox Addition
Damage or wear of bearing Replacement
Noise
Damage or wear of gear Replacement
Damage or wear of spare parts of synchronizer Replacement
Wear or damage of input shaft oil seal Replacement
Wear or damage of differential oil seal (oil seal wear
Replacement
is caused by poor quality of driving shaft surface)
Oil leakage Oil leakage at oil plug Replacement
Failure of sealant at the lock bolt for gear 1 and 2 Replacement
Failure of sealant at the lock bolt for gear 5 and
Replacement
reverse gear
15
IV. System Illustration
1. Schematic Diagram for Structure
Schematic Diagram for Structure of Gearbox
1-Gearbox casing bolt 2-Baffle plate bolt of reversing lamp switch 3-Baffle plate assembly for reversing
lamp switch 4-Gear 5 gear shifting fork bolt 5-Lock pressure plate bolt 6-Gear 5 synchronizer ring gear
7-Gear 5 gear assembly of intermediate shaft 8-Interlocking pin 9-Reversing lamp switch assembly
10-Left case sub-assembly 11-Gearbox casing bolt 1 12-Intermediate shaft sub-assembly 13-Gear lever
sub-assembly 14-Lock bolt assembly for gear 3 and 4 15-Gear shifting fork assembly for reverse gear
16-Gear shifting fork bolt for reverse gear 17-Lock spring for gear 1 and 2 18-Lock bolt for gear 5 and
reverse gear 19-Lock bolt for gear 1 and 2 20-Lock spring for gear 5 and reverse gear 21-Differential
sub-assembly 22-Closing pin 23-Locknut of intermediate shaft 24-Baffle plate for gear 5 synchronizer
slider 25-Gear 5 synchronizer sub-assembly 26-Gear shifting fork for gear 5 27-Gear 5 synchronizer
slider assembly 28-Input shaft nut 29-Gear 5 gear of intermediate shaft 30-Needle bearing 31-Bearing
pressure plate bolt 2 32-Bearing pressure plate bolt 1 33-Bearing pressure plate of left case 34-Rear
casing assembly 35-Gear 5 gear of input shaft 36-Interlocking bolt for gear 5 and reverse gear 37-Shift
control sub-assembly 38-Stop bolt for gear shifting 39-Left bearing shield ring of intermediate shaft
40-Left bearing shield ring of input shaft 41-Idle gear shaft for reverse gear 42-Gear shaft bolt for reverse
gear 43-Gear shaft bolt washer for reverse gear 44-Idle gear shaft washer for reverse gear 45-Idle gear
assembly for reverse gear 46-Input shaft sub-assembly 47-Lock steel ball for gear 1 and 2 48-Gear
shifting cable support 49-Gear shifting cable support bolt 50-Quick three-way pipe joint 51-Spider for oil
pipe of release bearing 52-Right case sub-assembly 53-No. 1 stud of gearbox 54-No. 2 stud of gearbox
16
2. Gear Transmission Line
Gear 1: Input shaft----gear 1 drive gear of input shaft---gear 1 transmission gear of intermediate
shaft---low-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---differential output
shaft---low-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---high-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---high-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
shaft---5-speed synchronizer---intermediate shaft---normally engaged drive gear of intermediate
Reverse gear: Input shaft----drive gear for reverse gear of input shaft---Idle gear for reverse
gear---transmission gear for reverse gear of intermediate shaft (toothed sleeve of low-speed
synchronizer) ---intermediate shaft---normally engaged drive gear of intermediate shaft---differential
output
3. Principle for Gear Shifting
When the complete vehicle is moving forward, the principle for gear shifting of gearbox is as follows: the
gear shifting for speed increase shall be conducted step by step from gear 1 to gear 5; the gear shifting
for speed decrease shall be conducted step by step from gear 5 to gear 1; but shifting into reverse gear
under condition of moving forward is forbidden. To avoid misoperation during gear shifting, the gearbox
is set with locking device which can prevent the gear shifting from gear 5 to reverse gear.
In principle, it is required to shift into reverse gear under condition that the complete vehicle is stationary
and it is forbidden to do so under condition of moving forward; further more, shifting to forward gear
under condition of reverse is also forbidden.
17
V. Gear Oil of Manual Transmission
1. Replacement of Gear Oil of Manual Transmission
1) Discharge
Fig. 1.2.001
① Dismantle the oil drain plug to discharge the
gear oil.
■ Tightening torque: 10~17 N•m
② Check the surface of oil drain plug for iron
chips. If any, remove them in time.
2) Filling
① Dismantle the filling plug to fill new gear oil
until the oil level approaches to the specified
limit which is close to the installation hole.
② Model and filling volume of gear oil: API GL-4
SAE 75W/90
Filling volume: 2.0 L
③ After completion of filling, check the oil level. Fig. 1.2.002

④ Tighten the filling plug.
2. Check of Gear Oil of Manual Transmission

Fig. 1.2.003
■ Confirm there is no gear oil leakage at and
around the manual transmission.
① Dismantle the filling plug.
Check the oil level through the installation hole of
filling plug, as shown in Fig. 1.2.002 and Fig.
1.2.003.
② Tighten the filling plug.
Attention:
■ When checking the oil level, don’t start the
engine.
18
VI. Oil Seal
1) Dismantlement
① Discharge the gear oil of gearbox. Please refer to “Gear Oil of Manual Transmission”.
② Dismantle the front drive shaft from drive axle. Fig. 1.2.004
Please refer to “Front Drive Shaft”.
③ Use slotted screw driver to dismantle the

differential side oil seal.
Attention:
■ Don’t bruise the differential casing.
2) Installation
① Mount the differential side oil seal onto the clutch casing and gearbox casing with special tools.
Attention:
■ Coat a proper quantity of grease on the lip of new oil seal.
② Install all dismounted spare parts in the reverse order with dismantlement.
③ Fill the gear oil of manual transmission and check the oil level. Please refer to “Check of Gear Oil of
Manual Transmission”.
3) Check the drive shaft for flexibility after installation.
19
VII. Gear Shift Control Device
1. Element
1
2
Diagram for Gear Shift Control Device
1-Gear shift wiredrawing 2-Gear shift control device 3-Gear shift handle
1) Dismantlement
① Dismantle the storage battery. Please refer to “Storage Battery”.
② Dismantle the air filter assembly. Please refer to “Air Filter Assembly”.
③ Set the gear shift handle at neutral position.
④ Dismantle the gear shift handle.
⑤ Dismantle the rear section of auxiliary facia console. Please refer to “Auxiliary Facia Console”.
20
⑥ Dismount the gear shift wiredrawing and Fig. 1.2.005

spring bearing (inner and outer).
Please refer to Fig. 1.2.005-Fig. 1.2.008.
Fig. 1.2.006
Fig. 1.2.007
Fig. 1.2.008
21
⑦ Dismantle the fixed bolt of gear shift

Fig. 1.2.009
wiredrawing on the side of engine
compartment plate.
■ Tightening torque: 20~30Nym
⑧ Dismantle the fixed bolt of gear shift control

Fig. 1.2.010
device.
⑨ Dismount the gear shift control device

assembly out of the vehicle.
Pay attention to the following points and install in

■ Mount the gear select wiredrawing and gear

shift wiredrawing correctly.
■ Pay attention to the installation direction of Fig. 1.2.012

spring bearing.
■ When the gear shift handle is set at the side of

gear 1-gear 2 or at the side of gear 5-reverse
gear, confirm that the gear shift handle can be
shifted to neutral position smoothly.
■ When the gear shift handle is shifted to each

gear, ensure that the gear shifting is smooth.
22
VIII. Manual Transmission Assembly
1) Dismantlement
① Cut off the negative connection of storage battery.
② Dismantle the storage battery and its support. Fig. 1.2.013

Please refer to “Storage Battery”.
③ Dismantle the air filter assembly. Please refer to

“Air Filter Assembly”.
④ Drain the hydraulic oil in the clutch and cut off

the oil pipe of clutch from the quick joint of
hydraulic release bearing of clutch. Please refer
to “Clutch Pipeline”.
Attention:
■ During dismantlement, don’t press on the clutch pedal.
⑤ Cut off the wire harness connectors of speed sensor, reversing lamp switch and crankshaft position
sensor form the gearbox.
⑥ Dismantle the crankshaft position sensor. Please refer to “Crankshaft Position Sensor”.
■ Tightening torque: 8~12 Nym
⑦ Dismantle the oil pipe clip of clutch from the support rack of left mounting of manual transmission to
cut off the oil pipe of master cylinder of clutch.
⑧ Cut off the gear shift wiredrawing of gearbox. Please refer to “Gear Shift Control Device”.
⑨ Mount the lifting frame on the hook of engine.
⑩ Dismantle the starter. Please refer to “Starter”.

⑪ Discharge the gear oil. Please refer to “Replacement of Gear Oil of Manual Transmission”.
⑫ Dismantle the front drive shaft. Please refer to “Drive Shaft”.
Attention:
■ After dismantling the front drive shaft, please put a suitable plug in the side oil seal.
⑬ Dismantle the deflector of engine.

⑭ Dismantle the engine support beam. Please refer to “Engine Support Beam”.
23
⑮ Dismantle the lower supporting rack and lower division plate of gearbox.
■ Tightening torque: M6 5~6 N•m
M8 12~15 N•m
⑯ Dismantle the support rack of left mounting of gearbox.

⑰ Use jack to lift the gearbox assembly and dismantle the fixed bolt between gearbox and engine.
⑱ Dismount the gearbox assembly from the vehicle.
2) Installation
Pay attention to the following points and install in the reverse order with dismantlement.
■ When mounting the gearbox assembly onto the engine, pre-tighten the fixed bolts at first, and then
tighten them complying with the following standard.
Tightening direction: 1: gearbox sidetengine side (1, 3, 5, 6, 7)
2: engine sidetgearbox side (2, 4)
Tightening torque: 1 50~70 Nym Fig. 1.2.014

3 1
2 50~70 Nym 5
3 50~70 Nym
7
6
4 50~70 Nym
4
5 50~70 Nym
2
6 50~70 Nym
7 50~70 Nym
■ Fill hydraulic oil of clutch and discharge the air in the pipeline of hydraulic system of clutch. Please
refer to “Clutch Pipeline”.
■ After installation, check the gear oil level of manual transmission, then check for the gear oil leakage
of gearbox and check the mechanical installation for looseness. Please refer to “Check of Gear Oil
of Manual Transmission”.
24
1) Disassembly
① Dismantle the oil drain plug to discharge the gear oil. Please refer to “Replacement of Gear Oil of
Manual Transmission”.
② Dismantle the filling plug. Fig. 1.2.015
③ Cut off the oil pipe of clutch from the clutch

Fig. 1.2.016
casing, and dismantle the hydraulic release
bearing.
④ Dismantle the speed sensor and reversing

lamp switch from the gearbox.
⑤ Dismantle the support of shift wiredrawing. Fig. 1.2.017
⑥ Dismantle the rear casing and the baffle plate

Fig. 1.2.018
of reversing lamp switch.
Attention:
■ As the oil delivery groove crosses the input

shaft, it shall be dismantled toward the axial
direction of input shaft.
25
⑦ Dismantle the locknut of intermediate shaft. Fig. 1.2.019

Attention:
■ When dismantling the locknut, don’t use any

pneumatic tool to prevent the gear from
damage.
⑧ Dismantle the gear 5 shifting fork bolt. Fig. 1.2.020
⑨ Dismount the gear 5 synchronizer and gear 5 Fig. 1.2.021

shifting fork.
⑩ Dismantle the nut of input shaft and use Fig. 1.2.022

calipers to dismount the outer circlip of rear
bearing of intermediate shaft.
26
⑪ Take off the gear 5 gear of intermediate shaft Fig. 1.2.023

and input shaft.
⑫ Dismantle the screw of interlocking plate to Fig. 1.2.024

take off the interlocking plate.
⑬ Dismantle the screw of bearing pressure Fig. 1.2.025

plate.
⑭ Take off the bearing pressure plate. Fig. 1.2.026
27
⑮ Dismantle the circlip of left bearing of Fig. 1.2.027

intermediate shaft.
⑯ Dismantle the circlip of left bearing of input Fig. 1.2.028

shaft.
⑰ Dismantle the bolt of gear shaft for reverse Fig. 1.2.029

gear and the gear limit bolt. Bolt of gear shaft for reverse
gear
Gear limit bolt
⑱ Dismantle the shift control sub-assembly. Fig. 1.2.030
28
⑲ Dismantle the fixed bolt of clutch casing. Fig. 1.2.031
⑳ Take off the gearbox casing. Fig. 1.2.032
Dismantle the fixed bolt of shifting fork for Fig. 1.2.033
reverse gear.
Fig. 1.2.034
Take off the shifting fork for reverse gear.
29
Take off the gear shaft and gear for reverse Fig. 1.2.035
gear.
Take off the intermediate shaft sub-assembly

and the input shaft sub-assembly.
Attention:
■ Take off the intermediate shaft sub-assembly

and input shaft sub-assembly, together with
shifting fork assembly for gear 1 and 2, gear
lever for gear 5 and reverse gear as well as
shifting fork for gear 3 and 4.
Fig. 1.2.036
Take off the differential sub-assembly from the
clutch casing.
Fig. 1.2.037
Dismantle the differential side oil seals on the
clutch casing and gearbox casing with slotted
screw driver.
Attention:
■ Don’t bruise the gearbox casing and clutch

casing.
Fig. 1.2.038
Dismantle the differential bearing outer rings
from the clutch casing and gearbox casing
with copper bar.
Attention:
■ Don’t bruise the clutch casing and gearbox

casing.
30
z Dismantle the oil delivery groove from the Fig. 1.2.039

gearbox casing.
2) Assemblage
① Mount the oil deliver groove on gearbox casing.
② Mount the differential side bearing outer ring with punch until it is level with the end faces of clutch
casing and gearbox casing.
③ Mount the differential side oil seals onto the clutch casing and gearbox casing according to the
following steps.
a. Coat gear oil of gearbox on the lip of new oil

Fig. 1.2.040
seal.
b. Mount the oil seal with punch. Fig. 1.2.041
JAC-T3B002
31
④ Mount the differential sub-assembly onto the Fig. 1.2.042

clutch casing.
⑤ Mount the sub-assemblies of input shaft,

Fig. 1.2.043
intermediate shaft and gear shifting fork.
Attention:
■ The shifting fork must be clamped in the

groove of synchronizer toothed sleeve.
■ The two gear levers must be fitted into their

corresponding holes.
■ Don’t scratch the input shaft oil seal when Fig. 1.2.044
assembling the input shaft sub-assembly.
⑥ Mount the gear and gear shaft for reverse

Fig. 1.2.045
gear.
32
⑦ Mount the gear shifting fork for reverse gear.

Fig. 1.2.046
⑧ Mount the gearbox casing onto the clutch

Fig. 1.2.047
casing.
Attention:
■ The sealant must be coated evenly and there

shouldn’t be any adhesive failure or
breakdown.
■ The installation must be conducted within 15

min after coating of sealant.
⑨ Mount the gear shaft bolt for reverse gear.

Fig. 1.2.048
⑩ Mount the self-locking mechanism of gearbox. Fig. 1.2.049

Note: The assemblage order is steel ball, spring
and bolt.
Attention:
■ Don’t reuse damaged spare parts.
33
⑪ Mount the gear shift control device. Fig. 1.2.050

Attention:
■ Pay attention to the installation direction.
⑫ Mount the interlocking bolt for gear 5 and Fig. 1.2.051

reverse gear and the limit bolt for gear shifting.
⑬ Mount the circlips of left bearings of input shaft

and intermediate shaft.
⑭ Mount the bearing pressure plate.

Fig. 1.2.052
⑮ Mount the interlocking pressure plate bolt. Fig. 1.2.053
34
⑯ Mount the interlocking pin and interlocking

pressure plate. Fig. 1.2.054
Fig. 1.2.055
⑰ Mount the gear 5 gear. Fig. 1.2.056
Attention:
■ When mounting the gear 5 gear of input shaft,

make the side with circular slot mark
downwards.
⑱ Mount the input shaft nut. Fig. 1.2.057
Attention:
■ Don’t reuse the spare parts that can’t be used

any more.
35
⑲ Mount the gear 5 gear needle and gear of Fig. 1.2.058

intermediate shaft.
⑳ Mount the baffle plate of gear 5 synchronizer Fig. 1.2.059

slider assembly.
Mount the intermediate shaft nut. Fig. 1.2.060
Attention:
■ Don’t reuse the spare parts that can’t be used

any more.
Fig. 1.2.061
Mount the gear 5 shifting fork bolt.
36
Mount the rear casing onto the gearbox Fig. 1.2.062
casing.
Attention:
■ The installation must be conducted within 15

min after coating of sealant.
For the remaining steps, assemble in the

reverse order with disassembly.
37
IX. Gearbox Casing (Left Case)
Disassembly Diagram for Gearbox Casing
1-Left bearing outer ring of differential 2-Oil delivery groove assembly bolt of gearbox casing cover 3-Oil
delivery groove assembly of gearbox casing cover 4-Oil delivery groove bolt 5-Oil delivery groove
assembly 6-Adjusting gasket of differential 7-Oil inlet plug screw 8-Differential oil seal 9-Gearbox
casing
38
1. Adjustment of Axial Clearance of Differential

Casing Fig. 1.2.063 Soldering tin
Attention:
■ Select an adjusting gasket to adjust the axial

clearance of differential casing.
1) Place suitable soldering tin on the gearbox

casing (the specific position is as shown in the
figure), and then mount the differential.
2) Mount the clutch casing and tighten the bolt to

the specified torque.
3) If the soldering tin is not flattened, use thicker soldering tin to repeat the steps 1) and 2).
4) Measure the thickness (T) of the flattened

soldering tin with micrometer and select the Fig. 1.2.064
adjusting gasket based on the following
formula.
Thickness of gasket:
(T-0.05 mm) to (T-0. 17 mm)
39
X. Clutch Casing (Right Case)
Disassembly Diagram for Clutch Casing
1-Bleeding plug screw 2-Right bearing outer ring of differential 3-Differential oil seal 4-Right bearing
outer ring of intermediate shaft 5-Oil deflector of intermediate shaft 6-Speed sensor assembly
7-Speed sensor bolt 8-Mounting bolt of release bearing 9-Hydraulic release bearing 10-Clutch
casing
40
Fig. 1.2.065
Essentials of Dismantlement and Installation:
1. Right Bearing of Intermediate Shaft
1) Installation Fig. 1.2.066 JAC-T3B005
Press in the bearing vertically.
Attention:
■ Make the side with model countermark

upwards.
2. Hydraulic Release Bearing (Input Shaft Oil Fig. 1.2.067

Seal)
1) Dismantlement
① Dismantle the hydraulic release bearing from

the clutch casing.
② Dismantle the input shaft oil seal with punch. Fig. 1.2.068
41
2) Installation
Fig. 1.2.069
① Fix the hydraulic release bearing casing.
② Mount the input shaft oil seal with special

punch.
3. Speed Sensor
Fig. 1.2.070
1-Speed gear 2-Speed sensor 3-O-ring
1) Dismantlement
Fig. 1.2.071
① Dismantle the fixed bolt of speed sensor.
② Take off the sensor.
2) Check After Dismantlement
■ Check the O-ring for aging and elastic

deformation.
3) Installation
Pay attention to the following steps and install in

the reverse order.
■ Coat the O-ring with gear oil of gearbox.
42
XI. Input Shaft and Gear
1. Element
Disassembly Diagram for Input Shaft and Gear
1-Left bearing of input shaft 2-Gear adjusting gasket for gear 4 of input shaft 3-Gear 4 gear assembly
of input shaft 4-Gear needle bearing for gear 4 of input shaft 5-Gear shaft sleeve for gear 4 of input
shaft 6-Ring gear of high-speed synchronizer 7-High-speed synchronizer sub-assembly
8-High-speed synchronizer slider assembly 9-Gear 3 gear assembly of input shaft 10-Gear needle
bearing for gear 3 of input shaft 11-Input shaft 12-Right bearing of input shaft
2. Disassembly and Installation Fig. 1.2.072

JAC-T1B001
1) Disassembly
Note: The disassembly shall be conducted on the

hydraulic bench.
① Dismantle the right bearing of input shaft.
Mount the special tools onto the right bearing of

input shaft.
43
② Dismantle the left bearing and gear adjusting Fig. 1.2.073

gasket for gear 4. Mount the special tools onto
the gear 4 gear.
JAC-T1B002
③ Take off the gear 4 gear assembly. Fig. 1.2.074
④ Take off the gear 4 needle bearing. Fig. 1.2.075
⑤ Take off the ring gear of high-speed

Fig. 1.2.076
synchronizer at the side of gear 4 gear.
44
⑥ Dismantle the gear shaft sleeve for gear 4.

Fig. 1.2.077
JAC-T1B001
Mount the special tools onto the gear 3 gear.
⑦ Take off the gear shaft sleeve for gear 4.

Fig. 1.2.078
⑧ Take off the high-speed synchronizer Fig. 1.2.079

sub-assembly at the side of gear 3 gear.
⑨ Take off the gear 3 gear assembly. Fig. 1.2.080
45
⑩ Take off the gear 3 needle bearing. Fig. 1.2.081
2) Check After Disassembly Fig. 1.2.082

① Input Shaft and Gear
Check the following items. If necessary, please

replace the spare parts with trouble.
■ Check the input shaft for damage, peeling,

dent, uneven wear, bending and other
abnormalities.
■ Check the gear for excess wear, damage, Fig. 1.2.083

peeling and other abnormalities.
② Synchronizer Fig. 1.2.084

■ Check the contact surface of the ring gear and

sub-assembly for damage and excess wear.
■ Check whether the rotation between the ring

gear and sub-assembly is smooth.
46
■ If the convex side of the ring gear or the Fig. 1.2.085

inserted working side is with crack, damage or
excess wear, please replace it.
■ Check the clearance between the upper ring

gear and gear of synchronizer.
Have the synchronizer ring gear cling to the

matching conical surface of gear. Check the
clearance between the conjoint tooth of gear and
the end face of ring gear. If the clearance reaches
or exceeds the limit, it is essential to replace the
spare parts.
Standard value: 0. 8~1.2 mm
Limit value: 0.5 mm
③ Bearing
Fig. 1.2.086
■ Check the bearing for damage or poor

rotation.
3) Assemblage Fig. 1.2.087

Attention:
■ Coat all spare parts with gear oil of gearbox.
① Assemble the high-speed synchronizer

sub-assembly in advance.
47
Attention:
Fig. 1.2.088
■ Installation direction of high-speed A
synchronizer hub
A: at the side of gear 4 gear
B: at the side of gear 3 gear
■ Installation direction of high-speed

Fig. 1.2.089
synchronizer sleeve
② Mount the gear 3 needle bearing.

Fig. 1.2.090
③ Mount the gear 3 gear assembly.

Fig. 1.2.091
48
④ Mount the high-speed synchronizer

Fig. 1.2.092
sub-assembly.
⑤ Mount the ring gear of high-speed

Fig. 1.2.093
synchronizer at the side of gear 4 gear.
⑥ Mount the gear shaft sleeve for gear 4. Fig. 1.2.094

JAC-T1B005
JAC-T1B006
JAC-T1B009
⑦ Mount the gear 4 gear assembly. Fig. 1.2.095
49
⑧ Mount the gear 4 needle bearing.

Fig. 1.2.096
⑨ Mount the gear adjusting gasket for gear 4.

Fig. 1.2.097
⑩ Mount the left bearing of input shaft. Fig. 1.2.098

JAC-T1B005
JAC-T1B006
JAC-T1B009
⑪ Mount the right bearing of input shaft. Fig. 1.2.099

JAC-T1B005
JAC-T1B006
JAC-T1B008
50
XII. Intermediate Shaft
1. Element
Disassembly Diagram for Intermediate Shaft
1-Gear shaft sleeve for gear 5 of intermediate shaft 2-Gear washer for gear 5 of intermediate shaft
3-Left bearing of intermediate shaft 4-Gear 4 gear of intermediate shaft 5-Gear spacer for gear 3 and
4 of intermediate shaft 6-Gear 3 gear of intermediate shaft 7-Gear 2 gear assembly of intermediate
shaft 8-Gear needle bearing for gear 2 of intermediate shaft 9-Gear shaft sleeve for gear 2 of
intermediate shaft 10-Ring gear sub-assembly of gear 2 synchronizer 11-Low-speed synchronizer
sub-assembly 12-Low-speed synchronizer slider assembly 13-Ring gear sub-assembly of gear 1
synchronizer 14-Gear 1 gear of intermediate shaft 15-Gear needle bearing for gear 1 of intermediate
shaft 16-Gear shaft sleeve for gear 1 of intermediate shaft 17-Intermediate shaft 18-Right bearing
inner ring of intermediate shaft 19-Right bearing shield ring of intermediate shaft
2. Disassembly and Assemblage Fig. 1.2.100

JAC-T1B001
1) Disassembly
Note: Conduct disassembly on the hydraulic

bench.
① Dismantle the gear shaft sleeve for gear 5,

gear washer for gear 5, left bearing and gear 4
gear.
51
② Take off the gear 3 gear. Fig. 1.2.101
③ Take off the gear spacer for gear 3 and 4.

Fig. 1.2.102
④ Take off the gear 2 gear assembly and ring

Fig. 1.2.103
gear sub-assembly of gear 2 synchronizer.
⑤ Take off the gear 2 needle bearing. Fig. 1.2.104
52
⑥ Dismantle the gear shaft sleeve for gear 2,

Fig. 1.2.105
ring gear sub-assembly of gear 1 synchronizer
JAC-T1B002
and gear 1 gear assembly.
⑦ Take off the gear 1 needle bearing.

Fig. 1.2.106
⑧ Dismantle the gear shaft sleeve for gear 1. Fig. 1.2.107

Mount the special tools onto the gear shaft sleeve
for gear 1.
JAC-T1B001
⑨ Dismantle the circlip with outside caliper and Fig. 1.2.108

take off the right bearing shield ring of
intermediate shaft and the right bearing.
53
2) Check After Disassembly
① Intermediate Shaft and Gear
Check the following items. If necessary, please replace the spare parts with trouble.
■ Check the intermediate shaft for damage, Fig. 1.2.109

peeling, dent, uneven wear, bending and other
abnormalities.
■ Check the gear for excess wear, damage,

Fig. 1.2.110
peeling and other abnormalities.
② Synchronizer
Fig. 1.2.111
■ Check the contact surface of the ring gear and

sub-assembly for damage and excess wear.
■ Check whether the rotation between the ring

gear and sub-assembly is smooth.
54
■ If the convex side of the ring gear or the Fig. 1.2.112

inserted working side is with crack, damage or
excess wear, please replace it.
■ Check the clearance between the upper ring gear and gear of synchronizer.
Have the synchronizer ring gear cling to the matching conical surface of gear. Check the clearance
between the conjoint tooth of gear and the end face of ring gear. If the clearance reaches or exceeds the
limit, it is essential to replace the spare parts.
Standard value: 0. 8~1.2 mm
Limit value: 0.5 mm
③ Bearing
Check the following items. If necessary, please replace the spare parts with trouble.
■ Check the bearing for damage or poor Fig. 1.2.113

rotation.
3) Assemblage
Attention:
■ Coat the junction surface of each spare part with gear oil of gearbox before assemblage.
① Assemble the low-speed synchronizer sub-assembly
55
a. Mount the synchronizer hub onto the Fig. 1.2.114

synchronizer sleeve.

■ Installation direction of low-speed
synchronizer hub
■ Installation direction of low-speed Fig. 1.2.116

synchronizer sleeve
b. Mount the slider assembly onto the Fig. 1.2.117

synchronizer sub-assembly.
56
② Assemble the gear 1 gear and ring gear Fig. 1.2.118

sub-assembly of gear 1 synchronizer.
a. Mount the upper ring gear.
b. Mount the elastic ring.

Fig. 1.2.119
Attention:
■ The elastic ring must be mounted completely.
c Mount the lower ring gear. Fig. 1.2.120

■ Pay attention to the installation position.
③ Assemble the low-speed synchronizer Fig. 1.2.121

sub-assembly and gear 1 gear assembly.
④ Mount the gear 1 gear spacer.
57
⑤ Mount the gear 1 gear assembly and low-speed synchronizer sub-assembly.
⑥ Mount the right bearing and its shield ring.

Fig. 1.2.122
⑦ Mount the gear 2 gear spacer. Fig. 1.2.123

JAC-T1B005
JAC-T1B007
JAC-T1B0011
⑧ Mount the gear 2 needle bearing. Fig. 1.2.124
⑨ Mount the gear 2 synchronizer sub-assembly Fig. 1.2.125

and gear 2 gear assembly.
58
⑩ Mount the gear 3 gear. Fig. 1.2.126
⑪ Mount the gear spacer for gear 3 and 4.

Fig. 1.2.127
⑫ Mount the gear 4 gear. Fig. 1.2.128
⑬ Mount the left bearing of intermediate shaft.

Fig. 1.2.129
JAC-T1B005
JAC-T1B006
JAC-T1B008
59
XIII. Differential
1. Element
Diassembly Diagram for Differential
1-Shield ring of planetary gear shaft 2-Planetary gear 3-Half shaft of differential 4-Planetary gear
shaft 5-Right inner ring of differential bearing 6-Induction ring gear 7-Differential bolt 8-Differential
casing 9-Differential casing pad 10-Main reduction gear 11-Left inner ring of differential bearing
60
1) Disassembly Fig. 1.2.130

① Dismantle the differential side bearing with JAC-T1B001
punch and suitable puller.
② Dismantle the shield ring on the differential

casing with snap ring pliers.
③ Dismantle the planetary gear and half shaft of

Fig. 1.2.131
differential on the differential casing.
Note: Rotate the planetary gear for dismantlement.
④ Dismantle the differential bolt in the reverse Fig. 1.2.132

order of that as shown in the figure, and cut off
the differential casing and main reduction
gear.
① Planetary Gear, Pad, Half Shaft of Differential, Induction Ring Gear and Casing
Check the planetary gear, pad, half shaft of differential, induction ring gear and casing. If necessary,
61
② Bearing
Fig. 1.2.134
Check the bearing for damage and poor rotation. If
necessary, please replace the spare parts with
trouble.
Attention:
■ When replacing bearing, replace complete

sets of left and right inner rings of bearing.

Pay attention to the following points and assemble
Bearing
in the reverse order with disassembly.
■ Ensure the shield ring is mounted in the slot

correctly.
■ Mount the differential side bearing with punch.
■ Coat the differential bolt with sealant. Fig. 1.2.136
62
XIV. Shift Control Sub-assembly
Disassembly Diagram for Shift Control Sub-assembly
1-Selector rod 2-Clamping band 3-Control casing 4-Bolt 5-Shift stopper 6-Return spring seat
7-Return spring 8-Interlocking plate 9-Control shaft 10-Control shaft head 11-Lock pin 12-Gear
lever 13-Oil seal of control shaft 14-Spring pin 15-Needle bearing
Essentials of Disassembly:
1. Lock Pin
1) Dismantlement
Knock out the lock pin with special tool Fig. 1.2.137
JAC-T3B003 towards the direction as shown in the
Lock pin
figure.
Control head
Knock-out
direction
63
2) Installation Fig. 1.2.138 Press-in direction
Press in the lock pin from the direction as shown in

the figure.
2. Needle Bearing
Fig. 1.2.139
1) Installation Control casing
Needle
Press in the needle bearing to the position as bearing
shown in the figure to make the model

Position of model
countermark towards the direction as shown in the countermark
figure.
3. Oil Seal of Control Shaft Fig. 1.2.140

1) Installation
Note: Coat the oil seal lip with gear oil of gearbox.
Install it with special tool JAC-T3B001.
4. Spring Pin Shifting fork Fig. 1.2.141

Guide rail
1) Installation
Please install it with special tool JAC-T3B003

according to the directions as shown in the figure. Press-in direction
Opening
Spring pin
64
XV. Gear Shifting Control Sub-assembly
Disassembly Diagram for Gear Shifting Control Sub-assembly
1-Shifting fork for gear 5 2-Shifting fork for gear 3 and 4 3-Shifting fork for gear 1 and 2 4-Shifting
fork for reverse gear 5-Shifting fork shaft for gear 1 and 2 6-Shifting fork shaft for gear 3 and 4
1. Check: Fig. 1.2.142

Check the contact surface and sliding surface of
shifting fork shaft for wear, damage and bending. If
necessary, please replace it.
65
XVI. Reversing Lamp Switch
1. Element Position Fig. 1.2.143
2. Check
Check the continuity between the ports.
Check Table for Reversing Lamp Switch
Gear Continuity
Reverse gear Yes
Except the reverse gear No
XVII. Maintenance Parameters
Table of Tightening Torque
No. Name Qty. Tightening Torque (N • m)

1 Lock bolt for gear 5 and reverse gear 1 10~16
2 Lock bolt for gear 1 and 2 1 10~16
3 Gear shifting fork bolt for reverse gear 1 18~28
4 Gear shifting fork bolt for gear 5 1 8~10
5 Mounting bolt of speed sensor 1 5~7
6 Gear shaft bolt for reverse gear 1 18~28
7 Bearing pressure plate bolt 7 8~12
8 Nuts of intermediate shaft and input shaft 2 80~100
9 Gearbox casing bolt 16 18~28
10 Reversing lamp switch assembly 1 15~20
11 Oil fill plug screw 1 10~17
12 Bleeding plug screw 1 10~17
66
13 Shift control casing bolt 4 8~12

14 Clutch casing bolt 6 8~12
15 Baffle plate bolt of reversing lamp 2 8~12
16 Lock bolt for gear 3 and 4 1 15~20
Mounting bolt of release bearing M6 X 1.0 X
17 3 7~10
20
18 Mounting bolt of cable support 2 19~25
19 Stop bolt for gear shifting 1 10~16
20 Interlocking bolt for gear 5 and reverse gear 1 10~16
2. Transmission Ratio
Table of Transmission Ratio of Each Gear
Max.
Speed Ratio of Each Gear Gear Main
Type of Input
Ratio of Reduction
Gearbox Torque Reverse
Gear 1 Gear 2 Gear 3 Gear 4 Gear 5 Odometer Ratio
(N.m) gear
MF514A02 160 3.583 2.043 1.412 1.105 0.881 3.615 26 4.250
MF514D02 160 3.583 2.043 1.412 1.105 0.881 3.615 26 4.059
67
Chapter II Traveling System
Section I Power Steering System

I. Precautions
1. The vehicle shall be at level and dry ground when checking its steering system.
2. The bolts of the steering system elements shall be tightened according to the specified torque.
3. The wheel location shall be checked after the check of steering gear and other steering mechanisms
is finished.
4. The following points shall be paid attention to during the steering gear disassembly:
1) The device outside shall be cleaned completely before disassembly.
2) The disassembly shall be carried out in the clean work area, in order to avoid the inner spare parts
being polluted by dust and other foreign matters.
3) Please put the disassembled spare parts on the parts shelf in order, to make the assembly much
easier and more correct.
4) The nylon cloth is recommended to be used for cleaning the spare parts, for the rag dust remaining
on the ordinary rag used in workshop will affect the operation of spare parts.
5) Please don’t use the disposable spare parts.
6) Please lubricate the specified spare parts with lubricating grease before assemblage.
68
II. Preparation
1. Special Tools
Steering For dismantling the

1 wheel JAC-T1D002 steering wheel
puller
2. General Tools
Table of General Tools
No. Tool Outline Diagram Illustration
For dismantling and mounting

Power
1 the bolts and nuts
tool
Trimming For dismantling the trimming

2 plate cover of steering column
detacher
69

The driving belt is loose or worn Check the driving belt
Check if the hydraulic oil pipe is damaged
The hydraulic oil pipe is blocked and blocked, or if its direction is wrong,
replace the oil pipe assembly if necessary
The steering fluid becomes smudgy Clean the whole steering system
Hard or excessively There is air mixing in the oil circuit Exhaust air in the system
easy steering The suspension ball joint is
Check the element of suspension ball joint
deadlocked
The steering gear is damaged Replace the steering gear
The steering column is damaged Check the steering connecting element
The power steering pump is
Replace the power steering pump
damaged
The ball joint of tie rod is damaged Replace the tie rod if necessary
The suspension ball joint is
Check the element of suspension ball joint
damaged
The dustproof boot for steering Check the element, and replace it if
gear is damaged necessary
Insensitive steering
The fixed bolt of steering gear is Check and replace it with a new fixed bolt if
(when rotating the
loose necessary
steering wheel, the
The fixed bolt of steering column is Check and replace it with a new fixed bolt if
direction is not
loose necessary
changed)
The fastening bolt connecting the
Check and replace it with a new fastening
steering column and steering
bolt if necessary
mechanism pinion is loose
The steering gear clearance is too
Replace the steering gear
large
IV. Power Steering Fluid

Fig. 2.1.001
1. Check of the Fluid Level
1) Check the fluid level when the engine is shut
off. MAX
2) Make sure the level is between MIN and MAX. MIN
Attention:
■ The level shall not exceed the maximum value
(MAX line), in order to avoid the leakage of the
power steering fluid.
Recommended oil: PSF3
3) Please don’t reuse the discharged power
steering fluid.
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2. Check of the Leakage of Steering Fluid
1) Check if the hydraulic joint has oil leakage, Fig. 2.1.002

crack, damage, looseness, and wear.
① Operate the engine to make the liquid
temperature of the stock solution tank reach Rupture of Oil pipe nut
the hose
50 ~ 80 ℃ (122 ~ 176 ℉), and keep the
engine operating at idle speed. Hose clamp
② Turn the steering wheel to the left and right

Rupture of the oil
limits for several times. pipe Eyebolt
③ Keep the steering wheel at the position of locked point for 5s, and check if there is oil leakage
meanwhile.
④ If the oil leakage is found at the joint, please unscrew the oil pipe nut and then retighten it to the
specified torque.
Attention:
■ Please don’t tighten the joint nut excessively, to avoid the damage of O-ring, gasket and joint.
⑤ If there is oil leaking from the power steering pump, please check the power steering pump. Refer to
“Power Steering Pump” please.
⑥ Check if there is oil aggregating on the dustproof boot of steering gear.
3. Air Exhaust of the Hydraulic System
If the air is not exhausted completely, the following symptoms will appear -
■ There is air bubble in the stock solution tank.
■ There is abnormal sound in the power steering pump.
Note: There will be liquid noise during the power steering pump operation, which will not influence the
performance or durability of the system.
1) Shut off the engine, and turn the steering wheel to the left and right limits for several times.
Attention:
■ When filling the stock solution tank with oil, rotate the steering wheel to make the level not lower
than the MIN line.
2) Start the engine and make it operate at idle-speed, meanwhile keep the steering wheel staying at
the locked position for 3s, and check if there is oil leakage
3) Repeat the step 2 for several times every 3s.
Attention:
■ Please don’t keep the steering wheel staying at the locked point for more than 10s, to avoid
damaging the power steering pump.
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4) Check if there is air bubble or white impurity in the oil.
5) If the air bubble or white impurity has not been exhausted completely, please shut off the engine.
When the air bubble or white impurity has been exhausted completely, then please carry out the
step 2) and step 3).
6) Shut off the engine, and check the oil level.
Attention:
■ Check if the oil level of the stock solution tank varies within 5 mm when the engine is in operation
and stop status.
■ If the variation is not in the range, the system shall be exhausted repeatedly.
4. Replacement of Power Steering Fluid
1) Lift the front wheels, and fix them with rigid support.
2) Dismantle the oil return pipe from the stock solution tank, and block the return opening of the stock
solution tank.
3) Connect the oil return pipe with general oil pipe, and discharge the power steering fluid into the
container.
4) Start the engine, turn the steering wheel to the left and right, and discharge the power steering fluid.
Attention:
■ The power steering fluid shall be added timely to keep the fluid level between MIN and MAX all the
while, which can avoid the dry grinding of the power steering pump.
■ The operating time of the engine should not be too long, when the fluid level is down to MIN position,
the engine should be shut off.
5) Connect the oil return pipe, and then add new power steering fluid to the standard position.
6) If the quality of the replaced power steering fluid does not meet the ideal requirement, it can be
achieved according to the step 2) ~ step 5).
Attention:
■ The air in the system shall be exhausted after replacement. Please refer to “Air Exhaust of the
Hydraulic System”.
V. Steering Wheel
1. On-vehicle Check
1) Check the installations
① Check the installations of steering gear assembly, front suspension, axle and steering column.
② Check if there is moving clearance during the up-and-down, left-and-right, and axial movements of
the steering wheel.
③ Check if the fixed nut and bolt of steering gear assembly are loose.
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2) Check the free play of the steering wheel
① Rotate the steering wheel to make the front wheels straight forwards. Start the engine, and rotate
the steering wheel slightly until the front wheels begin to move. Measure the movement of the
steering wheel on the excircle.
■ The free play of steering wheel: 30 mm
② When the measured value exceeds the standard value, check the installations of each steering
column joint and steering gear. Make adjustment according to the situation or replace the relevant
spare parts.
③ If the free play is still a limited value, then make the steering wheel in the middle position with the
engine being shut off, and apply a force of 5 N to steering wheel circle, and check the free play.
■ Standard value: <15 mm
④ If the standard value is exceeded, the steering gear should be dismantled to check the total torque
of the pinion.
3) Check the middle position
① Make sure the steering gear assembly, steering column, and steering wheel are mounted correctly.
② Check the middle position after the wheel location. Please refer to “Check of the Front Wheel
Location”.
③ Park the vehicle straight forwards, and ensure the steering wheel is in middle position.
④ Unscrew the locknut of tie rod and turn the adjusting rod to the left and right slightly to ensure the
steering wheel is in middle position.
4) Check static steering force of the steering wheel
① Park the vehicle on the level and dry ground, and pull up the parking brake handle.
② Start the engine.
③ Keep the engine operating, and raise the temperature of power steering fluid to the operating
temperature.
Note: The tyre pressure value shall be within the standard value.
④ Turn the steering wheel 360° from the middle position, and check the steering force of steering
wheel to see if there is obvious fluctuation.
■ The steering force of steering wheel: <34N allowable fluctuation: <5.9N
⑤ If the steering force of steering wheel exceeds the specified value, please check or adjust the
following items:
a. Check if the ball joint of lower suspension arm and ball joint of steering tie rod are damaged.
b. Check or adjust the preloading of the steering gear and the rotational torque of the ball joint of
steering tie rod.
c. Check or adjust the rotational torque of the ball joint of lower suspension arm.
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5) Check the self-return of the steering wheel

Attention:
■ Make slow or sudden turns to see if there is difference in applied force and return in left and right
directions.
■ This step must be carried out on the safe road and in the safe traffic conditions, and safety must be
paid more attention to.
① Rotate the steering wheel 90°, and drive the

vehicle at 35 km/h for several seconds, and Fig. 2.1.003
then release the steering wheel, the return
shall reach more than 70% at least.
Attention:
■ When the steering wheel is rotated rapidly,
there will be sense of “heaviness” temporarily,
which is due to the deficiency of oil supply for
the power steering pump in idle period, it is not
the trouble.
6) Check the steering angle of the front wheel
① Check the steering angle of the front wheel after the front wheel toe-in check. Put the front wheel on
the radius gauge to check the maximum steering angle of the inner and outer wheels of the left &
right wheel.
■ Inner wheel: 38° 52' Outer wheel: 33° 07'
② Rotate the steering wheel to the left and right limits to measure the steering angle, when the engine
is at idle speed.
■ If the measured value is not in the standard range, the tie rod shall be adjusted.
The adjusting method of the steering angle is as follows:
■ Unscrew the locknut of the left & right tie rods, and rotate the left & right tie rods with spanner
separately adjusting the steering angle to standard value, and then screw down the locknut to the
specified tightening torque.
Attention:
■ The length of left & right tie rods shall keep the same during the length regulation.
■ Tightening torque: 50~55 N • m
7) Check the dust cover of ball joint
① Press the dust cover with finger to check if there is crack or damage.
② If the dust cover is cracked or damaged, the tie rod ball joint shall be replaced.
Attention:
■ When the dust cover is cracked or damaged, it may damage the ball joint.
74
8) Check the rotational torque of the ball joint of the steering tie rod
① Swing the tie rod rapidly for 10 times.
② Measure the swinging resistance of the tie rod with spring balance.
■ Standard value: 2 ~ 5 Nym

Fig. 2.1.004
■ If the measured value is not within the
standard value, please replace it.
1) Dismantlement
① Cut off the negative battery terminal and keep
this state for more than 3 min.
② Dismantle the driver airbag module from the steering wheel.

Please refer to “Driver Airbag Module”.
③ Remove the fixed nut of steering wheel after the steering locking.
■ Tightening torque: 35 ~ 45 N-m

Fig. 2.1.005
④ Pull out the steering wheel from the steering
shaft.
Note: If it can not be pulled out easily, please use
the steering wheel puller.
2) Installation
Attention:
■ The installation must be carried out when the wheel is running straight forwards and the steering
wheel is in middle position. In addition, the steering wheel and fixed nut can be marked alternatively
before dismantlement, and the marks shall be corresponding during installation.
■ For the installation position of the clock spring (hairspring), please refer to “Clock Spring”.
■ Excessive torsion shall be avoided when the clock spring is tightened.
75
VI. Steering Column

1. Element
Diagram for Steering Column Assembly

Attention:
■ Please don’t apply axial force excessively to the steering column assembly during dismantlement
and installation.
■ Please don’t move the steering gear when dismantling the steering column.
1) Dismantlement
① Park the vehicle straight forwards.
② Cut off the negative battery terminal, and keep this state for more than 3 min.
③ Dismantle the driver airbag module from the steering wheel. Please refer to “Driver Airbag Module”.
④ Dismantle the steering wheel. Please refer to “Steering Wheel”.
⑤ Dismantle the upper and lower protecting covers of steering column and the lower part of console at
driver’s side. Please refer to “Console Assembly”.
⑥ Dismantle the combined switch assembly and the clock spring from the steering column. Please
refer to “Clock Spring”.
⑦ Cut off each wire harness joint mounted onto the steering column, and then remove the wire
harness from the steering column.
⑧ Dismantle connecting bolt of steering column connecting shaft, and separate the steering column
and steering gear.
■ Tightening torque: 15 ~ 20 Nym Fig. 2.1.006
76
⑨ Dismantle the fixed bolt of the steering column

Fig. 2.1.007
assembly, and lower the steering column to
take off the steering column assembly.
■ Tightening torque: 13 ~ 18 Nym
① Check if the steering column has the damages such as crack and deformation, if it has, please
replace it.
② Check if the spline of steering column is worn or has broken tooth, if it has, please replace it.
3) Disassembly
Disassembly Diagram for Steering Column
1-Special bolt 2-Steering lock support 3-Steering lock assembly 4-Snap ring 5-Steering shaft
assembly 6-Spring 7-Steering column assembly
77
① Disassembly
a. Unscrew the connecting bolt of steering column and connecting shaft universal joint, and then
dismount the universal joint.
b. Dismantle the steering lock if necessary.
Attention:
■ The special bolt must be replaced when the steering lock is remounted.
c. Dismantle the adjustable steering column

Fig. 2.1.008 Reversal thread screw tap
and support if necessary.
Special bolt
② Disassembly gists Steering lock
support
Dismantlement of the special bolt:
a. Drill the special bolt with electric drill to put in
the screw tap.
b. Dismount the special bolt with reversal thread
Steering lock body
screw tap.

① Check the crack and damage of the adjustable support and spring.
② Check if the operation of the steering lock mechanism is normal.
5) Assemblage
Assemble the steering lock assembly, steering lock support and special bolt.
Attention:
Fig. 2.1.009
■ When the steering lock assembly and steering
lock support are being mounted on the
steering column assembly, they shall aim at
the locking gap of steering column to lock up
the steering lock temporarily.
■ When making sure the operation of the
steering lock is correct, fasten the special bolt Gap
until the bolt head is locked out.
6) Installation
Attention:
■ Please don’t reuse the disposable spare parts.
■ Keep the steering wheel in middle position to mount the steering column assembly.
■ Please pay attention to the mounting position when mounting the connecting shaft on the steering
column.
78
Park the vehicle straight forwards, and turn the steering wheel to the left and right for several times to
make sure the steering wheel is operated flexibly.
VII. Steering Gear
1. Element
Diagram for Steering Gear Assembly
Attention:
■ Rotating the steering wheel while separating the steering column and steering gear may damage
the clock spring, therefore the steering wheel must be fixed to avoid its rotation.
1) Dismantlement
Fig. 2.1.010
Attention:
■ The oil in steering system shall be collected

firstly before dismantlement.
① Park the vehicle straight forwards.
② Dismantle connecting bolt of steering column
and steering gear from the cab, and separate the
steering column and steering gear.
■ Tightening torque: 15 ~ 20Nym
③ Dismantle the air filter assembly. Please refer to

Fig. 2.1.011
“Air Filter Assembly”.
④ Dismantle the oil pipe of steering gear.
79
⑤ Dismantle the tie rod locknut.

Fig. 2.1.012
■ Tightening torque: 50 ~ 55 N•m
⑥ Dismantle the ball joint of steering tie rod from

Fig. 2.1.013
steering knuckle with special tool, as is shown
in the figure.
Locknut
⑦ Dismantle the engine support beam assembly
and the gearbox rear suspension. Please refer Rope
to “Engine Support Beam”.
Attention:
Ball joint
■ Please use the jack to support.
⑧ Dismantle the steering gear fixed bolt from the

Fig. 2.1.014
firewall.
■ Tightening torque: 60 ~ 80 N • m
⑨ Move the steering gear assembly to the right,

and take it out from the left side of frame.
Attention:
■ Take it out carefully and slowly in order not to

damage the tie rod dustproof boot.

① Steering Gear
■ Check if the oil pipe joint is loose and damaged.
■ Check if the fixed liner of steering gear has damages such as abrasion, and crack.
■ Check if the pinion and rack operate well and if they are worn.
■ Check the preloading of the gear.
80
a. Rotate the gear with the speed of 4~6s per circle, and measure the gear preloading in the whole
stroke of the rack.
■ Standard value: 0.6 ~ 1.3 Nym
b. If the measured value is beyond the specification, the block shall be regulated, and then the gear
preloading shall be checked again.
c. If the specified gear preloading still can’t be obtained through block regulation, the block
sub-assembly shall be checked or replaced.
② Steering tie rod
Check the rotational torque of the steering tie rod.
a. Swing the tie rod rapidly for 10 times.
b. Measure the swinging resistance of the tie rod with spring balance.
■ Standard value: 2 ~ 5 Nym
If the measured value is not within the stated value, please replace it.
Attention:
■ If there is no excessive clearance while swinging the tie rod slowly, it can be used even the
measured value is lower than the standard value. If the measured value is lower than 4.3 N, the tie
rod must be replaced.
③ Tie rod dustproof boot
■ Check if the dustproof boot is damaged, if it is, please replace it.
■ Check if the dustproof boot is mounted to the right position.
3) Installation
Note: Please don’t reuse the damaged spare parts.
Attention:
■ Pay attention to the mounting position while connecting the steering gear and steering column.
■ Exhaust air in the steering hydraulic system after installation. Please refer to “Hydraulic Pipeline”.
■ Keep the tyre on the level ground in no load condition when dismantling the steering gear assembly,
and tighten the nut and bolt for the last time.
■ Check the wheel location. Please refer to “Location of Front Wheels”.
■ Turn the steering wheel to the left and right limits for several times to make sure the steering wheel
is operated flexibly.
81

1) Element
Disassembly Diagram for Steering Gear

1-Locknut 2-Block 3-Rack support spring 4- Rack support seat 5-Liner 6-Self-locking nut 7-Bearing
8-Steering gear casing 9-Open spring 10- Rack stop block 11-Gear liner assembly 12-Oil seal
13-Support pad 14-Oil pipe 15-Steering gear pinion with valve body assembly 16-Valve body casing
17-Gasket ring 18-Rack 19-Dust cover 20- Tie rod ball joint 21-Tie rod locknut 22-Clamp 23-Dustproof
boot 24-Clamping band 25-Tie rod 26-Joint washer
2) Disassembly
① Dismantle the tie rod ball joint from the tie rod.
② Dismantle the clamping band and clamp of dustproof boot, and take out the dustproof boot from the
tie rod.
③ Dismantle the oil pipe from the gear casing.
④ Move the rack slowly to discharge the oil from the gear casing.
⑤ Dismantle the end cap.
82
⑥ Rotate the rack clockwise to the lock position, and dismantle the self-locking nut.
⑦ Loosen the joint washer between the tie rod and rack with chisel, and dismantle the tie rod from the
rack.
⑧ Dismantle the block locknut to dismount the block.
⑨ Dismantle the rack support spring, support seat and liner from the gear casing.
⑩ Dismantle the valve casing.
⑪ Rotate the rack stop block clockwise until the end of open spring pops a gear casing slot.
⑫ After the end of open spring pops the rack casing groove, rotate the rack stop block anti-clockwise,
and then dismantle the open spring.
⑬ Move the rack stop block, rack liner and rack from the gear side and then dismantle them.
Attention:
■ The casing oil seal shall be replaced when the rack is dismounted.
⑭ Dismantle the O-ring and oil seal from the rack liner.
⑮ Dismantle the valve body, oil seal and ball bearing from the valve casing. And dismantle the ball
bearing and needle bearing from the gear casing.
Attention:
Take care not to damage the gear valve body in the gear casing.
3) Assemblage
Pay attention to the following items and assemble in the reverse order with disassembly.
■ Smear the sealant on the surface when mounting the block, and then tighten it to the specified
torque.
■ Tightening torque: 50 ~ 70 Nym.
83
4. Tie Rod
Disassembly Diagram for Tie Rod
1-Tie rod 2-Clamping band 3-Dustproof boot 4-Ball joint 5-Locknut
1) Dismantlement
① Fix the pinion and rack onto the bench clamp.
Attention:
■ Enwind a piece of cloth around the surface of the rack when mounting the rack. Tighten it carefully
in order not to damage the rack.
② Cut off the dustproof boot clamping band to dismount the dustproof boot
③ Dismount the tie rod.
① Check if the tie rod is damaged or deformed.
② Check if the dustproof boot is damaged or deformed.
③ Check the swinging torque of tie rod.
④ Check the swing and the axial clearance of tie rod ball joint.
3) Installation
① Mount the tie rod on the rack and tighten it, and then fix it in the slot with punch.
■ Tightening torque of tie rod and rack: 80 ~ 100 Nym
② Mount the dustproof boot on the gear casing, and then fix it with clamping band.
84
Attention:
■ The fixing strap for dustproof boot must be assembled after the regulation of toe-in.
■ Please don’t’ reuse the disposable spare parts.
③ Regulate the length of tie rod and tighten the locknut.
■ The length of tie rod (standard value): 175.3±1 mm
■ Tightening torque of the tie rod locknut: 50 ~ 55 N • m
VIII. Power Steering Pump
1. On-vehicle Check
1) Check of the released oil pressure
Attention:
■ Please confirm the belt tension rate before implementation. Refer to “Drive Belt”.
① Dismantle the flowline form the power steering pump, and connect the pressure gauge.
Diagram for Power Steering Pump Assembly
1-Thermometer 2- Stock solution tank 3-Power steering pump 4-Pressure gauge 5-Cut-off valve 6-Joint
85
② Open the valve, and exhaust air in the hydraulic pipeline. Please refer to “Air Exhaust of the
Hydraulic System”.
③ Start the engine, and turn the steering wheel for several times to make the oil temperature reach
about 50 ℃.
Attention:
■ The belt and the hoses of other spare parts must be kept clean when starting the engine.
④ Turn off the pressure gauge when the engine is at idle speed, and measure the released oil
pressure. Please refer to “Technical Specifications”.
Attention:
■ Please don’t let the valve be closed for more than 10s.
⑤ Open the valve slowly after measurement. If the released oil pressure is not within the standard
range, please replace the power steering pump.
⑥ Cut off the pressure gauge from the hydraulic pipeline after check, and then fill new oil and exhaust
air in the pipeline. Please refer to “Air Exhaust of the Hydraulic System”.
1) Dismantlement
① Discharge the power steering fluid from the Fig. 2.1.015

② Dismantle the belt of power steering pump.

Please refer to “Drive Belt”.
③ Dismantle the high pressure induction

manifold and flowline from the power steering
pump.
④ Dismantle the fixed bolt and then dismount the

Fig. 2.1.016
power steering pump.
■ Tightening torque: 40 ~ 60 Nym
2) Installation
① Install in the reversed order with

dismantlement.
② Carry out the following steps after installation.
■ Regulate the tension rate of the belt. Please refer to “Tension Rate Adjustment”.
■ Do air exhaust. Please refer to “Air Exhaust of the Hydraulic System”.
86
1) Element
Disassembly Diagram for Power Steering Pump

1-Hexagon bolt 2-End cap 3-O-ring 4-Needle bearing 5-Armature 6-Induction manifold 7-Pin
8-Compression spring 9-Oil seal 10-Shaft 11-Ball bearing 12-Valve core 13-Valve bolt 14-Spring guide
pin 15-Washer 16-Casing 17-Gasket ring 18-Fuel distributor 19-Blade 20-Needle 21-Stator
2) Check Before Disassembly
The power steering pump can be disassembled only when the following troubles appear:
■ The power steering pump leaks oil.
■ The power steering pump pulley has been damaged or deformed.
■ The performance of the power steering pump is not good.
3) Disassembly
Attention:
■ Please fix the power steering pump in the calipers if necessary.
① Dismantle the induction manifold and O-ring from the power steering pump.
② Dismantle the rear end cap, O-ring, needle, and stator.
87
③ Dismantle the armature, blade as well as fuel distributor.
④ Dismantle the inner and outer O-rings and gasket ring.
⑤ Dismantle the snap ring with pliers. Take out the ball bearing and shaft.
⑥ Dismantle the oil seal from the body of power steering pump.
⑦ Dismantle the valve screw to take out the valve core and compression spring.
① Check of the power steering pump casing and rear end cap.
■ Check if the casing and rear end cap are damaged. If they are, please replace the power steering
pump assembly.
② Check of the Flow Control Valve
■ Check if the flow control valve and spring are damaged (the specific checking procedures are as
follows), if they are, please replace them.
The check procedures of flow control valve:
a. Press the valve rod with hand, if it can move up and down freely, which shows that the valve core is
not seized or damaged, vise versa, it shows that the valve core has been seized or damaged.
b. Check if the valve core surface is scratched.
c. Take out the spring in the valve cavity, and check if it is deformed.
5) Assemblage
Pay attention to the following items and assemble in the reverse order with disassembly.
■ Clean the spare parts.
■ Smear the standard power steering fluid on the surface of the dismounted spare parts, of which the
oil seal and O-ring are included.
■ Fill new oil and exhaust air in the system. Please refer to “Air Exhaust of the Hydraulic System”.
88
IX. Hydraulic Pipeline

1. Diagram for Hydraulic Pipeline
Oil Circuit Diagram for Power Steering Hydraulic Pipe

1-Oil return pipe 2- Power steering pump 3-High pressure pipe 4-Power steering stock solution tank
5-Flowline 6-Oil return hose 7-Power steering gear 8-Steering tie rod 9-Radiator pipe
1) Insert the hose firmly until it touches the Fig. 2.1.017

tubular axle. Tubular axle
Attention:
■ Please don’t use the oil for lubrication.
Pipe Hose
2) The projection part of the eyebolt shall face to

Fig. 2.1.018
the notch of the pump side when mounting the Eyebolt
eyebolt, and then tighten it to the specified Eyebolt joint
torque.
Copper
washer
Sealing part
Power steering pump
89
X. Maintenance Data and Specifications

1. Technical Specifications
Table of Technical Specifications
Types of steering column and Energy-absorbing, cross shaft universal joint connection,
connecting shaft adjustable gradient of steering column
Type of steering gear Pinion and rack
Rack stroke 134 mm
Type of oil pump Impeller type
Flow of oil pump 8.5 mL/rev
Starting pressure of oil pump
1.5~ 2.0 MPa
pressure valve
Free play of steering wheel 0~ 30 mm
Max. wheel steering angle Inner: 38° 52°; Outer 33° 07
Steering force 23 N or smaller
Belt flexibility (under the applied
7 ~ 10 mm
force of 98N)
Pressure drop of oil pump 5.9 MPa
Rotational torque of steering pinion 0.6~ 1.3 N•m
Swinging torque of steering pull rod 2 ~ 5 N•m
2. Recommended Accessories
Table of Recommended Accessories
Item Recommended Lubricating Oil Fill Volume
Horn contact of steering wheel LONG TIME PD2 Proper
Power steering fluid Type PSF-3 0. 9L
Torque Torque
Item Item
(N•m) (N•m)
Steering wheel locknut 35~45 Steering gear mounting bolt 60 ~ 80
Assembly support of steering column
13~18 Steering pull rod locknut 50 ~ 55
and steering connecting shaft
Steering shaft and connector 15~20 Slotted nut of steering pull rod ball joint 15 ~ 34
Steering pinion and connector 15~20 Rack clearance adjusting nut 50 ~ 70
Bolt of oil pump support 20 ~ 27 Steering pull rod and rack connection 80 ~ 100
Valve body shell and rack shell
20 ~ 30 Oil pump adjusting bolt 25 ~ 33
assembly
Mounting clamping band of pressure Mounting bolt of pressure pipe and oil
8 ~ 12 55 ~ 60
pipe and oil return pipe pump
Pressure pipe and oil return pipe
12 ~ 18 Oil cooling pipe mounting bolt 8 ~ 12
connected with steering gear
Self-locking nut of steering pinion and Clamp plate of suction pipe support
20 ~ 30 3~5
rotary valve (with joint of oil pump suction pipe)
Block 50 ~ 70
90
Section II Front Axle

I. Precautions
1. The following items shall be paid attention to during the front axle maintenance
1) The spare parts needing minor repair, such as, the steering knuckle can not be dismantled.
2) Try to operate on a dustless workbench.
3) Before the disassembly and assemblage, please clean the external surface of the spare part.
4) During working, be careful to avoid smearing the spare parts and prevent entry of foreign matters.
5) The disassembled spare parts shall be reassembled in order. If the work is paused, the spare parts
shall be covered by clean hood.
6) As rags will be left on the spare parts if the fabrics are used, it is a must to use the paper cloth.
7) The disassembled spare parts (excluding rubber spare parts) shall be cleaned by the kerosene or
dried and wiped by the paper cloth.
2. Precautions for checking and repairing the system or replacing the spare parts
1) The stated torque check shall be done to the fasteners after the assemblage.
2) The necessary alignment check shall be conducted after the system assemblage.
3) The disposable spare parts can’t be reused.
4) Before repairing and replacing the spare parts, thorough check is required.
II. Preparation
Select proper maintenance tools for dismantlement and installation.
1. General tool
Table of General Maintenance Tool

1 Power tool dismantlement of bolts
and nuts
91
2. Special tool
Table of Special Maintenance Tool

Drawing
die for For dismantlement
1 steering JAC-T1D003 of the connecting
driving ball joint
rod

Offtracking of Wear of the steering knuckle of the drive shaft Replacement
the vehicle Wear, friction or click of the wheel bearing Replacement
Defects of the front suspension and the steering system Adjustment or
replacement
Vibration Wear, damage or bending of the drive shaft Replacement
Abnormal sound of the drive shaft and wheel hub spline Replacement
Wear, friction or click of the wheel bearing Replacement
Run-out Unbalanced wheel Adjustment or
replacement
Defects of the steering knuckle of the front axle Adjustment or
replacement
Loud noise Wear, damage or bending of the drive shaft Replacement
Wear of the wheel hub spline of the drive axle Replacement
Wear of the wheel hub spline of the drive shaft Replacement
Wear, burning or abnormal sound of the wheel bearing Replacement
Looseness of hub nuts Adjustment or
replacement
replacement
IV. Front Wheel Hub and Steering Knuckle
1. On-vehicle check
Check whether every element’s fixing (clearance) and wear status is normal.
1) Check of the wheel bearing
■ Push the wheel hub and the bearing assembly axially with hand; check whether there is any
looseness for the wheel bearing. If any, it is suggested that the bearing shall be replaced or
reassembled.
■ Rotate the wheel hub, and check whether there is any abnormal noise or other abnormalities. If any,
it is suggested that the bearing shall be replaced.
92

1) Element
Disassembly Diagram for the Front Axle

1-Lower suspension arm 2-Ball joint 3-Fixing bolt of the brake tongs 4-Dust guard 5-Wheel hub
assembly 6-Locknut 6-Cotter pin 7-Cotter pin 8-Gasket 9-Brake disk 10-Brake tongs 11-Steering knuckle
12-Shock absorber 13-Nut 14-Snap ring 15-Wheel bearing 16-Locknut of the lower suspension arm
2) Dismantlement
① Lift the vehicle and dismantle the tire of the front

Fig. 2.2.001
wheel. Please refer to “Wheel and Tire”.
② Dismantle the speed sensor from the steering knuckle.
Please refer to “Speed Sensor”.
Attention:
■ Do not pull the wire harness of the speed sensor.
■ While in installation, check the clearance between the
speed sensor and the wheel hub.
Standard value of clearance: 0.5 mm

③ Loosen the fixing bolt of the brake hose and remove the brake hose. Please refer to “Braking
Pipeline”.
④ Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front Brake Tongs”.
93
Attention:
■ Do not step on the brake pedal after the

Fig. 2.2.002
dismantlement of the brake tongs.
⑤ Dismount the stop bolt of the brake disk from
the wheel hub and remove the brake disk.
⑥ Dismantle the cotter pin and loosen the

Fig. 2.2.003
locknut of the wheel hub.
⑦ Knock the drive shaft gently with a hammer (or
other appropriate tools) and a wooden block to
separate the wheel hub and the steering
knuckle assembly. Then dismount the locknut
of the wheel hub.
Attention:
■ While putting down the drive shaft, make sure that the casing (universal joint component), axle and
other spare parts are supported.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, resort to
pullers (or appropriate tools).
⑧ Dismantle the ball joint of the steering tie rod

Fig. 2.2.004
from the steering knuckle.
Attention:
■ Use special or appropriate tools to avoid

damaging the dust wrapper of the ball joint.
94
⑨ Dismount the shock absorber and the fixing

Fig. 2.2.005
bolt from the steering knuckle.
■ Tightening torque:75~90 Nym
⑩ Dismantle the drive shaft from the wheel hub. Fig. 2.2.006
Attention:
■ The universal joint of the drive shaft shall be

positioned without too large angle to avoid
excessive stretching and the falling off of the
ball case.
⑪ Dismantle the ball joint of the lower

Fig. 2.2.007
suspension arm from the steering knuckle.
Please refer to “Lower Suspension Arm”.
Attention:
■ Use special tools to avoid damaging the dust

wrapper of the ball joint.
⑫ Remove the wheel hub and the steering knuckle assembly.
Attention:
■ Check whether there is any deformation, crack or any other damages of the element. If any, please
get it replaced.
■ Check whether there is any damage, too large axial clearance, or torsion for the dust wrapper of the
external ball joint of the tie rod. Please refer to” Tie Rod”.
4) Installation
■ Install in the reverse order with dismantlement. As for tightening torque, please refer to
“Maintenance Parameters”.
95
Attention: Please do not use damaged spare parts.

■ While installing the ball joint of tie rod, fix the nuts to avoid rotation and then screw them down.
■ Under no load conditions, screw down every spare parts which are dismounted in the process of
dismantling front wheel hub and the steering knuckle finally.
■ Check wheel alignment. Please refer to “Front Wheel Alignment Check”.
■ Check whether the wire harness of the wheel sensor is correctly connected. Please refer to “Speed
Sensor”.
1) Disassembly
Fig. 2.2.008
① Remove the snap ring with the inner snap ring
pliers.
② Dismount the wheel hub and the dust cover
③ Dismount the inner ring of the wheel bearing
from the wheel hub.
④ Dismount the outer ring of the wheel bearing
Attention:
■ Operate it according to the regulation; avoid the slide of the bearing which may cause physical
injury.
■ Tightening torque: 80 Nym~100 Nym
■ If the repeated attempts to separate the steering knuckle and the wheel bearing all fail, please
replace the steering knuckle assembly.
2) Check after the disassembly
① Steering knuckle
■ Check whether there is any scratch, crack or other damages on the contact surface of the steering
knuckle and the wheel bearing.
■ If any of the situations mentioned above occurs, please repair and replace it according to the actual
situation.
② Brake disc
Check whether there is any crack or other damages on the surface of the brake disk.
③ Snap ring
■ Check whether there is any crack or other damages on the snap ring.
Attention:
■ Please do not use damaged spare parts.
④ Wheel hub
■ Check whether the wheel hub bolt is stretched.
■ Check whether there is any scratch, crack or other damages on the contact surface of the wheel
hub and the wheel bearing.
96
■ If any of the situations mentioned above occurs, please repair or replace it.
3) Assemblage
① Apply appropriate amount of grease on the contact surface of the steering knuckle and the wheel
bearing.
② Press the new wheel bearing in the steering joint and install the new snap ring.
Attention:
■ Please do not press the inner ring of the wheel bearing to avoid damaging the wheel bearing
assembly.
■ The model of the left and right wheel bearing shall be the same.
■ Please avoid repeated usage of damaged spare parts.
③ Install the dust guard.
④ Press the wheel hub into the steering knuckle.
Attention:
■ Please do not press the outer ring of the wheel bearing to avoid damaging the wheel bearing
assembly.
4) Check after the assemblage
■ Check whether the wheel hub and wheel bearing is assembled appropriately.
■ Measure the axial clearance of the bearing.
Limit value: 0. 064~0. 088 mm
Attention:
■ If the axial clearance exceeds the limit value, please reassemble it.
4. Replacement of the wheel bearing
As for the dismantlement and installation, please refer to procedures mentioned in “Front Wheel Hub
and Steering Knuckle”.
Attention:
■ Please do not use damaged spare parts.
■ The model of the left and right wheel bearing shall be the same.
■ Please conduct necessary road test.
V. Front Drive Shaft
1. On-vehicle check and maintenance
1) Check whether there is any looseness or other damages on the drive shaft and the universal joint.
2) Check whether there is any crack or other damages on the dust wrapper.
Attention:
97
■ If there is any noise or vibration on the drive shaft, please replace the drive shaft assembly.
2. Replacement of the dust wrapper of the drive shaft
1) Lift up the vehicle and dismantle the tire of the front wheel. Please refer to “Wheel and Tire”.
2) Dismantle the speed sensor from the steering knuckle. Please refer to “Speed Sensor”.
Attention:
■ Please do not pull the wire harness of the speed sensor.
3) Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front Brake Tongs”.
Attention:
■ Do not step on the brake pedal after the dismantlement of the brake tongs.
4) Dismantle the cotter pin and loosen the locknut of the wheel hub.
5) Knock the drive shaft gently with a hammer (or appropriate tools) and a wooden block, separate the
wheel hub and the steering knuckle assembly and then dismount the locknut of the wheel hub.
Attention:
■ Make sure that the casing (universal joint component), shaft and other spare parts are supported
while putting down the drive shaft.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, please resort
to pullers (or appropriate tools).
6) Dismantle the ball joint of the steering tie rod from the steering knuckle.
Attention:
■ Special tools shall be used to avoid damaging the dust wrapper of the ball joint.
7) Loosen the fixing bolt and nut of the shock absorber and the steering knuckle.
8) Separate the drive shaft from the wheel hub and the bearing assembly.
Attention:
■ The universal joint of the drive shaft shall be positioned without too large angle to avoid excessive
stretching and the falling off of the ball case.
9) Dismantlement of the clamping band of the dust wrapper.
98
10) Screw the puller of the drive shaft (or other appropriate Fig. 2.2.009
tools) into the screw hole of the universal joint
subassembly and pull out the universal joint
subassembly from the shaft.
Attention:
■ If it is impossible to pull out the universal joint
subassembly; firstly, remove the drive shaft assembly
from the vehicle and then try again.
11) Dismount the snap ring from the drive shaft and remove the dust wrapper.
12) Wipe off the grease on the universal joint subassembly with a piece of paper towel.
13) Smear appropriate amount of grease in the teeth-shaped hole of the universal joint subassembly
until the grease begins to flow out from the circular groove and the teeth-shaped hole. After grease
smearing, wipe off the old grease flown out with a piece of cleaning cloth.
14) Wrap the spline with tapes to avoid damaging the dust
Fig. 2.2.010
cover. Install the new dust wrapper and its clamping
band on the drive shaft.
Attention:
■ Avoid repeated usage of the dust wrapper and its
clamping band.
Subassembly
15) Dismantle the tape wrapped on the shaft.

16) Put the snap ring on the grove on the shaft edge. Align the intermediate shaft on the shaft edge with
the universal joint subassembly. Then mount the shaft on the universal joint subassembly with the
snap ring.
Attention:
Fig. 2.2.011
■ Avoid repeated usage of the snap ring. Subassembly
■ It is suggested that special tools shall be used in the

installation of the snap ring.
17) Install the universal joint subassembly on the drive
shaft with a plastic hammer.
Attention:
■ Make sure that the universal joint subassembly is
properly engaged while rotating the drive shaft.
99
18) Smear appropriate amount of grease evenly in the dust

Prevent the deformation of
wrapper from its side with large diameter. Fig. 2.2.012 the dust wrapper
19) Install the dust wrapper in the groove as shown in the

figure.
Attention:
■ If there is any grease on the fixed surface of the dust
wrapper (indicated by *), the dust wrapper may fall off.
Wipe off all the grease on the surface of the dust wrapper.
Slotted screwdriver
20) Insert the slotted screwdriver from its side with large
diameter and exhaust all the air within. Adjust the
installation length of the dust wrapper to avoid its
deformation.
Attention:
Fig. 2.2.013
■ If the installation length of the dust wrapper is too long, it
may be broken.
■ Use the slotted screwdriver with care to avoid internal
damage of the dust wrapper.
21) Fix the new clamping band of the dust cover with tools.
Attention:
■ Avoid repeated usage of the clamping band of the dust wrapper.
22) Fix the universal joint subassembly and the drive shaft and then determine the correct position for
rotating the dust wrapper.
Attention: If the dust wrapper is installed at the wrong position, please reinstall it by new clamping band
of the dust wrapper.
23) Make sure that the snap ring on the side of the axle of the transmission is fully engaged.
24) Insert the drive shaft into the wheel hub and the bearing assembly, and then screw down the locknut
of the wheel hub.
25) Install fixing bolt and nut of the shock absorber and the steering knuckle.
26) Install the ball joint of the steering tie rod and screw down the locknut according to the standard
tightening torque.
Attention:
■ In the installation, fix the bolt first to avoid rotation and then screw down the nut.
27) Install the brake tongs component and fix the brake hose. Please refer to “Front Brake” and “Braking
Pipeline”.
28) Install the speed sensor on the steering knuckle. Please refer to “Speed Sensor”.
100
29) Screw down the locknut till reaching the standard torque.
30) Install the cotter pin.
Attention:
■ Avoid repeated usage of the cotter pin.
31) Install the tire and screw it down according to the standard torque. Please refer to “Maintenance
Parameters”.
1) Element
Diagram for Drive Shaft Assembly
2) Dismantlement
① Lift up the vehicle and dismantle the tire of the front wheel. Pease refer to “Wheel and Tire”.
② Dismantle the speed sensor from the steering knuckle. Please refer to “Speed Sensor.”
Attention:
③ Dismantle the front brake tongs assembly from the steering knuckle and hang and fix it. Please refer
to “Front brake Tongs”.
Attention:
■ Do not step on the brake pedal while dismantling the brake tongs.
④ Dismantle the brake disc.
⑤ Dismount the cotter pin and loosen the locknut of the wheel hub.
⑥ Knock the drive shaft gently with a hammer (or appropriate tools) and a wooden block to separate
the wheel hub and the steering knuckle assembly, then dismantle the locknut of the wheel hub.
101
Attention:
■ Make sure that the casing (universal joint component), shaft and other spare parts are supported
while putting down the drive shaft.
■ If operations mentioned above still fail to separate the wheel hub and the drive shaft, please resort
to pullers (or appropriate tools).
⑦ Dismount the ball joint of the steering tie rod from the steering knuckle.
Attention:
■ Special tools shall be used to avoid damaging the dust wrapper of the ball joint.
⑧ Loosen the fixing bolt and nut of the shock absorber and the steering knuckle.
⑨ Dismantle the drive shaft from the wheel hub and the bearing assembly.
⑩ Dismantle the drive shaft from the side of the transmission.
Attention:
■ In drive shaft dismantlement, the universal joint of the drive shaft shall be positioned without too
large angle. Avoid excessive stretching of the slip joint.
① Rotate the universal joint to check whether it operates flexibly or is seriously unloosened.
② Check whether there is any crack, damage or grease leakage of the dust wrapper.
③ If any situation inconsistent with the regulation occurs, please disassemble the drive shaft and
replace the defective spare parts.
4) Installation
Attention:
■ While installing the drive shaft, replace the oil seal at the side of the new transmission.
① Front drive shaft
■ Install in the reverse order with dismantlement. As for the tightening torque, please refer to
“Maintenance Parameters”
Attention: Avoid repeated usage of disposable spare parts.
■ While inserting the drive shaft into the side of the transmission, avoid damaging the oil seal.
Attention:
■ Make sure that the snap ring on this side is fully engaged.
■ Apply gear oil on the spline of the drive shaft.
■ Before installing the drive shaft, make the opening of the snap ring downward.
4. Disassembly and assemblage

1) Element
102
Disassembly Diagram for the Drive Shaft

1-Snap spring 2-Casing 3-Snap ring 4-Tripod assembly 5-Dust wrapper 6-Clamping band of the dust
wrapper 7-Locknut 8-Cotter pin 9-Washer 10-Dust guard 11-Ring gear of the speed sensor
2) Disassembly
① Side of the transmission
a. Fix the drive shaft into the caliper.
Attention:
■ While fixing the drive shaft in the caliper, please use aluminum or copper sheet to protect the drive
shaft.
b. Dismount the clamping band of the dust wrapper and then dismantle the dust wrapper from the
casing.
103
c. Mark the casing and the drive shaft with assembly signs Fig. 2.2.014 Matching mark
and then pull the casing out from the driving shaft.
Attention:
■ Please mark with paint or similar materials. Do not

scratch the surface.
d. Dismount the snap ring and then dismantle the tripod

assembly from the drive shaft. Fig. 2.2.015
e. Dismount the dust wrapper from the drive shaft.
f. Wipe off the old grease on the casing with a piece of

paper cloth.
② Side of the wheel Snap ring
a. Fix the drive shaft in the calipers.
Attention:
■ While fixing the drive shaft in the calipers, please use aluminum or copper sheet to protect the drive
shaft.
b. Dismount the clamping band of the dust wrapper and then dismantle the dust wrapper from the
universal joint subassembly.
c. Screw the puller (or appropriate tools) of the drive shaft in the screw thread of the universal joint
subassembly and then separate the universal joint subassembly from the drive shaft.
Attention:
■ If the attempts to dismantle the universal joint subassembly all fail, please replace the drive shaft
assembly.
d. Dismount the snap ring from the drive shaft and remove the dust wrapper.
e. Dismantle the dust guard and the speed sensor from the drive shaft.
f. Rotate the ball case and wipe off the old grease on the universal joint subassembly with a piece of
paper cloth.
① Drive shaft
Check whether there is any run-out, crack or other damages of the drive shaft. If any, please replace the
drive shaft assembly.
a. Universal joint subassembly (side of the wheel)
Check the following items:

104
■ Check whether the universal joint subassembly is excessively rotated and whether the drive shaft is
too loose.
■ Whether there is any foreign matter in the universal joint subassembly.
■ Whether there is any sign of pressure impact, crack or internal damage of the universal joint
subassembly.
If any situation inconsistent with the regulation occurs, please replace the universal joint subassembly.
b. Casing and tripod assembly (side of the transmission)
If there is any scratch or abrasion on the rolling contact surface of the casing and the tripod assembly,
please replace the casing and the tripod assembly.
Note:
The casing and tripod assembly are used in the same device.
② Dust wrapper and speed sensor
■ Check whether there is any crack or other damages. If any, please replace it.
4) Assemblage
① Side of the transmission
a. Wrap the spline on the drive shaft with tapes to avoid damaging the dust wrapper. Install the new
dust wrapper and its clamping band on the shaft.
Note: Please avoid repeated usage of dust

Fig. 2.2.016
wrapper and its clamping band.
b. Dismount the tapes around the spline of the

drive shaft.
Tape
c. While installing the tripod assembly, align it Cross shaft component

Fig. 2.2.017
with the paint matching mark, and with the
chamfer angle toward the shaft.
Matching mark
Matching
mark
Spline
Drive shaft
105
d. Fix the tripod assembly on the casing with the snap ring.
e. Smear the tripod assembly and the slide surface with the Fig. 2.2.018
recommended grease.
f. Install the casing on the tripod assembly and then smear
the recommended grease.
Snap ring
g. Install the clamping band in the groove as shown in the

Prevent the deformation of
figure. Fig. 2.2.019 the dust wrapper
Attention:
■ If there is any grease on the fixed surface of the dust
wrapper, the dust wrapper may fall off. Wipe off all the
grease on the surface.
h. Insert the slotted screwdriver from the side with large
diameter of the dust wrapper and exhaust all the air
within. Adjust the installation length of the dust wrapper Slotted screwdriver
to prevent its deformation.

Attention:
■ If the installation length of the dust wrapper is too long, it may be broken.
■ Use the slotted screwdriver with care to avoid damaging the internal part of the dust wrapper.
i. Use special tools to fix the new clamping band of the dust wrapper.
Attention:
■ Please avoid repeated usage of the clamping band of the dust wrapper.
J. Fix the casing and the drive shaft and then determine the correct position for rotating the dust
wrapper.
Note: When the dust wrapper is installed at the wrong position, please use new clamping band of the
dust wrapper to reinstall it.
k. Install the speed sensor and the dust wrapper on the casing.
② Side of the wheel
Assemble it according to the procedures 14 – 23 in “Replacement of the Dust Wrapper of the Drive
Shaft”
Attention:
■ In the installation, make sure that the universal joint subassembly and the drive shaft are in the
same line.
■ While installing, make sure that the speed sensor is fully engaged with the casing.
■ First press in the dust wrapper; and then install the speed sensor.
106
VI. Maintenance Parameters
1. Tightening torque
Tightening Tightening
Item Item
torque (N • m) torque (N • m)
Connecting nut of the rear
Locknut of the drive shaft 220~60 cantilever and the rear steering 130-150
knuckle
Connecting nut of the steering
Nut of the support rack of the
knuckle and the shock 75-90 17-26
antisway bar
absorber assembly
Connecting nut of the ball joint
Connecting nut of the antisway bar
of the lower suspension arm 60-72 35-45
and the pull-rod
and the steering knuckle
Wheel nut 90-110 100-120
cantilever and the body
Locknut of the rear wheel hub
180-220 Eccentric nut of the rear cantilever 80-100
bearing
shock absorber and the rear 75-90 Stop bolt of the brake disc 10~15
steering knuckle
107
Section III Rear Axle

I. Preparation
Dismantlement and installation shall be conducted with appropriate maintenance tools.
Table of Maintenance Tools
For the installation and

1 Power tool dismantlement of bolts
and nuts
II. Wheel hub
1. On-vehicle Check
Check whether every element‘s fixing (clearance) and wear status is normal.
1) Check of the wheel bearing
■ Push the wheel hub and the bearing assembly axially with hand; check whether there is any
looseness for the wheel bearing. If any, it is suggested that the bearing shall be replaced or
reassembled.
■ Rotate the wheel hub, and check whether there is any abnormal noise or other abnormalities. If any,
it is suggested that the bearing shall be replaced.
108
Diagram for Rear Wheel Hub Assembly
1-Dust guard 2-Axle head nut 3-Nut gasket 4-Rear hub assembly 5-Buffering and locating block 6-Rear
steering knuckle

① Wheel hub and bearing assembly
a. Lift up the vehicle and dismantle the tire of the

wheel. Please refer to “Tire and Wheel”.
b. Dismantle the dust guard of the wheel hub.
C Dismantle the axle head nut and the nut

Fig. 2.3.002
gasket.
109
d. Dismantle the stop bolt of the brake drum and Fig. 2.3.003
remove the brake drum.
e. Dismantle the rear wheel bearing assembly

Fig. 2.3.004
from the rear steering knuckle.
Attention:
■ Slowly remove the wheel bearing assembly

axially.
② Rear steering knuckle
a. Dismantle the wheel hub and the bearing assembly from the rear steering knuckle. Please refer to
“Wheel Hub and Bearing Assembly”.
b. Dismantle the speed sensor. Please refer to “Speed Sensor”.
Attention:
c. Dismantle the rear brake and the parking braking wiredrawing. Please refer to “Rear Brake” and
“Parking Braking System”.
d. Dismantle the hard tube of the rear brake. Please refer to “Brake Pipeline”.
Attention:
■ Collect the brake fluid with care to avoid Fig. 2.3.005

environmental pollution.
■ If there is any brake fluid on the brake

assembly, clean it with a piece of paper cloth.
e. Dismantle the fixing bolt of the brake bottom

plate and the rear steering knuckle, and
remove the rear brake bottom plate and the
buffering and locating block.
110
f. Dismantle the rear cantilever (A), the rear

Fig. 2.3.006
thrusting rod and the rear cantilever (B).
Please refer to “Rear Cantilever and Thrusting
Rod”.
g. Dismantle the fixing bolts and nuts of the rear

shock absorber and the rear steering knuckle.
h. Dismantle the rear steering knuckle.
2) Check after the dismantlement
① Check whether there is any deformation, crack or damages of the element. If any, get it replaced.
② Check whether there is any wear, noise or other damages of the bearing of the rear wheel hub.
③ Check whether there is any wear, scratch or crack on the inner surface of the wheel hub.
3) Installation
① Wheel hub and bearing assembly
Note: Do not use damaged spare parts.
■ Check whether the speed sensor is correctly connected.
■ In the assemblage, fix the dust guard first and then press in it axially with the stress exerted on the
outer edge of the dust guard of the steering knuckle.
■ Screw down the axle head nut to make its gasket press the inner ring of the wheel bearing until it
contacts the end of the spline.
■ The model of the left and right bearings shall be the same.
② Steering knuckle
Note: Do not use damaged spare parts.
■ Determine the mounting position of the buffering and locating block.
■ Finally screw down every spare parts dismounted in the dismantlement process of rear steering
knuckle under no load condition.
■ Check the wheel alignment.
■ Exhaust air in the braking system. Please refer to “Brake Fluid”.
111
III Maintenance Parameters
Item Tightening torque (N • m)

Axle head nut 220~260
Stop bolt of the brake drum 10~15
Connecting bolt between the brake bottom plate
56~70
and the rear steering knuckle
Connecting bolt between the rear shock absorber
75~90
and the rear steering knuckle
112
Section IV Front Suspension

I. Precautions
■ When mounting rubber liner, it is necessary to carry out the final tightening on condition that the tires
contact the ground and there is no load. As the engine oil will shorten the service life of rubber liner,
do clean up the overflowing engine oil.
－ No-load condition means that the fuel, engine coolant and lubricant have been filled normally, and
the spare tire, jack, driver tools and foot pad are in their designated positions.
■ After repairing the spare parts of suspension, do check the wheel alignment.
■ Reuse of locknut is forbidden. Always use new nut for installation.
II. Preparation
1. Special Tools
Drawing die
For dismantlement of
1 for steering JAC-T1D003
connecting ball joint
driving rod
Damping For dismantlement and
2 spring JAC-T1D004 installation of damping
detacher spring
113
III. Front Suspension Assembly
1. On-vehicle Check
Confirm whether the fixing (clearance) and wear of each element are normal.
1) Check of Tie Rod Clearance
① Stop the front wheels, making them straight forwards.
Note: Don’t press on the brake pedal.
② Place the crowbar (or similar tool) between the tie rod and steering knuckle.
③ Check the clearance by up-and-down leverage.
Attention:
■ Don’t damage the dust cover of ball joint.
■ Don’t apply too much force to avoid damaging the installation position.
2) Check of Damper
Check the installation position for oil leakage, damage and breakage.
2. Check of Front Wheel Alignment
1) Illustration
Check the wheel alignment under no-load condition.
Note: No-load condition means that the fuel oil, lubricating oil and engine coolant have been filled
normally, and the driver tools, spare tire and jack are in their designated positions.
2) Prior Check
① Check whether the tire pressure is normal and check the tire for wear. Please refer to ”Wheel and
Tire”.
② Check the wheel for run-out. Please refer to ”Wheel and Tire”.
③ Check the shaft end clearance of wheel bearing. Please refer to “Check of Wheel Assembly”.
④ Check the shaft end clearance of tie rod. Please refer to “Steering Gear”.
⑤ Check each fixed point of axle and suspension for looseness and deformation.
⑥ Check each suspension component, steering knuckle, damper and tie rod for crack, deformation
and other damages.
⑦ Check the car body height.
114
3. Check of Front Wheel Toe-in
Attention:
■ It is necessary to conduct wheel alignment on level ground and under no-load condition.
■ Front wheel toe-in value: -3~+3 mm
If the toe-in value is beyond the standard range, please conduct adjustment according to the following
steps:
1) Check the toe-in value setting on the four-wheel aligner.
2) Put the steering wheel in the right position and

Fig. 2.4.001
fix it.
3) Loosen the end locknut of tie rod.

Fig. 2.4.002
4) Rotate the left and right tie rods clockwise or
anticlockwise to adjust the toe-in value to
standard value.
Note: The rotation of left and right tie rods shall be

equivalent.
5) Lock the end locknut of tie rod well.
4. Check of Camber Angle, Castor Angle and Kingpin Inclination
■ Camber angle of front wheel: 0°±30'
■ Castor angle: 2°±30'
■ Kingpin inclination: 12°±30'
Attention:
■ The camber angle and castor angle have been set well before the car leaves the factory, so don’t
adjust them.
■ If the camber angle, castor angle and kingpin inclination are beyond the standard range, please
check the front suspension, steering knuckle, damper and tie rod for wear and damage. If the above
situations exist, please replace the suspect spare parts.
115
IV. Front Damper
1. Element
Disassembly Diagram for Front Damper
1-Trimming cover 2-Self-locking nut 3-Upper seat of spring 4-Upper vibration isolator of spring
5-Dust cover 6-Lower vibration isolator of spring 7-Helical spring 8-Front damper
1) Dismantlement
① Dismantle the front tires. Please refer to “Wheel and Tire”.
② Cut off the connector of speed sensor. Please Fig. 2.4.003

refer to “Speed Sensor”.
Attention:
■ Don’t pull the wire harness of speed sensor.
③ Dismantle the brake hose clip to cut off the

brake hose. Please refer to “Hydraulic
Pipeline”.
116
④ Dismantle the fixed nut of upper seat of damper.

■ Tightening torque: 20~30 Nym Fig. 2.4.004
⑤ Dismantle the connecting nut between the damper and
the ball joint of suspension arm.
⑥ Dismantle the fixed bolts and nuts of damper and
steering knuckle.
⑦ Dismantle the damper assembly.

Fig. 2.4.005
2) Installation
■ Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
Note: Don’t use damaged spare parts.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of
damper under no-load condition.
■ Check the wheel alignment. Please refer to “Check of Front Wheel Alignment”.
1) Element
Disassembly Diagram for Damper

1-Trimming cover 2-Self-locking nut 3-Upper seat of helical spring 4-Upper seat pad of helical
spring 5-Upper vibration isolator of helical spring 6-Buffer block of damper 7-Helical spring
8-Lower vibration isolator of helical spring 9-Dust cover 10-Damper casing
117
2) Disassembly
Attention:
■ Don’t damage the piston push rod of damper when dismantling the spare parts of damper.
① Dismount the trimming cover with slotted screw driver. Fig. 2.4.006 JAC-T1D004
② Compress the helical spring with spring compressor till it
is loosened completely.
Attention:
■ Compress the helical spring after confirming that the

compressor has been mounted properly.
■ Don’t use any pneumatic tool when tightening the bolt of

spring compressor.
③ Fix the end of piston pull rod to dismantle its locknut.
Attention:
■ Confirm that the compressed helical spring is loose.
④ Dismantle the upper seat of helical spring, upper vibration isolator of spring, dust cover and buffer
block.
⑤ Dismantle the helical spring with compressor, and then release the compressor slowly.
⑥ Dismantle the lower vibration isolator of spring and take off the damper casing.
① Damper
■ Check the damper for deformation, crack and damage. If any, please replace it.
■ Check the piston pull rod for damage, wear and deformation. If any, please replace it.
■ Check the piston for oil leakage. If any, please replace it.
② Vibration Isolator of Spring, Buffer Block and Dust Cover
Check them for crack and check the rubber spare parts for wear. If any, please replace them.
③ Helical Spring
Check the helical spring for crack, wear and damage. If any, please replace it.
④ Upper Seat of Spring
Check it for crack, wear, deformation and other damages. If any, please replace it.
118
4) Assemblage
Assemble in the reverse order with disassembly. With respect to the tightening torque, please refer to
■ Don’t damage the piston pull rod when mounting the spare parts onto the damper.
■ Make the large-diameter end of the helical

Fig. 2.4.007 Helical spring
spring downwards to align with the lower seat
of spring.
■ Confirm that the compressor has been

mounted onto the helical spring completely,
and then begin to compress the helical spring.
Lower spring seat
■ When loosening the compressor, check Place the spring in the
designated position
whether the installation position of the helical
spring is correct.
■ Check whether the assemblage mark is

correct.
V. Lower Suspension Arm
1. Element
Diagram for Lower Suspension Arm Assembly
119
1) Dismantlement
① Lift the vehicle to dismantle the tires. Please refer to “Wheel and Tire”.
② Dismantle the fixed bolt of front support of lower suspension arm.
③ Dismantle the rear fixed support bolt of lower Fig. 2.4.008

suspension arm.
Step 2
Step 3
④ Dismantle the locknut of ball joint of lower Fig. 2.4.009

suspension arm.
Note: During dismantlement, fix the ball joint of

lower suspension arm at first, and then loosen the
locknut to avoid rotation.
⑤ Dismantle the lower suspension arm

assembly.
⑥ Dismantle the bolt between the front rubber

sleeve and fixed support of lower suspension
arm.
⑦ Take off the fixed support.
① Visual Check
■ Check the liner for wear and damage. If any, please replace it.
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■ Check the lower suspension arm for deformation and other damages. If any, please replace it.
■ Check all fixed bolts and nuts. If any, please replace them.
2) Installation
■ Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
■ Tighten the bolt between the front rubber sleeve and fixed support of lower suspension arm in
advance to avoid distortion or deformation of the rubber sleeve.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of lower
suspension arm under no-load condition.
■ Check the wheel alignment. Please refer to “Check of Front Wheel Alignment”.
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VI. Stabilizer Bar
1. Element
Diagram for Stabilizer Bar Element
2. Dismantlement and Installation Fig. 2.4.010
1) Dismantlement
① Dismantle the connecting ball joints of left and

right front stabilizer bars.
Fig. 2.4.011
② Dismantle the fixed nuts of support racks of
left and right stabilizer bars, and take off the
support racks and liners.
③ Dismantle the stabilizer bar assembly.
Check the stabilizer bar, connecting ball joint of stabilizer bar, support rack of stabilizer bar and liner of
stabilizer bar for deformation and wear. If any, please replace them.
3) Installation
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Note: Don’t reuse disposable spare parts.
■ Pay attention to the installation direction when mounting the liner and support rack of stabilizer bar.
stabilizer bar under no-load condition.
VII. Connecting Ball Joint of Stabilizer Bar
1. Element
Diagram for Connecting Ball Joint Element of Stabilizer Bar
1) Dismantlement
① Dismantle the locknut at one end of the Fig. 2.4.012

connecting ball joint of stabilize bar from the
front damper. Step 1
② Dismantle the locknut at the other end of the

connecting ball joint of stabilize bar from the Step 2
stabilizer bar.
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① Check of Ball Joint
■ Move the ball joint stud manually to confirm its flexibility.
② Visual Check
■ Check the dust cover of ball joint for crack and other damages. If any, please replace it.
2) Installation
■ Before locking the locknut, fix the ball joint stud to avoid rotation.
VIII. Support Beam of Engine
1. Element
Direction of the vehicle‘s

forward movement 5
1
Schematic Diagram for Position of Engine Suspension
1-Front mounting 2-Left mounting 3-Rear mounting 4-Support beam of engine 5-Right mounting
124
1) Dismantlement
① Support the oil pan of engine with jack.
Attention:
■ A cushion shall be put between the oil pan of engine and the jack.
② Dismantle the fixed bolt of support beam of engine.
③ Dismantle the fixed bolts and nuts between fixed support of engine suspension and the front & rear
engine suspensions.
④ Take off the support beam of engine.
⑤ Dismantle the cushions for front and rear engine suspensions.
■ Check the cushion and liner for crack, wear and aging.
■ Check the fixed support for deformation and damage.
2) Installation
Fig. 2.4.013
① Install the front and rear cushions for engine
suspension.
Fig. 2.4.014
125
Installation of Liner of Engine Support Beam

Fig. 2.4.015
a. Fit the upper and lower liners in the installation
holes of engine support beam respectively, as
Attention:
■ After assemblage, the liner shall be

compressed evenly in the installation hole and
its surface shall be flat.
b. Press the steel bushing into the liner in

parallel.

■ The steel bushing and liner shall be matched
tightly, and the surface shall be flat.
②Install the support beam of engine Fig. 2.4.017

Attention:
Fig. 2.4.018
■ The bolts and nuts between the cushion of
engine suspension and the fixed support for
that shall be tightened in advance. The final
tightening shall be conducted after the engine
assembly is mounted completely.
126
IX. Common Trouble Diagnosis
Common Trouble Diagnosis

Improper front wheel alignment Adjustment
Rotation over the ball joint of lower support
Replacement
Hard steering frame
Too low tire pressure Air inflation
No power steering Repair or replacement
Centering of steerable wheel Improper front wheel alignment Adjustment
Trouble of damper Repair or replacement
Poor return Wear or damage of stabilizer bar Replacement
Wear or damage of helical spring Replacement
Wear of lower suspension arm liner Replacement
Abnormal wear of tire Too low or too high tire pressure Press adjustment
Insufficient steering resistance of lower
Offtracking of vehicle Replacement
suspension arm ball joint connection
Looseness or wear of lower suspension
Replacement
arm liner
Offtracking of vehicle to one Replacement
side
Bending of lower suspension arm Replacement
Replacement
Looseness or wear of lower suspension
Shimmy of steerable wheel Replacement
arm liner
Wear or damage of stabilizer bar Replacement
Sagging of vehicle
127
X. Maintenance Parameters
Technical Specifications
Item Parameters and Specifications
McPherson independent suspension with helical
Type of front suspension
spring
Type Two-way hydraulic telescopic damper
Stroke 139 mm
Damper
Damping force Extension 975±166 N
(0.3 m/s) Contraction 265±60 N
Color identification:
Helical spring Manual transmission Free height: 322 mm
white_wire 1
Wheel toe-in (front) 0+ 3 mm
Camber angle 0°±30'
Wheel
Kingpin inclination 12° ±30'
alignment
Castor angle 2° ±30'
Offset of king pin 5.94 mm
Steel wheel 0.6 mm
Radial
Aluminum wheel 0.3 mm
Wheel runout
Steel wheel 1.0 mm
Axial
Tightening
Tightening Torque
Item Item Torque
(N • m)
(N • m)
Nut of upper seat of front Bolt between the front liner and front
20~30 100~120
damper support of lower suspension arm
Front damper and front
75~90 Fixed support of stabilizer bar 17~26
steering knuckle
Self-locking nut of front Installation of front and rear cushions for
60~70 40—50
damper engine suspension
Connecting ball joint of
35~55 Support beam of engine 70~90
stabilizer bar
Front support of lower
60~80
suspension arm
Rear support of lower Installation of front and rear engine
60~80 60~80
suspension arm suspension supports and cushions
Locknut of ball joint of lower
60~72
suspension arm
128
Section V Rear Suspension

I. Precautions
1. Precautions for Maintenance
■ When mounting suspension, it is necessary to carry out the final tightening on condition that the
tires contact the ground and there is no load.
－ No-load condition means that the fuel, engine coolant and lubricant have been filled normally, and
the spare tire, jack, driver tools and foot pad are in their designated positions.
■ After repairing the spare parts of suspension, do check the wheel alignment.
■ Reuse of locknut is forbidden. Always use new nut for installation.
II. Preparation
1. General Maintenance Tools
Table of General Maintenance Tools
For installation and dismantlement

1 Power tool
of bolt and nut
2. Special Tools
No. Tool Outline Diagram No. Illustration
Drawing die
For dismantlement of
1 for steering JAC-T1D003
connecting ball joint
driving rod
Damping For dismantlement and
2 spring JAC-T1D004 installation of damping
detacher spring
129
III. Rear Suspension Assembly
1. Element
Disassembly Diagram for Rear Suspension Assembly
1-Thrusting rod 2-Support rack of thrusting rod 3-Rear suspension arm (A) 4-Rear stabilizer bar
5-Rear suspension arm (B) 6-Rear steering knuckle 7-Rear frame
2. On-vehicle Check
Confirm whether the fixing (clearance, looseness) and elements (wear, damage) are normal.
1) Check of Damper
Check the installation position for oil leakage and damage.
2) Check of Axial Clearance of Wheel Bearing
① Lift the vehicle and check the axial clearance when the vehicle is stationary.
Note: If there is axial clearance, dismount the wheel hub cover and release the parking brake handle.
Afterwards, continue the following steps.
② Check the axial clearance at the end of wheel bearing.
130
a. Place the micrometer on the surface of wheel hub, and then rotate the wheel hub to check the axial
clearance.
■ Standard clearance: 0~0.22 mm
b. If the axial clearance is beyond the specified range, tighten the nut of wheel bearing with the
specified torque. Afterwards, check the axial clearance again.
c. If it is impossible to adjust the axial clearance to be within the specified range, replace the bearing of
rear wheel.
3. Check of Rear Wheel Alignment
Attention:
■ The camber angle has been set well before the car leaves the factory, so it can’t be adjusted.
■ If the camber angle is beyond the standard range, please check or replace the deformed or
damaged spare parts.
Camber angle of rear wheel: -0° 30'~0° 30'
1) Illustration
Measure the wheel alignment under no-load condition.
Note: No-load condition means that the levels of fuel and various fluids of engine reach their standard
values, and the spare tire, jack, driver tools and foot pad are in their designated positions.
2) Prior Check
① Check whether the tire pressure is normal and check the tire for wear. Please refer to ”Wheel and
Tire”.
② Check the wheel for run-out. Please refer to ”Wheel”.
③ Check the shaft end clearance of wheel bearing. Please refer to “Check of Wheel Bearing”.
④ Check the clearance of each suspension element and check each fixed point for looseness.
⑤ Check the maneuverability of the damper.
⑥ Check each suspension arm for crack, deformation and other damages.
⑦ Check the body height.
3) Wheel Toe-in
Take the following steps to measure the wheel toe-in. In case of failure to comply with the specified value,
please check and replace the worn or deformed spare parts of rear suspension.
① Park the vehicle on the four-wheel aligner and obtain the data of rear wheel alignment.
131
② If the indicated data are beyond the standard Fig. 2.5.001

range, rotate the adjusting bolt of rear
suspension arm (A) for adjustment.
Rear wheel toe-in value: 1~5 mm.
Attention:
■ During adjustment, the rotation of the

adjusting bolts on both sides of rear
suspension shall be the same.
Note: One grid of clockwise adjustment leads to

2.4 mm of toe-in change. (The unilateral toe-in
angle is about 14°)
Attention:
■ The eccentric bolt can only be adjusted within 90° leftwards and rightwards respectively.
■ The necessary check by road test shall be conducted.
IV. Rear Damper
1. Element
Diagram for Rear Damper Assembly
1) Dismantlement
① Lift the vehicle to dismantle the tires. Please refer to “Tire Assembly”.
② Dismantle the brake hard pipe snap-in to remove the brake hard pipe. Please refer to “Brake
Pipeline”.
③ Dismantle the C-pillar upper trim board. Please refer to “Interior Trimming of Body”.
132
④ Dismantle the locknut of upper seat of damper. Fig. 2.5.002

⑤ Dismantle the fixed bolts and nuts of damper

Fig. 2.5.003
and rear steering knuckle.
Attention:
■ During dismantlement, prevent the damper

assembly from falling suddenly to avoid
physical injury.
⑥ Dismantle the rear damper assembly.
① Check for deformation, crack and other damages. If any, Please conduct replacement.
② Check for oil leakage. If any, Please conduct replacement.
3) Installation
① Install in the reverse order with dismantlement. With respect to the tightening torque, please refer to
② Conduct the final tightening to each spare part that is dismounted during the dismantlement of rear
damper assembly under no-load condition.
③ Check the wheel alignment. Please refer to “Check of Rear Wheel Alignment”.
133
1) Disassembly
Disassembly Diagram for Rear Damper
1-Self-locking nut 2-Upper seat of helical spring 3-Upper vibration isolator of helical spring 4-Buffer
block of damper 5-Helical spring 6-Dust cover of damper 7-Lower vibration isolator of helical spring
8-Damper casing
Attention:
■ Don’t damage the piston push rod of damper when dismantling the spare parts of damper.
① Dismount the trimming cover with slotted Fig. 2.5.004 JAC-T1D004

screw driver.
② Compress the helical spring with spring

compressor till it is loosened.
Attention:
■ Compress the helical spring after confirming

that the compressor has been mounted
properly.
■ Don’t use any pneumatic tool when tightening the bolt of compressor.
③ Fix the end of piston pull rod to dismantle its self-locking nut.
Attention:
■ Confirm that the compressed helical spring is loose.
④ Dismantle the upper seat of helical spring, upper vibration isolator of spring, dust cover and buffer
block.
⑤ Dismantle the helical spring with compressor, and then loosen the compressor slowly.
⑥ Dismantle the lower vibration isolator of spring and take off the damper casing.
134

① Damper
■ Check the damper for oil leakage. If any, please replace it.
■ Check the piston push rod for damage, wear and deformation. If any, please replace it.
■ Check the lower seat of helical spring for crack and deformation. If any, please replace it.
② Buffer Block, Dust Cover and Vibration Isolator
■ Check the buffer block, dust cover, upper vibration isolator of spring and lower vibration isolator of
spring for wear and damage. If any, please replace them.
③ Helical Spring
■ Check the free play of the helical spring. In case of inconformity, please replace it as required.
④ Upper Seat of Helical Spring
■ Check it for crack, wear, deformation and other damages. If any, please replace it.
3) Assemblage
Attention:
■ Don’t use damaged spare parts.
Assemble in the reverse order with disassembly. With respect to the tightening torque, please refer to
■ Don’t damage the piston push rod when mounting the spare parts onto the damper.
■ When mounting the lower vibration isolator of
spring, it is necessary to align the boss of Fig. 2.5.005
vibration isolator with the spring seat hole on Lower seat of
spring
the damper and mount it properly.
■ Make the large-diameter end of the helical Hole (3 places)
spring downwards to align with the lower seat

of spring. Boss (3 places)
■ Confirm that the compressor has been

mounted onto the helical spring completely,
and then begin to compress the helical spring.
■ When releasing the compressor, check whether Fig. 2.5.006

the installation position of the helical spring is
correct.
■ Check whether the assemblage mark is correct.
135
V. Rear Suspension Arm (A)
1. Element
Diagram for Rear Suspension Arm (A) Element
1) Dismantlement
① Dismantle the support bar assembly of rear stabilizer bar. Please refer to “Support Bar of Rear
Stabilizer Bar”.
② Dismantle the connecting bolt between the rear suspension arm (A) and the rear steering knuckle.
③ Dismantle the eccentric bolt of rear suspension arm (A).
Attention:
■ The matching mark shall be made in advance.
④ Take off the rear suspension arm (A) assembly.
■ Check the rear suspension arm (A) for deformation and check the liner for wear and other damages.
If any, please replace it.
■ Check the thread of eccentric bolt for distortion. If any, please replace it.
3) Installation
■ Tighten the connecting bolt and eccentric bolt in advance.
suspension arm (A) under no-load condition.
■ Check the rear wheel alignment of the vehicle. Please refer to “Rear Suspension Assembly”.
136
VI. Rear Suspension Arm (B)
1. Element
Diagram for Rear Suspension Arm (B) Element
1) Dismantlement
① Dismantle the connecting bolt between the rear suspension arm (B) and the rear steering knuckle.
② Dismantle the connecting bolt between the rear suspension arm (B) and the body.
③ Take off the rear suspension arm (B) assembly.
■ Check the rear suspension arm (B) for deformation and check the liner for wear and other damages.
If any, please replace it.
3) Installation
■ Tighten the connecting bolt in advance.
■ Conduct the final tightening to each spare part that is dismounted during the dismantlement of rear
suspension arm (B) under no-load condition.
137
VII. Thrusting Rod
1. Element
Diagram for Thrusting Rod Element
1) Dismantlement
① Dismantle the fixed bolt of rear parking wiredrawing. Please refer to “Parking Braking System”.
② Dismantle the fixed bolt of front fixed support of thrusting rod.
③ Dismantle the connecting bolt between the

Fig. 2.5.007
thrusting rod and the rear steering knuckle.
■ Check the thrusting rod for deformation and check the liner for wear and other damages. If any,
please replace it.
3) Installation
■ Tighten the connecting bolt in advance.
thrusting rod under no-load condition.
138
VIII. Rear Stabilizer Bar
1. Element
Disassembly Diagram for Rear Stabilizer Bar
1-Rear stabilizer bar 2-Bolt 3-Shaft sleeve 4-Washer 5-Locknut

1) Dismantlement
① Dismantle the self-locking nut of support bar of

stabilizer bar and take off the isolating shaft sleeve
of support bar and washer.
139
② Dismantle the bolts of support racks of left and

right stabilizer bars and take off the support Fig. 2.5.009
racks and liners.
③ Dismantle the stabilizer bar.
Check the stabilize bar, isolating shaft sleeve of

support bar and support rack of stabilizer bar for
deformation, crack and wear. If any, please replace
them.
3) Installation
■ Install in the reverse order with dismantlement. With regard to the tightening torque, please refer to
■ When mounting the support rack of stabilizer bar, please pay attention to the installation direction.
IX. Support Bar of Stabilizer Bar
1. Element
Diagram for Support Bar Element of Stabilizer Bar
For the dismantlement and installation, please

refer to “Stabilizer Bar”.
Attention:
■ The end of rear stabilizer bar shall be mounted

between the two rubber sleeves at the upper
part of the support bar in advance.
■ It is required that the distance A from the lower

end of bolt to the locknut be 28~30 mm.
140
X. Common Trouble Diagnosis

Common Trouble Diagnosis
Looseness of assemblage Fastening
Fatigue or damage of wheel bearing Replacement
Abnormal sound
Damage of damper assembly Replacement of damaged component
Tire quality defect Replacement
Too high tire pressure Pressure adjustment
Damage of damper assembly Replacement of damaged component
Difficult control Looseness of tire nut Fastening
Shortening or breakage of helical spring Replacement
Tire quality defect Replacement
Body tilt Shortening or breakage of helical spring Replacement
XI. Maintenance Parameters
Rear Suspension System Two-connecting rod
Type Two-way hydraulic telescopic damper
Stroke 209.5 mm
Damper
Extension 480 ± 92 N
Damping force
Contraction 165 ± 44 N
Type Standard
Helical spring Free height 336.5 mm
Color Black
Toe-in 3±2 mm
Wheel alignment
Camber angle 0° ± 30'
Tightening Torque Tightening Torque
Item Item
(Nym) (Nym)
Rear suspension arm (A) and Rear suspension arm (B) and
110~120 80~100
body body
Rear suspension arm (A) and Rear suspension arm (B) and
100~120 100~120
rear steering knuckle rear steering knuckle
Thrusting rod and rear steering
Support rack of thrusting rod 40~50 100~120
knuckle
Mounting nut of upper seat of Rear damper and rear steering
20~30 75~90
rear damper knuckle
Support rack of rear stabilizer
Locknut of rear damper 45~55 17~26
bar
141
Section VI Wheel and Tire

I. Wheel
Attention:
■ Please use original wheels.
1. Check
■ Check whether there is any abrasion or inappropriate charge of the wheel.
■ Check whether there is any crack or other damages on the wheel. If deformation is found, please
check the run-out of the wheel.
1) Dismantle the tire from the wheel and mount it

on the wheel balancer. Fig. 2.6.001
2) Set the dial indicator according to the figure.

As for the run-out of the wheel, please refer
to “Maintenance Parameters”. If the total
run-out value exceeds the limit, please get it Transverse
Radial
replaced. runout
runout
II. Tire
Attention:
■ For new tires in the running in period, avoid sudden start, sharp turn and emergency braking. Do not
drive in bad working conditions so as to prevent immature damage of new tires.
■ The new tire shall be balanced before its use. As for details, please refer to “Wheel Balance”.
1. Check
1) Check of tire pressure
■ Check the charge pressure of the tire. If it is not within the range of the standard value, please make
certain adjustments.
Standard value: 220±10 Kpa
Attention:
■ Qualified tyre gauge should be used to check tyre pressure.
■ Tire pressure should be checked in the cold state at least once a month.
Cold state refers to the vehicle situation that it has not been operated for more than three hours at the
least; or the one that it has not been operated for three hours and with the previous mileage of less than
1.6 km.
■ Tire pressure should be checked frequently in a dramatically-changed ambient temperature.
142
■ Inappropriate tire pressure will lead to:

a. Inadequate tire pressure will lead to rapid Fig. 2.6.002
wear on the shoulder of the tire, tire flexing
and increase the rolling resistance.
b. Excessive tire pressure will lead to rapid wear

on the middle part of crown and weaken the Fig. 2.6.003
cushioning capacity of the tire.
2) Check of the tire tread Fig. 2.6.004
① Check the depth of the tire tread.

Note: Tire specification: 175/65R14 82H
■ When the depth of the tire tread reaches, or is
smaller than, the limit, the wear mark will
appear on the tire tread. While this occurs,
please replace the tire.
② Check whether there is any foreign matter in Fig. .6.005

the tire tread. If any, remove them.
3) Change of tire position
■ When the vehicle has run 8,000 km, the
position of its tires should be changed. Tire
replacement should be accompanied by
change of tire position.
Note: The recommended change of tire position
is shown in the figure.
143
4) Replacement
① After the vehicle has normally run 50,000 km, its tires should be replaced.
② In case of one of the following situations, the tire should also be replaced:
■ There are at least three worn-out marks on the tire tread.
■ There are cord fabrics or cord threads on the tire rubber.
■ There are cracks on the tread or shoulder of the tire; or the cord layer appears.
■ The tire has bulges, knurls or layer separation.
■ The tire is punctured, scratched or damaged to such an extent that it can not be repaired.
III. Tire Assembly of the Wheel

① Dismantle wheel nuts.

② Dismantle the tire assembly of the wheel.
2) Installation
① Install the wheel cover. Fig. 2.6.007
Attention:
■ The valve cock of the wheel cover should be
aligned with the wheel rim and then get it
pretightened.
② Install the tire assembly of the wheel and tire
nuts.
Attention:
■ If the manual installation, it shall be pretightened in turn to ensure wheel alignment; and then it shall
be evenly screwed down in a diagonal order.
■ If the automatic fastening, the tightening torque should be adjusted to ensure one-pass fastening.
2. Wheel balance
1) Dismantlement
① Dismantle tires to be adjusted.
144
② Dismantle old weights on both sides of the wheel and remove foreign matters on the tire tread.
Note: In case of a new tire, remove all tapes from it.
Attention:
■ During the dismantlement, take care to avoid any scratch to the wheel.
2) Adjustment of wheel balance
① With the center hole as the direction, install the driving wheel on the wheel balancer and start the
wheel balancer.
② When unbalanced values of both the outside and the inside are shown on the display of the wheel
balancer, multiply the unbalanced value of the outside with 5/3 to determine the mass of the weight
in actual use. Then select the weight of the outside with a value closest to the calculated one and
install them in the specified outside position or in the specified angle to the wheel.
Attention:
■ After the installation of outer weights, install the inner weights as well.
■ Before the installation of weights, make sure a clean and tidy matching surface for the wheel.
a. Install the weight at the position indicated by

the figure. Fig. 2.6.008
b. While installing weight on the driving wheel, as Bonding weight
shown in Fig. 2.6.008 on the right, position it in Center of gravity
the groove area on the inner wall of the driving Alignment

with the
groove
wheel to align the center of the weight with the
position (or angle) indicated by the wheel Position (angle) indicated by
the wheel balancer
balancer.
Attention:
■ Avoid repeated usage of weights and use new weights every time.
■ Weights installed should be no more than three.
■ Use original weights only.
c. If the calculated mass of the weight is more than 50 g, install the two weights in a line.
145
Attention:
■ Do not put one weight on the other. Fig. 2.6.009
③ Restart the wheel balancer.
④ Knock weights in from the inside of the driving
wheel in accordance with the position (or
angle) indicated by the wheel balancer.
Position (angle) indicated by
the wheel balancer
Attention:
■ The weights installed should be no more than two.
⑤ Start the wheel balancer. Make sure that the remaining unbalanced values on both the inner and
outside are no more than 5 g.
■ If the remaining unbalanced value on any side is more than 5 g, repeat the procedure of installing
the weights.
IV. Common Trouble Diagnosis for Tire Assembly of the Wheel

Offtracking of Wear of the steering knuckle of the drive shaft Replacement
the vehicle Wear, friction or click of the wheel bearing Replacement
replacement
Vibration Wear, damage or bending of the drive shaft Replacement
Abnormal sound of the drive shaft and wheel hub spline Replacement
Wear, friction or click of the wheel bearing Replacement
Run-out Unbalanced wheel Adjustment or
replacement
Defects of the steering knuckle of the front axle Adjustment or
replacement
Loud noise Wear, damage or bending of the drive shaft Replacement
Wear of the wheel hub spline of the drive axle Replacement
Wear of the wheel hub spline of the drive shaft Replacement
Wear, burning or abnormal sound of the wheel bearing Replacement
Looseness of hub nuts Adjustment or
replacement
replacement
146
V. Maintenance Parameters
1. Technical specifications
Item Parameter
Run-out of the wheel Radial direction Steel wheel 0.6 mm
Axial direction Steel wheel 1.0 mm
Tire pressure (cold state) 220±10 KPa
Tire specification 175/65R14 82H
Item Tightening Torque
Wheel nuts 90~110 Nym
147
Maintenance Manual of Tojoy Sedan Braking System
Chapter III Braking System
Section I Parking Braking System
I. Precautions
■ The parking braking system should be checked and adjusted under normal braking conditions.
■ When the parking braking system is checked, the vehicle should be parked on the level ground with
the wheels fixed by the corner blocks.
II. Parking Braking System Fig.3.1.001
1. On-vehicle check
1) Stroke of the parking control handle
■ Pull up the parking braking control handle with

a force of 196 N. Make sure that the ratchet is
in the specified groove (check it through
hearing and calculating the ratchet sound).
Standard value: 5~7 teeth
2) Check of elements
① Check whether every elements are fixed normally.
② Check whether there is any bending, damage or crack on the parking braking control handle. If any,
get it replaced.
③ Check whether there is any abrasion or damages on the parking braking wiredrawing. If any, get it
replaced.
④ Check whether the switch of the parking braking warning lamp is normal. If it is out of work, please
check or get it replaced.
3) Adjustment
Attention:
■ Adjust the parking braking system under normal braking conditions.
① Dismantle the rear part of the auxiliary facia console. Please refer to “Auxiliary Facia Console”.
② Release the parking braking control handle and insert both the left and the right wiredrawing joints
into the mounting hole of the balance plate of the braking control handle.
③ After the mounting of the wiredrawing, screw down the adjusting nut to ensure the specified
distance between the adjusting nut and the end of the wiredrawing.
148
Disassembly Diagram for the Parking Control Handle Assembly

1-Parking control handle assembly 2-Parking wiredrawing joint 3-Adjusting nut
4-Thread brace rod
■ L: 35~40 mm
④ After the adjustment, pull up the braking control handle with a force of 196 N vertical to the handle at
the position 25 mm from the end of the handle and adjust the adjusting nuts to enable the pull-up of
5~7 teeth for the handle. Otherwise, L should be adjusted through the adjustment of the adjusting
nut.
Note: If the number of the teeth pulled up is less than 5, reduce L; vice versa.
Attention: After the adjustment, check whether there is any drag of the wheel while the parking braking
control handle is completely released.
2. Element
Disassembly Diagram for the Parking Braking Wiredrawing

1- Parking control handle assembly 2-Fixed junction clip of both the left and the right wiredrawings
3-Right parking braking wiredrawing assembly 4-Left parking braking wiredrawing assembly
5-Clamp spring
149
1) Dismantlement and installation

Fig.3.1.002
① Dismantlement
a. Dismantle the rear part assembly of the
auxiliary facia console. Please refer to
“Auxiliary Facia Console”.
Fig.3.1.003
b. Loosen the adjusting nut and dismantle the

parking wiredrawing on both the left and the
right side from the inside of the wiredrawing
bayonet.
c. Disconnect the wire harness of the parking

braking switch and dismantle the parking Fig.3.1.004
braking control handle assembly.
d. Dismantle the tire of the rear wheel. Please
refer to “Wheel and Tire”.
e. Dismantle the rear brake shoe. Please refer to
“Rear Brake”.
i
f. Dismantle the parking braking wiredrawing
from the pull rod of the brake shoe.
Fig.3.1.005
150
g. Dismantle the fastening bolt of the parking

Fig.3.1.006
braking wiredrawing. Left
h. Withdraw the parking braking wiredrawing

assembly from the mounting hole at the
bottom of the body.
Fig. 3.1.007
Right
② Check after dismantlement
■ Check whether the buttons are normal. If they can not return to the original position, please get them
replaced.
■ Check whether there is any wear at the ratchet of the parking braking control handle.
■ Check whether there is any deformation, wear, bending or looseness in the parking braking
wiredrawing. If any, please get it replaced.
③ Installation
■ Make sure that the wiredrawing runs in a smooth way while installing the wiredrawing.
■ Check and adjust the stroke of the parking control handle. Please refer to “Adjustment”.
151
Section II Braking System

I. Precautions
1. ”D0T4" brake fluid is recommended for use.
2. Please do not reuse the discharged brake fluid.
3. Pay attention not to spilling the brake fluid on the painted surface in order to prevent it from
damaging the paint. Please wash the painted surface with water immediately if the brake fluid is spilt
on it.
4. Please wash all the spare parts of the brake wheel cylinder with clean brake fluid.
5. Please do not use mineral oil such as petrol and kerosene in order to prevent it from damaging the
rubber spare parts of hydraulic system.
6. Please use special flare nut wrench to dismantle or mount the oil pipes.
7. The tightening torque must be checked while mounting the brake oil pipe.
8. The brake joint surface shall be run in after the brake drum (disc) and brake shoe are repaired or
replaced, or when the spongy brake appears after a short traveling distance. Please refer to "Steps
of Front Brake Running In".
II. Preparation
Special maintenance tools must be used for dismantlement and installation if necessary.
Table of Maintenance Tools
For dismantling and

Flare nut
1 mounting brake oil
wrench
pipes
For dismantling and

2 Power tool
mounting bolts and nuts
153
III. Brake Pedal
1. Check and Adjust Fig. 3.2.001 Locknut
The Adjustment of clearance between the brake

pedal and brake limit switch bolt:
1) Dismantle the lower part of the console. Please

refer to "Console".
2) Cut off the connector of stop lamp switch, and

Brake pedal dog
screw off the locknut of stop lamp. Then loosen plate
the brake pedal, and turn the switch to make
the clearance between the switch and brake
pedal is within 0.5 ~ 1.0 mm.
2. Free Play of Brake Pedal

1) Press the brake pedal 2 ~ 3 times when the Fig. 3.2.002
engine is shut down.
2) Press the pedal with hand when the vacuum of
the brake vacuum booster is confirmed to be
eliminated.
3) Check if the free play of the pedal is within the
standard range before the occurrence of
resistance.
■ Standard value: 3 ~ 8 mm
4) If the free play is beyond the standard range, it

shall be adjusted.
Attention:
■ If the free play cannot be adjusted within the

standard range, please replace the damaged
spare parts.

Fig. 3.2.003
1) Dismantlement
① Dismantle the lower part of the console. Please
refer to "Console".
② Cut off the connector of the stop lamp switch.
③ Dismantle the connecting lockpin of the brake

vacuum booster to disconnect it with the brake
vacuum booster.
154
④ Dismantle the fixed bolt of brake pedal and

body, as well as the fixed nut of brake vacuum Fig. 3.2.004
booster.
■ Tightening torque: 20~ 25 N•m
⑤ Take out the brake pedal.

① Brake pedal
■ Check if the movable pin of brake pedal is worn
or deformed.
■ Check if the brake pedal has the damages
such as crack and distortion.
② Lockpin and liner
■ Check if the lockpin and liner are damaged or
deformed, if they are, please replace them.
③ Stop lamp switch
a. Check the two terminals of the stop lamp switch Fig. 3.2.005
with multimeter to see if they are conducted
when pressing on or releasing the stop lamp
strut. Non-conduction Conduction
b. As the figure shows, when the strut is pressed
more than 4 mm, there is non-conduction
between the terminals, but when it is released,
there is conduction between the terminals,
which shows that the stop lamp switch works
normally.
3) Installation
Attention:
■ Check if the brake pedal operates smoothly.
■ Check and adjust the brake pedal free play
after installation.
■ Check the clearance between the brake pedal
and stop lamp limit switch.
155
IV. Brake Master Cylinder
1. On-vehicle Check
Check if the master cylinder mounting surface, stock solution tank mounting surface and brake pipe
connector leak.
Attention:
■ Don't splash the brake fluid on the painted surface, or else it will damage the oil paint. If there is
brake fluid on the painted surface, please clean it with water immediately.

① Discharge the brake fluid. Please refer to
"Discharge and Fill”.
② Dismantle the air filter assembly. Please refer

to “Air Filter Assembly”.
③ Dismantle connector of brake fluid level switch.
④ Cut off the brake hard pipe of the master Fig. 3.2.007
cylinder with flare nut wrench.
⑤ Dismantle the connecting pipe of brake Fig. 3.2.008

master cylinder and clutch master cylinder as
well as the fixed nut of master cylinder, and
then dismount the master cylinder
sub-assembly.
156
2) Installation
Attention:
■ Please refill the brake fluid "D0T4".
■ Please don't reuse the discharged brake fluid.
■ Apply the lubricating grease to the axis pin of master cylinder before installation: SAE J310 or the
similar product.
① Mount the master cylinder on the brake vacuum booster, and tighten the nut.
Attention:
■ Please don't damage the slip surface of piston push rod, and don't let the foreign matters drop on its
surface.
② Mount the brake hard pipe on the master cylinder sub-assembly, and pretighten it.
③ Tighten the brake oil pipe nut with flare nut wrench or the similar tools. Please refer to "Hydraulic
Pipeline Diagram".
④ Mount the connector of the brake fluid level switch.
⑤ Fill new brake fluid and exhaust air. Please refer to "Exhaust Air in the Hydraulic Pipeline".
V. Brake Fluid
Fig. 3.2.009
1. Check of the Brake Fluid Level
■ Make sure the level of brake fluid in the stock

solution tank is within the specified range
(between marks of MAX and MIN).
MAX
■ Check visually if there is leakage around the
MIN
■ Please check if the braking system leaks if the
oil level is too low.
■ Release the parking brake handle, and observe

if the brake alarm lamp goes out. If the lamp
does not go out, please check if the braking
system leaks.
2. Discharge and Fill

Attention:
■ Please refill the brake fluid "D0T4".
■ Please don't splash the brake fluid on the painted surface, to avoid damaging the oil paint. If there is
157
1) Insert the ethylene tube into the exhaust valve. Fig. 3.2.010
2) Press the brake pedal, release the exhaust

valve, and then discharge the brake fluid
slowly.
3) Clean the inside of the stock solution tank, and Fig. 3.2.011
fill new brake fluid.
4) Release the exhaust valve, press the brake

pedal slowly to the end, and release it. Repeat
the steps every 2s or 3s until the new brake
fluid flows out, and press the brake pedal still to
shut off the exhaust valve. Repeat the same
operation for each wheel.
5) Exhaust air. Please refer to "Exhaust Air in the

Brake Pipeline".
3. Exhaust air in the brake pipeline.
Attention:
■ Pay attention to the level of brake fluid in the stock solution tank of master cylinder when exhausting
the air.
1) Insert the ethylene tube into the exhaust valve of right rear brake wheel cylinder.
2) Press the brake pedal to the end 4 or 5 times.
3) Press the brake pedal still, release the exhaust valve to exhaust the air in brake pipeline, and then
tighten the exhaust valve immediately.
4) Repeat step 2) and step 3) until all the air is exhausted from the brake pipeline.
5) Tighten the exhaust valve.
6) Repeat the above steps and fill up half of the stock solution tank of master cylinder at least, and
exhaust the air in brake pipeline according to the following sequence.
■ The air exhaust sequence of the four wheels: Right rear brake wheel cylinder, left front brake wheel
cylinder, left rear brake wheel cylinder, and right front brake wheel cylinder
158
VI. Brake Pipeline
1. Diagram for Hydraulic Pipeline
Diagram for Hydraulic Pipeline of Braking System
1-Rear right wheel 2-Rear wheel cylinder 3-Speed sensor 4-Brake pedal 5-Vacuum booster with brake
master cylinder assembly 6- Right front wheel cylinder 7- Right front wheel 8- Left front wheel cylinder 9-
Left front wheel 10-ABS module 11- Left rear wheel cylinder 12- Left rear wheel
Attention:
■ None of the brake hoses and brake pipes shall be excessively bent, twisted or stretched.
■ Make sure there is no interference with other spare parts during steering.
■ The brake pipeline and hose are significant safety spare parts, if there is leakage of brake fluid, the
fixing device shall be tightened all the while. If there are damaged spare parts, please replace them
with new and applicable ones.
■ Please don't splash the brake fluid on the painted surface, to avoid damaging the oil paint. If there is
■ When the brake pipeline and hose are cut off, please seal the open end properly to avoid the
entering of dust.
■ The brake fluid "D0T4" shall be refilled.
159
1. Front Brake Pipe and Hose

Fig. 3.2.012
1) Dismantlement
① Dismantle the wheel tyre. Please refer to

"Wheel and Tyre".
② Dismantle the brake hose bolt.
Attention:
■ Take care not to let the bolt gasket drop off.
③ Dismantle the connector of brake hose and Fig. 3.2.013

brake hard pipe with flare nut wrench to take
off the clamping piece.
④ Dismantle the fixed bolt of brake hose clip

from the damper.
⑤ Dismount the brake hose and brake pipe.
2) Installation
① Mount the fixed bolt of brake hose clip and copper gasket.
Attention:
■ Please don't reuse the gasket.
■ Pay attention to the mounting direction of the brake hose connector.
② Pretighten the locknut of brake hose and brake hard pipe, mount the card and then tighten it with
flare nut wrench.
Note: Pretighten it with hand as much as possible.
③ Tighten the fixed bolt of brake hose clamping piece.
④ Please refer to "Exhaust Air in the Brake Pipeline".
160
2. Rear Brake Pipeline and Brake Hose Fig. 3.2.014
1) Dismantlement
① Dismantle the hard pipe of the rear brake

wheel cylinder with flare nut wrench.
② Dismantle the rear brake hose and brake hard Fig. 3.2.015
pipe to dismount the clamping piece.
③ Dismantle the brake hose and brake hard

pipe.
3) Installation
① Pretighten the connector of brake hose and brake hard pipe, mount the snap-gauge, and then
tighten it with flare nut wrench.
② Mount the hard pipe of the rear brake wheel cylinder.
③ Fill new brake fluid and exhaust air. Please refer to "Exhaust Air in the Brake Pipeline".
3. Brake Hard Pipe of Brake Master Cylinder and ABS Pump or Brake Distribution Valve

① Dismantle the air filter assembly. Please refer
to "Air Filter".
② Dismantle the oil pipe connector of brake

master cylinder.
161
③ Cut off the connector of brake master cylinder Fig. 3.2.017

and ABS pump or brake distribution valve, and
then cut off other connectors in turn.

4个
Attention:
■ The brake fluid in the ABS pump shall not be

discharged completely.

① Pretighten the connector of oil pipe of brake
master cylinder and ABS pump or brake
distribution valve.
② Pretighten other oil pipe connectors in turn.
③ Pretighten the above connectors with flare nut 6个

wrench.
④ Mount the air filter assembly.
⑤ Fill new brake fluid and exhaust air. "Exhaust

Air in the Brake Pipeline".
Attention:
■ If the connector of brake pipe and brake hose leaks, please tighten it; or if there are spare parts
damaged, please replace them.
① Check if the brake hose, brake pipe and connector leak fluid, or if they are damaged, twisted,
deformed, or in contact with other spare parts and loose.
② Apply certain brake force for several seconds when the engine is in operation, and then check if the
spare parts leak fluid.
VII. Brake Vacuum Booster
1. On-vehicle Check
1) Operation Check
Shut down the engine, and press the brake pedal for several times, to keep the vacuum pressure of the
brake vacuum booster the same with atmospheric pressure. Press the brake pedal to the end to start the
engine, and when the vacuum meets the standard, make sure the clearance between brake pedal and
floor is shortened.
162
Attention:
■ The interval of stepping down the brake pedal is Fig. 3.2.019
5s.
2) Check of Air Tightness

Fig. 3.2.020
■ The engine shall be shut down when it Good Poor
operates at idle speed for 1 min and the brake
vacuum booster becomes vacuum. Press the
brake pedal normally to relieve the vacuum.
Make sure the clearance between brake pedal
and floor increases gradually. Third
■ Press the pedal when the engine is in Second
operation, and then step down the pedal for First
30s to shut down the engine, after that make
sure the pedal stoke does not change.
Attention:
■ The interval of stepping down the pedal is 5s.
Attention:
■ Please don't bend the brake pipe when
dismantling the brake vacuum booster.
■ Please replace the damaged lockpin.
■ Please don't damage the thread of brake
vacuum booster fixed bolt.
1) Dismantlement
① Dismantle the air filter assembly. Please refer Fig. 3.2.021
to "Air Filter".
② Dismantle the vacuum hose from the brake
vacuum booster.
163
③ Dismantle the lockpin from the brake pedal. Fig. 3.2.022
④ Dismantle the connecting nut of the brake Fig. 3.2.023

pedal and brake vacuum booster.
⑤ Dismantle the vacuum booster from the

engine compartment.
2) Check after Dismantlement Fig. 3.2.024

Length of input rod
① Check of the length of push rod
a. Apply the vacuum pressure of -66.7 KPa to

the brake vacuum booster with hand-operated
vacuum pump. Preload
b. Check the length of push rod.
② Vacuum hose
Check if it is damaged or cracked. If it is, please

replace it.

Input rod
① Unscrew the locknut to adjust the length of
push rod in the standard range, and then
pretighten it. See the figure (3.2.025).
■ Standard value B: 157 mm

Locknut
② Mount the brake vacuum booster onto the fire
wall according to the specified tightening
torque.
164
③ Mount the brake pedal lockpin. Please refer to "Brake Pedal".
④ Mount the vacuum hose.
Attention:
■ Insert the vacuum hose at least 20 mm during installation.
■ Please don't use the lubricating oil during installation.
⑤ Please refer to "Adjustment of Brake Pedal". Adjust the free play of the brake pedal.
⑥ Tighten the push rod locknut according to the specified torque.
⑦ Mount the air filter assembly. Please refer to "Air Filter".
⑧ Fill new brake fluid and exhaust the air. Please refer to "Exhaust Air in the Hydraulic Pipeline".
VIII. Front Disc Brake Tongs Fig. 3.2.025

1. On-vehicle Check
1) Wear check of the brake shoe
■ Check the thickness of brake shoe from the

access hole of brake wheel cylinder. Check
with graduated scale if necessary.
Standard thickness: 9.0 mm
Wear limit thickness: 2.0 mm
165
2. Element
Disassembly Diagram for Brake Tongs
1- Brake tongs body 2- Dust wrapper of slide pin 3-Piston 4-Dust cover of piston 5-Piston guide ring
6-Caliper support rack 7-Exhaust screw 8-Spring pad 9-Brake shoe 10- Brake shoe muffler plate
Attention:
■ The brake wheel cylinder and brake shoe shall be cleaned thoroughly, to minimize the damage
caused by the particle in air and other substances.
■ Please don't step down the brake pedal when dismantling the brake wheel cylinder, in order to avoid
the piston being ejected.
■ Please don't damage the dust wrapper of the piston.
■ Please don't dismantle the support rack of the brake wheel cylinder and the bolt on brake hose
unless disassembling or replacing the brake wheel cylinder. The brake wheel cylinder can be hung
with rope to avoid pulling the brake hose.
■ If the brake shoe muffler plate is seriously worn, please replace it with new muffler plate.
■ The muffler plate shall be replaced when the brake shoe is replaced.
■ Make sure there is no brake fluid on the brake disc.
166
3. Dismantlement and Installation of Brake Shoe

Fig. 3.2.027
1) Dismantlement
"Wheel and Tyre".
② Dismantle the sliding pin of lower brake wheel
cylinder.
③ Lift the brake wheel cylinder with rope, and
then dismantle the brake shoe, and brake
shoe muffler plate.
2) Installation
① Mount the inner and outer muffler plates on Fig. 3.2.028
their brake shoes separately.
Attention:
■ Mount the muffler plate based on its fixed
direction.
② Mount the brake shoe onto the support rack of
brake wheel cylinder.
③ Keep pressing the piston when mounting the
brake shoe, and then mount the brake wheel
cylinder onto its support rack.
Note: The piston can be pressed continuously with
the disc-type brake piston tools.
■ Pay attention to the level of brake fluid in the
brake stock solution tank.
④ Mount the sliding pin of lower brake wheel
cylinder, and tighten it.
⑤ Fix the brake disc with tyre nut, and step down
the brake pedal until it works.
⑥ Check the brake rotation resistance.
⑦ Mount the wheel tyre.
4. Dismantlement and Installation of Brake
Tongs Sub-assembly
1) Dismantlement
"Wheel and Tyre".
② Dismantle the brake hose bolt, and then cut
off the brake hose.
167
■ Take care not to let the bolt gasket drop off.
③ Dismantle the bolt of the support rack of the

brake wheel cylinder, and then dismantle the
brake tongs sub-assembly.
2) Installation
Attention:
■ Refill the brake fluid "D0T4".
① Mount the brake tongs sub-assembly on the steering knuckle, and then tighten the fixed bolt of the
support rack of the brake wheel cylinder to the specified torque.
Attention:
■ The engine oil and water on the joint surfaces of steering knuckle and brake tongs sub-assembly,
fixed bolt of the brake hose, and fixed bolt gasket shall be avoided.
② Mount the brake hose on the brake tongs sub-assembly, and tighten the fixed bolt of brake hose to
the specified torque.

■ Please don't reuse the fixed bolt gasket of the
brake hose.
■ Limit, align and connect the brake hose and

brake tongs sub-assembly.
③ Fill brake fluid and exhaust air. Please refer to

"Brake Fluid".
④ Check the rotation resistance of the brake.
⑤ Mount the wheel tyre.
168
5. Disassembly and Assemblage of Brake Tongs Sub-assembly
1) Disassembly
① Dismantle the sliding pin of brake wheel cylinder, and dismantle the brake wheel cylinder from its
support rack. Dismantle the brake shoe and its muffler plate from the support rack of brake wheel
cylinder.
Attention:
■ Please don't let the brake shoe and its muffler plate drop off from the support rack of brake wheel
cylinder.
② Dismantle the sliding pin and sliding pin dust wrapper from the support rack of brake wheel cylinder.
③ As the figure shows, put a proper wood block, Fig. 3.2.031

and blow air evenly to the fixed bolt hole of the
brake hose, to dismantle the piston and its
dust wrapper.
Attention:
■ Take care not to let the finger clamped by the

piston.
④ Dismantle the piston seal ring from the brake Fig. 3.2.032
wheel cylinder with slotted screwdriver. Piston seal ring
Attention:
■ Don't damage the inner wall of the brake wheel

cylinder body.
2) Check after Disassembly
① Brake wheel cylinder body
Attention:
■ Clean the cylinder body with new brake fluid. Please don't use petrol or kerosene.
■ Check if the inner wall of brake wheel cylinder body is worn or damaged. If it is, please replace the
brake wheel cylinder.
② Support rack of the brake wheel cylinder
■ Check if the support rack is worn, cracked or damaged. If it is, please replace it.
③ Piston
■ Check if the piston surface is rusty, worn, or damaged. If it is, please replace it.
169
■ Please don't grind the piston surface with sand paper.

④ Sliding pin, pin bolt or pin dust wrapper.
■ Check if the sliding pin, pin bolt and pin dust wrapper are worn and cracked. If they are, please
replace them.
3) Assemblage
Fig. 3.2.033
Attention: Piston seal ring
■ The specified rubber grease shall be used
during assemblage.
① Apply rubber grease to the piston seal ring, and
mount the piston seal ring in the cylinder body.
Attention:
■ Please don't reuse piston seal ring.
② Apply brake fluid to the piston, and apply
rubber grease to the piston dust wrapper.
Cover the piston port with piston dust wrapper,
and then slowly fixed the side of cylinder body
which is on the piston dust wrapper in the
groove of the cylinder body.
Attention: Piston dust Fig. 3.2.034

cover
■ Please don't reuse piston dust wrapper. Piston
③ Put hand in the cylinder body and insert the

piston edge of the piston dust wrapper in the
piston groove.
Attention:
■ Apply an even force to press down the piston in
order to avoid rubbing the inner wall of the
cylinder body.
④ Mount the sliding pin and sliding pin dust
wrapper on the support rack of brake wheel
cylinder separately.
⑤ Mount the shoe muffler plate on the brake
shoe.
Attention:
■ Mount it based on the fixed direction of the
muffler plate.
⑥ Mount the brake shoe sub-assembly on the
support rack of brake wheel cylinder.
170
⑦ Keep pressing the piston when mounting the Fig. 3.2.035

brake shoe, and then mount the brake wheel
cylinder on the support rack of brake wheel
cylinder.
⑧ Tighten the pin bolt.
6. Check of the Brake Disc
1) Visual Check
■ Check if the surface of brake disc is unevenly worn, cracked and seriously damaged. If it is, please
replace it.
2) Check of the Runout

Fig. 3.2.036
① Fix the brake disc on the wheel hub.
② Check the runout with dial gauge. (It can be
measured at the place which is 10 mm away
from the inside edge of brake disc)
■ Runout limit: 0.05 mm
Note: Make sure the axial clearance of wheel
bearing is within the specified value before
measurement. Refer to "Check of the Wheel
Bearing". Fig. 3.2.037
③ If the runout is beyond the specified value,
please replace it or do some necessary
processes.
3) Check of Thickness
■ Check the thickness of brake disc with dial
gauge. If the thickness is lower than the wear
limit, please replace the brake disc.
Standard thickness: 19 mm
Wear limit: 17 mm
7. Steps of Brake Running In
If the spongy brake appears after the brake disc is repaired or replaced and the brake is replaced, or
after a short distance travel, please run in the joint surface of brake disc and brake shoe according to
following steps.
■ If the brake effect is not good before running in, please pay attention to controlling the speed.
171
■ These steps shall be carried out only when the pavement and traffic conditions are safe. Pay
attention to your safety.
1) Drive the vehicle on the smooth road.
2) Control the force of stepping down the brake pedal to brake the vehicle within 3s ~ 5s.
3) Drive some distances continuously to make the braking system cool down.
4) Repeat steps 1~ 3 until the brake shoe and brake disc are run in completely.
IX. Rear Brake Fig. 3.2.038

1. On-vehicle Check
1) Wear check of brake shoe
■ Check the thickness of brake shoe from the

access hole of brake bottom plate.

1) Dismantlement

"Wheel and Tyre".
② Release the parking brake.
③ Dismantle the rear wheel hub dust cover,

locknut and gasket of the wheel bearing
assembly, and take off the wheel bearing
assembly. Please refer to “Wheel Hub and
Bearing”.
④ Dismantle the stop bolt of the rear brake drum,

and take off the brake drum.
⑤ Dismantle the rear brake hard pipe. Please Fig. 3.2.040

refer to "Brake Pipeline".
⑥ Dismantle the speed sensor. Please refer to

"Speed Sensor".
172

■ Please don't pull the speed sensor harness.
⑦ Dismantle the rear brake shoe and parking
brake wiredrawing.
⑧ Dismantle fixed bolt of brake bottom plate

Fig. 3.2.042
■ Tightening torque: 45~ 55 N•m
⑨ Take off the rear brake from the rear steering
knuckle.
2) Check after Dismantlement Fig. 3.2.043

Inner diameter
① Brake drum
■ Check if the inner diameter and circular runout
of brake drum are within the standard value. If
they are not, please process or replace it.
Standard value: 204 mm
Circular runout: < 0.05 mm
② Brake shoe
Fig. 3.2.044
■ Check the thickness of brake shoe and its
connection with brake drum. If they do not
conform to the standard, please replace the
brake shoe.
Standard thickness of brake shoe (A): 5 mm
Allowable limit thickness (A): 1 mm
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③ Brake bottom plate
Check if the brake bottom plate has wear and other damages.
3) Installation
■ Tighten the fixed bolt of brake bottom plate according to the diagonal sequence.
■ The diameter of brake shoe shall be adjusted within φ 204 ± 0.25 mm in order to conveniently mount
the brake drum.
■ The inner surface of brake drum shall be cleaned during installation, and the grease shall be
avoided for the contact surface of brake shoe and brake drum. If the contact surface is stained with
grease, it shall be cleaned with acetone, if it is stained seriously, please replace it with a brake shoe
assembly with same model.
■ The brake pedal shall be stepped down for several times after mounting the brake drum to place the
brake shoe in position.
Attention:
■ The brake is equipped with automatic clearance adjusting device. The brake shoe clearance will be
adjusted automatically to the normal value in the above braking processes.
■ The parking wiredrawing shall be adjusted. Please refer to "Parking Brake System".
■ Exhaust the air in braking system. Please refer to "Brake Fluid".
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1) Element
Disassembly Diagram for Rear Brake
1-Adjusting spring 2-Dial plate 3-Rear brake wheel cylinder 4-Washer 5-Bolt 6-Upper return spring
7-Adjusting rod 8-Brake shoe and arm assembly 9-Compression spring of brake shoe 10-Compression
spring pull rod 11-Support bar protecting sleeve 12-Support bar 13-Lower return spring 14-Brake bottom
plate 15-Access hole plug 16-Brake shoe assembly
2) Disassembly Fig. 3.2.045
① Dismantle the adjusting spring.
Fig. 3.2.046
② Dismantle the compression spring of brake

shoe and the compression spring pull rod.
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③ Stretch the shoe, dismantle the upper and Fig. 3.2.047

lower return springs and adjusting rod.
④ Dismantle the parking wiredrawing from the
brake shoe arm, and take off the brake shoe.
⑤ Dismantle the fixed bolt of brake wheel
cylinder, and take off the brake wheel cylinder
from the brake bottom plate.
3) Check after Disassembly Fig. 3.2.048

① Brake wheel cylinder
Check if the brake wheel cylinder outside has wear
or other damages, and if the piston is flexible as
well as if the contact surface of piston and brake
shoe is worn or leaks oil. If the above conditions
exist, please replace the wheel cylinder assembly.
② Return spring, arm, and adjusting rod Fig. 3.2.049

Check the elasticity of spring, and check if the arm
and adjusting rod have deformation and other
damages.
Pay attention to the following items and install in

■ Mount the upper return spring first, and then
mount the lower return spring. Forward
■ Apply the lubricating grease in the shadow
area as shown by the arrow.
■ Pay attention to the mounting direction of the
adjusting rod.
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X. Troubleshooting
1. Rear Braking System
Table of Common Troubleshooting for Rear Braking System

1. The pipeline connector and cup of brake wheel cylinder 1. Tighten or replace it after cleaning
leak fluid 2. Exhaust
2. The residual air in the pipeline is not exhausted 3. Readjust
completely 4. Frictionize or replace
Insufficient 3. The clearance between brake shoe and brake drum is 5. Replace, reduce the temperature, and
brake force too large exhaust the air
4. The brake shoe surface is stained with oil or is
hardened
5. The brake drum is overheated, and there is
air-resistance in the pipeline
1. The oil return hole of rear brake wheel cylinder is 1. Do troubleshooting or replace
blocked or the cup is expansive 2. Readjust
2. The clearance between brake shoe and brake drum is 3. Replace
The brake
too small 4. Modify or replace
is hard to
3. The elasticity of the brake shoe return spring wanes or
release
the brake shoe return spring is broken
4. The brake shoe or bottom plate is deformed, and the
return is resisted.
1. The rear brake shoe is seriously worn 1. Replace
2. The brake drum is out of circularity. 2. Honing, and check of the balance
3. When the rear brake surface is too smooth, the friction performance
coefficient is small, while the brake pressure is high, 3. Clean the foreign matter, and grind the
Noise there will be frictional noise when the smooth surface rear brake shoe with sandpaper
frictionizes as sliding, or due to the foreign matter
seized in the friction pair pressing the friction surface
1. The brake clearance and the pedal free play are too 1. The brake clearance shall be readjusted
small, when releasing the brake pedal, the brake force in that case
has not disappeared, causing the friction pair to be 2. Adjust it according to the specification if
frictionized in long term; the initial starting is difficult, the necessary.
operation is powerless, and the wheel drum is hot when 3. The troubleshooting can be done by
touching its surface overhauling or replacing the return spring
The brake 2. The brake handle is not released completely due to
drum improper adjustment or operation mistake, Which
heating due causes the friction pair to be heated for having been
to braking frictionized for a long time
drag 3. The heat generated by brake results in the return spring
deformation, the elasticity reduction or disappearance,
and if it cannot make sure the rear brake shoe
assembly return timely after braking, it cannot stop the
brake drum heating for the brake cannot being released
timely either
The common wiredrawing or rusty sleeve, broken, falling off Check if the surfaces of brake control
stiff spring or disappeared elasticity cause that the parking wiredrawing and braking system components
Parking brake control wiredrawing or brake wiredrawing cannot be are damaged, if the handle is controlled
brake pulled flexibly in their jackets, therefore the parking brake flexibly and clamped; Check if the wiredrawing
failure can not be released and it will fail to work connector and the fixed part is loose or
damaged, repair or replace the parts if
necessary.
177
2. Braking System
Table of Common Troubleshooting for Braking System

Trouble Possible Causes Troubleshooting
The air pressure of left and right tyres is insufficient Adjust
The adjustment of front wheel is incorrect Adjust
Off tracking at one side The brake shoe is of poor contact Adjust
when the vehicle is There is lubricating grease or oil on the surface of brake shoe replace
braked The brake drum is eccentric or is not worn evenly replace
The brake wheel cylinder is not mounted properly Adjust
The automatic adjusting device has trouble Adjust

The brake fluid is very little or is polluted Add or replace
There is air in the braking system Exhaust air in the system

The brake booster has trouble Adjust
The brake shoe is of poor contact Adjust
Insufficient brake force There is lubricating grease or oil on the surface of brake shoe Replace
The drag of brake shoe results in overheated rotary spare parts of Adjust
the brake
The brake pipeline is restricted Adjust
The proportional valve has trouble Replace
There is air in the braking system Exhaust air in the system
Pedal stroke increase The brake fluid leaks Adjust

(the distance from The automatic adjusting device has trouble Adjust
pedal to floor shortens) The clearance between push rod and brake master cylinder is too Adjust
large
The parking brake is not released completely
The parking brake is adjusted improperly Adjust

The brake pedal return spring is worn Replace
The oil return hole of brake master cylinder is restricted Adjust
The brake return spring of the rear drum is damaged Replace
Braking drag
The sliding spare parts is short of lubrication Lubricate
The one-way valve of brake master cylinder or piston return spring Replace
has deficiency
The clearance between push rod and brake master cylinder is too Adjust
small
The rear brake shoe is damaged Adjust
Inadequate parking There is lubricating grease or oil on the surface of rear brake shoe Replace
brake function The parking brake cable is seized Adjust
The stroke of parking brake handle is too large Adjust
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XI. Maintenance Parameter
Item Specification Item Specification

Type Tandem Type Rear wheel mechanical
Brake master
brake
cylinder Parking brake
Cylinder diameter 22.22 mm Brake type Lever-type
Type Vacuum booster Cable layout V-type layout
Effective 228. 6mm Model Magneto-electricity
Brake booster diameter
Transmission 6.1:1 Resistance 1 ~ 2 KQ
ratio
Speed sensor
Type Floating caliper / with Output voltage AC
ventilated disc
Brake disc 241 mm Air clearance 0. 2 ~ 1.1 mm
diameter
Front brake Brake disc 19 mm Type Alarm lamp module
diameter
ABS, EBD
Friction block 9 mm Operating voltage 12V
alarm lamp
thickness
Cylinder diameter 51 mm Operating current 80 mA
Type Leading and driven Diameter of brake 17.46 mm
brake wheel cylinder
Rear brake Rear brake
Brake drum 204 mm Clearance Automatic
diameter adjustment
2. Technical Parameters
Item Standard Item Standard Limit

value value
Height of the brake pedal 151.7 mm Thickness of the front disc brake 9.0 mm 2.0
shoe mm
Stroke of the brake pedal 125.6 mm Thickness of the front disc 19 mm 17 mm
The distance between stop lamp switch outside and 0.5 ~ 1.0 Front disc runout 0.05 mm
pedal dog plate mm
Free play of the brake pedal 3 ~ 8mm Thickness of the rear drum 5 mm 1 mm
brake lining
The distance from booster push rod to brake master 0 Brake drum diameter 204 mm 206
cylinder mm
The stroke of parking brake lever (when the dog plate 5 ~ 7 teeth Clearance between brake wheel 0.15
assembly applying the force of 196N) cylinder and piston mm
The length of booster push rod B 157 mm
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Section III Anti-lock Braking System

I. Precautions
While repairing the anti-lock braking system (ABS), pay attention to the following items to avoid
damaging the ABS.
1. Disconnect the connector on the ABS control module before the electrical welding.
2. As the spare parts of the ABS are extremely sensitive to electromagnetic interference (EMI), much
attention shall be paid to the direction, position, installation and location of all the spare parts of the
ABS. Equal care shall be given to check whether there is any interference on the wiring, the joint,
the clip and the bracket.
3. Do not start the engine with a quick charger or charge the connected storage battery. This can
cause the failure of the storage battery or damage the spare parts of the ABS.
4. It is a must to close the ignition switch first; then disconnect the negative pole of the storage battery,
and disconnect the connector of the ABS control module assembly.
5. Do not attempt to repair any spare parts of the ABS and all of them shall be replaced if the repair is
required.
6. Do not hang the spare parts of the suspension system on the wire harness of the speed sensor to
avoid damaging the wire harness of the speed sensor.
7. Do not expose the ABS control module in an environment with a temperature higher than 105 ℃.
8. Do not use petroleum-based fluid in the brake master cylinder and do not use the container which
was used to hold petroleum-based fluid. The oil may lead to swelling and deformation of the rubber
spare parts of the hydraulic brake system.
9. In ABS operation, it is normal that the brake pedal may vibrate gently and mechanical noise can be
heard.
10. Turn the ignition switch to the ON position and start the vehicle. The brake pedal may vibrate and
the work noise of the motor of the ABS hydraulic assembly can be heard. These are all normal.
11. While the vehicle travels on bumpy, sandy or snow-covered (relatively deep new snow) pavement,
the braking length may be longer than that of the vehicle without ABS.
12. While any trouble of the braking system occurs, figure out it is caused by the ABS or the common
braking system. As for the latter, check whether there is any trouble in components such as the
vacuum booster, the hydraulic braking system and the brake.
13. If the tire dimensions and models are not used correctly in combination or if the brake shoes are not
the original spare parts of JAC, the braking length and the steering stability may be influenced
negatively.
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II. Preparation
Common maintenance tools and special tools may be used in the maintenance.
X-431
For trouble
1 diagnostic JAC-T1Z001
diagnosis of ABS
tester
III. System Illustration
1. System Diagram
ABS Diagram
1- Left front brake assembly 2-Vacuum booster with brake master cylinder assembly 3-ABS assembly
4-Brake pedal assembly 5-Right front brake assembly 6-Braking pipeline 7- Right rear brake assembly
8- Left rear brake assembly
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2. Functions of the ABS
The ABS can prevent wheel lock by controlling the hydraulic brake pressure of the four wheels in case of
emergency braking or braking on dangerous pavements. The ABS has follows advantages:
(1) It enables the vehicle to turn safely while encountering a barrier in an emergency braking situation.
(2) It enables the vehicle to be parked stably at the driver’s option in case of emergency braking on a
curve.
Attention:
■ If the electrical system is disconnected, the fail safe mode will be started and the ABS will become
inoperative and the ABS warning lamp will be on.
■ Special diagnostic tester provided by JAC can be used to diagnose the ABS electrical system.
■ In the braking process, the brake pedal may vibrate gently and mechanical noise can be heard.
These are normal in ABS operation.
3. Functions of EBD
Electronic brake force distribution (EBD) is a kind of proportional system which is used to maintain
vehicle stability in the braking period. Under normal braking conditions, equal wheel speed is required to
ensure effective balanced braking. Under conditions where the braking is hard to achieve, given that the
vehicle weight is shifted to the front wheel and the brake force required by the rear wheel is relatively
small, EBD will provide effective braking and vehicle stability by taking advantage of the brake pressure
required by the rear pressure increasing valve and the pressure reducing valve in maintaining the
stability of the rear wheel.
4. Protective Functions to Troubles
If the ABS has electrical trouble, the ABS warning lamp will be on. If the EBD has electrical trouble, the
brake warning lamp and the ABS warning lamp will be on.
Meanwhile, the ABS will change to one of the following situations of the protective functions to troubles.
1) For ABS troubles, activate EBD only and the vehicle status is the same with that of the vehicle
without ABS.
2) For EBD troubles, both the EBD and the ABS are out of use and the vehicle status is the same with
that of the vehicle without ABS and EBD.
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5. Basic Diagram for the ABS Hydraulic System
Left Right
front/LF front /RF
Right Left
rear/RR rear/LR
Basic Diagram for the ABS Hydraulic System
1-Master cylinder 2-Inlet valve /LF 3-Outlet valve /LF 4- Inlet valve /RR 5- Outlet valve /RR 6-Damper 7-
Oil return pump 8-Accumulator 9- Inlet valve /RF 10- Outlet valve /RF 11- Inlet valve /LR 12- Outlet valve
/LR
IV. Anti-lock Braking Mode
While the wheel slips in the braking period, the ABS will enter into the anti-locking braking mode. During
the anti-lock braking period, hydraulic circuit pressure of all the wheels will be within the control to
prevent wheel slip. Each wheel is equipped with independent hydraulic pipelines and valves.
The ABS can reduce, maintain or increase the braking hydraulic pressure of all the wheels. Whereas,
the ABS can not increase the hydraulic pressure to the extent which exceeds the pressure transmitted
by the main cylinder during the braking period. During the anti-lock braking period, a series of rapid
vibration of the brake pedal can be felt. The position of each valve changes rapidly in accordance with
the required wheel speed and as a result, vibration occurs. Pedal vibration occurs in the anti-lock braking
period and stops under normal braking conditions or while the vehicle is completely stopped. The action
noise caused by the rapid circulated usage of the solenoid valve can be heard. When the ABS is started
on dry pavement, the tire on the edge of skidding will produce high-pitched noise intermittently. Those
noises and pedal vibration are normal in the ABS braking operation period. The operation of the brake
pedal shall be the same with the operation without the ABS. Balanced pedal force can ensure vehicle
stability and the shortest parking distance as well.
184
1. Pressure maintenance
While the ABS control module detects wheel slip, it will close the inlet valve and the outlet valve of the
hydraulic assembly so as to isolate the system. By doing this, it can maintain a stable pressure on the
brake to avoid reducing or increasing the hydraulic pressure.
2. Pressure reduction
Under the pressure maintenance mode, if the ABS control module can still detect wheel slip, it will
reduce the pressure of the influenced wheel by closing the inlet valve and opening the outlet valve.
Redundant fluid/pressure will be stored temporarily in the accumulator of the hydraulic assembly until
the motor pump can transport the brake fluid back into the stock solution tank of the master cylinder.
3. Pressure increase
Under pressure maintenance or pressure reduction mode, when the ABS control module detects fewer
wheel slip, the ABS control module will increase the wheel pressure by taking advantage of the pressure
of the master cylinder with the opened inlet valve and closed outlet valve. Partial or whole pressure from
the brake master cylinder will be applied on the wheel.
4. Working process of the ABS
In the traveling process, every speed sensor will produce a voltage signal which is proportional to the
wheel speed. The ABS control will receive the wheel speed data and judge whether one or more wheels
decelerate too quickly compared with the reference vehicle speed, and this is called slip. The ABS
controller will activate the module in accordance with the requirement, and the module will control the
brake pressure of every wheel to achieve optimization.
V. Speed Sensor
The speed sensor consists of the sensor body and the ring gear, and every wheel is equipped with one
group. This vehicle type can be operated with the driving speed sensor and the external power supply
(12 V). The sensor can provide a constant amplitude signal regardless of the wheel speed.
Fig.3.3.001
1. Element
2. Dismantlement
1) Front wheel
① Lift the vehicle.
② Disconnect the sensor connector.
185
③ Unscrew the fixing bolt of the sensor and remove the sensor slowly.
■ Tightening torque: 8~10 N.m
Attention:
■ Please do not pull the wire harness of the speed sensor forcedly.
■ While in installation, pay attention to the clearance between the speed sensor and the signal ring
gear.
Standard value: 0.2~1.1 mm
2) Rear wheel
① Lift the vehicle and dismantle the tire of the rear wheel.
Attention:
Fig.3.3.002
■ Unscrew the fixing bolt of the tire before lifting
the vehicle.
② Disconnect the sensor connector.
③ Unscrew the fixing bolt of the speed sensor

and remove the speed sensor slowly.
Attention:
■ Do not pull the wire harness of the speed

sensor forcedly.
■ While in installation, pay attention to the

clearance between the speed sensor and the
signal ring gear.
Standard value: 0.2~1.1 mm
3. Check after dismantlement
1) Check whether there is any foreign matter in the mounting hole of the sensor and whether there is
any foreign matter like sweepings on the surface of the brake disc.
2) Before installation, clean the mounting hole of the sensor and the surface of the brake disc.
4. Installation
Install in the reverse order with dismantlement, and screw down the bolt to the specified toque.
Attention:
■ There shall be no twisting for the wire harness after installation.
186
VI. ABS Hydraulic Assembly

Fig.3.3.003
1) Dismantlement
① Close the ignition switch and disconnect the
negative terminal of the storage battery.
② Dismount the connector of the ABS control
module.
③ Step down the pedal for a distance larger than
60 mm; fix it with the pedal bracket.
Fig.3.3.004
■ Close the centre valve of the hydraulic
assembly to prevent the brake fluid leakage
from the outlet when the system is opened.
④ Dismount the brake hard pipe connected with
the master cylinder from the hydraulic
assembly and make marks; then block the
outlet with a plug immediately.
⑤ Dismount the hard pipes leading to wheels
and make marks; then block the outlet with a
plug immediately.
⑥ Dismount the bolt from the support rack of the
ABS hydraulic assembly.
⑦ Dismantle the whole ABS hydraulic assembly
from the rack.
2) Installation
Install the ABS hydraulic assembly in the reverse order with dismantlement.
Attention:
■ The connector of the braking pipeline connected with the ABS hydraulic assembly shall be screwed
down to the specified torque.
Tightening torque: 13~17 N.m
■ Dismantle the plug of the hydraulic opening on the hydraulic assembly only when the brake hard
pipe is prepared to be installed, so as to avoid foreign matters entering the braking system. As for
the following procedures, please refer to “Braking Pipeline”.
① Install the ABS hydraulic assembly on the rack and screw it down to the specified torque.
② Dismount the plug on the hydraulic opening, and install the brake hard pipe and make sure that the
hard pipe is correctly connected.
③ Connect the hydraulic assembly to the brake hard pipe of the master cylinder.
④ Assemble the brake hard pipe and screw it down to the specified torque.
187
⑤ Fill new brake fluid into the stock solution tank till the fluid level reaches the MAX position; and then
exhaust air with the specified method.
⑥ When the ignition switch is turned to the ON position, the ABS warning lamp shall be on and then be
off.
⑦ Clear trouble codes in memory; and then read it again to see whether there is still any trouble code.
⑧ Finally, conduct the final drive to check whether the ABS functions are normal.
Note:
If there is any trouble with the ABS hydraulic assembly, replace the assembly.
VII. ABS Control Module Fig.3.3.005
1. Element. This kind of vehicle type adopts

BOSCH ABS 8 FWD –X ABS, in which the ABS
control module and the hydraulic assembly are
integrated.
2. Illustration of the pins of the ABS control module
Illustration Table of Pins of the ABS Control Module
Pin Pin
Illustration Illustration
No. No.
Power supply end of the motor
1 20 Signal terminal of the speed sensor (left rear)
(anode)
2 N. C. 21 N. C.
Speed sensor output (right rear
3 22 Signal terminal of the speed sensor (left front)
wheel )
4 Driving ABS warning lamp 23 N. C.
5 N. C. 24 N. C.
Signal terminal of the speed sensor
6 25 Power supply end of the valve relay
(right front)
7 N. C. 26 CAN-high
8 N. C. 27 Speed sensor output (right front wheel )
9 N. C. 28 N. C.
10 N. C. 29 N. C.
11 N. C. 30 Input of the stop lamp switch
12 N. C. 31 Signal terminal of the speed sensor (right rear)
Power supply end of the ABS control module
13 Grounding terminal of the motor 32
(ignition power supply line)
14 CAN-low 33 Power supply end of the speed sensor (left rear)
15 N. C. 34 Power supply end of the speed sensor (left front)
16 Driving EBD warning lamp 35 N. C.
17 Diagnosis of K line 36 N. C.
Power supply end of the speed
18 37 N. C.
sensor (right front)
Power supply end of the speed
19 38 Grounding wire of the ABS control module
sensor (right rear)
188
Diagram for Pin Position of the ABS Control Module
3. Check of the ABS control module
Attention:
■ First conduct basic check to the braking system.
1) Basic check of the braking system
① Check the brake fluid level; if the fluid level is too low, fill new brake fluid.
② Check whether there is any leakage near the braking pipeline and the ABS hydraulic assembly. If
any, conduct the following check:
a. If there is any looseness of the connecting part of the ABS hydraulic assembly; screw down the oil
pipe nut of the pipeline to the specified torque (18~30 N.m). Check the leakage again and make
sure that there is no leakage of the brake fluid.
b. If the connecting part of the oil pipe nut and the thread part of the actuator are broken, replace the
damaged spare parts. Check the leakage again and make sure that there is no leakage of the brake
fluid.
c. If there is leakage in any places rather than the connecting part of the actuator, please wipe the fluid
with a piece of clean cloth and check the leakage again. If leakage is still found, replace the
damaged spare parts.
d. If there is any leakage on the hydraulic assembly, wipe the fluid with a piece of clean cloth and then
check the leakage again. If leakage is still found, replace the hydraulic assembly.
Attention:
■ Do not disassemble the ABS hydraulic assembly unless there is a special requirement.
③ Check whether there is any wear for the brake shoes.
④ Check whether there is any looseness of the terminal of the power circuit and check the storage
battery.
■ Check whether there is any looseness on the anode and cathode of the storage battery. Meanwhile,
check whether the voltage of the storage battery is normal.
189
2) Check of the ABS warning lamp and the brake warning lamp
① If the ignition switch is turned to the ON position, the ABS warning lamp will be lightened for 1 s and
the brake warning lamp will be lightened as well. If they are not lightened, please refer to “Common
Troubles and Analysis Procedure for the ABS”.
② Check whether the ABS warning lamp is off when the ignition switch is turned to the ON position for
about 1 s. If it is not off, please refer to “Common Troubles and Analysis Procedure for the ABS”.
③ If the ABS warning lamp does not become off when the engine starts and runs for more than 10 s,
please refer to “Common Troubles and Analysis Procedure for the ABS”.
Attention:
■ The brake warning lamp will be lightened in the operation of the parking braking (when the switch is
turned to the ON position) and the brake fluid level sensor (inadequate brake fluid).
3) Check ABS control module with diagnostic tester
Check the control data and the memorial trouble code of the control module with the diagnostic tester. If
any abnormality is found, repair it according to the trouble prompts. Please refer to “Trouble Diagnosis”.
4) Table of the ABS trouble code
Table of the ABS Trouble Code
Trouble Trouble
Illustration Illustration
code code
Trouble of the left front charged solenoid
C0011 Trouble of the ABS warning lamp C0061
valve
C0012 Trouble of the brake warning lamp C0062 Trouble of the left front relief solenoid valve
Contact of the system breaker and open circuit of Trouble of the right front pressure solenoid
C0014 C0063
the coil valve
C0017 Grounding trouble of the motor pump C0064 Trouble of the right front relief solenoid valve
C0018 Short circuit of the motor pump and the storage
Trouble of the left rear charged solenoid
battery or open circuit of the motor grounding /with C0065
valve
high electrical resistance value
C0021 Speed of left front wheel= 0 kph C0066 Trouble of the left rear relief solenoid valve
Trouble of the right rear charged solenoid
C0022 Speed of right front wheel= 0 kph C0067
valve
C0023 Speed of left rear wheel= 0 kph C0068 Trouble of the right rear relief solenoid valve
C0024 Speed of right rear wheel= 0 kph C0091 Failure of the brake pedal in deceleration
Too great change of speed for the left front wheel Failure of the brake pedal in deceleration in
C0025 C0093
speed the previous ignition period
Trouble of no deceleration with effective
C0026 Too great change of speed for the right front wheel C0094
brake pedal
C0027 Too great change of speed for the left rear wheel C0095 Open circuit of the brake switch
Trouble related to the left rear charged
C0028 Too great change of speed for the right rear wheel C0118
solenoid valve
The opening of the circuit of the left front wheel
Trouble related to right rear charged solenoid
C0032 speed or the grounding/short circuit of the storage C0121
valve
battery
190
C0033 The opening or grounding of the right front wheel C0122 Trouble related to relief or front pressure
speed circuit/ short circuit of the storage battery solenoid valve
C0034 The opening or grounding of the left rear wheel C0127 Trouble of no deceleration with effective
speed circuit/ short circuit of the storage battery brake pedal in the previous ignition period
C0035 The opening or grounding of the right rear wheel C0151 The relief time of the left front wheel is too
speed circuit/ short circuit of the storage batter long
C0036 Too low voltage C0152 The relief time of the right front wheel is too
long
C0037 Too high voltage C0153 The relief time of the left rear wheel is too
long
C0042 Open circuit of the motor pump C0154 The relief time of the right rear wheel is too
long
C0043 Stop of the motor pump C0191 Starting current of the pumpless motor
C0055 Internal trouble C0192 Current overload of the pump motor
C0056 The system relay is connected always C0194 Short circuit current of the pump motor
VIII. Exhaust of ABS

1. Exhaust conditions of the ABS
If one of followings occurs, conduct the exhaust procedure of the ABS immediately.
1) The braking pipeline can not reach the required pedal height or feeling by exhausting air in the
traditional way.
2) Replace the ABS hydraulic assembly.
3) Excessive amount of fluid has been consumed.
4) Doubt of air intake.
■ This procedure adopts the diagnostic tester to drive the system valve, to operate the pump motor
and exhaust air in the secondary circuits. Those circuits are always closed and are only opened in
the initialization period of the vehicle starting and the ABS operation period. The automatic exhaust
procedure will open those secondary circuits to make all the air flow out and get it collected in the
hydraulic assembly where it can be exhausted from the system.
2. Exhaust of ABS
1) Required items
① Diagnostic tester with proper software.
② Brake fluid.
③ Lifting jack.
④ Exhaust bottle with hoses which can be used to recycle vehicle fluid.
⑤ Proper safety equipment including safety glasses.
⑥ Two maintenance personnel are required: One steps down the brake pedal and controls the
diagnostic tester, and another one maintains the hydraulic oil level in the primary chamber of the
brake master cylinder and switches on or off the exhaust screw according to the diagnosis process.
191
2) Preliminary Check
① Check the charging status of the storage battery and repair the storage battery and the charging
system as required.
② Connect the diagnostic tester and select current and historical trouble code. Before implementing
the ABS exhaust procedure, clear all the trouble diagnostic codes. If those codes can not be cleared,
conduct the troubleshooting first.
③ Check whether there is any damage or leakage of the appearance. Conduct maintenance if
required.
3) Operation before exhaust
① Start the engine.
② Connect the diagnostic tester and establish communication with the ABS.
③ Lift the vehicle and make it properly supported.
4) On-vehicle exhaust
Attention:
The automatic exhaust procedure can be stopped at any time by pressing the EXIT key on the
diagnostic tester.
① Select “Automatic Exhaust Procedure” on the diagnostic tester and implement the procedure
according to the illustration. (Please refer to the actual diagnosis procedure)
② In the basic and automatic exhaust process, step down the brake pedal and maintain the brake fluid
level of the brake master cylinder.
③ While exhausting air for one wheel, make sure that the hose is connected with the exhaust screw
and that the air is exhausted into the chamber of the brake fluid. This chamber must be 30 mm
higher than the hose bolt filled with brake fluid so as to prevent the reentry of air into the braking
pipeline.
④ The first step is the basic exhaust. This step must be carried out before the automatic exhaust so as
to obtain good pedal height and pedal feeling and to ensure the optimal performance of the ABS.
⑤ The first step of automatic exhaust procedure is to rotate the pump and the relief valve for about 30
s. The exhaust bolts are not required to be switched on or off at this step. The brake pedal keeps on
decreasing or increasing pressure alternatively in the whole process.
⑥ In the next step, the diagnostic tester will require the maintenance personnel to open one of the
exhaust bolts. Then the diagnostic tester will conduct periodic check of the pressure valve and the
pump motor for about 30 s. The brake pedals are required to decrease or increase pressure
alternatively in the whole process.
⑦ As for the remaining exhaust bolts, the diagnostic tester will repeat procedure 6 to exhaust air.
⑧ When the automatic exhaust procedure ends, the diagnostic tester will display corresponding
information.
⑨ Step down the brake pedal, and measure and feel the pedal height. Repeat procedures from 1 to 8
until the pedal is acceptable.
192
Attention:
■ In the repeated operation, the automatic exhaust procedure may stop temporarily and the “Cool
Down” waiting mode may be activated.
5) Automatic exhaust mode
It will not start again until ovetiming is indicated by the running time meter. In addition, this process can
not be skipped.
On-vehicle diagnosis procedure:
① Enter into the special trouble diagnosis LAUNCH

system of Jianghuai sedans. Special Trouble diagnosis system of
Jianghuai sedans
Developed by Launch Tech Company
Limited
Please register in time
Start
Original BDX
Exit Help
version information
Start 17:53
② Select the whole V10.01 system

exclusively for Jianghuai sedans.
Please diagnose the software version
The whole V10.01 system exclusively for

Jianghuai sedans
This procedure can diagnose all the

electrical control systems of the Jianghuai
automobiles produced in 2007 or before.
Page up Page down Enter

③ Enter into the automatic exhaust Back Help
procedure and operate it according to Start 18:37
prompts.
193
Exhaust mode
Start the exhaust mode
Please operate it in strict observance of

the system prompts
Yes No
Start 18: 46
④ The first step of the system exhaust.
Exhaust mode
The first step:

Please close all the exhaust bolts and
then step down the brake pedal.
Continue the process by pressing the
“Yes” button.
Yes No
⑤ The exhaust process in progress. Start 18: 47
Exhaust mode
The exhaust mode is in active use.

Start the pump and keep it run for 20 s.
The home page of the diagnosis

⑥ The first step is completed.
Start 18:47
194
Exhaust mode
The first step is completed.
Enter
Start 18:48
⑦ The second step of the exhaust.
Exhaust mode
The second step:

Start to exhaust air in the right rear wheel.
Please connect the oil drain pipe; open
the right rear exhaust bolt and then step
down the brake pedal.
Enter
Start 18:48
⑧ The exhaust process in progress.
Exhaust mode

Start the pump and keep it run for 20 s.

Start 18:48
⑨ The third step.
195
Exhaust mode
The third step: Start to exhaust air in the

left rear wheel. Please connect the oil
drain pipe and open the left rear exhaust
bolt; and then step down the brake
pedal.
⑩ The exhaust process in progress. Enter

Start 18:49
Exhaust mode
The exhaust mode is in active use. Start

the pump and keep it run for 20 s.
Enter
Start 18:49
The third step is completed.
Exhaust mode
The third step is completed.
Enter
The fourth step. Start 18:49
196
Exhaust mode
The fourth step: Start to exhaust air

in the left front wheel. Please connect
the oil drain pipeline, open the left
front exhaust bolt; and then step
down the brake pedal.
Enter
The exhaust process in progress.

Start 18:49
Exhaust mode

Start the pump and keep it run for 20
s.
Start 18:49
The fourth step is completed.
Exhaust mode
The fourth step is completed.
Enter
Start 18:50
The fifth step
197
Exhaust mode
The fifth step:

Start to exhaust air in the right front
wheel. Please connect the oil drain pipe;
open the right front exhaust bolt and
then step down the brake pedal.
Enter
The exhaust process in progress.
Start 18:50
Exhaust mode
The exhaust mode is in active use. Start

the pump and keep it run for 20 s.
Start 18:50
The exhaust process is completed.
Exhaust mode
The exhaust process is completed.
Enter
Start 18:51
198
IX. Trouble Diagnosis
1. Brief introduction to the trouble diagnosis
1) Conduct the trouble diagnosis and achieve a thorough understanding of various systems of the
vehicle (control and mechanism).
2) Be familiar with the clients’ complaints before the check; and then inquire their dissatisfaction
carefully after obtaining a thorough understanding of troubles.
3) Conduct trouble check at the beginning stage for the thorough trouble repairing. For intermittent
trouble, it is of great significance to reappear the troubles according to the communications with the
clients and the past cases. Do not carry out check according to special cases. Most of the
intermittent troubles are caused by poor contact; if it is the case, it is an effective method to sway the
suspicious wire harness or connectors.
4) After the diagnosis, “clear the trouble code” must be implemented.
199
2. Diagnostic flow chart
The diagnostic flow is as follows:

Determine the
trouble
Get to know the “Precautions” and how to

diagnose; find out the trouble quickly
Conduct preliminary
check
Whether the ABS trouble

lamp is lightened
Yes
No
Check the ABS actuator, wire
Whether the diagnostic tester harness between the electrical units No
displays the trouble code and the data connector
Yes
Conduct the diagnostic
Conduct automatic procedure for troubles
diagnosis
Abnorm
Check and repair the

defective spare parts
Abnorm
Affirm the troubles

Clear the automatic diagnostic results, and
drive the vehicle with a speed no less than 30
km/h for a minute at least.
Normal
Normal
Conduct the automatic

diagnosis again
Check results
200
3. Diagnostic information and flow
1) Automatic diagnosis
ABS control module can conduct automatic diagnosis for the system and detect system troubles. Once
the trouble is found, the automatic diagnosis will set the diagnostic trouble code (DTC), lighten the ABS
warning lamp and meanwhile, close the ABS.
2) Display the diagnostic trouble code
Use special scan tools (diagnostic tester) to display the diagnostic trouble code.
3) Clear the diagnostic trouble code
Use scan tools (diagnostic tester) to clear diagnostic trouble codes in the memory of the ABS control
module.
Attention:
■ After the completion of the clear procedure, check whether the system operation is normal and
whether the diagnostic trouble code will not reappear.
■ The diagnostic trouble code can not be cleared by dismantling the connector of the ABS control
module, disconnecting the storage battery wire or switching off the engine.
4) Intermittent troubles including those caused by poor contact are mainly caused by the following
situations:
① Wrong electrical wiring.
② Wrong electrical connection.
③ Seizure of the relay and the solenoid valve.
5) Initialization sequence
The ABS control module will conduct initialization test at the beginning of every ignition period.
Initialization sequence is solenoid valve and motor pump in succession, so as to check whether the
operation of spare parts is normal. If any trouble is detected, the ABS control module will set
corresponding diagnostic trouble code. While the initialization sequence is conducted, some sounds can
be heard and some movements may be felt. These are part of the normal system operation. If the ABS
control module finds out that there is no signal input in the brake switch (with the feet releasing from the
brake pedal), it will start the initialization process immediately. If there is any signal input in the brake
switch (with the feet stepping down the brake pedal), the initialization process will not be started until
there is no signal input in the brake switch (with the feet releasing from the brake pedal) or until the
vehicle speed reaches 16 km/h.
4. Check of the diagnostic circuit
1) System illustration
The diagnostic circuit can detect problems caused by ABS/EBD system troubles. The diagnostic circuit
check will guide the maintenance personnel to enter into the next step of trouble diagnosis.
201
2) Diagnostic procedure
The maintenance procedure for ABS / EBD system is as the follows:
① Check whether there is any mechanical trouble related to the braking system of the vehicle.
■ Check whether the fluid level of the braking stock solution tank is correct.
■ Check whether the brake fluid of the master cylinder is polluted.
■ Check whether there is any leakage of the brake master cylinder/ ABS hydraulic assembly.
■ Check the braking spare parts of all the wheels.
■ Check whether there is any braking drag.
■ Check the braking stability (no pre-tensioning and no forward rotation).
■ Check whether there is any wear/damage for the brake shoe.
■ Check whether there is any damage for the wheel bearing.
■ Check the wheel (speed) sensor and the wire harness.
■ Check whether there is any damage of the wheel sensor connector/ring gear. Check the depth/
wear status of the tire tread.
■ Conduct road test for the vehicle and make modifications according to the actual situation.
② Check the diagnostic circuit and carry it out in accordance with applicable trouble diagnosis
procedure. While all the systems’ trouble codes have been cleared, the ABS diagnostic trouble
codes shall be cleared.
Table of Trouble Diagnosis
Step Diagnosis Yes No

1 1. If possible, connect or install all the spare parts that were To step 2 To step 4
disconnected or dismantled before.
2. Turn the ignition switch to the ON position and turn off the
engine.
3. Install proper diagnostic tester on the DLC and make it
communicate with the ABS control module.
2 Are there any trouble codes that are saved currently or before? To step 3 To step 7
3 1. Record current trouble code.
2. Record diagnostic trouble code in the past.
3. Record historical data such as the times set by various
diagnostic trouble codes, times by the automatic diagnosis trouble
codes for the first time, times by automatic diagnosis trouble codes
last time, speed set at diagnosing trouble code and other
augmented data which can help the diagnosis.
4. Do not clear the diagnostic trouble code before recording
information from the diagnostic tester.
4 Can the diagnostic tester communicate with other modules on the To step 5 To step 6
same data line?
5 To “No Communication with the ABS Control Module” in the
trouble procedure of the ABS control module.
202
6 To the unit of the data chaining connector of the electrical terminal.

7 1. Stop the engine. To step 8 To step 9
2. Wait for 10 s.
3. Start the engine.
4. Watch the ABS warning lamp after starting.
8 Is there any lamp still on? To step 9 To step 10
9 To the “Switch on” trouble procedure of the corresponding lamp
10 To “Out-of-work” trouble procedure of the corresponding lamp
5. Common Troubles and Analysis Procedure for the ABS
1) No communication with the ABS control module
Typical causes for the inability of communicating with ABS control module:
■ Poor contact of the diagnostic terminal.
■ Ungrounded ABS control module.
■ No voltage by the storage battery for the ABS control module.
■ No voltage by the ignition switch for the ABS control module.
■ Open circuit/short circuit of the data circuit.
■ Over high electrical resistance of the data circuit.
2) The ABS warning lamp is not lightened/no diagnostic trouble code
The typical causes for the failure of the ABS warning lamp and no setting of diagnostic trouble code are
as follows:
■ ABS warning lamp trouble/ loosened socket.
■ Disconnection of the fuse on the console.
■ The driving module of the warning lamp of the device has trouble.
■ ABS control module trouble.
■ Open circuit or short circuit between the ABS control module and the device.
3) ABS warning lamp is lightened/ no diagnostic trouble code
Typical causes for the lightening of the ABS warning lamp without setting of the diagnostic trouble code
are as follows:
■ Open circuit between the device and the ABS control module.
■ Ungrounded ABS control module.
■ Short circuit between the device and the ABS control module.
■ The driving module of the device warning lamp has trouble.
203
4) The lightening of the brake warning lamp
Typical causes for the lightening of the brake warning lamp without setting of diagnostic trouble code are
as follows:
■ Parking braking switch trouble.
■ Too low brake fluid level or the brake fluid switch trouble.
■ Trouble situations with diagnostic trouble codes C0055, C0065 or C0067 (refer to the table of
diagnostic trouble code) occur.
■ Any situation mentioned below in the ABS will lead to the failure of EBD.
a. Failure of two coaxial speed sensors.
b. Open circuit of the storage battery and the short circuit of grounding.
c. Grounding of the motor and the short circuit of the storage battery.
e. Open circuit of the grounding of the ABS control module and the short circuit of the storage battery.
f. Open circuit of the ignition switch and the short circuit of the grounding.
■ Open circuit of the device and the ABS control module.
■ Trouble of the warning lamp circuit.
■ Device trouble.
■ Trouble of the ABS control module.
5) The brake warning lamp is not lightened /no diagnostic trouble code setting
Typical causes that the brake warning lamp is not lightened and no setting of diagnostic trouble code are
as follows:
■ Lamp trouble/ looseness of the socket.
■ Disconnection of the console fuse.
■ Device trouble.
■ Grounding of the circuit between the ABS control module and the device.
204
Maintenance Manual of Tojoy Sedan Electrical Appliance of Vehicle Body
Electrical Appliance & Structure Volume of Vehicle Body
Chapter I Electrical Appliance of Vehicle Body.................................................................................1
Section I Safety Airbag System ......................................................................................................1
I. Precautions .....................................................................................................................1
II. Preparation......................................................................................................................2
III. Principles of Safety Airbag System..................................................................................3
IV. Safety Airbag Module at Driver’s Seat Side.....................................................................5
V. Safety Airbag Module at the Second Driver’s Seat Side..................................................7
VI. Safety Belt .......................................................................................................................9
VII. Pretensioner of Front Seat Safety Belt ..........................................................................15
VIII. Clock Spring of Safety Airbag ........................................................................................16
IX. Control Module of Safety Airbag (SDM) ........................................................................18
X. Trouble Diagnosis..........................................................................................................20
XI. Overhaul of Safety Airbag System.................................................................................22
XII. Disposal Methods of Safety Airbag System Components..............................................24
Section II Air Conditioning System................................................................................................28
I. Precautions ...................................................................................................................28
II. Preparation....................................................................................................................30
III. Check of System ...........................................................................................................32
IV. Control of System..........................................................................................................35
V. Illustration on Function, Location and Check of System Elements ................................41
VI. Dismantlement and Installation of System (Evaporator\Warm air blower\3

Motors\Resistor\Panel) ..................................................................................................54
VII. Filter of Air Conditioner ..................................................................................................64
VIII. Maintenance Data .........................................................................................................66
Section III Information and Time Electronic Control System (ETACS)..........................................67
I. Precautions ...................................................................................................................67
II. Schematic Diagram of Elements ...................................................................................67
III. Illustration on Functions.................................................................................................68
1
IV. Definition of ETACS Control Module Terminals .............................................................83
V. Operation Illustration of ETACS Key Code ....................................................................83
VI. Replacement of ETACS Module and Alarm...................................................................84
VII. Technical Parameters ...................................................................................................87
Section IV Combined Switch ........................................................................................................88
I. Illustration ......................................................................................................................88
II. Test of Elements ...........................................................................................................91
III. Replacement of Combined Switch ................................................................................91
Section V Lighting System............................................................................................................94
I. Precaustions:.................................................................................................................94
II. Headlamp ......................................................................................................................94
III. Front Fog Lamp...........................................................................................................104
IV. Tail Lamp.....................................................................................................................107
V. Highmounted Stop Lamp.............................................................................................115
VI. License Plate Lamp .....................................................................................................116
VII. Illuminating Lamp of Boot ............................................................................................118
VIII. Side Turn Signal Lamp ................................................................................................119
IX. Illuminating Lamp of Glove Box...................................................................................121
X. Reading Lamp .............................................................................................................123
XI. Maintenance Data and Specification ...........................................................................125
Section VI Combined Device ..................................................................................................... 127
I. Illustration on Functions...............................................................................................127
II. Illustration on Connector Terminal of Combined Device ..............................................130
III. Replacement of Combined Device ..............................................................................130
IV. Speed Meter and Odometer ........................................................................................132
V. Tachometer .................................................................................................................134
VI. Water Thermometer ....................................................................................................136
VII. Fuel Oil Meter..............................................................................................................138
VIII. Alarm Lamp of Engine Oil Pressure ............................................................................140
IX. Alarm Lamp of Braking System ...................................................................................141

2
X. Alarm Lamp of Door Open...........................................................................................141
Section VII Windscreen Wiper and Its Cleanser .........................................................................142
I. System Composition ...................................................................................................142
II. Precautions .................................................................................................................142
III. Front Windscreen Wiper..............................................................................................142
IV. Rear Windscreen Wiper ..............................................................................................152
V. Cleanser of Windscreen Wiper....................................................................................155
VI. Overhaul for Trouble ...................................................................................................159
Section VIII Horn and Cigar Lighter ............................................................................................164
I. Location of Elements ...................................................................................................164
II. Basic Diagram .............................................................................................................164
III. Check of Horn .............................................................................................................165
IV. Overhaul for Trouble....................................................................................................165
V. Replacement of Horn ..................................................................................................167
VI. Replacement of Horn Button .......................................................................................168
VII. Cigar Lighter................................................................................................................170
Section IX Audio System ............................................................................................................171
I. Location Plan of Elements...........................................................................................171
II. Basic Diagram of Audio System ..................................................................................171
III. Illustration of Audio Changer .......................................................................................172
IV. Replacement of Audio Changer and Antenna..............................................................172
V. Replacement of Rear Loudspeaker of Three-carriage Car..........................................174
VI. Replacement of Rear Loudspeaker of Two-carriage Car.............................................175
VII. Replacement of Front Door Loudspeaker....................................................................176
Section X Parking Auxiliary System ............................................................................................178
II. Basic Diagram .............................................................................................................179
III. Testing of Elements .....................................................................................................179
IV. Replacement of Control Module of Parking Auxiliary System......................................181
3
V. Replacement of Buzzer of Parking Auxiliary System...................................................182
VI. Replacement of Sensor of Parking Auxiliary System...................................................183
VII. Common Troubles and Maintenance Methods ............................................................184
VIII. Trouble Diagnosis Procedure ......................................................................................185
IX. Trouble Maintenance Methods ....................................................................................186
Section XI Rear View Mirror........................................................................................................188
II. Basic Diagram .............................................................................................................189
III. Testing for Elements ....................................................................................................189
IV. Replacement of Internal Rear View Mirror...................................................................191
V. Replacement of External Rear View Mirror .................................................................194
VI. Replacement of Electric Rear View Mirror Switch .......................................................196
Section XII Central Control Door Lock ........................................................................................198
I. Basic Diagram .............................................................................................................198
II. Replacement of Outside Handle of Door .....................................................................198
III. Replacement of Door Lock Assembly .........................................................................199
IV. Replacement of Actuator of Trunk Door Lock..............................................................202
V. Replacement of Controller of Trunk Door Lock ...........................................................204
VI. Analysis for Troubles ...................................................................................................205
Section XIII Electric Window .......................................................................................................206
I. Illustration on Elements ...............................................................................................206
II. Illustration on Functions...............................................................................................206
III. Basic Diagram .............................................................................................................208
IV. Replacement of Element .............................................................................................209
V. Trouble Diagnosis .......................................................................................................215
Chapter II Structure of Vehicle Body..............................................................................................216
Section I Engine Hood and Door ................................................................................................216
I. Engine Hood Assembly ...............................................................................................216
II Fender .........................................................................................................................222
4
III Replacement of Front Door Assembly .........................................................................226
IV Replacement of Rear Door Assembly .........................................................................251
V. Boot Cover ..................................................................................................................264
VI. Oil Filler of Fuel Tank...................................................................................................275
VII. Replacement of Locking System .................................................................................278
Section II Interior & Exterior Trimmings ......................................................................................285
I. Precautions .................................................................................................................285
II. Replacement of Front Bumper ....................................................................................285
III. Replacement of Front Bumper Frame .........................................................................288
IV. Wheel Cover................................................................................................................289
V. Replacement of Ceiling Stripe .....................................................................................291
VI. Replacement of Rear Bumper .....................................................................................292
VII. Replacement of Rear Bumper Frame..........................................................................293
VIII. Replacement of Sun Visor...........................................................................................295
IX. Replacement of A-pillar Trim Board.............................................................................296
X. Replacement of Front Door Pedal ...............................................................................296
XI. Replacement of A-pillar Lower Trim board...................................................................297
XII Replacement of Rear Door Pedal................................................................................298
XIII. Replacement of B-pillar Trim board .............................................................................299
XIV. Replacement of C-pillar Trim board.............................................................................303
XV. Replacement of Auxiliary Handle.................................................................................305
XVI. Replacement of Ceiling ...............................................................................................306
XVII. Replacement of Carpet................................................................................................307
XVIII. Replacement of Front Trimming Plate of Coatrack......................................................308
XIX. Replacement of Protecting Plate of Rear Boot Cover .................................................309
XX. Replacement of Front Seat..........................................................................................310
XXI. Replacement of Rear Seat ..........................................................................................311
XXII. Replacement of Name Plate........................................................................................314
XXIII. Replacement of Front Windshield ...............................................................................316
Section III Console......................................................................................................................324

5
I. Precautions .................................................................................................................324
II. Replacement of Driver Airbag Module .........................................................................324
III. Replacement of Steering Wheel ..................................................................................324
IV. Replacement of Trimming Cover of Steering Column..................................................328
V. Replacement of Clock Spring of Safety Airbag ............................................................329
VI. Replacement of Lower Protective Cover of Console at Driver’s Side..........................329
VII. Replacement of Ignition Switch ...................................................................................330
VIII. Replacement of Glove Box..........................................................................................331
IX. Replacement of Auxiliary Fascia Console ...................................................................332
X. Replacement of Steering Column................................................................................336
XI. Replacement of Combined Device ..............................................................................337
XII. Replacement of Control Panel of Air Conditioner ........................................................338
XIII. Replacement of Console .............................................................................................340
XIV. Replacement of Console Support................................................................................344
6
Chapter I Electrical Appliance of Vehicle Body
Section I Safety Airbag System

I. Precautions
Warning:
■ During maintenance, if the proper processes aren’t followed, the airbag system may be ignited
accidentally, which will result in serious accidents.
■ The mistakes during maintenance will make the airbag incapable of ignition when it is required to,
which will result in serious accidents.
■ Before the maintenance (including dismantlement, installation, check or replacement of spare parts),
do carefully read the following notes, and operate according to the proper process defined in the
maintenance manual.
1. Don’t disassemble the safety airbag components such as safety airbag assembly at driver’s seat
side and safety airbag assembly at the second driver’s seat side.
2. Don’t repair the following parts but use the replacements to replace them.
1) Safety airbag at driver’s seat side.
2) Safety airbag at the second driver’s seat side.
3) Safety belt tensioner.
4) Control module of safety airbag.
5) Clock spring.
3. Don’t make the airbag exposed to the high temperature or flame.
4. Immediately use a dry cloth to wipe if the liquid exists on the airbag such as butter, detergent,
engine oil or water.
5. Don’t make the airbag fall and the fallen airbag is not allowed to use.
6. The original replacements shall only be obtained from the authorized dealer.
7. After disassembling the airbag, store it in a stable place with its face upwards. Don’t put any articles
on its top.
8. Check whether the replacement part number is correct. Don’t use the parts of other vehicles as the
replacement of this vehicle.
9. Even if the airbag is not ignited in light impacts, the pad surface and airbag sensor shall be checked.
If the situations such as sunken, crack or deformation are found, a new airbag assembly shall be
used.
10. When the vehicle or airbag is discarded, the airbag shall be dealt with first.
1
11. After the airbag is ignited, the inflation device will become very hot, so, it shall be handled after
natural cooling. Don’t use water to cool it.
12. It is not allowed to measure the circuit resistance of airbag module, for it will result in the ignition of
airbag.
II. Preparation
General tools and special tools are required to use during maintenance.
Table for Special Tools

Tool Diagram Application
Ignition tool To ignite airbag.
Inspector of module wire

Diagnosis inspector
harness
Simulator connector used

Simulator for checking the resistance
of wire harness
2
III. Principles of Safety Airbag System
1. Opening Condition of Airbag
Diagram for the Impact Angle Which may Result in the Openness of Airbag
The airbag will open if the frontal impact happens within the 30°away from the center line of vehicle and
impact force is big enough.
2. Schematic Diagram for Element Location
Schematic Diagram for Element Location of Airbag
1-airbag at driver’s seat side 2-airbag at the second driver’s seat side
3
3. Working Principle of Restraint System
The impact will result in the rapid change of vehicle speed. Due to the inertia, the passenger keeps on
moving forward, and then the impact between passenger and inner structures happens. And the function
of occupant restraint system is to avoid or alleviate the hurt caused by the impact between passenger
and inner structures through restraint system (including seat, safety belt, airbag and so on).
1) Working schematic diagram of restraint system
Airbag system
Control
Impact sensor Ignite Airbag
/Diagnosis
system
Restrain
Pretensioner Restrain
Safety belt
Driver/the
second driver
Load restriction
Pretensioner system of safety

belt
Working Schematic Diagram of Restraint System
2) Working principle of airbag
Before the impact between passenger and inner structures, an airbag inflated with air is quickly inserted
between them. Through the breathability of airbag itself and exhaust throttle function of discharging hole,
the kinetic energy of passenger is absorbed to alleviate the fierce impact and the passenger is separated
from the inner structures, so that the passenger is protected.
Fig.1. 1.001
4
3) Working Principle of Safety Belt
First of all, frap in time, that is, at the first moment of accident, with the help of impact acceleration,
incline angle of vehicle and acceleration created by mesh belt, the safety belt “presses” the passenger
on the seat; then, relax properly, that is, when the impact force peak is over or passenger has been
already protected by airbag, the safety belt relaxes properly.
Initial state At the moment of impact, the Mesh belt withdraws.

pretensioner bursts.
Working Schematic Diagram of Safety Belt
IV. Safety Airbag Module at Driver’s Seat Side
1. Element
Fig.1. 1.002
The safety airbag module at driver’s seat side
locates on the steering wheel.
2. Specification:
■ Airbag Volume: 50 L
5
Attention:
Fig.1. 1.003
■ When the safety airbag module at driver’s seat
side is dismantled or the new safety airbag module
at driver’s seat side is mounted, the face of pad
shall be upward.
■ The electric resistance of airbag module shan’t be

measured, or else, the accidental ignition of airbag
will happen.
Wrong Placement
■ The safety airbag module at driver’s seat side shall
be stored in the place with an ambient temperature
lower than 80°C which is away from electrical
noise.
■ When the welding work is conducted, the negative

Fig.1. 1.004
pole of storage battery shall be disconnected as
well as connector of airbag.
■ When the vehicle or airbag is discarded, the

special tools shall be used to ignite the airbag.
Correct Placement
3. Dismantlement steps:
Fig.1. 1.005
1) Disconnect the negative pole of storage battery
for over 3 minutes.
Warning:
■ When the engine is running, don’t disconnect the

negative pole of storage battery, or else, the
electrical system of vehicle will be damaged.
■ Before the negative pole of storage battery is

disconnected, make sure that there is no required
information in the engine control module. No
matter whether the control module is dismounted
or not, disconnecting the negative pole of storage
battery will delete all of the trouble codes and
control parameters in the control module memory
(KAM).
6
2) Use a cross-screwdriver to loose the clamping

Fig.1. 1.006
screws at two sides.
3) Take the connector apart, and take the airbag

Fig.1. 1.007
module out.
4) Properly place the airbag module according to

the requirements.
4. Installation steps:
Assemble in the reverse order with dismantlement.
V. Safety Airbag Module at the Second Driver’s

Seat Side Fig.1. 1.008
1. Schematic diagram of sub-assembly
The safety airbag module at the second driver’s

seat side locates on the console before the second
driver’s seat.
Attention:
■ Please don’t put or post any articles on the

surface of airbag module.
2. Specification:
■ Airbag Volume: 90 L
Attention:
7
3. Dismantlement Fig. 1. 1.009

for over 3 minutes.
2) Dismount the glove box. Refer to the

Fig.1. 1.0010
replacement of glove box.
3) Dismount the glove box lamp. Refer to the Fig.1. 1.0011

replacement of glove box lamp.
8
4) Dismount the front seat airbag from the Fig.1. 1.0012

dismantlement hole.
5) Take the connector apart, take out the front

Fig.1. 1.0013
seat airbag module and place it properly in
accordance with the requirements.
4. Installation
Assemble in the reverse order with dismantlement

steps.
VI. Safety Belt

Fig.1. 1.0014
1. Schematic diagram of front-seat safety belt
sub-assembly
2. Dismantlement of front-seat safety belt
Attention:
■ Before dismantlement or installation, make

sure that ignition switch is shut off and negative
pole of storage battery is disconnected, and
then wait for at least 3 minutes.
9
1) Adjust the front seat in proper position.

Fig.1. 1.0015
2) Dismount the front door pedal. Refer to the Fig.1. 1.0016

replacement of front door pedal.
3) Dismount the trimming plate of rear door pedal.

Fig.1. 1.0017
Refer to the replacement of rear door pedal.
4) Dismount the fastening bolt at the end of safety

Fig.1. 1.0018
belt.
10
5) Dismount the B-pillar lower trimming plate.

Fig.1. 1.0019
6) Take off the trimming cover of fastening bolt at the

Fig.1. 1.0020
upside of safety belt.
7) Dismount the fastening bolt at the upside of safety

belt.
8) Dismount the fastening bolt of safety belt body. Fig.1. 1.0021
9) Disconnect the connector of pretensioner, and take

Fig.1. 1.0022
the safety belt assembly out. Attention:
■ To disconnect the connector of pretensioner, insert

the screw driver wrapped with tape into the incision
to raise the lock.
10) Check the safety belt assembly carefully.
Attention:
■ Don’t use the electric test devices to check the

pretensioner of safety belt.
11
■ Don’t use the disassembled snap ring or safety belt assembly.
■ Replace it immediately if the fastening bolt is deformed or worn.
■ Don’t lubricate the tongue depressor and snap ring.
■ If the spare parts and components of safety belt assembly have any problems, they shan’t be
repaired. Directly replace the assembly.
■ If the safety belt has defects such as rupture, abrasion or damage, replace the safety belt assembly.
■ When the safety belt assembly is replaced, authentic JAC safety belt assembly shall be used.
3. Installation of Front Seat Safety Belt
Attention:
■ Before the installation of front seat safety belt, the B-pillar upper trim board is required to install
eudipleurally. And the mortise lock of safety belt buckle shall be mounted on the seat.
■ Make sure that the connection of safety belt pretensioner connector is reliable.
■ Put the safety belt body into the space corresponding to B pillar and make it aim at the mounting hole.
Use the bolt of 7/16 British System to make it fastened to B pillar with the tightening torque of 40〜55
N•m.
■ Make the bolt of 7/16 British System go through the upper protecting plate of B pillar to fasten the
guide components of safety belt to the sheet metal of B pillar with the tightening torque of 40～55
N•m.
■ After the installation of B-pillar lower trim board, use the bolt of 7/16 British System to fasten the end
of safety belt to the vehicle body sheet metal with the tightening torque of 40～55 N•m.
4. Dismantlement of Rear Seat Safety Belt Fig.1. 1.0023

1) Dismount the rear seat cushion.
12
2) Dismount the backrest of rear seat.

Fig.1. 1.0024
3) Dismount the clamping screw at the end of

Fig,1. 1.0025
safety belt.
4) Dismount the trimming plate of rear coatrack.

Fig.1. 1.0026
5) Dismount the C-pillar upper trim board.

Fig.1. 1.0027
13
6) Dismount the C-pillar lower trim board.

Fig.1. 1.0028
7) Dismount the fastening bolt at upper side of

Fig.1. 1.0029
safety belt.
8) Dismount the body fastening bolt of safety

belt.
9) Take the safety belt assembly out.
■ Check the safety belt assembly and replace it if

it is damaged.
5. Installation of Rear Seat Safety Belt
Attention:
■ Align the locating pin hole with bolt hole and use the bolt of 7/16 British System to fasten the safety
belt body with the tightening torque of 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the guide components to the sheet metal of C pillar, then
go though the upper trim board of C pillar. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to fasten the mounting point below C pillar and the mounting point
is at the end of safety belt. The tightening torque is 40〜55 N•m.
■ Use the bolt of 7/16 British System to eudipleurally fasten the 3 safety belt latch assemblies and 1
middle 2-point safety belt to the floor. The tightening torque is 40〜55 N•m.
14
VII. Pretensioner of Front Seat Safety Belt
1. Specification
■ The ambient temperature for air generator: -35℃〜+105℃
Attention:
■ Using the safety belt and supplemental restraint system such as airbag and pretensioner of safety
belt at the same time is helpful for driver and passenger at the front seat to reduce the danger of
injury when impacts happen.
■ In order to avoid increasing danger of personal casualty caused by the failure of airbag when impacts
happen, all of the maintenance operations shall be conducted by authorized JAC service centers.
■ The improper maintenance, including wrong dismantlement and installation of safety belt
pretensioner may result in the wrong behavior of system so that accidental personal injuries happen.
■ It is not allowed to use electrical test devices to test any circuit of airbag system except the
operations specified in this manual.
2. Dismantlement and Installation of Pretensioner of Front Seat Safety Belt
Refer to “Safety Belt”.
Attention:
■ Before the dismantlement or installation, make sure that the ignition switch is shut and negative pole
of storage battery is disconnected, and then, wait for over 3 minutes.
■ Don’t use electrical test device to check the pretensioner of safety belt.
15
VIII. Clock Spring of Safety Airbag Fig.1. 1.0030

1. Schematic diagram of sub-assembly
2. Dismantlement of clock spring of safety airbag

Fig.1. 1.0031
for over 3 minutes.
2) Dismount the safety airbag module at driver’s

Fig.1. 1.0032
seat side.
16
3) Dismount the clamping nut of steering wheel

Fig.1. 1.0033
and take the steering wheel out.
Attention:
■ The clamping nut can be taken out only when

the steering wheel is loose, or else, the steering
wheel will result in personal injury.
4) Disconnect the connector of horn and clock

Fig.1. 1.0034
spring.
5) Dismount 4 clamping screws.

Fig.1. 1.0035
6) Take the clock spring of safety airbag out.

Fig.1. 1.0036
17
3. Installation of clock spring of safety airbag

Install it in the reverse order with dismantlement.
Attention:
■ Take the clock spring of safety airbag out from the package and check whether it is intact and
whether the anchor pin is on the spare part.
■ Open the gland bush of connector, insert the airbag wire harness connector into the jack and then
fasten the gland bush.
■ Before the installation of clock spring of safety airbag, first make sure that the front wheel direction is
in the middle (towards).
■ Before the installation of clock spring of safety airbag, make sure that the clock spring is in the middle
(clockwise rotating to the end and then rotating reversely for 2.5 turns).
IX. Control Module of Safety Airbag (SDM)
1. Specification and function of control module of safety airbag (SDM).
1) To sense the vehicle impact.
2) To ignite the airbags both at driver’s seat side and the second driver’s seat side.
3) To ignite the safety belts with pretensioners both at driver’s seat side and the second driver’s seat
side.
4) To monitor the working state of airbag system.
5) To report the airbag system state to driver through warning indicator light: ready or in trouble.
6) To conduct the diagnosis maintenance for airbag system through the serial diagnosis communication
port.
7) To record the working state of each component of airbag system and relevant impact information
data.
2. Pins of control module of safety airbag (SDM)
Diagram for Pins of Control module of safety airbag
18
3. Dismantlement steps
Fig.1. 1.0037
1) Shut the ignition switch, disconnect the
negative pole of storage battery and wait for at
least 3 minutes until the discharge of reservoir
capacitance inside the SDM is finished.
2) Dismount the extension trimming plates at two

Fig.1. 1.0038
sides under the central control console.
3) Loose and pull out the connector of SDM wire harness, dismount 4 bolts which are used for fixing
SDM and take out SDM. Attention:
■ Don’t make the SDM fall or impact.
4. Installation
Install it in the reverse order with dismantlement.
Attention:
■ When installing it, pay attention to the direction of SDM, and make sure that the arrowhead marked
on SDM is in accordance with the travel direction of vehicle.
19
The direction pointed by the

arrowhead on the label of SDM is the
travel direction of vehicle.
Schematic Diagram for Mounting Direction of SDM
X. Trouble Diagnosis
1. Airbag system diagnosis
After the ignition switch is shifted to “ON” position, the airbag indicator light on the console will twinkle for
a few seconds and go out, which means the airbag is in the normal working state, if it doesn’t light or
keeps lighting, then the airbag system has troubles. In order to further confirm the reason for trouble, a
special trouble diagnosis apparatus shall be used to diagnose.
1) Use a diagnosis apparatus to read the trouble code.
2) Maintain according to the prompt provided by trouble code.
3) Use the diagnosis apparatus to eliminate trouble codes. Attention:
■ Please do the troubleshooting according to the content of “Overhaul of Airbag System”.
■ After the trouble is eliminated, the diagnosis apparatus shall be used to delete the trouble code
stored in the system.
20
2. Table for Trouble Code
Table for Trouble Code of Airbag System
Trouble Code Meaning

B1021 The impedance of airbag before driver is overlarge.
B1022 The impedance of airbag before driver is too small.
The airbag before driver is short-circuited to the
B1024
ground.
The airbag before driver is short-circuited to the
B1025
power source.
The impedance of driver’s safety belt pretensioner is
B1015
overlarge.
The impedance of driver’s safety belt pretensioner is
B1016
too small.
The driver’s safety belt pretensioner is
B1018
short-circuited to the ground.
The driver’s safety belt pretensioner is
B1019
short-circuited to the power source.
The impedance of airbag before second driver’s
B1041
seat is overlarge.
The impedance of airbag before second driver’s
B1042
seat is too small.
The airbag before second driver’s seat is
B1043
The airbag before second driver’s seat is
B1044
The impedance of passenger’s safety belt
B1045
pretensioner is overlarge.
The impedance of passenger’s safety belt
B1046
pretensioner is too small.
The passenger’s safety belt pretensioner is
B1047
The passenger’s safety belt pretensioner is
B1048
B1031 The voltage of storage battery is overhigh.
B1032 The voltage of storage battery is too low.
B1061 The alarm light has troubles.
B1051 Frontal impact record
B1058 Safety belt pretensioner impact
B1056 Driver’s side impact record
B1054 The maximum reuse times are in excess.
Interior trouble (replacing control module of safety
B1071
airbag(SDM))
21
XI. Overhaul of Safety Airbag System
1. Precautions after impact
Attention:
■ The safety belt assembly of all the seats shall be checked after any impact, including retractor and
other metallic spare parts and components.
■ It is suggested by our company that all the safety belt assemblies used during impact shall be
replaced. Or else, serious personal injuries may happen in an accident. For example, the frontal
impact which results in the ignition of airbag happens, even if the safety belt is not used, the
pretensioner of safety belt shall be replaced.
Please replace the safety belt assembly (including the fastening bolt) if the following conditions happen:
■ The safety belt is used when the impact happens (except that the impact is very light and safety belt,
retractor and snap ring are not damaged and their functions are normal).
■ The safety belt is damaged entirely during an accident. (That is, the safety belt is broken; retractor
bends or slide groove appears).
■ The fastening point of safety belt is entirely damaged during an accident. Before the installation of
new safety belt assembly, whether the fastening area of safety belt is damaged or deformed shall be
checked and repair it when necessary.
■ The fastening bolt is deformed or worn.
2. If the airbag is not ignited when the vehicle impacts in low speed, and a side impact, a side-rollover
or pileup happens, the following items shall be checked:
■ Check whether the SDM shell and installation support have dints, cracks or deformations.
■ Check whether the connector is damaged or whether the terminal is deformed.
■ Check whether the installation bolt and grounding wire are in good condition.
3. Maintenance and Check of Airbag System
1) Airbag module
① Check whether the pad cover has dints, cracks or deformations.
② Check whether the connector is damaged, whether the terminal is deformed and whether the wiring
is stuck.
③ Check whether the air generator shell of airbag has dints, cracks or deformations.
④ Install the airbag sub-assembly to the steering wheel and check the matching and alignment
condition.
2) Clock spring
① Check whether the clock spring connector and protecting sleeve are damaged and whether the
terminal is deformed.
22
② Check whether the shell is damaged with naked eye.

3) Steering wheel and steering column
① Check whether the electrical wiring (inside the steering wheel) and connector are damaged and
whether the terminal is deformed.
② Install the airbag sub-assembly to the steering wheel and check the matching and alignment
condition.
③ Check whether the steering wheel has noises, whether the operation is flexible and whether the
looseness is overlarge.
Attention:
■ First calibrate the clock spring which is at the bottom of steering wheel, and then mount the steering
wheel on the steering column.
■ Calibration method of clock spring:
First shift the protecting sleeve of clock spring to the dead center, and turn about 2.5 circles back to
make the protecting sleeve aim at the mounting groove on lower cover of steering column.
4) Other spare parts
■ Check whether the wiring is stuck, whether the connector is damaged or has a poor connection and
whether the terminal is deformed.
■ All the airbag parts shall be replaced after troubles appear. Don’t use them even if they have been
repaired.
■ If the spare parts of airbag system are required to dismantle or replace for maintenance and
troubleshooting, the operating sequence shall be obeyed.
5) Warning/attention brand marks
There are a lot of warning/attention brand marks about SRS on vehicle.
■ On the frame of steering wheel.
■ On the airbag sub-assembly at driver’s side.
■ On the clock spring.
■ On the airbag sub-assembly at the second driver’s seat side.
■ On the control module of safety airbag (SDM).
■ On the sunroof at the upward side of front windshield.
■ The illustrations on brand marks shall be obeyed when the overhaul of SRS is being done. And if the
brand marks are dirty or damaged, they shall be replaced.
6) Control module of safety airbag (SDM)
Attention:
■ The faulty SDM shall be replaced rather than repaired.
23
XII. Disposal Methods of Safety Airbag System Components
Before the airbag or vehicle with airbag is discarded, the following disposal methods shall be
used to ignite them.
1. Disposal methods for unignited airbag module
1) If the vehicle is discarded, the airbag shall be ignited inside the vehicle. And if the vehicle will still be
used and only the airbag is discarded, the airbag shall be ignited outside the vehicle.
2) There will be a lot of smoke caused by the ignition of airbag, so, you shall be careful of not breathing
in. Otherwise, it will irritate the throat and may result in asphyxia. Therefore, the resident area shall
be avoided as much as possible.
3) Due to the loud noise caused by the ignition of airbag, the resident area shall be avoided as much
as possible. If someone is around, a warning for the imminent noise shall be given to him.
4) Only one airbag module shall be ignited for every time.
5) When the airbag module and safety belt pretensioner are ignited, the person shall be at least 10 m
away from the ignited component.
6) Due to the high temperature, the airbag module shall be placed at least 30 minutes after ignition.
7) The person in charge of this mission or persons in site shall wear proper protective articles for ears.
2. Disposal methods of ignition inside vehicle (when the vehicle is discarded)
1) Move the vehicle to the isolated place.
2) Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from vehicle.
Attention:
■ After the negative pole of storage battery is disconnected, at least 3 minutes shall be waited for until
the next step.
3) Airbag module ignition (at driver’s side):
① Dismount the lower cover of steering column.
② Disconnect the connection between pin connector of clock spring of safety airbag and harness
connector of body airbag.
Attention:
■ After the connector of clock spring of safety airbag is disconnected from the harness of airbag of
vehicle body, the pole of connector of clock spring will automatically create a short circuit to prevent
the accidental ignition of airbag due to static and so on.
24
4) Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each
other (short circuit) to prevent the sudden and accidental ignition of airbag.
5) Connect the pin connector of airbag to the airbag adapter wiring, and extend the wire used for
ignition outside the vehicle.
6) In order to restrain the ignition noise as much as possible, all the doors and windows shall be shut
and a vehicle cover shall also be used.
Attention:
■ If the window glass has any trace of damage, it will fall to pieces during ignition. Therefore, a vehicle
cover is required to be used.
7) Disconnect the 2 connected wires in the place which is far away from the vehicle as much as
possible, and then connect them to 2 terminals of storage battery (this battery has already been
dismounted from the vehicle) to ignite the airbag.
Attention:
■ Before using this method to ignite the airbag, first check and make sure that nobody is around or
inside the vehicle.
■ Please wear the protective eyeglasses.
■ The aerator is very hot immediately after ignition, therefore, it shall be moved at least 30 minutes
later. Although the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And
please refer to disposal methods of ignited airbag components for the move rules of airbag after
ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
8) After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
3. Disposal methods of ignition outside vehicle
1) This ignition shall be conducted in an open even ground where is away from barriers and persons
over 10 m.
2) The ignition can’t be conducted outside in windy days. Even if in breezy days, the airbag module
shall be ignited on the lee of storage battery.
① Disconnect the positive and negative cables from the terminals of storage battery, and then
dismount the storage battery from the vehicle.
25
Attention:
■ After disconnecting the cables of storage battery, at least 3 minutes shall be waited for until the next
step.
② Dismount the airbag module from the vehicle.
Attention:
■ The airbag sub-assembly shall be put on an even ground with its lining cover upward. And no
articles shall be put on its top.
3) When the airbag module at driver’s side is ignited:
Connect 2 wires with a length of over 10 m to the 2 lead wires of airbag adapter wiring, and use the
insulating tape to pack the joint. Besides, the other end of these two wires shall be connected each other
(short circuit) to prevent from the sudden and accidental ignition of airbag.
4) The airbag module is set as follows-
① Hold the airbag adapter wire connected with the above wire, make it cross the underside of old tire
assembly prepared and connected it to the airbag module.
② Make the thick wire go through the mounting hole of airbag sub-assembly, and then fasten the
airbag sub-assembly to the old tire of wheel with the pad upward.
Attention:
■ Leave a little space for the adapter wiring under wheels. If not, the counterforce caused by ignition
of airbag may destroy the adapter wiring.
③ Lay three old tires without hubs on the top of tire which fixes the airbag sub-assembly.
④ Disconnect the 2 connected wires in the shielded place which is far away from the airbag module as
much as possible, and then connect them to 2 terminals of storage battery (this battery has already
been dismounted from the vehicle) to ignite the airbag.
Attention:
■ Before ignition, make sure that nobody is around.
■ The ignited gas generator is very hot, therefore, it shall be moved at least 30 minutes later. Although
the gas created by the ignition of airbag is innoxious, it can’t be breathed in. And please refer to
disposal methods of ignited airbag components for the move rules of airbag after ignition.
■ If the airbag sub-assembly can’t be ignited according to the above methods, don’t walk towards it.
Please contact local dealers.
26
■ After ignition or operation, please dispose this airbag sub-assembly in accordance with the disposal
methods for ignited airbag sub-assembly.
4. Disposal methods for ignited airbag
After the ignition of airbag, it shall be disposed as other spare parts, and the followings shall be
especially paid attention to:
1) The gas generator is very hot after ignition, therefore, it shall be moved at least 30 minutes later.
2) Don’t splash water or oil on the airbag after ignition.
3) The substance which will irritate eyes and skin may adhere to the ignited airbag sub-assembly,
therefore, gloves and eyeglasses shall be worn when the ignited airbag sub-assembly is being
moved.
Attention:
■ If any substance still enters eyes or adheres to skin after these attentions are obeyed, abundant and
clean water shall be used immediately to wash. And if the skin or other physical parts rankle,
medical cares shall be obtained.
4) Tightly seal the powerful PVC bag which contains the discarded airbag sub-assembly.
5) The hands must be washed after these works.
27
Section II Air Conditioning System

I. Precautions
Caution:
■ The following precautions must be complied with when checking and repairing air conditioning
system. Otherwise, it may lead to damage of vehicle and physical injury.
Attention:
■ As the refrigerant is of low freezing point and high volatility, do wear gloves and glasses to avoid
chilblain, blindness, etc. when the skin contacts with refrigerant.
■ If the eye or skin contacts with refrigerant, wash it with water immediately and see an oculist or
dermatologist. Don’t rub the eye with hands or handkerchief.
■ The site shall be ventilated when conducting operations related to refrigerant. Great emission of
refrigerant in a closed place will lead to oxygen deficit.
■ The allowable emission of refrigerant is 1,000 ppm (4,184 mg/m2).
Excessive emission of refrigerant will lead to abnormality or allergy of heart and cardiovascular
system, immune system and respiratory system, or skin disease.
■ When conducting operations related to refrigerant, there shouldn’t be any foreign substances such
as moisture, dust in the surrounding environment. These foreign substances which flow into the air
conditioning system are harmful to the system.
■ When conducting operations related to refrigerant, it is necessary to prepare a gas leakage detector.
When the R-134a refrigerant contacts with high-temperature objects, it will produce harmful gas.
Thus, it is necessary to prevent gas leakage.
■ The refrigerant adopted for this model must be R-134a refrigerant. Otherwise, there will be harmful
effect for the components of system.
■ R-134a refrigerant is incompatible with R-12 refrigerant. Thus, even the amount is extremely small,
they can not be mixed together.
■ When conducting operations related to refrigerant, there shouldn’t be any pyrophorus or

inflammable materials around the vehicle. Besides, the refrigerant tank exposed to the heat source
will lead to explosion. Thus, please pay careful attention to it.
■ As the R134a container is under high pressure, it is definitely forbidden to put it under high
temperature. Meanwhile, check if the temperature of storage environment is lower than 52℃.
■ Generally, there is a dust guard to prevent the sewage, dust, moisture from flowing into the
components of air conditioner. The dust guard shall be removed before operation and sealed up
after operation.
28
■ The synthetic (PAG) refrigerant oil which is applicable to R-134a is easier to absorb moisture than
R-12, and its absorption rate is 10 times higher than that of mineral (MINERAL) refrigerant oil. If the
moisture is too much, the compressor, lubricating function and endurance will be affected.
■ Since moisture is extremely harmful to the air conditioner, it is better to avoid operation in rainy
days.
■ When mounting the air conditioning system again after dismantlement, do coat the “O” ring with
refrigerant oil. Especially for the screw-type connecting parts, assemble them with 2 spanners after
manual installation.
■ When assembling flange-type connecting parts, connect the nut and bolt while gently pushing the
pipeline.
■ When mounting air conditioner, if the torque

Fig. 1.2.001 Bolt Locating pin
used is over than the specified one or if the
“O” ring is clamped, there will be leakage of
refrigerant. Thus operations shall be
Male connecting Female connecting
Nut
conducted with the specified torque. piece piece
Push
■ The hose shall not be twisted.
■ It is forbidden to separate the air conditioning system before completely recycling the refrigerant.
Otherwise, refrigerant and refrigerant oil will be discharged under the system pressure and bring
pollution to the surrounding environment.
■ When replacing components of air conditioner, fill refrigerant oil (model: PAG56) when filling
refrigerant.
29
II. Preparation
General tools and special tools will be used during maintenance.
Table of Special Tools for Overhaul of Air Conditioning System
Name of Tool Figure of Tool Name of Tool Figure of Tool
High Intensity
Digital Multimeter Invisible Light
Lamp
R-134A Manifold
Cable Removing
Measuring
Caliper
Instrument
Halogen Leakage Tracing Paint

Detector Injector
R134A Tracing
Microthermometer
Paint
Forward Flow Shaft Seal

Control Valve Protective Device
50-pound
Pressure Test
Rechargeable
Adaptor
Recycling Tank
30
Name of Tool Figure of Tool Name of Tool Figure of Tool
Withdrawal Tool for Air

“O” Ring
Conditioning System
Withdrawal Tool
Lip Seal
Valve Core Withdrawal “O” Ring

and Installation Tool Installation Tool
Spring Clamp
Spring Clamp Caliper
Caliper
Refrigerant
Passive Test
Recycling/Regenerating
Lamp
and Refilling System
31
III. Check of System
1. Check of Air Conditioner and Filling of Fig. 1.2.002 Low

High
Refrigerant
Mount refrigerant filling device

Off
1) Close the manual valves at both sides of the
On
refrigerant filling device.
2) Mount the filling pipe of refrigerant filling

device to the connecting position. Connect the
low-pressure pipe with the low-pressure
nozzle; connect the high-pressure pipe with
the high-pressure nozzle and then screw up
the nut by hand.
2. Operation for Discharging Refrigerant
1) Connect the refrigerant filling device to the system.
2) Put a clean cloth on the open position of central hose.
3) Gradually open the high-pressure manual valve and discharge the refrigerant.
Attention:
■ If discharging too fast, the refrigerant oil of compressor will be discharged from the system.
4) Check if there is refrigerant oil on the cloth. If there is, slightly close the manual valve.
5) When the reading on the scale of filling device is lowered to 3.5 kg/cm2, slowly open the
low-pressure manual valve.
6) To reduce the system pressure, slowly open the high-pressure and low-pressure manual valves until
the reading on the filling scale is 0 kg/cm2.
3. Operation for Vacuumizing the Air Conditioning System
Attention:
■ The system must be vacuumized after discharging the refrigerant so as to remove the air and
moisture flowing into the system. Conduct vacuumization for 15 minutes after mounting each
component.
1) Make sure if the engine is “off”.
2) Connect the filling device to the connecting position of compressor and close the two sides.
3) Make sure if the refrigerant is discharged from the system.
4) Connect the central pipeline to the suction position of vacuum pump.
5) After operating vacuum pump, open the high-pressure and low-pressure valves of filling device.
32
6) 10 minutes later, the reading on the scale of low pressure detector shall be more than 0.96 kg/cm2,
(vacuum). Otherwise, there is leakage of system. Repair it according to the following steps:
■ Fill the system by using refrigerant container.
■ Find out the leakage position with leakage detector and repair it.
■ Discharge the refrigerant and vacuumize the system.
■ If there isn’t any leakage, keep on vacuumization.
7) Operate the vacuum pump again.
Low High
Fig. 1.2.003
Close
Close
Air
Vacuum pump
8) The reading on the scales of filling device at both sides shall be kept as 0.96 kg/cm2 (vacuum).
9) Keep on vacuumization until the reading on the scale is 0.96 kg/cm2.
10) After 15 minutes of vacuumization, close the pressure valve of filling device, stop vacuum pump and
separate the pipeline from vacuum pump so as to fill refrigerant.
4. Utilization of Refrigerant Control Valve
1) Before connecting the valve and refrigerant container, completely rotate the handle anticlockwise.
2) Locate the disk to the highest position anticlockwise.
3) After connecting the central pipeline to the valve device, rotate the disk by hand clockwise.
4) Rotate the handle clockwise and drill on the upper part of sealing.
5) Unscrew the nut at the connecting pipeline of central connector of filling device.
6) Screw up the nut after exhausting for several seconds.
33
5. Filling of Refrigerant (Gas State)

Fig. 1.2.004 Low High
Attention:
■ This operation is for filling the gas refrigerant

to system by the device at low pressure side. On Off
In this case, the refrigerant container shall be
put vertically to let the gas refrigerant flow into
Refrigerant
the system.
1) Mount the refrigerant container to the

adjusting valve.
2) Open the low-pressure valve and adjust it to make the reading on low pressure scale lower than 4.2
kg/cm2.
3) Start the engine and air conditioner.
Attention:
■ Put the container vertically to prevent filling the liquid refrigerant into the compressor through air
suction port.
4) Close the low-pressure valve after filling specified amount of refrigerant.
■ Specified filling amount of refrigerant: 480 g.
5) If the refrigerant filling speed is too slow, put

Fig. 1.2.005
the container to a water container at around
40 ℃.
Attention:
Put it into water and heat it to
■ In any case, don’t heat the water to higher around 40℃.
Refrigerant
than 52℃.
■ The high-temperature light shall not shine on

the container.
6. Filling of Refrigerant (Liquid State)
Attention:
■ This operation is for filling by the device at high pressure side. In this case, the refrigerant container
shall be inverted to let the refrigerant flow into the system.
1) After vacuumizing the system, completely close the high-pressure and low-pressure valves.
2) Mount the adjusting valve of refrigerant container.

34
3) Completely open the high-pressure valve and

Fig. 1.2.003
then invert the container.
4) If the system is over filled, the discharging

pressure will be increased. Thus, fill by correct
Refrigerant
amount while weighting the refrigerant, and
then close the high-pressure valve.
■ Specified filling amount of refrigerant: 480g.
5) Close the valve of filling device after filling

specified amount of refrigerant.
6) Check for gas leakage by leakage detector.

Attention:
■ Don’t start the engine when filling by the

device at high pressure side.
■ Don’t open the low-pressure valve when filling

with liquid refrigerant.
■ Conduct a performance test before separating

the filling detector.
IV. Control of System
1. Summary of System
Manual control air conditioning system is adopted for this model. The condenser is overcooling
condenser, so the refrigeration performance is improved. To improve defrosting performance, it will
automatically shift to external circulation mode when the mixed mode and defrosting mode are selected.
On the basis of different vehicle speeds, cooling water temperatures and refrigerant pressures, the fan of
condenser is controlled by low and high stages. The increase of air volume of blower and the air mixing
capacity will lead to improvement of heating and refrigeration performances.
Figure of Air Conditioning Control Panel
35
2. Basic Diagram for Refrigeration
High-temperature Low-temperature
High-pressure Low-pressure
Gas Liquid
High-temperature Low-temperature
High-pressure Low-pressure
Liquid Gas
Condenser:
Condenser is
Evaporator:
mounted at the front When the vaporous refrigerant
part of vehicle. It is is changed into gas, the heat
used for transferring will be absorbed from the air
the gas refrigerant passing through the evaporator
into liquid refrigerant by the blower.
with high
temperature and
high pressure.
Blower:
It is for sending the air to
evaporator and sending the
Drying Bottle: Compressor: cooled air into the vehicle.
The gas refrigerant with low
It will absorb the
temperature and low pressure
moisture of refrigerant
will be transferred into
and keep the refrigerant.
high-temperature
high-pressure gas by belt Expansion Valve:
pulley of engine and then sent
It will expand the
to the compressor. It is
refrigerant quickly and
controlled by clutch.
transfer it into
low-temperature
low-pressure liquid.
Basic Diagram for Refrigeration of Air Conditioning System
36
3. Schematic Diagram for Sub-assembly
Schematic Diagram for Air Conditioning System Sub-assembly
1-Heat installation assembly 2-Blower/evaporator/internal/external circulation 3-Condenser/drying bottle

4-Cooling fan 5-Compressor 6-Compressor support 7-Control panel 8-Internal/external circulation switch
9-Rear demister switch 10-Pipeline/expansion valve 11-Pipeline 12-Heater inlet pipe 13-Heater outlet
pipe
37
4. Illustration on Control Mode and Function of Air Conditioning Control Panel

The air conditioning is manually controlled. The panel integrates the rear defrost switch. The
temperature control adopts wire control mode, the internal and external air circulation mode and blowing
mode are controlled by servo motor, the panel illumination adopts backlight/LED and the button symbol
adopts paint spraying and laser carving. The functions of the buttons and knobs on the panel are shown
in the following figure.
Schematic Diagram for Air Conditioning Control Panel

1-Temperature adjustment knob 2-A/C switch 3-Blowing mode knob 4-Internal/external circulation button
5-Blower air volume knob 6-Rear defrost button
Table of Function Illustration of Air Conditioning Panel Buttons
Name of Button Function Illustration
The wire controlled knob is of pinion/rack structure. It is used for changing the
Temperature
mixing ratio of hot and cold air by adjusting the position of air door with
Adjustment Knob
wiredrawing, so as to conduct temperature adjustment.
It is for starting the compressor when the blower motor is under operation. The
A/C Switch
control element is the thermostat which is mounted at the evaporator.
The actuating element is the blower mode motor which is set on the warm air
Blowing Mode Knob blower. It is for adjusting five modes, i.e. face-blow, face-blow/feet-blow,
feet-blow, defrost/feet-blow and defrost.
The actuating element is air inlet servo motor which is set at the air door of
Internal/External blower. The armature of motor is connected to the air inlet door with connecting
Circulation Button rod. The change over switch will drive the connecting rod to rotate clockwise
and anticlockwise so as to change the angle of air door.
Blower Air Volume Knob It is for controlling four air speed gears.
Rear Defrost Button It is for defrosting by controlling the heat installation on the rear windscreen.
38
5. Operational Function of Knob and Button

Operational Function Table of Knob and Button
Operational
Function Operation of System Removal of Function
Switch
- There are “off” position, and gear 1~4 for
air volume of blower.
Adjusting air - When the air gear switch is turned to - The air volume won’t be affected
Air Gear Switch
volume “OFF” position, the blower is off; the AC is when operating other switches.
shut down and the indicator light of AC is
off when it is at “OFF” position.
- There are 36 gears in total distributed
evenly between the full cooling and the
Adjusting the full heating mode. If rotating clockwise,
Temperature position of the air will be warmer; if rotating - The air volume won’t be affected
Knob temperature air anticlockwise, the air will be cooler; along when operating other switches.
door the clockwise direction, the starting
position is the coldest and the final
position is the hottest.
- There are five modes. If rotating the mode
Adjusting the air - The air volume won’t be affected
Mode Switch knob, the mode air door will be switched
outlet mode when operating other switches.
to the corresponding position.
Air Gear Switch
- When pressing down [AC] button - When it is at OFF position, the
repeatedly, the compressor will be started AC is forced to be shut down;
Controlling the
A/C Button and shut down repeatedly. In this case, Mode Switch
compressor
the A/C indicator light will be on and off - The AC is forced to be started
correspondently. when it is under defrost mode
and feet-blow/defrost mode.
The inside/outside air mode won’t be
affected by the operation of air gear
- When operating this button under fresh air switch and AC button, temperature
mode, it will be changed into return air knob;
mode and the indicator light will be on; Mode Switch
Inside/Outside Controlling
- When operating this button under return - When it is under defrost mode
Air Selection inside/outside air
air mode, it will be changed into fresh air and feet-blow/defrost mode, it
Button mode
mode and the indicator light will be off; will be fresh air automatically. In
- When the air gear is at OFF position, it this case, if operating the
can still be operated. inside/outside air button, the
automatic fresh air will be
changed into return air mode.
6. Control of Compressor
Switch on the A/C and make there is A/C signal output only when the blower motor is working; A/C signal
is connected in series with the temperature switch and the signal is input to the engine ECM through
pressure switch; the engine ECM controls the switching on/off of compressor.
Attention:
■ When operating for more than 4 seconds at temperature lower than 1℃, shut down the compressor.
7. Constraint Control of Motor
The output time for the motor (actuator) of air conditioning system is 40 s. When it can’t arrive at the
control position, it is deemed that the motor is constrained; when the motor is constrained, conduct
motor protection and constraint and then confirm its function (output for 3 times).
39
8. Basic Diagram for Control Circuit and Illustration of Pin
Blower relay
Signal of
turning on of
A/C Blower
End of small
lamp relay Blower
switch switch
Speed regulating
End of resistance
dimming A/C
switch relay
Blowing mode
motor
Compressor Air
conditioning
control panel
Radiator fan
relay
Air intake
Radiator
mode motor
fan
3-phase pressure switch

Condenser fan relay
Thermostat
Condenser fan
Protecting Sleeve Model of A108 Control Panel:

KET 050 23M MG 642179
Basic Diagram for Control Circuit of Air Conditioning System and Illustration of Pin
40
V. Illustration on Function, Location and Check of System Elements
1. Function of Evaporator and Blower
The blower consists of motor and fan. It is for shifting inside/outside air mode by the air door motor at the
air suction port, and for suction of the inside or outside air.
The function of the air door motor at the air suction port is realized by the inside/outside air button on the
controller. When it is under internal circulation mode, air will be taken in from the two lateral air inlets;
when it is under external circulation mode, air will be taken in from the filter mounted on the front
protecting cover at the front of vehicle.
In this case, the air is taken in by the blower. After heat exchange by evaporator, the cooled air will be
sent into the vehicle.
When the refrigerant in the evaporator passing through the expansion valve, the low-temperature
low-pressure liquid will absorb the heat from the air coming from outside and be changed into gas
refrigerant to lower the temperature.
2. Names of Main Parts of Evaporator and Blower
Component Diagram for Evaporator and Blower
1-Air bellow-evaporator 2-Air bellow-upper part 3-Air bellow-lower part 4-Air intake motor 5-Cooling pipe
6-Blower 7-Speed regulating resistance 8-Thermistor (evaporator temperature sensor) 9-Air filter 10-Air filter
cover 11-Wire harness 12-Heat insulating trimming
41
3. Evaporator Temperature Sensor

Fig. 1.2.007
1) Function
It is for sensing the temperature of the core body of
evaporator to prevent the evaporator from being
frozen.
2) Installation Location
It is assembled at the core body of evaporator.
Since there is thermistor with negative temperature
coefficient in the sensor, the resistance will
increase when the temperature is decreased and
reduce when the temperature is raised.
3) Parameter Table
(temperature-resistance-output voltage)
Parameter Table of Evaporator Temperature Sensor
Temperature Temperature
Resistance (kΩ) Voltage (V) Resistance (kΩ) Voltage (V)
(℃) (℃)
30 1.977 6. 54 6. 54 6. 54 2. 37
25 2. 45 6. 87 6. 87 6. 87 2. 44
20 3. 063 6. 54 6. 54 6. 54 2. 50
15 3. 85 6. 87 6. 87 6. 87 2. 56
10 4. 876 6. 54 6. 54 6. 54 2. 63
5 6. 221 6. 87 6. 87 6. 87 2. 69
4 6. 54 6. 54 6. 54 6. 54 2.71
3 6. 87 6. 87 6. 87 6. 87 2. 82
4. Speed Regulating Resistance
1) Function
When connected in series with the blower, the speed regulating resistance may be used to regulate the
rotating speed of blower.
2) Installation Location Fig. 1.2.008
42
3) Appearance
Fig. 1.2.009
4) Parameters
Diagram for Parameters of Speed Regulating Resistance
■ At 25℃, the specification of resistance is: HI-MH: 0.65Ω, HI-ML: 1.3Ω, HI-LO: 2.3Ω.
5. Inside/Outside Air Door Motor
1) Function
It is mounted at the inside/outside air inlet duct of evaporator and blower and its function is realized by
controlling the inside/outside air selection button.
2) Location
Fig. 1.2.010
43
3) Appearance Fig. 1.2.011
4) Circuit and Detection Method
Operation Method
Input Voltage Output Direction
(Reference for
Terminal ① Terminal ②
Installation)
+ - Outside Air
- + Inside Air
Diagram for Inside/Outside Air Door Motor Circuit and Detection Method
6. Blower Motor
1) Function
With the vehicle power, it may rotate the fan to generate air volume required by the system.
2) Specification
Fig. 1.2.012
Rotation direction: Clockwise (At the Location of the
Fan)
Fan: Φ147 × 76.2 H
Motor: Φ68, 234 W
3) Detection “+” pole “-” pole
Apply any voltage on “+” terminal and conduct

inspection after grounding the “-” terminal. Generally,
the higher the voltage is applied, the higher the
rotating speed of blower is.
44
7. Expansion Valve
1) Function
The expansion valve is assembled at the inlet of evaporator. With releasing function, it may transfer the
liquid refrigerant with high temperature and high pressure which flows from the condenser into saturated
refrigerant steam with low temperature and low pressure, so as to help the evaporator to evaporate the
refrigerant.
2) Location Fig. 1.2.013

It is at the inlet of evaporator.
3) Specification:
Type: H type
Capacity: 1.5 RT
Attention:
■ When the cover of expansion valve falls, the heat of engine will be transferred to the thermo-bulb,
thus the pressure of expansion valve will be increased and the refrigerant in evaporator will be
excessive. If the evaporator is not working normally, the liquid refrigerant will flow to the compressor
and result in damage.
8. Heat Installation Assembly

Fig. 1.2.014
Based on different degree of opening and closure
of temperature control air door, part of the air
passing through the evaporator will be sent to the
heat installation core body and the rest of them will
be sent to the upper part of heat installation
housing. To control the regulation of indoor
temperature and the mixture of air, mix the air
passing through the heat installation core body and
the air which flows into the upper part of heat
installation housing at the rear part of the heat
installation housing. The mixed air will be sent to
the specified air outlet by function of mode air door
motor to regulate the indoor temperature and
defrosting/demisting. That is to say, the heat
installation assembly regulates the mixture of air
and controls the temperature and air outlet
direction.
45
9. Mode Air Door Motor

Fig. 1.2.015
1) Function
It is assembled at the left part of heat installation

housing and controlled by the signal of mode
switch on the air conditioning panel (FTAC). It
starts the small motor in the air door motor to
regulate the position of air mode door. The variable
voltage difference, when starting the motor, will be
fed back to the FATC which will judge the feedback
signal. When the air door arrives at the specified
position, the motor will stop.
3) Circuit and Detection Method Fig. 1.2.016
Circuit Diagram for Mode Air Door Motor
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the VENT
(face-blow) direction.
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the DEF
(demist) direction.
46
10. Temperature Control Air Door Motor
1) Function
It is mounted at the lower part of heat installation housing and controlled by the operational signal of
temperature switch on the air conditioning panel (FTAC). It starts the small motor to regulate the position
of temperature control air door. The variable voltage difference, when starting the motor, will be fed back
to the FATC which will judge the feedback signal. When the air door arrives at the specified position, the
motor will stop.
Fig. 1.2.017
3) Circuit and Detection Method
Circuit Diagram for Temperature Control Air Door
■ Detection:
When ① is connected to + pole and ② is connected to – pole, the motor operates towards the COOL
(refrigeration) direction.
47
When ① is connected to – pole and ② is connected to + pole, the motor operates towards the HOT
(heating) direction.
11. Condenser and Drying Bottle
1) Function
It may cool the gas refrigerant with high temperature and high pressure coming from the compressor at
ambient temperature. The cooling of condenser depends on the running air and the forcible air volume of
fan. The condenser for this model is of overcooling type and works with drying bottle. By overcooling, it
improves the refrigeration performance and reduces the amount of refrigerant required by the system.
Besides, the incorporation with drying bottle reduces the amount of components. In the past, when there
is pollution of system, it is required to replace the drying bottle. But for this model, after separating the
cover at the lower part of drying bottle, it is only required to replace the dryer.
2) Installation Location Fig. 1.2.018
3) Schematic Diagram for Dismantlement and Installation
Schematic Diagram for Dismantlement and Installation

1-Bolt 2-Buffer 3-Buffer block 4-Dryer 5-Filter 6-Snap ring
48
12. Cooling System
1) Concept of Cooling Fan Control
After comparing the input vehicle speed, the load of air conditioner and the cooling water temperature,
the engine ECM is divided into two stages (high/low) to control the rotating speed of cooling fan.
■ When there is trouble with speed sensor and cooling water temperature sensor, the engine ECM
drives the cooling fan to run at high rotating speed.
■ When the air conditioner compressor is shut down due to overheating, the starting temperature is
115℃.
2) Cooling Fan Control
Table of Cooling Fan Control
Water Temperature (℃)

91. 5 94. 5 99 102 104 107
A/C Speed Low speed On
OFF km/h of fan Off
High speed On
V<45 of fan Off
Low speed On
45≤ of fan Off
V<80 High speed On
of fan Off
Low speed On
of fan Off
V>80
High speed On
of fan Off
A/C Medium-voltage
switch is
Fan running at low speed
disconnected (low
signal)
ON Medium-voltage
switch is connected Fan running at high speed
(high signal)
49
3) Circuit of Cooling Fan Control
Ignition switch Storage battery
Compressor relay
Fan relay
Pressure switch
Cooling fan
Fan relay
Fan relay
Fan
Circuit Diagram for Cooling Fan Control
50
4) Location of Cooling Fan
Fig. 1.2.019
5) Specifications
■ Fan
Type: PUSH TYPE Dimension: Φ 304
■ Motor
Type: FLATE Dimension: Φ 99 × 41.5 Power: 120 W
13. 3-phrase Pressure Switch
1) Function
In the 3-phrase pressure switch, a medium pressure is added between the two end pressures of air
conditioner. When the system pressure increases, the pressure switch will be started and send signal to
engine ECM.
At that time, the engine ECM drives the cooling fan to run at high rotating speed to avoid lower
performances as a result of increased pressure. Besides, in this way, the air conditioning system may be
protected when the pressure is abnormal (high/low pressure).
Fig. 1.2.020
51
3) Circuit Diagram
Circuit Diagram for 3-phrase Pressure Switch
4) Specifications
Specification Table of 3-phrase Pressure Switch
Classification ON OFF Remarks

2 2
High 26.0 (kg/cm ) 32.0 (kg/ cm )
Low 2. 3 2.0
Medium 18.0 14.0
14. Internal/External Circulation Switch Fig. 1.2.021

1) Appearance
52
2) Circuit and Terminal Diagram
Circuit and Terminal Diagram for Circulation Switch
15. Rear Demister Switch Fig. 1.2.022

1) Appearance
2) Circuit and Terminal Diagram
Circuit and Terminal Diagram for Rear Demister Switch
53
VI. Dismantlement and Installation of System (Evaporator\Warm air blower\3

Motors\Resistor\Panel)
1. Dismantlement and Installation of Evaporator Blower Assembly
1) Dismantlement
① Use special refrigerant recycling equipment to recycle the refrigerant in the system.
② Cut off the negative terminal of storage battery.
Fig. 1.2.023
③ Dismantle the console assembly. Please refer to “Dismantlement and Installation of Console” for the
dismantlement steps.
④ Open the engine cabin and dismantle the fixed bolt of expansion valve.
⑤ Dismantle the fixed bolt of the evaporator blower assembly.
⑥ Cut off the connector of the circuit and take off the evaporator blower assembly.
2) Installation
Fig. 1.2.024
2. Dismantlement and Installation of Warm Air Blower
1) Dismantlement
① Cut off the negative terminal of storage battery.
54
Fig. 1.2.025
② Dismantle the console assembly. Please refer to “Dismantlement and Installation of Instrument
Desk” for the dismantlement steps.
③ Open the engine cabin and cut off the joint of warm air blower water pipe.
Fig. 1.2.026
④ Dismantle the fixed bolt of warm air blower.
■ Tightening torque: 23 ± 4 N.m
Fig. 1.2.027
⑤ Cut off the connector and take off the warm air blower assembly.
2) Installation

55
3. Dismantlement and Installation of Temperature-controlled Motor
1) Dismantlement
Fig. 1.2.028
② Dismantle the console. Please refer to “Dismantlement and Installation of Console”.
③ Cut off the connectors and dismantle the fixed bolt of temperature-controlled motor.
Fig. 1.2.029
④ Take off the temperature-controlled motor.
Fig. 1.2.030
2) Installation
56
4. Dismantlement and Installation of Mode Air Door Motor
1) Dismantlement
Fig. 1.2.031
③ Cut off the connectors and dismantle the fixed bolt of mode air door motor.
Fig. 1.2.032
④ Take off the mode air door motor.
Fig. 1.2.033
2) Installation
57
5. Dismantlement and Installation of Inside/Outside Air Door Motor
1) Dismantlement
Fig. 1.2.034
③ Cut off the connectors and dismantle the fixed bolt of inside/outside air door motor.
Fig. 1.2.035
④ Take off the inside/outside air door motor.
Fig. 1.2.036
2) Installation
58
6. Dismantlement and Installation of Power Amplifier
1) Dismantlement
Fig. 1.2.037
③ Cut off the connectors of power amplifier wire harness and dismantle the two fixed bolts.
Fig. 1.2.038
④ Pull the power amplifier upwards and take it off.
Fig. 1.2.039
2) Installation
59
7. Dismantlement and Installation of Air Conditioning Panel
Fig. 1.2.040
1) Pry out the trimming frame of air conditioning panel with slotted screw driver.
Fig. 1.2.041
2) Dismantle the fixed bolt of air conditioning panel and take the panel off.
Fig. 1.2.042
3) Installation
60
8. Dismantlement and Installation of Condenser Fig. 1.2.043

1) Dismantlement
① Use special refrigerant recycling equipment to

recycle the refrigerant in the system. Please
refer to “Recycle of Refrigerant”.
② Cut off the negative terminal of storage

battery.
③ Dismantle the front bumper. Fig. 1.2.044

Please refer to “Replacement of Front Bumper”.
④ Dismantle the front bumper frame. Please Fig. 1.2.045

refer to “Replacement of Front Bumper
Frame”.
⑤ Discharge the coolant and dismantle the Fig. 1.2.046

radiator assembly.
61
⑥ Cut off the connection of each pipeline. Fig. 1.2.047

⑦ Dismantle the fixed bolt of condenser.
⑧ Take off the condenser assembly towards the engine.
2) Installation
Attention:
■ Air conditioning pipe of drying bottle
Tightening torque: 9 ± 2 N.m
■ Fixed bolt of condenser
Tightening torque: 23 ± 4 N.m
9. Compressor Assembly
Fig. 1.2.048
1) Disassembly of Compressor
① Dismantle suction cup
Use special tools to dismount the suction cup as

62
② Dismantle the clamp spring. Fig. 1.2.049

■ Dismantle the armature and coil.
■ Use special tools to dismount the bearing cap

and retainer.
2) Check of Safety Valve Fig. 1.2.050

① When the high pressure of the air conditioning
system which is under operation is over than
Spring
3,550 kPa, discharge part of the refrigerant
into the air with high-pressure relief valve for
Valve
protection.
Compressor
② Once the system pressure is lower than 2,400
kPa, close the high-pressure relief valve to
make the machine keep on working.
③ If there is leakage at A position, replace the high-pressure relief valve. If there is no leakage, the
valve still can be used.
④ If there is leakage at B position, please tighten the valve. If there is still leakage after tightening,
replace the seal gasket.
3) Installation
Fig. 1.2.051 Clearance Gauge
Attention:
■ Check if the clutch clearance is within the

range of standard value.
■ Standard value: 0.3~0.75 mm
■ If the clearance is not within the range of

standard value, adjust the number of gasket to
adjust the clearance.
63
VII. Filter of Air Conditioner
1. Function
The air conditioner adopts particulate filter to remove the foreign substances and odor in the vehicle, so
as to keep a comfortable indoor environment. For convenience of replacement, a 2-plate filter is
adopted.
Fig. 1.2.052
2. Replacement Cycle
If the filter is not replaced for a long time, the filter will be blocked by foreign substances, the noise of
blower will be increased and the air outlet volume will be reduced, etc.
The replacement cycle is 5,000~12,000 km. It is necessary to check and replace the filter frequently in
region with serious air pollution or poor road condition.
3. Replacement Steps Fig. 1.2.053

1) Hold the two sides of glove box and dismantle
it downwards.
64
2) Push the glove box towards the two sides and push the air conditioner filter upwards to separate it.
Fig. 1.2.054
3) Hold the upper air conditioner filter and pull it Fig. 1.2.055
out.
4) Hold the lower air conditioner filter, move it

upwards and pull it out. Fig. 1.2.056
5) Assemble in the reverse order with dismantlement.
Attention:
■ When replacing filter, the arrow shown at the front end shall points to the core body. Don’t assemble
constrainedly.
65
VIII. Maintenance Data

1. Trouble Protection Mode
Table of Trouble Protection Mode
Item Trouble Function
Indoor temperature Short circuit and
25℃ control
sensor open circuit
Outdoor (environment) Short circuit and
20℃ control
temperature sensor open circuit
Short circuit and
Air duct sensor -2℃ control
open circuit
Short circuit and Set to face-blow (VENT) when it is no more than 25℃.
Mode motor
open circuit Set to defrost (DEF) when it is more than 25℃.
Temperature-controlled Short circuit and Set to the coldest position when it is no more than 25℃.
motor open circuit Set to the hottest position when it is more than 25℃.
2. Specification of Tightening Torque
Item Tightening Torque (N.m)

Mounting bolt of compressor 20~30
Mounting bolt of expansion valve 8~12
Mounting nut of expansion valve 10~15
Connecting nut of compressor and refrigerant pipe 5~7
Connecting nut of air suction pipe and hydraulic pipe 5~7
3. Filling Specification of Refrigerant Oil
Table of Refrigerant Oil Filling Specification
Filling of refrigerant 480 cc

Replacement of condenser 30 cc
Replacement of drying bottle 30 cc
Replacement of evaporator 50 cc
Replacement of pipeline 30 cc
66
Section III Information and Time Electronic Control System (ETACS)
I. Precautions
Strictly comply with the precautions for operation of SRS, or else, damage to vehicle and people
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
connector of electrical appliance, or else, vehicle damage will be caused.
■ Use cloth to protect the dismounted spare parts from being damaged and scratched during
dismantling and installing the elements.
■ Wrap the right-angled screwdriver blade with cloth, when dismantling the metal clip from trimmings.
■ Pay no attention to damaging the vehicle body elements.
■ Make sure the clips are firmly mounted into the plate hole of the body before installing body
trimmings, and then pressed the trimmings into the body carefully.
■ The dismantlement and installation of some large elements which cannot be completed by one
worker shall be carried out by two workers to avoid falling off.
■ Please don’t dismantle and mount the rubber trimmings forcedly, for too much force may cause the
distortion of spare parts.
II. Schematic Diagram of Elements
Alarm
ETACS module
Location Plan of ETACS Elements
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III. Illustration on Functions
1. Front/rear Washing Apparatus Associated Wiper Control
Ignition switch
More than 0.6s
Front/rear washing
switch
Front/rear wiper
T1: 0. 6 ± 0.1s T2: 2. 5—3. 8s T3: 0. 2—0. 6s (MAX) T4: One wiping period
When the ignition switch is turned to the “ON” position, after the washing switch is turned on for more
than 0.6s, the wiper will operate after T1 (0.6 ± 0.1s) of the wiper switch turns on until it is turned off, and
the wiper will wipe for another three periods T2 (that is 3 times); after the time of the washing switch
turned on is within 0.2 ~ 0.6s, the wiper will wipe once again.
2. Intermittent Control of Speed Sensitive Type
Ignition switch
Front pause switch
Front wiper
T1: 0.3s T2: 0. 7 ± 0. 1s
T3: when the speed = 0Km/h, it can be adjusted in the range of 2.6 ± 0.7s (VR = OKΩ) ~ 18. 0 ± 1 s (VR
= 50KΩ).
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When the speed is more than 100Km/h, it can be adjusted in the range of 1.0 ± 0.2s (VR = OKΩ) ~ 10. 0
± 1 s (VR = 50KΩ). The ignition switch is at “ON” position, the pause switch has been turned on for T1
(0.3s) and then begins to act, and the wiper acts. The finished time of each wiping action is T2 (0.7 ±
0.1s), when the speed=0Km/h, the interval of each wiping action can be adjusted within the range of 2.6
± 0.7s (VR = 0KΩ) ~ 18.0 ± 1s (VR = 50KΩ. When the speed is more than 100Km/h, it can be adjusted in
the range of 1.0 ± 0.2s (VR = 0KΩ) ~ 10.0 ± 1s (VR = 50KΩ).
3. Defrost Time Control of Rear Windscreen
"L" end of
generator
Defrost switch
Defrost relay
T1: 20 ± 2ms
When the generator is in operation, turn on the defrost switch, the defrost relay begins to work and it will
last for T1 (20 ± 2ms). If the interval of pressing the defrost switch is less than T1, the defrost function will
be disabled when defrost switch is pressed for the second time.
4. Illumination Control of the Ignition Key Hole
When the ignition switch is the OFF position, any one of the left and right front doors can be open, the
ignition lock lighting is on, and it will be off after T1 (10 ± 1s) of the door closed; if the front door is open,
the lighting will be off after the ignition switch is turned to the “ON” position.
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Ignition switch
IGN. S/W
Front door switch

DR S/W
Illumination of
ignition lock
hole
T1: 10 ± 1s
5. Illumination Control of the Driver’s Front Dome Lamp
Set the front dome lamp in the DOOR position, the front door is open and the front dome lamp is on,
when the door is closed and after the ignition switch is at the ACC position, the front dome lamp will go
out gradually after T1 (5.5 ± 0.5s); and after the ignition switch is at the “ON” position, the front dome
lamp will go out directly.
Front door switch
Igniton switch
Illumination of front
dome lamp
T1: 5. 5±0.5s
6. Starting and Braking Alarm Control
When the ignition switch is at “ON” position and the parking handle is not released, after the speed is
more than17Km/h, the door bell will ring at the interval of T1 (0. 3 ± 0. 1s), and if the parking handle is
released at this moment, the door bell will stop ringing; and when the speed is less than17Km/h, the door
will not ring.
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Ignition switch
Parking brake
switch
More than 17km/h
Speed sensor
Less than 17km/h
Harmonic bell
T1: 0. 3 ± 0. 1s
7. Acousto-optic Control of Safety Belt
Ignition switch
Take off
Safety belt switch
Enable
Safety belt alarm

light
Harmonic bell
T1: 0. 3 ± 0. 1s T2: 0. 45 ± 0.1s T3: 6 ± 1s
When the ignition switch is at the “ON” position and the driver does not wear the safety belt, the safety
belt alarm lamp flashes with the duty cycle of 50% at the interval of T1 (0.3 ± 0.1Is), and the door bell will
ring at the interval of T2 (0.45 ± 0.1s) and with the period of T3 (6 ± 1s); when the driver wears the safety
belt, the alarm lamp will flash for one period and give out a warning tone; the alarm lamp will flash and
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give out a warning tone if the safety belt is unfastened, indicator lamp for not wearing safety belt will be
still on after flashing for one period, vise versa, the safety belt indicator lamp will go out after flashing for
one period.
8. Time Control of the Electric Window
When the ignition switch is at the “ON” position and the front door is closed, the electric window can
operate. When the ignition switch is at the LOCK or ACC position, the electric window can operate within
T1 (30 ± 3s); if the front door opens in T1 (30 ± 3s), the electric window can’t operate.
Ignition switch
Front door switch

DR S/W
Electric window
motor
T1: 30±3s
9. Automatic Control of the Tail Lamp Extinction
When the lamp switch (left switch of the combined switch) is turned to “ON” from OFF in any case, the
tail lamp will turn on.
The tail lamp will go out automatically at the following conditions:
1) The lamp switch (left switch of the combined switch) is turned from “ON” to OFF.
2) After the key is drawn out, the door at driver’s side will be open, and meanwhile the tail lamp will go
out; if inserting the key at this moment, the tail lamp will turn on.
Note: Here the tail lamp refers to the small lamp system.
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Insert
Ignition Key
Draw out
Small lamp switch
Door switch at the

driver’s seat side
Tail lamp relay
10. Rear Fog Lamp Control
When the ignition switch is at the OFF position, the lamp switch is turned on (at the left side of combined
switch), and the front fog lamp switch is turned on, the rear fog lamp will not be lighted when the rear fog
lamp switch is turned on; when the ignition switch is at the “ON” position, the lamp switch is turned to the
gear of small lamp (at the left side of combined switch), and the front fog lamp switch is turned on, the
rear fog lamp will be lighted when the rear fog lamp switch is turned on, while the front fog lamp is turned
off at this moment, the rear fog lamp will be turned off at the same time; when the ignition switch is
turned to other lamp positions, the work of the rear fog lamp is not controlled by the front fog lamp, that is,
when the front fog lamp switch is turned off, the rear fog lamp switch can control the rear fog lamp
automatically.
Tail lamp relay
Ignition switch
Front fog lamp

switch
Rear fog lamp

switch
Rear fog lamp
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11. Electric Door Lock Control
There is a central control door lock which can control the four doors at the driver’s side and passenger’s
side. When the door is shut at the driver’s side, the fastener outputs the lockout signal, and the door is
locked; when the door is opened at the driver’s side, the fastener outputs the unlock signal, and the door
is opened. The control process of door lock at passenger’s side is also the same with that of at driver’s
side.
Pull up
Door switch at the

driver’s side
Press
Pull up
Door switch at the
passenger’s side
Press
Door lockout
output
Door unlock output
12. Vehicle Key Management Control
When the key is not removed and the door at driver’s side is open, the fastener output a signal, and the
door can not be locked; if the fastener switch is pressed continuously, the fastener outputs an unlock
signal, after that it outputs the unlock signal for 3 times; if the door at driver’s side is closed in T3 (0s
<T3<0.5s) of the fastener switch being pressed, the fastener switch is released, meanwhile, the fastener
will output an unlock signal, and the door is not locked.
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Insert in
Ignition key
Draw out
Turn on
Door switch at the
driver’s side Turn off
Lockout
Door lock switch
Unlock
Unlock the front
door
Output
T1: 0. 5 ± 0. 1s T2: 1 ± 0.1s T3: 0 s<T3<0. 5s
13. Central Control Automatic Opening
When the collision occurs, the airbag will be unfolded, meanwhile the airbag control module will output
an OV signal to ETACS, and then the ETACS will output an unlock signal to the fastener, subsequently
the fastener will output an unlock action of T3 (5s) after T2 (40s). After that the door will be unlocked.
Unfolded
The airbag
unfolded condition
Folded
Airbag module
Collision signal
Unlock
The electric door is
open
Lockout
Output signal
T1: 200ms T2: 40ms T3: 5s
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14. Automatic Lockout
When the ignition switch is at “ON” position and the door is not locked, if the vehicle travels with a speed
of more than 40Km/h for T1 (1 ± 0.3s), the door will be locked automatically; if the fastener unlocks
during traveling, the door will be locked automatically again after T1 (1 ± 0.3s).
Ignition switch
More than 40km/h
Speed sensor
Less than 40km/h
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 1 ± 0. 3s
15. Automatic Unlock by Key Removal
When drawing out the key under locked state of the vehicle door, the lockout relay will send an unlock
signal of T1 (0.5 ± 0.1s), after that the door will be unlocked.
Insert
Ignition switch
Remove
Unlock
Lockout switch of
the entire door Lockout
Lockout relay
T1: 0. 5 ± 0. 1s
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16. Guard Function
When the doors and the engine cover are closed, the door shall be locked with remote controller, the
hazard alarm lamp will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status; when there is door not
closed, it shall be locked with remote controller, after that the hazard alarm lamp will not flash, and the
vehicle is not in the guard status at the moment; when the doors are all locked, the hazard alarm lamp
will flash for T2 (1.0 ± 0.2s), and the vehicle is in guard status.
Open
Front cover of
each door Closed
Remote control
Lockout relay
Guard
Guard status
Guard release
Hazard alarm
lamp
T1: 0. 5 ± 0. Is T2: 1. 0 ± 0. 2s
17. Guard Release Function
When releasing guard with remote controller, the door is unlocked, and the hazard alarm lamp will flash
for T1 (0.5 ± 0.1s), and it will flash for another T1 after T2 (0.5 ± 0.1s). Moreover, when adopting the
remote controller to open the door, if the door is not open after 30s, the vehicle will be in guard status
automatically.
This function is set up to prevent the door from being opened accidentally.
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Remote control
opening the door
Unlock relay
Guard
Guard status
Guard release
Hazard warning
light
Illumination of the
driver’s dome lamp
Door switch DR
S/W
Lockout relay
T1: 0. 5 ± 0. 1s T2: 0. 5 ± 0. 1s T3: 1 ± 0. 1s T4: 30 ± 1s
18. Alarm Function
When the vehicle is in guard status, after opening the door or the engine cover, the siren will alarm for Tl
(27 ± 2s) at one inteval of T2 (10 ± 1s). After repeating for 3 times, the vehicle is under guard status, the
hazard alarm lamp will flash for T3 (0.5 ± 0.1s) with the duty cyle of 50%, with same flash time as that of
the siren.
Guard
Guard status
Guard release
Open
Front cover of
each door Closed
Rear boot door
Siren
Hazard alarm
lamp
78
T1: 27 ± 2s T2: 10 ± 1s T3: 0. 5 ± 0. 1s

19. New Abnormalities Occured in the Guard Status
When the vehcile is in guard status, each door and engine cover are open, the siren sounds alarm, and
the hazard alarm lamp flashes; if the door acts during 3 alarms, the vehicle is in guard status after 3
alarms.
Open
Front cover of
each door Closed
Rear boot door
Starter relay
Siren
Hazard alarm light
20. Releasing Guard with Remote Controller in Guard Status

When the vehicle is in guard status, the guard can be released with remote controller, the unlock relay
outputs an unlock signal, and the door is in unlocked status; when the vechicle is in guard release status,
the siren will cease sounding, and the hazard alarm lamp will stop flashing after flashing for twice. At this
moment, the vehicle is guard released.
Remote control
opening door
Unlock relay
Guard
Guard status
Guard release
Starter relay
Siren
Hazard alarm
lamp
79
T1: 0. 5 ± 0. 1s T2: 0. 5 ± 0. 1s
21. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Locked
When the vehicle is in guard status and the door is locked, the remote controller shall be adopted for
lockout, the relay shall be started to deenergize, and the hazard alarm lamp will go out after flashing for
T1 (1 ± 0.2s). At this moment, the vehicle is in guard status.
Open
Front cover of each
door
Rear boot door is
closed
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
T1: 1 ± 0.2s
22. Lockout with Remote Controller When the Vehicle is in Guard Status and the Door is Unlocked
When the vehicle is in guard status and the door is unlocked, the remote controller shall be adopted for
lockout, and the lockout relay outputs a lockout signal, and the relay shall be started to deenergize; if all
the doors are locked, and the hazard alarm lamp will flash once for T1 (1 ± 0.2s). At this moment, the
vehicle is in guard status.
Front cover of Open

each door
Rear boot door Closed
Remote control
locking door
Lockout relay
Starter relay
Hazard alarm
lamp
80
T1: 1 ± 0.2s
23. The Lost of Remote Key Releasing Guard in Guard Status
When the vehicle is in guard status, after the igniton switch is turned to the “ON” position, the vehicle will
be guard released after 30s.
Insert
Ignition key
Remove
Ignition
switch
Siren
Guard
Guard status
Guard release
24. Abnoramal Opening of the Door after Guard Status
After the guard status, the door re-opens abnormally, the siren still sounds alarm, and the initial guard
status is repeated.
Front cover of Open

each door
Rear boot door Closed
Starter relay
Siren
Hazard
alarm lamp
25. Dismantling and Mounting the Storage Battery in Guard Status and During Alarm
Mount the storage battery after dismounting the storage battery in guard status and during alarm, at this
moment the vehicle is still in guard status, and the siren sounds.
81
Guard
Guard status
Guard release
Front cover of each Open

door
Closed
Rear boot door
Dismount
Battery Mount
Starter relay
Siren
26. Dismantling and Mounting the Storage Battery in Guard Status
Dismantle the storage battery in guard status, and then mount it, at this moment the vehicle is guard
released.
Dismount
Battery
Mount
Guard
Guard
status Guard
release
82
IV. Definition of ETACS Control Module Terminals
Table of ETACS Control Module Terminals Definiton
Definiton of Connector A Definiton of Connector A

1 Room lamp 13 Small lamp realay
2 Anti-theft relay 14 Burglar alarm
3 Front wiper relay 15 Electric window relay
4 Rear defrost relay 16 Rear wiper relay
5 Safety belt alarm lamp 17 Door switch at the second driver’s side
6 Rear fog lamp relay 18 Hazard alarm relay
7 Rear wiper pause switch 19 Grounding
8 Door lockout relay 20 Key hole illumination
9 Buzzer power supply 21 Rear water-jet switch
10 B+ 22 Rear wiper low-speed switch
11 Door lockout realay 23 NC
12 Switch of the boot 24 Speed signal
Definiton of Connector B Definiton of Connector B

1 Door switch at the driver’s side 13 Small lamp realay
2 Rear fog lamp switch 14 Door lock switch at the driver’s side
3 Rear door lock switch 15 Unlock switch of the boot
4 Front water injector switch 16 Safety belt switch
Door lock switch at the second
5 17 Storage code
driver’s side
6 Hand brake switch 18 IG1
7 Rear defrost switch 19 Intermittent front wiper switch
8 Front fog lamp switch 20 Engien cover switch
9 ON 21 Airbag signal
10 Door switch 22 Front wiper intermittent adjustment
11 Door alarm switch 23 Generator L
12 Headlamp switch 24 External antenna
V. Operation Illustration of ETACS Key Code
1. Turn on the decoder switch.
2. Press any key on the remote controller, and re-press it after 3s.
3. Check by remote control.
4. If there are several remote controllers to be memorized, the step1, 2, and 3 can be repeated, one
key can be memorized each time, and 6 keys in all can be memorized.
83
VI. Replacement of ETACS Module and Alarm
1. Dismantle the negative pole of the storage battery.
2. Dismantle the console bottom cover at the diver’s side.
Fig.1.3.001
3. Dismount the engine cover handle.
Fig.1.3.002
4. Dismount the connectors of each connecting switch (front fog lamp switch, rear fog lamp switch,
combined device brightness adjustment switch, lighting distance adjustment switch of the front
headlamp).
Fig.1.3.003
84
5. Cut off the relevant connectors of the steering column.
Fig.1.3.004
6. Dismount the ETACS module fixed screw.
Fig.1.3.aa0
7. Cut off the ETACS module connector to dismount the ETACS module.
85
Fig.1.3.006
8. Dismantle the alarm assembly.
Fig.1.3.007
9. Install in the reverse order with dismantlement.
86
VII. Technical Parameters
Item Specification
Operating volatage DC12V
Range of operating voltage DC9V ~ DC16V
Quiescent current MAX 10mA (at 12.8V)
Insultation resistance 100MΩ (DC500V megameter）
Operating temperature -40°C ~ 5°C
Storage temperature -55°C ~ 150°C
Front/rear wiper relay DC 12V, 200mA (relay load）
Defrost relay of rear windscreen DC 12V, 200mA (relay load）
Illumination of ignition key hole DC 12V, 1.4W (bulb load）
Illumination of dome lamp for driver DC 12V, 10WX2 (bulb load）
Acousto-optic device of safety belt DC 12V, 1.4W (bulb load）
Electric window relay DC 12V, 200mA (relay load）
Tail lamp realy DC 12V, 200mA (relay load）
Rear fog lamp relay DC 12V, 200mA (relay load）
Electric door relay DC 12V, 200mA (relay load）
Alarm DC 12V, 260mA (relay load）
Warning tone DC 12V, 350mA (relay load）
87
Section IV Combined Switch

I. Illustration
Diagram for Combined Switch Assembly

1-Lamp switch 2-Self-return switch 3-Switch of windscreen wiper
This combined switch assembly contains three functional components:
1. Lamp Control
Diagram 1 for Lamp Switch
1-Right turn lamp switch 2-0FF 3-Left turn lamp switch
88
Diagram 2 for Lamp Switch
4-Dipped headlamp 5-Small lamp 6-OFF 7-Overtaking lamp 8-High beam lamp
Control the signals of left/right turn lamp, headlamp, side turn lamp, and of overtaking lamp. In the mode
of headlamp, it can also realize two function options: shifting from high beam to low beam, or shifting
from low beam to high beam.
1) Turn Lamp
The turning signal level has two upwards (right turn) positions and two downwards (left turn) positions,
which are used for sending turning signal.
Put the level to the end upwardly or downwardly to send turning signal. When the turning movement is
fulfilled, the level will automatically return. One of the arrows on the combined device will flicker and
show the turning direction.
In order to send turning signal, you need only lift or press down the level until the arrow begins to filcher,
and hold the level there until the vehicle lane-changing is fulfilled. When you release the level, it will
automatically return. When you sending the turning signal, if the turning arrow flickers too fast, the signal
lamp maybe broken, and the other drivers can’t successfully notice the turning signal you send.
If some bulb is burned out, it shall be replaced, in case of traffic accidents. If the driver sends out turning
signal, but the arrow doesn’t flicker at all, you shall check whether the bulb is burned out, and then check
the fuse.
2) Headlamp/Dipped Headlamp Shifter
If you want to shift the headlamp from low beam to high beam, push the turning signal/ multi-functional
level in the direction deviating from you. When the high beam is powered on, if you turn on the ignition
switch, the combined device will display the high beam lamp signal.
If you want to shift the headlamp from high beam to low beam, you need pull the turning
signal/multi-functional level towards you.
89
3) Overtaking Flash
This function can help the driver send overtaking signal to the vehicle in front of him by the usage of high
beam headlamp. For using this function, pull the turning signal/multi-functional level towards the driver
until the high beam of the headlamp is turned on, and then release the level to turn off the headlamp.
2. Control Switch of Windscreen Wiper

Fig. 1.4.001
1) Operating Modes of Wiper Controlling (Washing, Interval, Low Speed, High Speed)
At the interim gear, the wiper has three different modes, viz. high, medium, and low modes for selection.
The front windscreen wiper is operated only when the ignition switch is powered on. Use the level at the
right side of the steering column to operate the front windscreen wiper.
HI (high): turning the level to this position can realize the high speed wiping function.
LO (low): turning the level to this position can realize the stable low speed wiping function.
INT (interim): turning the level to this position can choose wiping delayed for a cycle.
Turn the middle section of the wiper level towards the LO direction, and the delay is prolonged; while,
turn it towards the HI direction, and the delay is shortened. Only when the level is in the INT position can
the wiping speed be adjusted.
2) Washing Solution of Front Windshield
In order to wiping the front windscreen, pull the washing solution level of front windscreen wiper towards
you, with the ignition switch powered on, and the washing solution of the windscreen wiper will be
injected from the spray nozzle.
Attention:
■ In cold weather, the wiper is not allowed to be used until the front windscreen is preheated.
Otherwise, the washing solution will get frozen on the front windscreen and interfere with your view.
■ When you release the level, the washing apparatus will stop working, however, the wiper will
continue to work for other three cycles and then either stop or recover to the wiping speed you
select before.
90
II. Test of Elements
Inspect the on-state between each terminals of the lead wire connector according to the following charts.
If the on-state doesn’t confirm with the following charts, replace the switch.
Dipped headlight
Small light
High beam light
Big light
Overtaking
Terminal
Function
Interm
Low speed
High speed
Front washer
Intermission
time adjusting
Rear washer
Rear wiper on
Rear wiper off
Inspection Diagram for Combined Switch
III. Replacement of Combined Switch
Precaution:
Strictly comply with the precautions for operation of SAS, or else, damage to vehicle and people
may be caused.
91
Dismount the negative pole of storage battery and wait for at least 1min before dismounting the
1. Dismantlement Steps:
1) Dismount the negative pole of the storage battery.
2) Dismount the steering wheel. Refer to the “Replacement Steps of Steering Wheel”.
3) Dismount the upper and lower covers of steering column cap. Refer to the “Replacement Steps of
Upper and Lower Cover of Steering Column Cap”.
4) Dismount the clock spring of safety airbag. Refer to the “Replacement Steps of Clock Spring of
Airbag”.
5) Disconnect the connector of combined switch.
Fig. 1.4.002
6) Dismount the three clamping screws of the combined switch.
92
Fig. 1.4.003
7) Take off the combined switch assembly.
8) Mount back the clamping screws of the

Fig. 1.4.004
combined switch.
2. Installation Steps:
■ Tightening torque for the clamping screw: 2 N·m
93
Section V Lighting System

I. Precaustions:
may be caused.
Dismount the negative pole of storage battery and wait for at least 1min before dismounting the
II. Headlamp
1. Location Plan of Element
Location Plan of Headlamp Element
94
2. Basic Diagram of Headlamp
Power Power
supply supply
Relay of lower
Relay of beam lamp
upper
beam
lamp
Left lower beam
Right lower beam

Left upper beam
Right upper
beam lamp
Lower beam
lamp
lamp
lamp
Upper beam Headlamp
Overtaking Small lamp
Grounding Grounding Grounding
Basic Diagram of Headlamp

3. Detection of Headlamp Element
1) Switch of headlamp
Check the continuity with multimeter according to the figure below. If the actual condition doesn’t
conform to the figure, please replace the headlmap switch.
Lower beam
Headlamp Upper beam
Small lamp
Overtaking
Inspection Diagram for Headlamp Switch

95
2) Relay of headlamp
Less than 2Ω
Multimeter
Storage battery
Inspection Diagram for Headlamp Relay

As it is shown in above figure, when the negative pole of the battery connects with the terminal 85 of
relay and the positive pole connects with terminal 86 of relay, check if the terminals 30 and 87 are
conducting with multimeter. The measured resistance value should be less than 2Ω, or else, replace the
headlamp relay.
96
4. Replacement of Headlamp
1) Dismantlement steps:
① Cut off the negative pole of storage battery.
Fig. 1.5.001
② Dismount the front bumper. Please refer to

“Replacement of Front Bumper”.
③ Dismount the fixed bolt under headlamp.
Fig. 1.5.002
④ Dismount the fixed bolt above headlamp.
Fig. 1.5.003
97
⑤ Move the headlamp carefully and dismount

the electrical connector.
Fig. 1.5.004
⑥ Dismount the headlamp assembly.
Fig. 1.5.005
2) Installation steps:
① Connect the electrical connectors of headlamp
assembly.
② Mount the headlamp assembly and fixed bolt.
Tightening torque: 5N•m
Fig. 1.5.006
98
③ Mount the front bumper. Please refer to

“Replacement of Front Bumper”.
Fig. 1.5.007
④ Mount the negative pole of storage battery.
Fig. 1.5.008
⑤ Check if the light meets the requirement.

If not, adjust it. Please refer to “Adjustment of Headlamp Light”.
5. Replacement of Lower/upper Beam Lamp Bulb
Attention:
Don’t dismount the headlamp from reflector for a long time, or else, the performance of lamp may be
affected due to ingress of dust, moisture, smoke, etc. Once the bulb in reflector of headlamp is
dismounted, mount a new bulb as soon as possible.
The headlamp is of semi-closed beam type, and the replaceable halogen bulb is applied. The
replacement of bulb can be carried out in engine compartment after the dismantlement.
When dealing with the bulb, hold the plastic seat of bulb rather than touch the glass shell.
Don’t shake or screw the bulb during its dismantlement.
99
Dismantlement steps:
Fig. 1.5.009
② Turn the seal cover of upper/lower beam lamp

anti-clockwise to dismount it.
Fig. 1.5.010
③ Disconnect the connector from the rear of bulb and loose the snap-in.
④ Dismount the headlamp bulb carefully.
⑤ Don’t shake or screw the bulb during dismantlement.
2) Install in the reverse order with dismantlement.
Attention:
6. Replacement of Turn Lamp Bulb of Headlamp
Attention:
100
Don’t shake or screw the bulb during dismantlement.
Fig. 1.5.011
② Screw off the seat of turn lamp seat

anti-clockwise.
Fig. 1.5.012
③ Slightly press down the bulb and screw off the

bulb of turn lamp.
Fig. 1.5.013
101
④ Replace the bulb of turn lamp.
Fig. 1.5.014

7. Replacement of Small Lamp Bulb of Headlamp
Attention:
Don’t shake or screw the bulb during dismantlement.
Fig. 1.5.015
102
② Screw off the seat of small lamp anti-clockwise.

Fig. 1.5.016
③ Dismount the bulb of small lamp.

Fig. 1.5.017
④ Replace the bulb of small lamp.
Fig. 1.5.018

8. Adjustment of Headlamp Light
1) Make sure that the pressures of all tyres are normal.
2) Place the vehicle and tester on the same level surface.
3) Make sure the vehicle is under no load when the driver (or article with equal weight on driver’s seat)
is not taken into account (the coolant and engine oil is filled to normal level and the fuel tank is full).
103
4) Turn on the lower beam lamp of headlamp.

5) Carry out aim adjustment with adjusting screw.
Screw down the adjusting screw at first, and then loose it for adjustment. If the front of vehicle body is
repaired or the headlamp assembly is replaced, check the aiming and adjust it to be in proper condition
with light detector.
6) Carry out aiming in accordance with alignment meter until it is properly adjusted.
III. Front Fog Lamp
Location Plan of Element of Front Fog Lamp

2. Replacement of Front Fog Lamp
Fig. 1.5.019
104
② Dismount the front bumper. Please refer to “Replacement of Front Bumper”.
Fig. 1.5.020
③ Dismount the clamping screw on fog lamp from front

bumper.
Fig. 1.5.021
④ Disconnect the electrical connector and dismount the fog

lamp assembly.
① Mount the fog lamp assembly.
Tightening torque of fixing screw: 2N•m Fig. 1.5.022
② Connect the electrical connector.

③ Mount the front bumper. Please refer to “Replacement of Front Bumper”.
④ Mount the negative pole of storage battery and detect the light. If the requirements are not met,
adjustment should be carried out. Please refer to “Adjustment of Beam of Front Fog Lamp”.
105
3. Replacement of Front Fog Lamp Bulb.

1) Dismantlement steps: Fig. 1.5.023
① Prize up the fixed snap-in on connector of fog

lamp assembly.
② Screw the rubber cover of bulb seat

anti-clockwise .
③ Dismount the connector of fog lamp and take
off the rubber cover of bulb seat
④ Dismount the fixed snap-in for bulb seat.
Fig. 1.5.024
⑤ Dismount the fog lamp bulb from bulb seat.

⑥ Replace the fog lamp bulb.
Detect the light after installation. If the requirements are not met, carry out adjustment. Please refer
to “Replacement of Beam of Front Fog Lamp”.
4. Replacement of Beam of Front Fog Lamp
Attention:
Correct road lighting can be provided only after the adjustment of beam of front fog lamp.
As the mounting support for front fog lamp may be disturbed by installation of new fog lamp
assembly or repair of forehead of vehicle, the adjustment of beam of front fog lamp must be
checked.
The beam of front fog lamp assembly of this model can not be adjusted horizontally.
1) To assure the precise adjustment of vertical beam of front fog lamp, make preparation for the
vehicle according to following steps at first.
① If other maintenance has been carried out for the vehicle, make sure all the components of vehicle
are available firstly.
106
② Make sure the fuel achieves the full level or slightly below.
③ Stop the vehicle on level ground and keep a 1.52m distance with target screen.
④ Stop other operations carried out on the vehicle.
⑤ Rock the vehicle to make the suspension be available.
⑥ Cover the headlamp during the adjustment of beam of fog lamp.
2) Turn on the front fog lamp.
3) Insert the cross screwdriver through the space under front bumper to get close to the vertical
adjusting screw.
4) Adjust the fog lamp upward/downward to make the top edge of highlight area be 102mm lower than
the horizontal centerline (2). The area shown in target screen is the ground boundary (5) which is
0mm below the horizontal centerline (3).
5) Turn off the front fog lamp.
Fig. 1.5.025
IV. Tail Lamp

Location Plan of Element of Tail Lamp
107
2. Replacement of Tail Lamp

Fig. 1.5.026
② Open the boot cover.
Fig. 1.5.027
③ Dismount the trim strip of boot cover. Please refer to “Replacement of Trim Strip of Boot Cover”.
④ Take off the cover plate of spare tyre. Please refer to “Replacement of Cover Plate of Spare Tyre”.
Fig. 1.5.028
108
⑤ Dismount the sill panel of boot.

Please refer to “Replacement of Sill Panel of Boot”.
Fig. 1.5.029
⑥ Dismount the side guard plate of boot. Please

refer to “Replacement of Side Guard Plate of
Boot”.
Fig. 1.5.030
⑦ Dismount the fixed bolt for tail lamp.
Fig. 1.5.031
109
⑧ Pull out the connector of tail lamp and take off the tail lamp.
Fig. 1.5.032

Attention:
Check if the tail lamp is in good condition before installation.
Don’t damage the tail lamp during installation.
Check if the tail lamp is properly mounted after installation and if the matching clearance with body
is proper. If not, re-mount the tail lamp.
Don’t dismount the bulb for a long time, or else, the performance of lamp may be affected due to
ingress of dust, moisture, smoke, etc. Once the bulb is dismounted, mount a new bulb as soon as
possible.
3. Location Plan of Each Element of Tail Lamp
1-Tail lamp assembly Fig. 1.5.033

2-Rear fog lamp
5
3-Small lamp
4-Turn lamp 4
5-Stop lamp 6
3
6-Reversing lamp
110
4. Replacement of Stop Lamp Bulb

① Dismount the inner guard plate of tail lamp.
② Screw off the stop lamp seat anti-clockwise.
③ Slightly press the bulb down and screw off the stop lamp bulb anti-clockwise.
④ Replace the stop lamp bulb.
Attention:
Check if the bulb is in good condition before installation.
Mount the bulb properly on the lamp seat.
Carry out alignment for mounting hole during installation of lamp seat and mount it properly.
Conduct inspection after installation.
possible.
5. Replacement of Turn Lamp Bulb
Fig. 1.5.034
② Screw off the turn lamp seat anti-clockwise.

③ Slightly press down the bulb and screw off the turn lamp bulb anti-clockwise.
111
④ Replace the turn lamp bulb.

Attention:
possible.
6. Replacement of Reversing Lamp Bulb

Fig. 1.5.035
② Screw off the reversing lamp seat
anti-clockwise.
③ Dismount the reversing lamp bulb.
④ Replace the reversing lamp bulb.
2) Install in the reverse order with
dismantlement.
Attention:
Check if the bulb is in good condition before
installation.
Carry out alignment for mounting hole during
installation of lamp seat and mount it properly.

possible.
112
7. Replacement of Rear Fog Lamp Bulb

② Screw off the rear fog lamp seat anti-clockwise.
③ Slightly press down the bulb and screw off the rear fog lamp bulb anti-clockwise.
④ Replace the rear fog lamp bulb.
Attention:
possible.
8. Replacement of Small Lamp Bulb
Fig. 1.5.036
② Screw off the small lamp seat anti-clockwise.
113
③ Dismount the small lamp bulb.
Fig. 1.5.037
④ Replace the small lamp bulb.

Attention:
possible.
114
V. Highmounted Stop Lamp

Location Plan of Element of Highmounted Stop Lamp
2. Replacement of highmounted stop lamp

Fig. 1.5.038
② Dismount the rear seats. Please refer to

“Replacement of Rear Seat”.
③ Dismount the fixed tapping screw on coatrack.
Fig. 1.5.039
④ Remove the coatrack and disconnect the

electrical connector of highmounted stop lamp
on coatrack.
115
⑤ Take out the coatrack and replace the

high-mounted stop lamp.
Fig. 1.5.040
2) Assemble in the reverse order with

dismantlement.
VI. License Plate Lamp

Location Plan of Element of License Plate Lamp

2. Replacement of License Plate Lamp
① Dismount the tail guard plate. Please refer to “Replacement of Tail Guard Plate”.
② Prize up the license plate lamp with Fig. 1.5.041

right-angled screwdriver.
116
③ Disconnect the electrical connector. Fig. 1.5.042
④ Take off the license plate lamp and replace it.

Fig. 1.5.043

3. Replacement of License Plate Bulb
1) Dismount the license plate lamp. Please refer to “Replacement of License Plate Lamp”.
2) Screw off the license plate lamp seat anti-clockwise.
3) Replace the license plate lamp bulb.
Attention:
117
VII. Illuminating Lamp of Boot

Location Plan of Element of Boot Illuminating Lamp

2. Replacement of Illuminating Lamp of Boot
① Open the boot cover.
② Prize up the illuminating lamp of boot with screwdriver.
Fig. 1.5.044
③ Disconnect the electrical connector.

④ Replace the illuminating lamp of boot.
118
3. Replacement of Illuminating Lamp Bulb of Boot

1) Dismount the illuminating lamp of boot. Please refer to “Replacement of illuminating lamp of boot”.
2) Take off the bulb from boot illuminating lamp seat.
3) Replace the bulb of illuminating lamp of boot.
Fig. 1.5.045
VIII. Side Turn Signal Lamp

Location Plan of Element of Side Turn Signal Lamp
119
2. Replacement of Side Turn Signal Lamp

① Disconnect the side turn signal lamp from the fender with right-angled screwdriver.
Fig. 1.5.046
② Dismount the electrical connector.
Fig. 1.5.047
① Connect the electrical connector.
② Mount the side turn signal lamp on the fender.
4. Replacement of Side Turn Signal Lamp Bulb
① Dismount the side turn signal lamp. Please refer to “Replacement of Side Turn Signal Lamp”.
② Anti-clockwise screw the turn lamp seat out from the mounting hole.
③ Dismount the bulb from the side turn signal lamp seat.
④ Replace the bulb of side turn signal lamp.
Attention:
120
possible.
IX. Illuminating Lamp of Glove Box

Fig. 1.5.048
2. Replacement of illuminating lamp of glove box

Fig. 1.5.049
① Open the glove box.
② Prize up the illuminating lamp of glove box

with right-angled screwdriver. Fig. 1.5.050
121
③ Disconnect the electrical connector.
Fig. 1.5.051
④ Replace the illuminating lamp of glove box.

3. Replacement of Bulb of Illuminating Lamp of Glove Box
1) Dismount the illuminating lamp of glove box. Please refer to “Replacement of illuminating box of
glove box”.
2) Take off the bulb from the seat of illuminating lamp of glove box.
3) Replace the bulb of illuminating lamp of glove box.
Fig. 1.5.052
122
X. Reading Lamp
Location Plan of Element of Reading Lamp
2. Replacement of Reading Lamp

Fig. 1.5.053
① Prize up the lampshades of reading lamp
orderly.
② Dismount the clamping screws for reading
lamp orderly.
③ Dismount the reading lamp from the roof inner

liner carefully and disconnect the connector. Fig. 1.5.054
④ Replace the reading lamp.

dismantlement.
123
3. Replacement of Reading Lamp Bulb

① Dismount the reading lamp. Please refer to “Replacement of Reading Lamp”.
② Dismount the reading lamp bulbs in turns from the mounting base.
③ Replace the reading lamp bulb.
Fig. 1.5.055

Attention:
Select the bulb to be replaced according to the condition in practical operation.
Mount the bulb properly on the mounting base.
Check if the requirements are met after installation.
124
XI. Maintenance Data and Specification

1. Light Parameter and Bulb Specification
Table of light parameter and general bulb specification
Bulb Type Power

Halogen headlamp (upper/lower beam lamp) Bayonet type 55/60W
Parking lamp Sucking fit 5W
Front turn lamp Bayonet type 21W
Side turn lamp Sucking fit 5W
Rear turn lamp Bayonet type 21W
Stop lamp/tail lamp Bayonet type 21/5W
Reversing lamp Bayonet type 21W
License plate lamp Bayonet type 5W
2. Power of Bulb and Light Color

Table of lighting fitting parameter
Name Bulb Type Power of Bulb Light Color

Front position Bulb (W) 2X5W White
lamp
Headlamp Upper/lower Tungsten-halogen lamp 2X60(55)W White
beam lamp (H4)
Turn lamp Bulb (P25-1) 2X21W Amber
Side turn lamp Bulb (WY) 2X5W Amber
Front fog lamp Bulb (H3) 2X55W White
Stop lamp Bulb (P) 2X21W Red
Rear turn lamp Bulb (PY) 2X21W Amber
Rear
Reversing lamp Bulb (W) 2X21W White
combination
Rear position Bulb (R) 2X5W Red
lamp
lamp
Rear fog lamp Bulb (P) 2X21W Red
License plate lamp Bulb (W) 5WX2 White
Highmounted stop lamp Bulb (P) 21W Red
Reading lamp Bulb (KD) 40W White
Left/right front door lamp Bulb (P) 5WX2 Red
Illuminating lamp of boot Bulb (KHA) 5W White
Illuminating lamp of LED / -
instrument
Illuminating lamp of glove Bulb (KHA) 5W White
box
Illuminating lamp of cigarette Bulb (KD) 1.2W White
lighter
Illuminating lamp of ignition Bulb (KD) 1.4W -
switch
125
4. Lighting Switch
Table of lighting switch parameters
Name of Switch Load Rated Load

Switch of small lamp Relay of small lamp 180mA (inductive load)
Switch of lower beam lamp Headlamp relay 180mA (inductive load)
Switch of upper beam lamp Upper beam lamp 180mA of bulb load (driven by relay)
Overtaking switch Upper beam lamp 180mA of bulb load (driven by relay)
Switch for left turn Left turn lamp Relay
Switch for right turn Right turn lamp Relay
Switch of front fog lamp Relay of front fog lamp 180mA (inductive load)
Switch of rear fog lamp Relay of rear fog lamp 180mA (inductive load)
Switch of alarm lamp Left/right Turn lamp Relay
Stop lamp, highmounted
Switch of brake pedal Bulb load
stop lamp
Contact switch of door Left/right front door lamp Bulb load
Switch of boot Illuminating lamp of boot Bulb load
Dimming switch - -
Illuminating lamp of glove
Contact switch of glove box Bulb load
box
2. Torque Specification
Table of Torque Specification
Name N•m Lb-lf Lb-in

Fixed bolt for headlamp 10 ― 53
assembly
126
Section VI Combined Device

I. Illustration on Functions
Fig.1.6.001
1. Speed meter: the pointer moves according to the signals which are from speed sensor, showing the
travel speed of vehicle.
2. Tachometer: the pointer moves according to the rotate speed signals inputted by ECM of engine,
showing the rotate speed of engine.
3. Water thermometer: the pointer moves according to the signals which are from the coolant
temperature sensor, showing the temperature of engine coolant.
4. Fuel oil meter: the pointer moves according to the signals which are from the fuel oil sensor,
showing the amount of remained oil in the fuel tank.
5. Odometer: it calculates the total (accumulated) travel distance of vehicle through pulse signals
which are from speed sensor and it can switch short trips (subtotal).
127
6. Table for Symbols of Warning Functions
Table for Symbols of Warning Functions
Input Mode of
No. Name of Indicator Lamp Symbol Color Remarks
Signal
Charge-discharge indicator
1 Red Low level LED
lamp
Alarm lamp of engine oil
2 Red Low level LED
pressure
3 Fuel oil alarm lamp Yellow Low level LED
4 Engine trouble lamp Yellow Trouble LED
5 Distant light Indicator lamp Blue Low level LED
6 Indicator lamp of rear fog lamp Yellow Low level LED
7 Left turn indicator lamp Green Low level LED
8 Right turn indicator lamp Green Low level LED
Braking system trouble

9 Red Trouble LED
indicator lamp
10 Indicator lamp of safety belt Red Low level LED
11 Indicator lamp of safety airbag Red Trouble LED
12 ABS trouble alarm lamp Yellow Trouble LED
13 Indicator lamp of door open Red Low level LED
14 Boot cover indicator lamp Red Low level LED
Water temperature alarm

15 Red Trouble LED
indicator lamp of engine
16 EOBD indicator lamp EOBD Yellow Trouble LED
Burglarproof indicator lamp of

18 Red Red Reserved
engine
128
7. Relevant Parameters of Combined Device
Parameters of Combined Device
Structural form Imitation type

Symbol of indicated unit Km/h
Indication range 0～200
Speed meter
Maximum vehicle speed >160
Driven by stepper
Drive mode
motor
Symbol of indicated unit X100rpm
Indication range 0〜8000rpm
Tachometer
Red zone 6000〜8000rpm
Driven by stepper
Drive mode
motor
Symbol of oil level EF
Four-meter scale Red zone for empty oil level 1/8
Fuel oil meter Indication range E~F
Range for warning 1/8
Driven by stepper
Drive mode
motor
Structural form Analogue
Temperature symbol °C
C(50°C)〜
Indication range
H(120°C)
Temperature for alarm 115°C〜120°C
Water thermometer Red zone for indication of hot
115°C
temperature
Range of normal working
Below 100°C
temperature
Driven by stepper
Drive mode
motor
LCD (segment Subtotal of mileage (Trip) 0〜9999. 9
code) Accumulated mileage (0D0) 0〜999999
Display mode Negative Image
LCD Adjusting method Dutyfactor
Dimension of display screen Double-line display
Illumination color of
Orange
back-lighting of dial
Illumination color of
Illumination Color -
scale/character
LCD illumination color Yellow
Illumination color of pointer Red
129
II. Illustration on Connector Terminal of Combined Device
The illustration on connector terminal of combined device is as follows:
3
1
Illustration Diagram for Connector Terminal of Combined Device
1-Connector A (Black） 2-Connector B (Blue） 3-Connector C (White)
III. Replacement of Combined Device
① Dismount the negative pole of storage battery.
② Dismount the clamping screw for exterior cover of combined console.
Fig.1.6.002
130
③ Dismount the clamping screw for combined

device.
Fig.1.6.003
④ Cut off the connector of combined device and

dismount the combined device assembly.
Fig.1.6.004
① Put in the combined device assembly, and

connect the connector of combined device.
Fig.1.6.005
② Mounting the clamping screw for combined device.
Torque of clamping screw: 1.7~2.3 N•m
131
③ Put in the exterior cover of combined device.
Fig. 1.6.006
4) Mounting the clamping screw of exterior cover Fig.1.6.007

of combined device.
Tightening torque: 1.5~2.5 N•m.
IV. Speed Meter and Odometer
1. Principle
1 2
Basic Diagram for Speed Meter and Odometer
1-Speed meter 2-Odometer
The crossed coil speed meter and odometer are used in this vehicle to indicate the vehicle’s traveling
speed and accumulated traveling mileage, and a digital odometer is also set. A magnetic-type structure
is adopted for measuring vehicle speed while a multifunctional LCD is used to control the recording of
mileage.
132
When the speed meter doesn’t work, the pointer will be at the zero position. When the vehicle travels,
the lines of magnetic force of permanent magnet driven by a driving gear in the transmission to cut the
HALL vehicle speed sensor will make the HALL vehicle speed sensor produce pulse-width signals and
provide them for the cross coil speed odometer so as to drive the pointer of speed meter to move.
Meanwhile, it provides the control mileage for the multifunctional LCD which records the mileage.
2. Testing
1) Testing:
① Adjust the tire pressure to the specified value.
② Put the vehicle on the speed test-bed.
③ Make sure that the behavior of parking brake is correct.
④ In order to prevent the vehicle from moving around, the left and right of vehicle shall be fixed.
⑤ In order to prevent the vehicle from rushing out, a chain or steel wire shall be used to fasten the rear
and make sure the ends of chain or steel wire are fixed tightly.
⑥ Check whether the indication of speed meter is within the range of standard value.
Comparison Table for Indicated Standard Range and Frequency of Speed Meter
Speed Meter Instrument (Pin27)

Speed Frequency
60Km/h 40.1Hz
100Km/h 66.1Hz
160Km/h 107.3Hz
Attention:
During test, don’t operate the clutch suddenly or increase and reduce the speed rapidly.
Check whether the circuit and plug resistance of combined device and speed sensor are conducted.
And the electrical resistance value shall be less than 0.5Ω.
Detect the waveform between input terminal of combined device and grounding of vehicle body, and
it shall be the rectangular wave with 12V.
Verify the change of frequency:
Verify the change of frequency along with vehicle speed, that is, the frequency shall increase with the
times of 7.08 Hz when the vehicle speed is increased from 10 to 20 to 30 km/h.
133
V. Tachometer
1. Principle
The tachometer of engine is used for indicating the running speed of engine. When the engine is running,
its rotating speed sensor will send rotating speed signals to ECM of engine. The ECM will send an
impulse square wave to the combined device according to the rotating speed of engine, then, the
combined device controls the pointer of tachometer of engine according to this signal in order to indicate
the actual rotating speed of engine.
Location Plan for Tachometer of Engine
2. Check for Tachometer
1) Connect the tachometer of engine.
Remarks：
It had better to use a fluxmeter type tachometer of engine to conduct the check. (Because the
fluxmeter only needs clipping on the high-voltage wire.)
2) Compare the reading of tachometer of engine with reading of tachometer in the vehicle under each
rotating speed of engine, and make sure that the difference between them is within the range of
standard value.
134
Comparison Table for Indicated Standard Range and Reference Frequency of Tachometer
Standard Rotating Speed (r/min) Reference Frequency (Hz)
750 25Hz
1050 35Hz
1500 50Hz
3000 100Hz
4500 150Hz
6000 200Hz
7500 250Hz
3. Trouble Check Process
Possible Cause
The tachometer doesn’t work. 1 The tachometer has troubles.

2 The wiring or connector has troubles.
Disconnect the connector B and C, and 1 is Check the

Abnormal
Repair it.
measure at the wiring’s side: abnormal. connector.
1. Measure whether there is a
pulsed voltage between #1
terminal of C and grounding part of
vehicle body when the engine is
running. Normal
Normal: there is a pulsed voltage.
2. Measure the continuity condition
between #2 terminal of B and
grounding part of vehicle body. Check the rotational speed
Normal: in conducted. sensor of engine, and repair it
if necessary.
Normal
2 is
abnormal. Check the wiring, and repair
Replacing the tachometer. it if necessary.
135
VI. Water Thermometer
An analog water thermometer (coolant thermometer) driven by stepper motor is used. And it is shown in
the following diagram.
Location Plan of Water Thermometer
The adopted coolant temperature sensor is a thermistor sensor, and its location is shown as the
following diagram:
The coolant temperature sensor is assembled

in the small circulating path of coolant behind Fig.1.6.008
engine.
1. Illustration on Water Thermometer
Below C——Low temperature zone
During start and warm-up, the engine will work in this zone for a short time. And in this temperature zone,
the engine shall be prevented from running with a high rotate speed, at the same time its working load
shan’t be overlarge.
136
Between C and H——Normal temperature zone The pointer shall be within this range when the
vehicle is traveling normally.
When the outside temperature is very high and load of engine is very heavy, the pointer may deviate
from this range. As long as the coolant alarm lamp doesn’t flash, the vehicle still can travel normally.
However, if it flashes to warn, the engine shall be shut and the cooling system shall be checked.
Above H——Overheated zone
If the pointer enters this red zone, it means that the engine is overheated. Please safely stop the vehicle
immediately, shut down the ignition switch and find out the cause after the engine is cooled off.
Illustration:
If the auxiliary headlamp is mounted in front of cold air inlet which is under the front bumper, it will affect
the circulation of cooling air and be harmful for cooling of engine. If the outside temperature is very high
and engine is working with a heavy load, the engine is easy to be overheated. The front spoiler is also
helpful for guiding cooling air. If it is damaged or even ruptures due to impact, the overheating of engine
may happen.
2. Check for Coolant Temperature Sensor of

Engine Fig.1.6.009
1) Dismount the coolant temperature sensor of

engine.
2) Immerge the sensor in hot water to measure

the electrical resistance.
3) See the following table for standard value.
4) Reassemble it after check.
Table for Electrical Resistance Parameters of Temperature Sensor
Temperature (℃) Resistance Value (Ω)/(PinA8)

60 153
85 66
110 29
125 20
3. Check for Water Thermometer
If the electrical resistance value of coolant temperature sensor of engine is normal, the circuit of sensor
and water thermometer shall be checked. If not, the maintenance or replacement shall be conducted.
Please refer to “Maintenance Volume of Circuit”.
137
VII. Fuel Oil Meter
The working condition of fuel oil meter is basically the same with the water thermometer, that is, an
analog instrument driven by stepper motor is used.
Location Plan for Fuel Oil Meter
When the floater changes with the oil level in fuel oil tank, the sliding contact linked with floater rod
responds to change the electrical resistance value of thick-film resistor. Therefore, when the fuel oil tank
is filled with fuel oil, the electrical resistance value of thick-film resistor is the smallest, and the pointer of
fuel oil meter points to the maximum scale value F. On the contrary, when the fuel oil in fuel oil tank is
used out, its electrical resistance value is the largest, and the pointer points to the minimum scale value
E.
1. Testing Method
1) Check the operation of fuel oil meter
When the pointer reaches the empty position (E), there is fuel oil of about 10 L in the fuel tank. And it
leaves the full position (F) only when the vehicle has traveled for a distance after the fuel tank is filled.
With oil remained, the quantity of fuel oil that can be added will lower than the marked capacity when the
oil is added renewedly.
138
2. Simple Check Process of Fuel Oil Meter
Dismount the connector of fuel oil meter

sensor sub-assembly.
Use special tools to connect the testing

Replace the fuel oil meter sensor
lamp (12V -3.4V) to the connector at the
sub-assembly.
side of wiring.
Normal
When ignition switch is at ON position, the Normal

testing lamp turns on. The pointer of fuel oil meter swings.
Abnormal
Repair the electrical wiring.

Replace the fuel oil meter.
Abnormal
Repair the electrical wiring.
3. Check for Fuel Oil Meter Sensor Sub-assembly

In order to check, please dismount the fuel oil meter sensor sub-assembly from fuel oil tank.
4. Electrical Resistance of Fuel Oil Meter Sensor Sub-assembly
1) Check whether the electrical resistance values among terminals of fuel oil meter sensor are within
the range of standard value when the floater of fuel oil meter sensor sub-assembly is at F position
(highest) and E(lowest) position.
Comparison Table for Electrical Resistance and Instrument Indication of Fuel Oil Meter Sensor
Scale Line Reference Resistance Value ( )

Empty 244±6
1/8(RED) 154±5
1/4 124±5
3/8 104±5
1/2 85±4
5/8 71±4
3/4 58±3
7/8 49±3
FULL 40±2
139
2) Check whether the electrical resistance value Fig.1.6.010

changes stably when the floater moves slowly
Stopper
between F (highest) and E (lowest) position.
Position F
5. Height of Floater of Fuel Oil Meter Sensor
(Highest)
Sub-assembly
Position E
(Lowest)
Move the floater and measure the height A of F
Stopper
(highest) and height B of E (lowest) when the
floater rod contacts the stopper.
Indicated reference value:
A: 275 mm
B: 158.8 mm
VIII. Alarm Lamp of Engine Oil Pressure
1. Illustration on Indicator Lamp
When ignition switch is on, this indicator lamp shall light immediately and go out after the engine is
started. If this lamp doesn’t go out after engine starting or it lights when the rotating speed of engine
exceeds 2000 r/min during traveling, stop the vehicle immediately, switch off the engine and check the
oil level of engine oil. If the oil level is too low, add oil immediately.
2． Testing of Indicator Lamp
Disconnect the connector from alarm lamp switch, and connect the connecting terminal in the end of
wiring to earth. Shift the ignition switch to “ON”, and alarm lamp shall light. If not, the bulb shall be tested.
3. Engine Oil Pressure Switch
Engine oil pressure switch
Combined
device
Basic Diagram for Circuit of Engine Oil Pressure Switch

① Disconnect the connector from switch.
② When engine stops, the terminal and earth shall be conducted.
③ When engine runs, the terminal and earth shan’t be conducted.
Notes: The engine oil pressure shall be higher than 24. 5 kPa (0.25 kilopond/cm2, 3. 55 Lbf/Square
inch). If the actual conditions don’t comply with the specified conditions, the switch shall be replaced.
140
IX. Alarm Lamp of Braking System
1. Illustration on Alarm Lamp of Braking System
This lamp works when ignition switch is turned on.
And it keeps on when the parking brake is placed.

Diagram for Alarm Lamp of Braking System
If the lamp is still on after the parking brake is released, then the oil level of brake fluid is too low.
Therefore, the brake fluid shall be added until its level is between MIN and MAX marks.
2. Testing of Alarm Lamp of Braking System
Disconnect the connector from the switch of alarm lamp of brake fluid, loose the parking brake, and start
the engine. At this moment, the alarm lamp shall turn on, if not, test the bulb and wiring.
3. Check for the Switch of Alarm Lamp of Brake Fluid Level
Dismount the stock solution tank cover and strainer screen, disconnect the connector, and shift the
switch to “OFF” position (the floater floats). At this moment, the terminals shall not be conducted. Use a
siphon to suck out the liquid in stock solution tank and shift the switch to “ON” position (the floater falls).
And now, the terminals shall be conducted. At last, pour the liquid back in stock solution tank. If the
actual conditions don’t comply with the above conditions, the switch shall be replaced.
X. Alarm Lamp of Door Open
1. The alarm lamp shall light when any door or trunk is opened.
2. If the alarm lamp doesn’t light, disconnect the connector of courtesy lamp switch and connect the
terminal 1 at the end of wiring to earth. In this condition, it shall turn on, if not, check the bulb or
wiring.
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Section VII Windscreen Wiper and Its Cleanser

I. System Composition
As the traveling safety will be affected when the dust and dirt on the windscreen is not cleared in time,
the wiper washing system is applied on the vehicle. This model of vehicle equipped the wiper with 2
speeds and intermittent working mode and consists of drive motor, worn gear mechanism, rocker arm,
wiper blade, etc.; the washing system consists of washer reservoir, motor, pipeline, spray nozzle and so
on.
II. Precautions
Before dismounting the electrical connecting wire of system, dismount the negative pole of storage
battery and wait for at least 1min, otherwise, it may cause physical injury.
III. Front Windscreen Wiper
The motor of front windscreen wiper, which is controlled by combined switch and timing relay of
windscreen wiper, can run at 2 speeds and connect with a limit switch for stop position.
When the ignition switch is set at “ON” position, the following 4 functions are available:
1) Shutdown.
2) Intermittent operation of windscreen wiper.
3) Low-speed operation of windscreen wiper.
4) High-speed operation of windscreen wiper.
142
Location Plan of Element of Front Windscreen Wiper
ETACS module
Windscreen wiper
switch
Terminal
Function
Intermittent
relay of front
windscreen
wiper
Intermittent
Low speed
High speed
Adjustment of
interval
Motor of front windscreen wiper
Schematic Diagram of Windscreen Wiper
3. Pressure Check at Wiper Arm End
1) Make the wiper arm and wiper blade run to the middle position.
2) Dismount the wiper blade from the wiper arm.
143
3) Connect the spring to one end of the wiper arm and measure the required torque for lifting the
wiper arm to normal working height when it is vertical to the windscreen (the specified value is
6~8N•m).
4) Replace the wiper arm when the measured value does not conform to the specified value.
5) Mount the wiper blade on the wiper arm.
4. Adjustment and Check of Wiper Blade Rubber Strip
1) Dismount the wiper blade from the wiper arm,
2) Check the length of rubber strip of wiper blade.
3) Replace the rubber strip of wiper blade when the rubber parts contacting with the windscreen is not
within wiper blade centerline ±15°.
4) Mount the wiper blade on the wiper arm.
5. Check of Front Windscreen Wiper Switch
During the application of the following 4 functions of front windscreen wiper switch: OFF, intermittent
operation, low-speed operation and high-speed operation, check if its conductivity complies with the
figure below. If not, replace the switch.
Terminal
Function
Intermittent
Low speed
High speed
Adjustment of
interval
Inspection Diagram of Front Windscreen Wiper Switch

6. Check of Front Windscreen Wiper Motor
1) Dismount the connector of windscreen wiper motor.
Circuit Diagram of Windscreen Wiper Motor
144
2) Connect the positive pole of storage battery with pin 4 of front windscreen wiper motor and connect
the negative pole with pin 2, so that the motor of front windscreen wiper will operate at high speed. If
not, please replace the motor of front windscreen wiper.
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed. If
not, please replace the motor of front windscreen wiper.
the negative pole with pin 1, so that the motor of front windscreen wiper will operate at low speed.
Then cut off the connection between pin 1 of motor terminal and negative pole of storage battery
during the operation of windscreen wiper motor. Check the conductivity between pin 4 and 5 with
multimeter. If the specification is not complied with, please replace the motor of front windscreen
wiper.
7. Replacement of Windscreen Wiper Arm
① Push it to the bottom of clamp of windscreen wiper blade and dismount the windscreen wiper blade
from the inner side of wiper arm.
② Take out the wiper arm from the opening of wiper blade.
① Place the wiper blade claw groove inside the wiper arm claw.
② Pull the wiper blade claw groove into the wiper arm claw until the claw groove is fixed into the hook.
③ Actuate the windscreen wiper and check if it is working normally.
8. Replacement of Rubber Strip of Windscreen Wiper Blade
Attention:
If the rubber strip from windscreen wiper blade is dismounted, replace it with a new one.
① Dismount the wiper blade from wiper arm. Fig. 1.7.001

Please refer to “Replacement of Windscreen Wiper
Blade and Arm”.
② Dismount the lower claw of wiper blade from
the scotch in rubber strip of wiper blade.
③ Take out the rubber strip of wiper blade
through the claw of wiper blade.
145
Attention:
Keep the wiper blade claw in the slide track of rubber claw of wiper rubber strip, and do not let the
wiper blade claw contact with the metal groove of wiper rubber strip.
① Insert the opening end of rubber strip of wiper blade into the lower claw of wiper blade.
② Introduce the rubber strip of wiper blade into the sub-assembly of wiper blade claw.
③ Insert the lower claw of wiper blade rubber strip into the wiper blade notch.
④ Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
9. Replacement of Front Windscreen Wiper Arm

① Set the ignition switch at OFF position.
② Set the wiper switch at OFF position.
③ Take off the nut cap.
④ Dismount the nut from wiper arm.
⑤ Dismount the wiper arm form the drive shaft of

Fig. 1.7.003
wiper transmission by rocking.
① Set the ignition switch at “ON” position.
② Set the wiper switch at low-speed position and shut down the low-speed gear after the wiper motor
is actuated.
③ Turn off the ignition switch when the transmission system of windscreen wiper is stopped.
④ Mount the wiper arm on drive shaft of wiper transmission.
146
⑤ Mount the nut on the drive shaft of wiper transmission and the wiper arm and tighten it.
Tightening torque: 10~12N'm
⑥ Mount the nut cap.
⑦ Operate the windscreen wiper to check if its operation is normal.
10. Replacement of Transmission Parts of Front Windscreen Wiper

① Disconnect the negative pole of storage
battery.
② Dismount the wiper arm from the drive shaft of

wiper driving rod. Please refer to “Replacement of
Windscreen Wiper Blade”.
③ Prize up the waterproof strip of engine
department.
Fig. 1.7.005
④ Dismount the 2 screws on the right ventilation Fig. 1.7.006

window.
147
⑤ Dismount the right ventilation window. Fig. 1.7.007
⑥ Dismount the 2 screws on the left ventilation Fig. 1.7.008

window.
⑦ Dismount the left ventilation window. Fig, 1.7.009
⑧ Dismount the rocker arm of wiper motor from Fig. 1.7.010

the wiper driving rod.
148
⑨ Disconnect the connector of front windscreen Fig. 1.7.011

wiper.
⑩ Dismount the fixing screw for front windscreen Fig. 1.7.012

motor assembly.
⑪. Take off the front windscreen wiper motor

assembly.
⑫. Dismount the fixing screw for wiper
transmission system.
Fig. 1.7.013
⑬. Dismount the driving rod assembly of

windscreen wiper.
149
① Mount the driving rod assembly of windscreen
wiper.
② Mount the fixing screw for wiper transmission
system.
■ Tightening torque: 9~12N•m.
Fig. 1.7.014
③ Mount the front windscreen wiper motor Fig. 1.7.015

assembly.
④ Dismount the screw for the front windscreen
wiper motor assembly.
■ Tightening torque: 3.5~4.5N•m.
⑤ Mount the connector on the wiper motor. Fig. 1.7.016

⑥ Connect the driving rod of windscreen wiper
with the rocker arm of windscreen wiper motor.
⑦ Mount the left ventilation window.
150
⑧ Mount the 2 screws for left ventilation window.

■ Tightening torque: 1.4N•m.
Fig. 1.7.017
⑨ Mount the right ventilation window.
Fig. 1.7.018
⑩ Mount the 2 screws for right ventilation

window.
■ Tightening torque: 1.4N•m
Fig. 1.7.019
151
⑪. Mount the waterproof strip of engine

compartment. Fig. 1.7.020
⑫. Mount the wiper arm on the drive shaft of

wiper driving rod. Please refer to Fig. 1.7.021
“Replacement of Windscreen Wiper Arm”.
⑬. Mount the negative pole of storage battery.
⑭. Operate the wiper to check if its operation is

normal.
IV. Rear Windscreen Wiper
Fig. 1.7.022
152
2. Circuit Diagram
Rear windscreen wiper switch
Intermittent relay of rear

Terminal
windscreen wiper
Function
Rear windscreen
wiper ON
Rear windscreen
wiper OFF
Circuit Diagram of Rear Windscreen Wiper

3. Detection of Element
1) Check of rear windscreen wiper switch
Turn on the rear windscreen wiper switch and check if the conductivity between terminal 2 and 3
conforms to the figure below. If not, replace the switch.
Terminal
Function
Rear windscreen wiper

ON
Rear windscreen wiper

OFF
Terminal Diagram of Rear Windscreen Wiper Switch
2) Check of rear windscreen wiper motor
① Disconnect the connector of rear windscreen wiper motor.
② Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor, and
then connect the negative pole with terminal 2, so that the rear windscreen wiper motor will be
actuated. If not, replace the rear windscreen wiper motor.
153
Circuit Diagram of Rear Windscreen Wiper Motor
③ Connect the positive pole of storage battery with terminal 1 of rear windscreen wiper motor and
connect the negative pole with terminal 2. Then cut off the connection between terminal 2 of motor
and negative pole of storage battery during the operation of rear windscreen wiper motor. Check the
conductivity between pin 3 and rear windscreen wiper motor with multimeter. If the specification is
not complied with, please replace the motor of rear windscreen wiper.
4. Replacement of Rear Windscreen Wiper Arm
① Set the ignition switch at “ON” position.
② Set the wiper switch at OFF position.
③ Turn off the ignition switch when the rear windscreen wiper arm is stopped.
④ Dismount the nut cap.
Fig. 1.7.023
⑤ Dismount the nut and gasket from the motor shaft.

⑥ Dismount the rear windscreen wiper arm.
⑦ Dismount the wiper blade from the windscreen wiper. Please refer to “Replacement of Windscreen
Wiper Arm and Blade”.
154
① Mount the wiper blade on wiper arm. Please refer to “Replacement of Windscreen Wiper Arm and
Blade”.
② Mount the rear windscreen wiper arm on the motor shaft:
Set the ignition switch at “ON” position.
Set the rear windscreen wiper switch at OFF position.
Turn off the ignition switch when the transmission system of windscreen wiper is set at stop position
and doesn’t move.
Mount the rear windscreen wiper arm on the motor shaft.
③ Mount and tighten the washer and nut on motor shaft.
Tightening torque: 10.0~11.0N•m
④ Press down the cap.
⑤ Operate the rear windscreen wiper to check if its operation is normal.
V. Cleanser of Windscreen Wiper

Fig. 1.7.024
155
2. Schematic Diagram
EATCS module
Terminal
Function
Windscreen wiper switch

Intermittent
Low speed
High
speed
Front
Intermittent relay of front

Intermittent windscreen wiper washing
relay of
rear Adjustment
windscreen of interval
wiper
Rear washing
Rear windscreen
wiper ON
Rear
water Rear windscreen
spray wiper OFF
motor
Rear windscreen wiper Front windscreen wiper

motor motor
Front water spray
motor
Schematic Diagram of Cleanser of Windscreen Wiper

3. Detection of Element
Terminal
Function
Intermittent
Low speed
High
speed
Front washing
Adjustment of
interval
Rear
washing
Rear
windscreen
wiper ON
Rear
windscreen
wiper OFF
Terminal Diagram of Cleanser Switch of Windscreen Wiper

156
1) Check of Cleanser of Windscreen Wiper

① Open the cleanser of rear windscreen wiper to check if the conductivity between terminal 1, 2 and 3
conforms to the figure below. If not, replace the switch.
② Open the cleanser of rear windscreen wiper to check if the conductivity of terminal 5 and 8 conforms
to the figure below. If not, replace the switch.
2) Check of cleanser motor of windscreen wiper
① Dismount the connector of cleanser motor of windscreen wiper.
② Connect the positive pole of storage battery with terminal 1 of cleanser motor of windscreen wiper,
and then connect the negative pole with terminal 2, so that the cleanser motor of windscreen wiper
will be actuated. If not, replace the cleanser motor of windscreen wiper.
Circuit Diagram of Cleanser Motor of Windscreen Wiper

4. Replacement of Solvent Tank, Pump Nozzle and Hose of Cleanser
② Dismount the front bumper. Please refer to “Replacement of Front Bumper”.
③ Dismount the headlamp. Please refer to “Replacement of Headlamp”.
④ Dismount the front wheel cover. Please refer to “Left Front Wheel Cover”.
⑤ Disconnect the hose on cleanser pump.
⑥ Disconnect the electrical connector on cleanser pump.
⑦ Dismount the nut on flange of solvent tank of cleanser.
157
⑧ Dismount the solvent tank of cleanser from the

right side of vehicle. Fig. 1.7.025
⑨ Dismount the pump on solvent tank of

cleanser.
⑩ Dismount the pump seal from solvent tank.
⑪ Dismount the clamp from claw groove of Fig. 1.7.026

engine hood.
⑫ Dismount the connecting hose of nozzle from
the engine hood.
⑬ Dismount the nozzle assembly from the
engine hood.
① Mount the nozzle assembly on engine hood.
② Mount the hose assembly on engine hood.
③ Connect the nozzle and hose, and then mount the nozzle on engine hood.
④ Mount the sealing element on solvent tank of cleanser.
⑤ Mount the water injection pump on solvent pump of cleanser.
⑥ Mount the solvent pump of cleanser at the right side in front of vehicle.
⑦ Mount the nut to fix the solvent tank.
■ Tightening torque: 1.5~2.0N•m
⑧ Connect the hose and pump.
⑨ Mount the hose clamp on the claw groove of engine hood.
⑩ Connect the electrical connector with water injection pump.
⑪ Mount the negative pole of storage battery.
158
5. Replacement of Rear Nozzle and Rear Hose
① Disconnect the rear hose on cleanser pump.
② Dismount the seal ring from the left side of vehicle.
③ Dismount the rear nozzle from rear lift gate and disconnect the rear hose on rear nozzle.
④ Dismount the claw grooves from rear lift gate and left side of vehicle.
⑤ Dismount the rear hose from the left side of vehicle body.
① Mount the ear hose on left side of vehicle body.
② Mount the seal ring on left side of vehicle body.
③ Connect the rear hose and cleanser pump.
④ Get the hose through claw groove and mount the rear hose in rear lift gate.
⑤ Mount the claw groove on rear lift gate and left side of vehicle body.
⑥ Connect the hose and rear nozzle, and then mount the rear nozzle on rear lift gate.
VI. Overhaul for Trouble
Check List for Common Troubles
Common Trouble Trouble Cause and Troubleshooting Method

1. Jamming of movable parts 1. Eliminate the jamming trouble
2. Disconnection of power supply and falling 2. Connect the power supply
Operation stop
of wire end of connector 3. Replace the motor with a new
3. Burnout of motor one
1. Abnormal sound arising from inside of 1. Replace the motor
motor 2. Eliminate the trouble of hit and
Abnormal sound and 2. Hit and rub of interlock mechanism during rub
operation movement 3. Clean the windscreen
3. Abnormal sound arising from the place
between blade and windscreen
Judder of blade during Fill detergent into washing solution kettle to decrease the friction during water
scraping injection and scraping
Out-of-level of blade Dismount the wiper arm for reinstallation to keep the blade leveled
1. Uncleanness of windscreen 1. Wash the windscreen to be
2. Severe abrasion of blade clean
Failure of wiping 2. Replace the blade (it is
recommended to replace it every
3 months)
159
1) Check of Cleanser System of Windscreen Wiper
Check List of Cleanser System of Windscreen Wiper
Step Measure Normal Result Abnormal Result

The windscreen wiper operates at
low speed. The cleanser keeps
Set the ignition switch at spraying to windscreen when its
RUN position. Keep the switch is set at “ON” position. After The cleanser fails to
1
cleanser switch at “ON” the switch is turned off, the cleanser work.
position. stops working and the wiper returns
to stop position after wiping for 2~4
times.
The delay mode of wiper
Set the windscreen wiper The wiper operates for a cycle, fails to work.
2 switch at delay (pulse mode) pauses for 1-22s, and then operates The defogging, delay
position. for next cycle. and low-speed modes of
wiper fail to work.
The cleanser keeps spraying to The cleanser fails to
windscreen when its switch is set at work.
Set the windscreen wiper “ON” position. The windscreen wiper The delay mode of wiper
switch at delay position and operates at low speed during water fails to work.
3
keep the wiper switch at injection and continues to operate for The defogging, delay
“ON” position for 1-2s. 2-4 times after the cleanser switch is and low-speed modes of
turned off. Then the wiper will go wiper fail to work.
back to pulse operation mode.
Set the windscreen wiper The defogging, delay
The wiper continues to operate at low
4 switch at low-speed and low-speed modes of
speed.
position. wiper fail to work.
The high-speed mode of
Set the windscreen wiper at The wiper continues to operate at wiper fails to work while
5
high-speed (HI) position. high speed. the low-speed mode is
available.
The windscreen wiper
Set the windscreen wiper at The wiper gets back to stop position can not stop working
6
OFF position. at low speed. The wiper keeps
working.
The delay mode of wiper
fails to work due to
Set the rear windscreen
malfunction. The
7 wiper switch at “ON” The wiper pauses for about 8s.
defogging, delay and
position.
low-speed modes of
wiper fail to work.
160
2) Diagnosis Procedure for Windscreen Wiper/Cleanser System
Trouble mode: the wiper and cleanser fail to work no matter of the position the wiper switch is set at
Step Measure Yes No

1 Check if the wiper fuse is broken. To step 3 To step 2
Dismount the wiper switch and check if it is in good condition.
Measure the wire harness with digital multimeter.
2 To step 5 To step 4
Check if the pressure within the area between connector and
wiper switch is normal.
3 Replace the broken fuse. To step 2
Check the console wire harness between fuse and wiper switch
4 and repair it when necessary. To step 5
Make sure the wiper switch and connector of wire harness contact
properly. Disconnect the wire harness and wiper motor, check the
5 To step 6
console wire harness between wiper switch & fuse and wiper
motor according to circuit diagram and repair it when necessary.
Check the wiper motor and repair it when necessary. Make sure
6 the wiper motor is in good condition and the connector of wiper To step 7 -
motor contacts properly.
Check the earth wire of wiper motor at wire harness of console
7 To step 8
and repair it when necessary.
8 Check if the system is in good condition.
3) Trouble mode: only the high-speed gear fails to work
Step Measure Yes No

Disconnect the wire harness connector from the wiper motor.
1 Measure the pressure of pin at wire harness side is normal with To step 2 To step 3
digital multimeter.
Check the internal structure of wiper motor and replace or repair it
2
when necessary.
Dismount the wiper switch and check if it is in good condition. Check
the console wire harness between wiper switch and wiper motor and
3
repair it when necessary.
4) Trouble mode: only the mid-speed gear fails to work
Step Measure Yes No

Disconnect the wire harness connector from the wiper motor. Check
1 if the pressure of pin measured at wire harness side with digital To step 2 To step 3
multimeter is normal.
Check the internal structure of wiper motor and replace or repair it
2
when necessary.
Dismount the wiper switch and check if it is in good condition.
3 Replace or repair it when necessary. To step 4
Check the console wire harness between wiper switch and wiper
4 motor and repair it when necessary.
161
5) Trouble mode: only the interval gear fails to work
Step Measure Yes No

Dismount the wiper relay, set the ignition device at “ON” position
and turn the wiper switch to the inner gear position. Check if the
pressure of pin measured on the relay with digital multimeter is
normal.
Dismount the wiper switch and check if it is in good condition; if
2 To step 3
not, replace or repair it when necessary.
3 To step 7
relay and repair it when necessary.
4 Check the earth wire at relay is properly earthed. To step 6 To step 5
5 Repair the earth wire and make sure it is earthed properly.
6 Replace the wire relay. Check if the system is in good condition.
Check the console harness between wiper switch and relay to
make sure it is in good condition.
Dismount the new wiper relay and check if the pressure measured
8 To step 10
at relay with digital multimeter is normal.
Please check if the console wire harness is in good condition and
9 To step 10
repair it when necessary.
Check if console wire harness between relay and wiper motor is in
10 good condition and repair the console when necessary; check if
the system is in good condition.
6) Trouble mode: the wiper blade does not stop at its original position
Step Measure Yes No

Dismount the wiper switch and check its internal structure. Replace
1 or repair the switch when necessary and make sure it is in good To step 2
condition.
Disconnect the connector of wiper motor; check if the pressure of
pin measured at wire harness side with digital multimeter is normal.
Check if the console wire harness between the fuse and wiper
3 To step 4
motor is in good condition according to the circuit diagram.
Dismount the wiper motor to check the structure; repair or replace it
4
when necessary. The system is in good condition.
162
7) Trouble mode: the wiper keeps working
Step Measure Yes No
1 Check if the fuse is in good condition. To step 2 To step 3

2 Replace the broken fuse. To step 3
Dismount the wiper switch and check if the pressure measured at
3 the switch with digital multimeter is normal. To step 5 To step 4
Check the console wire harness between the fuse and wiper switch
and repair it when necessary.
Check the internal structure of wiper switch and replace or repair
5 the switch when necessary. Make sure the switch is in good To step 10
condition. Check if the system is in good condition.
Disconnect the connector from wiper motor, set the ignition switch
at “ON” position, turn the wiper switch to high-speed position and
check if the pressure measured at the connector pin (wire harness
side) with digital multimeter is normal.
Check if the console wire harness between wiper switch and wiper
relay is in good condition.
8 Check if the earth wire is earthed properly with digital multimeter.
Dismount the wiper motor and repair or replace it. The system is in
9 To step 10
good condition.
motor according to circuit diagram; repair it when necessary and
10
make sure it is in good condition. Check if the system is in good
condition.
8) Trouble mode: the cleanser fails to work
Step Measure Yes No

Dismount the wiper/cleanser switch; set the ignition switch at “ON”
1 position; check if the pressure of pin measured at the original position To step 3 To step 2
of switch with digital multimeter is normal.
Check the console wire harness between fuse and wiper/cleanser
2 switch and repair it when necessary. Make sure it is in good condition. To step 3
Check the internal structure of wiper switch. Repair or replace it when

3 necessary and make sure it is in good condition. Check if the system is To step 4
in good condition.
Mount the wiper/cleanser switch; disconnect the connector of cleanser
motor and set the wiper/cleanser switch at “Washing” position. Check if
the pressure of pin measured at the connector of cleanser motor (wire
harness side) with digital multimeter is normal.
Check and repair the wire harness between wiper/cleanser and
5 To step 6
cleanser motor according to circuit diagram.
Please check if the console wire harness between wiper motor and
6 wiper/cleanser switch is in good condition according to the circuit To step 7
diagram.
7 Replace the cleanser motor. Check if the system is in good condition.
163
Section VIII Horn and Cigar Lighter

I. Location of Elements
1. Horn button Fig.1.8.001
2. Horn Fig.1.8.002
II. Basic Diagram
Connect the storage battery
Bass horn
Horn
button
Basic Diagram of the Horn System
164
III. Check of Horn
1. Dismantle the front bumper. Refer to “Replacement of Front Bumper”.
2. Disconnect the connector of the horn.

Fig.1.8.003
1 2
3. Connect terminal 1 of the horn with the positive pole of the storage battery and connect terminal 2
with the negative pole of the storage battery, and then the horn will sound.
4. If the horn doesn’t sound, replace it.
IV. Overhaul for Trouble
Steps Measure Normal Result Abnormal Result

When the horn button is pressed
Press and release the down, the horn will sound; when the The horn is out of work.
1
horn button horn button is released, the horn will Horn-with abnormal noise
stop sounding.
1. The horn is out of work.
Steps Measure Yes No

Check whether the horn fuse is broken.
1 To step 3 To step
Is the horn fuse burned out?
1. Pull out the connector of the horn assembly.
2. Connect terminal 1 of the connector of the horn
2 assembly with terminal 2 with the test lamp. To step 4 To step 5
3. While pressing down the horn button, watch the test
lamp. Is the lamp lightened?
To “Check of the
3 Replace the horn fuse _
Horn System”
To “Check of the
4 Replace the horn assembly _
Horn System”
1. Connect the horn again.
2. Disconnect the horn relay.
165
3. Connect pin 4 and pin 8 of the relay with the test lamp.
Does the horn sound?
1. Install the horn relay again.
2. Disconnect the electrical system of the airbag.
3. Dismantle the lead of the horn switch from the steering
wheel.
4. Connect joint 1 and joint 2 of the horn button with the
test lamp. Does the horn sound?
To “Check of the
7 Replace the button horn -
Horn System”
1. Place the test lamp at the same position (between joint 1
and joint 2 of the horn button).
8 2. Connect pin 4 with the pin 8 of the horn relay terminal To step 9 To step 10
temporarily with a 5 A fuse.
Is the test lamp lightened?
To “Check of the
9 Replace the horn relay -
Horn System”
Check whether the grounding is good and connect the test
lamp:
10 1. Terminal 8 of the horn relay and the ground. To step 11 To step 12
2. Terminal 1 of the horn button and the ground.
Is the test lamp lightened?
To “Check of the
11 Repair lead of bad grounding _
Horn System”
To “Check of the
12 Repair circuits of poor contact _
Horn System
2. Abnormal noise of the horn

1) Press the horn button to identify items concerned by the vehicle owners. Please refer to “Check of
the Horn System”.
2) If the horn has obviously abnormal noise, conduct the following routine check:
① Check whether the terminal is poorly contacted, if any, repair it.
② Check the grounding connection for obviously poor contact, if any, repair it.
③ Make sure that the fixed bolt of the horn assembly is properly fixed.
④ Make sure that there is no contact between the horn assembly and any other objects. If the contact
occurs, re-determine the correct positions of other objects or bend the support of the horn assembly
as required.
3) Press the horn button and check whether the situation still exists. If it still exists, please figure out
the type of the tone produced by the horn:
■ Low tone.
■ High-pitched and weak tone.
166
① With obviously low tone, the current voltage may be too high and the circuit check is required. If the
circuit is normal, replace the horn assembly. Refer to “Replacement of Horn”.
② With obviously high-pitched and weak tone, the horn may have foreign substances on it. Dismantle
the horn assembly and check whether there are any foreign substances on it. Refer to
“Replacement of Horn”.
③ Wipe off the adhesive foreign substances and re-install the horn assembly.
④ If any adhesive foreign substances are found or such substances can’t be wiped off, replace the
horn assembly.
4) Press the horn button and check that the concerned items have been rehabilitated. Refer to “Check
of Horn”.
V. Replacement of Horn
Precautions:
■ Strictly comply with the precautions for operation of the airbag system. Refer to “Airbag System”.
① Open the engine hood and dismantle the front bumper. Refer to “Replacement of the Front
Bumper”.
② Dismount the fixing bolt of the horn.
Fig.1.8.004
③ Disconnect the connector of the horn. Fig.1.8.005
④ Dismantle the horn assembly.
① Install the horn assembly.
■ Tightening torque: 5 N•m
167
② Connect the connector of the horn assembly. Fig.1.8.006
③ Close the engine hood.
VI. Replacement of Horn Button
① Dismantle the negative pole of the storage

battery.
② Turn the ignition switch to the “OFF” position.
③ Dismantle the fixing bolt of the driver airbag

module.
■ Rotate the steering wheel with its center as

the axis so as to take off the second screw.
④ Remove the driver airbag module and Fig.1.8.007

disconnect the connector of the module
electrical appliance.
⑤ Disconnect the connector of the horn button Fig.1.8.008

on the steering wheel.
⑥ Dismount the fixing screw of the left and right

horn buttons.
⑦ Take off the horn button assembly.
168
① Place the horn button assembly in.
② Connect the connector of the horn button on the steering wheel.
③ Install the left and right fixing screws of the horn button (four screws).
■ Tightening torque: 2 N•m.
Fig.1.8.009
Attention:
■ L refers to left side and R, right side.
④ Put in the driver airbag module. Connect the
connector of the module electrical appliance.
While installing, make sure that the circuit
installation is correct and reliable.
⑤ Install the fixing screw of the driver airbag
module.
■ Tightening torque: 2 N•m Fig.1.8.010
⑥ Install the negative pole of the storage battery.

⑦ Check the following components:
■ Horn
■ Steering wheel
■ Airbag system
169
VII. Cigar Lighter

Light the cigar after the cigar lighter is heated. Press the cigar lighter into the socket of the cigar lighter
and while the cigar lighter rebounds, light the cigar.
1. Schematic Diagram
Connect the storage battery
Small lamp relay
Cigar
lighter
Schematic Diagram of the Cigar Lighter

2. Trouble Diagnosis
1) Check of the cigar lighter system
Step Measure Normal Result Abnormal Result

Press the cigar lighter into the socket While the negative pole is electrified,
The cigar lighter is
1 of the cigar lighter until the click the cigar lighter will jump to the edge
out of work.
sound is heard. of the cigar lighter.
The lamp of the cigar lighter is The cigar lighter is
2
lighted. off.
2) The cigar lighter is out of work.
Step Measure Yes No

Check the fuse
Is the fuse broken?
Connect the positive pole and the negative pole of the
2 cigar lighter with a test lamp and check whether there To step 5 To step 3
is current and whether the test lamp is lightened?
3 Is the cigar lighter lightened? To step 6 To step 7
4 Replace the fuse - To “Check of System”
5 Replace the cigar lighter - To “Check of System”
6 Replace the lamp of the cigar lighter - To “Check of System”
7 Repair connections of bad contact - To “Check of System”
170
Section IX Audio System

I. Location Plan of Elements
1. Main machine of audio 2. Rear loudspeaker
II. Basic Diagram of Audio System
Small lamp relay
CD player Antenna
Left high
loudspeaker
loudspeaker
loudspeaker
Right door
Right high
loudspeaker
loudspeaker
Left rear
pitch
Right rear
Left door
pitch
loudspe
aker
Basic Diagram of Audio System
171
III. Illustration of Audio Changer
Illustration Table of Audio Changer
No. Function No. Function

1 Automatic antenna (+) 9 Illumination (+)
2 Left rear loudspeaker (+) 10 Right rear loudspeaker (-)
3 Left front loudspeaker (+) 11 Right front loudspeaker (-)
4 Right front loudspeaker (+)) 12 Empty
5 Right rear loudspeaker (+) 13 Empty
6 Empty 14 Left front loudspeaker (-)
7 Ignition switch 15 Left rear loudspeaker (-)
8 Memory power supply (+) 16 Grounding
IV. Replacement of Audio Changer and Antenna Fig.1.9.001
1. Replacement of Audio Changer
① Disconnect the negative pole of the storage

battery.
② Dismantle the cover plate of the middle console.
Precautions:
■ Only the comparison of front loudspeaker with

other front loudspeakers, and the rear
loudspeaker with other rear loudspeakers can be
carried out. Don’t compare front loudspeakers
with rear loudspeakers, for the front loudspeaker
and the rear loudspeaker may be of different
types and their different installation
environments may lead to different sound
effects.
172
③ Dismantle the glove box with two fixed bolts. Fig.1.9.002
④ Unscrew the nuts of the audio changer. Fig.1.9.003
⑤ Pull out the audio changer forward, disconnect

Fig.1.9.004
the electrical connector and dismantle the
audio changer assembly.
2) Install in reverse order with dismantlement, and check whether the audio changer works normally.
2. Replacement of the antenna signal cable
① Remove the right-side carpet located in front of the front passenger and dismantle the interior plate
of the door. Refer to “Replacement of the Trimming Plate—Carpet and Interior Plate in Interior
Trimming”.
173
② Disconnect the antenna signal cable from the lead of the antenna amplifier. Disconnect the antenna
signal cable at the back of the audio changer. Refer to “Replacement of the Audio Changer”.
Fig.1.9.005
2) Installation steps: Fig.1.9.006

① Install the antenna signal cable.
② Connect the antenna signal cable at the back

of the radio and install the radio. Please refer
to “Replacement of the Radio”. Connect the
antenna signal cable with the lead of the
antenna amplifier.
③ Install the insulator of the right console. Refer to “Replacement of the Console”.
V. Replacement of Rear Loudspeaker of Fig.1.9.007

Three-carriage Car
1) Dismantle the trimming plate of the rear

window. Refer to “Replacement of the
Trimming Plate”.
2) Disconnect the electrical connector of the rear

loudspeaker.
174
3) Dismantle the 6 bolts for the rear loudspeaker, including 3 ones on the left and 3 ones on the right.
Fig.1.9.008
4) Dismantle the rear loudspeaker
1) Mount 6 bolts of the rear loudspeaker.
2) Connect the electrical connectors of the rear loudspeaker.
3) Install the rear trimming shelf panel. Refer to “Replacement of the Trimming Plate—Rear Shelf
Panel in the Interior Trimming”
VI. Replacement of Rear Loudspeaker of Two-carriage Car
1) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at Boot’s
Side”.
2) Dismount 6 fixed bolts for the rear loudspeaker.
3) Gently lift the rear part of the loudspeaker outward.
4) Disconnect the electrical connector of the rear loudspeaker.
5) Dismantle the rear loudspeaker.
1) Connect the connector of the rear loudspeaker.
2) Install 6 bolts of the rear loudspeaker.
3) Dismantle the lateral trimming plate. Refer to “Replacement of the Inner Trimming Plate at the
Boot’s Side”.
175
VII. Replacement of Front Door Loudspeaker
1) Dismantle the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming
Plate of the Front Door”.
2) Disconnect the electrical connector of the front Fig.1.9.009

door loudspeaker.
3) Dismount the bolts for the front door Fig.1.9.010

loudspeaker.
4) Dismantle the front door loudspeaker. Fig.1.9.011

1) Put the front door loudspeaker in.
2) Mount 3 bolts for the front door loudspeaker.
3) Connect the electrical connector of the front door loudspeaker.
176
Fig.1.9.012
4) Install the inner trimming plate of the front door. Refer to “Replacement of the Inner Trimming Plate
of the Front Door”.
177
Section X Parking Auxiliary System

Parking auxiliary system (reversing radar) consists of sensor, control module and warning device. On
the basis of ultrasonic ranging principle and computer data fuzzy processing technology, the parking
auxiliary system can judge whether there are any obstacles in the reversing direction of vehicle, and
suggest the distance from the nearest obstacle. When the gear is shifted to reverse, the reverse switch
is turned on, and the reversing light goes on. After the controller receives the reversing signal, it will
command the ultrasonic sensor to send out ultrasonic signal, then based on the self-transmitting and
self-receiving and multiple transmitting and single receiving principles, the echoed signal is completely
and accurately transmitted to the controller. Upon the echoed signal is analyzed and processed by the
controller, it will determine whether there’s any obstacle in the detection range, and the distance from the
nearest obstacle, and then it communicates with the buzzer, gives out the warning tones of different
frequencies according to different distance ranges, to suggest the distance from obstacle, and realize
the function of safety warning.
Location Plan for Elements of Parking Auxiliary System
1- Sensor of parking auxiliary system 2- Parking auxiliary system Module 3- Buzzer
178
II. Basic Diagram
Sensor Sensor Sensor
Buzzer
Power supply
Controller
Assembly
Ground
Basic Diagram of Parking Auxiliary System
III. Testing of Elements
1. Check whether the power supply of parking auxiliary system sensor is working normally (9V〜16V).
2. The parking auxiliary system connects the control module assembly, sensor assembly and buzzer
assembly together through the wire harness; the terminals of each assembly are defined as follows:
Definition List of Sensor Terminals
Connector Diagram Pin Number Signal Name Note
1 Signal Probe signal
2 GND Ground
179
Definition List of Terminals of Buzzer Assembly
1 BUZ Driving signal
2 GND Ground
Definition List of Terminals of Parking Auxiliary System Module

Power supply of
l R_shift
reverse gear
2 NC
3 NC
4 NC
5 NC
6 NC
7 S_L Left probe
8 S-CL Middle probe
9 NC
10 NC
11 NC
12 NC
13 NC
14 BUZ Buzzer control
15 S-R Right probe
16 GND Ground
180
IV. Replacement of Control Module of Parking Auxiliary System
1. Steps of dismantlement
1) Cut off the negative pole of storage battery.
Fig. 1.10.001
2) Dismount the inner trimming plate of boot.
See also “Dismantlement of Interior and Exterior

Trimmings”.
Fig. 1.10.002
3) Dismount the fixing bolts of parking auxiliary

system module.
Fig. 1.10.003
181
4) Disconnect the connetors. Fig. 1.10.004
5) Take out the parking auxiliary system module. Fig. 1.10.005
V. Replacement of Buzzer of Parking Auxiliary System
1. Cut off the negative pole of storage battery. Fig. 1.10.006
2. Dismount the lower trimming plate of steering wheel. See also “Dismantlement of Consoles of
Interior and Exterior Trimmings”.
182
3. Dismount the clamping screws of buzzer.
Fig. 1.10.007
4. Disconnect the connectors, and take out the buzzer.
VI. Replacement of Sensor of Parking Fig. 1.10.008

Auxiliary System
1. Cut off the negative pole of storage battery.
2. Dismount the rear bumper. See also “Replacement of Rear Bumper”.
3. Dismount the sensor, and disconnect the connectors.
Fig. 1.10.009
183
4. Install in the reverse order with

Fig. 1.10.010 Lock catch
dismantlement.
Adjusting
plate
Sensor body
VII. Common Troubles and Maintenance Methods
1. The system is unworkable
Concrete symptom: when the vehicle is shifted into reversing condition, the buzzer gives out no warning
tone.
Trouble cause: the parking auxiliary system is unworkable, and this is usually caused by the
disconnection of working power supply, generally speaking, if the vehicle storage battery is working
normally, the cause should be the poor contact of power cord.
Maintenance method: Check whether the DC+12V power supply is connected into the control module,
this circuit of power supply is the same as the power supply circuit of vehicle reversing light; if the power
supply is working normally, please replace the control module.
2. The sensor is unworkable
Concrete symptom: when the vehicle is shifted into reversing condition, one of the sensors can not
detect the obstacles all the time.
Trouble cause: the parking auxiliary system is working, but one of the sensors is unworkable.
Maintenance method: when the vehicle is shifted into reversing condition, put your ear close to the
surface of sensor, listen carefully to judge whether the there’s slight “click” from it (by contrast with a
normal one); if the sound is normal, it means that the power supply of sensor is working normally, hence,
please check whether the connection of signal wire between the sensor and controller is normal; in case
the signal wire is normally connected, please replace the sensor.
3. The performance of sensor is poor
Concrete symptom: when the vehicle is shifted into reversing condition, the detection performance of
one of the sensors is always poor.
Trouble cause: the parking auxiliary system is working, but the detection performance of one of the
sensors is poor.
Maintenance method: please clear the foreign matters on the surface of the sensor.
184
When the reverse running is performed on rough roads, it is normal that the system gives an alarm
occasionally.
When the reverse running is performed on narrow laneways, it is normal that the system gives an
alarm occasionally.
VIII. Trouble Diagnosis Procedure
There’s no reminder for starting The main frame is damaged,

up when the vehicle is in replace the main frame
reverse gear
Check if the voltage of Whether the harness

main frame terminal is is correctly
12 V connected
The voltage is not 12 V Connect up the harness

through again
Whether the
connectors of main Reconnect the connectors
frame is connected of main frame
correctly
The connectors of main

frame is connected well
Whether the harness is Replace the

damaged harness
The harness is good,

recheck it
185
When the vehicle is in reverse gear, the

main frame gives two beeps, and the
sensor indicator lamp on the display
goes on
Whether the connectors Reconnect the connectors

of main frame is of main frame
connected correctly
The connectors of main frame

has been connected well
Whether the harness is Replace the

damaged harness
The harness is
good
Whether the sensor is Replace the

damaged sensor
Shift into reverse gear Replace the

again, and see whether it is main frame
working normally
Continue using it
186
IX. Trouble Maintenance Methods
List of Trouble Maintenance Methods
Maintenance Methods and

Number Trouble Symptom Trouble Causes Remarks
Techniques
The system is 1. Poor connection 1. Check whether the harness is
unworkable during between the harness correctly connected to the
the reverse running. and the main power power supply.
1
supply. 2. Reconnect all the sockets
2. Incorrect socket correctly
connection
The indicator lamp The position of socket is Reconnect all of the inductor sockets
of power supply incorrect, so that the correctly.
2 lighting, but the inductor is unworkable.
system is
unworkable.
The buzzer is 1. The body or ground 1. Install the inductor correctly
continuously giving is detected by according to the instruction, and
warnings, while the system. turn to professional technician
display showing a 2. Incorrect installation for instruction and inspection if
same data, but of inductor, or necessary.
3 there’s no obstacle inductor falling off 2. If the inductor is damaged,
behind the vehicle 3. The inductor is please replace it in a timely way.
damaged. 3. Check whether the harness is
4. The connecting wire free from damage.
of inductor is
damaged.
It can not correctly 1. The voltage of 1. Check whether the voltage of
display the distance storage battery is storage battery is normal.
from obstacles. abnormal. 2. Shut off the system, and
2. The socket position correctly reconnect all the
4 is incorrect. sockets.
3. The inductor 3. Check whether there’s any
harness is disturbed. contact between the connecting
wire of inductor and the exhaust
pipe and muffler.
There’s no reminder 1. The buzzer is 1. Check the buzzer connecting
for starting up, but misconnected. wire and socket, and reconnect
the other parts are 2. The buzzer is the buzzer correctly.
5
working normally damaged. 2. Replace the buzzer.
without warning
tone.
187
Section XI Rear View Mirror

With internal rear view mirror and external rear view mirrors in kind which are fixed on the upper part of
front wind shield, left and right sides of the outer vehicle body respectively, rear view mirror is used for
observing the situation inside the carriage and behind the vehicle. It consists of mirror, fixing parts,
direction adjusting parts and mirror seat, etc.
1. Electric Rear View Mirror Assembly

Fig. 1.11.001
2. Electric Rear View Mirror Switch

Fig. 1.11.002
188
II. Basic Diagram
ACC/ON Power
Console of rear
UP/DOWN Switch LEFT/RIGHT Switch view mirror switch
Option switch of left and right

exterior rear view mirror
Left exterior rear Right exterior rear

Grounding
view mirror view mirror
Basic Diagram of Electric Rear View Mirror
III. Testing for Elements
1. Check of Electric External Rear View Mirror

Fig. 1.11.003
1) After pressing the left/ right direction adjusting
buttons of rear view mirror, the mirror shall
move leftward or rightward smoothly.
2) After pressing the up/down direction adjusting

button of rear view mirror, the mirror shall
move upward/downward smoothly.
If it doesn’t meet the requirement, continue the

check.
189
2. Check of Electric Rear View Mirror Switch
Check the conductivity state between terminals of lead connector according to the following diagram. If it
is not the same as what is listed in the diagram, please replace the switch.
Wiring
terminal
Gear
Upward
Downward
Left Leftward
Rightward
Upward
Downward
Right Leftward
Rightward
Terminal Diagram of Electric Rear View Mirror
3. Check of Electric Rear View Mirror Motor
1) Dismount the lead connector of electric rear view mirror actuator.
Up Left
Down Right
Circuit Diagram of Rear View Mirror Motor
2) Connect the storage battery (12V) between terminals according to the following table, and check
whether the actuator works normally. If not, replace the actuator.
190
Terminal
Position
Up
Down
Left
Right
Testing Diagram of Electric Rear View Mirror Motor
IV. Replacement of Internal Rear View Mirror
1. Dismantlement Steps
Fig. 1.11.004
■ Dismantle the internal rear view mirror from
the internal rear view mirror bearer with a
small right-angled screwdriver.
Fig. 1.11.005
191
2. Installation Steps
Fig. 1.11.006
1) Clip the internal rear view mirror into the rear
view mirror bearer, and make sure that it is
fixed firmly.
2) Mount the internal rear view mirror.
Attention:
■ Internal rear view mirror is fixed on the internal rear view mirror bearer which is glued on the wind
shield by plastic polyvinyl-butyral adhesive. The following objects are needed while mounting an
independent rear view mirror or a new spare part:
■ Loctite™ instant adhesive 312.
■ (According to the installation step 4 and 5, prepare) original internal rear view mirror bearer, or
replace it with new internal rear view mirror bearer.
■ Waxy marker pen or wax crayon.
■ Isopropyl alcohol.
■ Cleaning paper towel.
■ Fine emery cloth or abrasive paper (320 or 360).
1. Measure the dimension from the upper part (1) to internal rear view mirror bearer (2), and the
dimension is 70 mm.
Schematic Diagram 1 of Mounting Internal Rear View Mirror
2. Make a mark on the exterior surface of wind shield. Draw a big circle on the exterior surface (3) of
wind shield along the circle of rear view mirror bearer.
192
Schematic Diagram 2 of Mounting Internal Rear View Mirror
3. Use the paper towel that has been soaked in the glass cleanser of general type (general part number)
or polishing agent to clean the glass marked with the big circle on the interior surface of wind shield
until it is completely clean and dry. Then clean it with the paper towel moistened with isopropyl
alcohol to remove the cleaning powder or the mark left by cleaning agent.
Precautions:
■ If the original internal rear view mirror bearer is reused, clean all marks of adhesive left by plant
installation before its reinstallation.
4. Use a fine (320 or 360) emery cloth or abrasive paper to polish the new internal rear view mirror
bearer or the original adhesive surface of internal rear view mirror bearer left by plant installation.
5. Use the paper towel soaked with isopropyl alcohol to wipe the sanded internal rear view mirror
bearer clean, and then let it dry in air.
6. Before mounting on the wind shield, prepare the internal rear view bearer according to the illustration
for components provided by the manufacturer.
7. Place the internal rear view mirror bearer on the marked position beforehand correctly, and prevent
the round hole of rear view mirror from pointing upward; Press the internal rear view mirror bearer on
the wind shield for 30s to 60s with constant force.
8. After 5 minutes, use the paper towel soaked with isopropyl alcohol or window cleaning agent to
remove redundant adhesive.
9. Remount internal rear view mirror. Refer to the “Replacement of Internal Rear View Mirror”.
193
V. Replacement of External Rear View Mirror
Mirror casing
Base plate (201x75x68)

Retainer ring
Machine core
Mirror bracket
Pressure spring
Rotary shaft (ø72 x 43)

Triangle seat
Screw Inserted nut
Mirror
Disassembly Schematic Diagram of External Rear View Mirror
Attention:
■ Make sure that the washer is placed correctly.
1) Cut off the negative pole of storage battery.
2) Pry up the cover plate of rear view mirror carefully with a right-angled screwdriver.
Fig. 1.11.007
194
3) Cut off the connector of rear view mirror.

Fig. 1.11.008
4) Dismount the three fixed nuts of rear view

Fig. 1.11.009
mirror.
5) Dismount the rear view mirror assembly.

Fig. 1.11.010
2. Installation Steps Fig. 1.11.011

1) Place the rear view mirror assembly in.
195
2) Mount the three fixed nuts of rear view mirror.

Fig. 1.11.012
3) Connect the connector of rear view mirror.

Fig. 1.11.013
4) Mount the cover plate for rear view mirror of front
door.
5) Mount the negative pole of storage battery.
VI. Replacement of Electric Rear View Mirror Switch Fig. 1.11.014

1. Pry up the electric rear view mirror switch along the
edge of switch plate to loosen the grab and clip.
196
2. Cut off the switch of the side window in the

Fig. 1.11.015
cab and the connector for electric rear view
mirror.
3. Dismount the switch assembly.
4. Mount the switch of electric rear view mirror in

reverse order with dismantlement.
197
Section XII Central Control Door Lock

I. Basic Diagram
Lock or unlock all doors by key lock core. The ETACS control module controls the central control
lock relay after receiving the unlock or lock signal to make the door lock motor open or close. In
spite of the location of the ignition switch, the electric door lock is in operational state.
When the vehicle runs in a speed of higher than 40km/h, all doors are closed and the acceleration
pedal is stepped down, the ETACS control module automatically locks all doors. After the engine
cuts out and the ignition switch is shut down, the central control door lock automatically opens.
The doo lock motor is controlled by the central controller. The positive and negative poles of the storage
battery are connected to the two terminals of the motor to make the motor rotate toward one direction.
The current is opposite and the rotation speed of the motor is opposite.
II. Replacement of Outside Handle of Door
1. Pry off the lock core trim cover of the door

Fig. 1.12.001
outside handle.
2. Dismount the outside handle of the door and

Fig. 1.12.002
install the fixing bolt of the bracket.
198
3. Disconnect the outside handle of the door

from the mounting bracket and then take off Fig. 1.12.003
the washer.
4. Dismount the outside handle of the door.

Fig. 1.12.004

dismantlement.
III. Replacement of Door Lock Assembly

1. Dismount the inner trimming plate of door.
Refer to “Replacement of Inner Trimming
Plate of Door”.
2. Dismount the waterproof membrane. Refer to
“Replacement of Waterproof Membrane”.
3. Dismount the sealing strip of window glass.
Refer to “Replacement of Sealing Strip of
Window Glass".
4. Dismount the window glass. Refer to
“Replacement of Window Glass”.
5. Dismount the glass regulator. Refer to

Fig. 1.12.005
“Replacement of Glass Regulator”.
6. Pry off the lock core trim cover of the outside
handle of the door.
199
7. Dismount the outside door handle and install

the fixing screw on the bracket. Fig. 1.12.006
8. Disconnect the outside handle of the door

Fig. 1.12.007
from the mounting bracket on the outside door
handle, and take off the washer.
9. Dismount the outside handle of the door.

Fig. 1.12.008
10. Dismount another screw on the mounting

Fig. 1.12.009
bracket of the outside handle of the door.
200
11. Loosen the tie rod on the outside handle of the Fig. 1.12.010
door and lock core tie rod.
12. Take off the fixing bracket of the outside

Fig. 1.12.011
handle of the door.
13. Dismount the fixing screw of the door lock

Fig. 1.12.012
body.
14. Cut off the connector of the door lock motor Fig. 1.12.013
and take off the door lock body assembly.
201
15. Cut off the tie rod on the lock body, and take
Fig. 1.12.014
off the lock body.

dismantlement.
Notes:
■ Install in the original locations.
■ Check the door switch for being normal and

the door lock for being reliable after the
installation. If it is abnormal or unreliable,
re-install or re-adjust it.
IV. Replacement of Actuator of Trunk Door

Fig. 1.12.015
Lock
1. Open the trunk door.
2. Dismount the trunk door sill plate. Refer to “Replacement of Trunk Door Sill Plate”.
202
3. Plug off the connector of the actuator harness.

Fig. 1.12.016
4. Loosen the fixing screw of the actuator by

Fig. 1.12.017
screwdriver.
5. Cut off the pull wire of the actuator.

Fig. 1.12.018
6. Dismount the actuator.
Notes:
■ After the assembly, open and close the rear cabin cover to validate the lock body function.
■ Suppose the meshing of the lock body and hook offtracks, loosen the two fixing bolts of lock hook,
adjust the lock hook to an appropriate location and then tighten the fixing bolt.
203
V. Replacement of Controller of Trunk Door Lock
1. Open the trunk.
2. Cut off the negative terminal of the storage battery.
3. Dismount the inner trimming plate of the trunk lid. Refer to “Replacement of Inner Trimming Plate of
Trunk Lid”.
4. Dismount the bolts for fixing the trunk lock controller.
■ Tightening Torque: 24±4 N•m
Fig. 1.12.019
5. Cut off the tie rod and then take off the trunk
Fig.
lock controller.
Lock body of
trunk

dismantlement.
204
VI. Analysis for Troubles
Analysis Table on Troubles of Central Control Door Lock
Step Troubleshooting Yes No

1 Check the fuse for being in good state? To Step 2 To Step 3
2 Replace the damaged fuse. To Step 3
Check the fuse for being in good state according to the circuit To Step 4
3 To Step 5
diagram.
4 Replace the damaged fuse with new fuse. To Step 5
Separate the connector between the instrument panel and To Step 7
rear body lead harness; measure the voltage at the
5 To Step 6
instrument lead harness side by digital multimeter. The
voltage is normal or not?
Check and repair the instrument panel lead harness from fuse To Step 7
6
to connector. Make sure it is ok.
Measure the voltage of the connector (at the instrument panel To Step 9
7 lead harness side) by a digital multimeter to see the voltage To Step 8
for being normal?
Check and repair the instrument panel lead harness from the To Step 9
8
fuse to the connector, and make sure it is ok.
Dismount the central door lock module, dial the ignition To Step 11
device to the ON position and the wiper switch to the inner
9 To Step 10
gear position. Measure the voltage by a digital multimeter to
see the voltage for being normal?
Check and repair the rear vehicle body lead harness from the To Step 11
10 connector to the central door lock module in accordance with
the circuit diagram and make sure it is ok.
Replace the central door lock module with a new one to see
11 To Step 12
the system for being normal?
Measure the grounding wire of the central door lock module To Step 13
12 by a digital multimeter to see the grounding for being in good To Step 14
state?
Separate the connector between the rear vehicle body and To Step 16
left front door (right front door and tail trunk lid) lead harness,
13 To Step 15
and measure the grounding wire by a digital multimeter to see
the grounding for being in good state?
Repair the grounding wire of the rear body lead harness to To Step 13
14
see the system for being normal?
Repair the grounding wire at connector to make sure its To Step 16
15
grounding is in good state.
Cut off the connector of the central door lock motor and
switch connector of doors; test or check the lead harness of
rear vehicle body, left and right front vehicle doors, rear
16 vehicle door as well as tail trunk lid by a digital multimeter in To Step 17
accordance with the circuit diagram. If necessary, repair the
lead harness. Make sure the lead harness is ok and the
system is normal?
Check the inner structure of the central door lock switch and
17 door lock motors of door locks. When necessary, replace or
repair them. The system is in good state.
205
Section XIII Electric Window
Electric window system could raise or lower the window glass electrically via operation of switch on each
trimming plate of door. The main switch on trimming plate of driver side front door could not only help the
driver to raise or lower the passenger side window glass, but also could lock every separate switch on
the side door. Only when the ignition switch is located at “on” position, the electric window system could
receive the voltage of storage battery via circuit breaker in junction box. The electric window system
includes the electric window switch on the trimming plate of door, ETACS control module and electric
window motor in each door. The window motor together with the glass frame riser is an assembly. If the
window motor needs to be replaced, the glass frame riser should be replaced as well.
I. Illustration on Elements
1. Electric Window Switch
The electric window is controlled by window/door interlock switch on the trimming plate of front door. The
driver side window/door interlock switch could help the driver control all of the window glasses. The
passenger side windows could receive the electricity from storage battery and grounding power supply
via the window/door interlock switching circuit. The power supply for the electric window switch of every
separate passenger side door from storage battery would be cut off when the interlock switch of electric
window is located at “lock" position.
2. Electric Window Motor
Permanent magnet reversible electric motor could drive the movement of glass frame riser via integrated
gear box mechanism. The positive and negative poles of storage battery are connected to the two
terminals of motor and enable the motor to turn round in one direction. The counter current flowed
through the two same junctions would enable the motor to turn round in the reverse direction. Moreover,
every electric window motor is equipped with an integrated self-reset circuit breaker to avoid the
over-load.
II. Illustration on Functions
1. Elevation of Electric Window
The electric window could be operated by the elevating button on the door. The elevating operation of
electric window would be allowed when ignition switch is located at “on” position. The operation of rear
windows is invalid after pressing the child lock at any time. The electric window could be operated after
shutdown of ignition switch as well unless the following situations occur:
1) The closing time of ignition switch is over 10 minutes.
2) Any door is opened.
3) The door is locked from the outside.
206
2. Child Lock Button
Child lock button could lock the electric window buttons on the right front door and left & right rear doors.
When the child lock button is locked, the window buttons on the driver’s door that control the right front
window, right & left rear windows are valid as well.
3. Operation Mode
Operation modes of electric window: manual elevation, and auto drop.
Manual rise: press the “up” button of window over 300ms, the corresponding window would be raised
and the rising of the electric window would be stopped by releasing the button.
Manual drop: press the “down” button of window over 300ms, the corresponding window would be fallen
and the dropping of the electric window would be stopped by releasing the button.
Auto drop: press the “down” button less than 300ms, the corresponding window would drop to the
bottom or to the position till pressing the “down” button of the electric window again.
207
III. Basic Diagram
Electric Window
Relay
Main Switch of Window
Elevation
Left Front Electric Right Front Left Rear Electric Right Rear
Motor Electric Motor Motor Electric Motor
Elevation Switch of
Right Front Window Elevation Switch of Elevation Switch of
Left Rear Window Right Rear Window
Ground of
Combined
Wiring Joint
Electric Power
Source of Combined
Wiring Joint
208
IV. Replacement of Element
1. Replacement of Switch of Electric Window Glass Frame Riser
1) Prize up the switch of glass frame riser by flat

Fig. 1.13.001
head screwdriver.
2) Cut off the harness connector of the switch.

Fig. 1.13.002
3) Dismount the switch of the electric window

glass framer riser.

dismantlement. Attention:
■ Check if the function of buttons is normal after

installation.
■ Reinstall and replace the switch if it’s

abnormal or it doesn’t work.
2. Replacement of Front Window Glass
1) Dismantlement
① Dismount the inner trimming plate of door. Refer to “Replacement of Inner Trimming Plate of Door”.
② Dismount the waterproof membrane. Refer to “Replacement of Waterproof Membrane”.
③ Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
④ Reinstall the switch of window glass frame riser and adjust the height of window glass to a suitable
position so as to dismount the fixing screw of window glass.
209
Fig. 1.13.003
⑤ Dismount the fixing screw of window glass.

Fig. 1.13.004
⑥ Take off the window glass.

3. Replacement of Front Window Glass Frame Riser
1) Dismount the inner trimming plate of door. Refer to
“Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to
3) Dismount the sealing strip of window glass. Refer to
“Replacement of Sealing Strip of Window Glass".
4) Dismount the window glass. Refer to “Replacement
of Window Glass”.
5) Dismount the fixing nut of glass support.
Fig. 1.13.005
210
6) Dismount the fixing nut of electric motor of

glass frame riser. Fig. 1.13.006
7) Cut off the connector on electric motor of

glass frame riser. Fig. 1.13.007
8) Take out the glass frame riser.

Fig. 1.13.008
4. Replacement of Rear Window Glass
1) Dismount the inner trimming plate of door. Refer to ““Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to “Replacement of Waterproof Membrane”.
3) Dismount the sealing strip of window glass. Refer to “Replacement of Sealing Strip of Window
Glass".
211
4) Connect the switch of glass frame riser and

lower the glass to a suitable position. Fig. 1.13.009
5) Dismount the glass sealing strip on the door.

Fig. 1.13.010
6) Screw off the fixing screw in the locating slot

Fig. 1.13.011
of quarter window glass.
7) Dismount the locating slot of quarter window

glass. Fig. 1.13.012
8) Dismount the quarter window glass.
212
9) Connect the switch of glass frame riser and

lower the glass to a suitable position. Fig. 1.13.013
10) Dismount the fixing screw of window glass.

Fig. 1.13.014
■ Tightening torque: 7.5N • m
11) Take off the window glass.

Fig. 1.13.015

dismantlement.
213
5. Replacement of Rear Window Glass Frame Riser
1) Dismount the inner trimming plate of door. Refer to

“Replacement of Inner Trimming Plate of Door”.
2) Dismount the waterproof membrane. Refer to

3) Dismount the sealing strip of window glass. Refer to

“Replacement of Sealing Strip of Window Glass"
4) Dismount the window glass. Refer to

“Replacement of Window Glass”.
5) Dismount the fixing nut of glass frame riser support.

Fig. 1.13.016
■ Tightening torque: 7.5N • m
6) Dismount the fixing nut on electric motor of glass

Fig. 1.13.017
frame riser.
7) Cut off the connector on glass frame riser and take

out the whole body of glass frame riser. Fig. 1.13.018
214
V. Trouble Diagnosis
See table below for the trouble diagnosis on electric window control system.
Trouble Diagnosis Table on Electric Window Control System
Trouble Possible Cause Trouble Shooting
Replace the fuse and check for

Breakage of fuse
short-circuit
All of the electric windows are
Trouble of main relay of power
out of work Check the relay
source
Trouble of wiring or grounding Repair as required
Main control electric window Trouble of door lock control relay Check the relay
is out of work
Trouble of wiring Repair as required
One-way trigger electric Trouble of main switch of electric

Check the switch
window is out of work window
215
Maintenance Manual of Tojoy Sedan Structure of Vehicle Bodyy
Chapter II Structure of Vehicle Body

Section I Engine Hood and Door
I. Engine Hood Assembly
Precautions:
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
1. Replacement of Heat Insulating Mattress of

Fig. 2.1.001
Engine Hood
① Open the engine hood.
② Dismount the snaps-in on the heat insulating

mattress of engine hood. Fig. 2.1.002
216
③ Dismantle that heat insulating mattress. Fig. 2.1.003
2) Installation steps: Fig. 2.1.004

① Place the heat insulating mattress onto the
engine hood.
② Align the hole position for fixing the engine

hood to that on the engine hood.
③ Mount and fix the heat insulating mattress of

engine hood.
④ Cover the engine hood properly.
2. Replacement of Support Bar of Engine Hood
Precaution:
■ When dismantling and installing the support

bar of engine hood, additional support bar
must be adopted to avoid possible vehicle
damage and personnel injury.

① Open and support the engine hood.
217
② Lift the retaining clip on the support for fixed

Fig. 2.1.006
support bar of engine hood.
③ Dismount the engine support bar from the

retaining clip. Fig. 2.1.007
2) Installation steps Fig. 2.1.008
① Pull the support bar of engine hood through

the retaining clip and then lock the clip.
② Dismantle the additional support of engine

hood.
③ Cover the engine hood properly.
218
3. Adjustment of Engine Hood
The engine hood is fixed on the hinges of engine hood by bolts. The longitudinal adjustment of the hood
can be achieved by the movement in hinge holes. Through adjusting the length of the long and short
buffer bumper and the major latch on the engine hood, the engine hood can be adjusted vertically. The
tolerance clearance is 4.0 mm±1.0 mm, and the smoothness tolerance is 0 mm to 1.0 mm.
Fig. 2.1.009
1) Open the engine hood.

Fig. 2.1.010
2) Loosen the bolts between engine hood and 图 2. 1.008

Fig. 2.1.011
hinges.
3) Adjust the position of engine hood and front

fender.
4) Cover the engine hood properly.
219
5) Check the alignment.

Fig. 2.1.012
6) Open the engine hood and adjust it to the
qualified position.
7) Adjust the buffer stopper of engine hood

accordingly.
8) Check the alignment.
9) Adjust the engine hood lock body. Refer to the

“Replacement of Engine Hood Lock”.
10) Fasten the bolts between engine hood and

Fig. 2.1.013
hinges.
11) Cover the engine hood properly.

Fig. 2.1.014
4. Replacement of Engine Hood
② Place the protective liner board on the vehicle

body and the glass near the engine hood.
220
Precautions:
■ When dismantling and installing the support device of engine hood, alternative support must be
adopted to avoid possible damage on vehicle and personnel injury.
③ Dismount the cleaner nozzle and hose.

Fig. 2.1.015
Refer to the “Replacement of the Solvent Tank for
Solvent Tank of Cleanser, Spray Nozzle of Pump
and Hose”.
④ Dismantle the fixed bolts on the engine hood

Fig. 2.1.016
with the help of the assistant.
⑤ Dismantle the engine hood with the help of the

Fig. 2.1.017
assistant.
221
⑥ Dismount the heat insulating mattress of Fig. 2.1.018

engine hood, and please refer to the
“Replacement of Heat Insulating Mattress of
Engine Hood”.
⑦ Dismount the rubber buffer stopper on the

engine hood.
⑧ Dismount the lock loop of support bar of

engine hood.
① Mount the lock loop of support bar of engine hood.
② Mount the rubber buffer stopper of the engine hood.
③ Mount the heat insulating mattress of engine hood, and please refer to the “Replacement of Heat
Insulating Mattress of Engine Hood”
④ Place the engine hood on the position of vehicle body with the help of the assistant.
⑤ Mount the bolts between engine hood and hinges with the help of the assistant.
⑥ Check the matching of engine hood and vehicle body and adjust the engine hood as per required.
Please Refer to the “Adjustment of Engine Hood”.
⑦ Mount the cleaner nozzle and hose. Please Refer to the “Replacement of the Solvent Tank of
Cleanser, Spray Nozzle of Pump and Hose”
⑧ Fasten the bolts of engine hood hinges.
⑨ Remove the protective liner board.
⑩ Cover the engine hood properly.
II Fender
Precautions:
■ Use cloth to protect the dismounted spare parts from being damaged and scratched when
dismantling and installing the elements,
■ Wrap the right-angled screwdriver blade with cloth,when dismantling the metal clip from trimmings.
■ Make sure the clips are firmly installed into the plate hole of the body before installing body
222
■ Please don’t scratch the exterior surface of vehicle body during the assembly process.
■ Dismount the front bumper before the dismantlement of fenders. Refer to the “Replacement of Front
Bumper”.
■ Dismount the door assembly before the dismantlement. Refer to the “Replacement of Door
Assembly”.
■ It is better to dismount the engine hood to facilitate the dismantlement of fender. Refer to the
“Replacement of Engine Hood”.
① Dismantle the front bumper. Refer to the “Replacement of Front Bumper”.
② Dismantle the clamping screws on the front end of the fender.
Fig. 2.1.019
③ Dismantle the clamping screws on the rear

Fig. 2.1.020
part of the fender.
223
④ Dismantle the clamping screws of the fender

and those of the front wheel cover. Fig. 2.1.021
⑤ Dismantle the clamping screws on the upper

Fig. 2.1.022
part of the fender.
⑥ Take off the fender and pull out the turn light Fig. 2.1.023
connector.
① Put in the fender and connect the turn light

connector.
② Mount the clamping screws on the upper part

of the fender.
224
③ Mount the clamping screws of fender and those of front wheel cover.
④ Mount the clamping screws on the rear part of the fender.
⑤ Mount the clamping screws on the front end of the fender.
⑥ Mount the front bumper. Refer to the “Replacement of Front Bumper”
Precautions:
■ Check the following items after installation: check for the fender being mounted on the right position;
check for the proper fit clearance between the fender and the vehicle body, and if not, the fender
should be adjusted and reinstalled.
■ The replacement steps of left fender or right fender are the same.
225
III Replacement of Front Door Assembly
Precautions:
■ The dismantlement/installation methods of each door assembly are the same
■ Protect door and vehicle body with cloth when dismantling and installing the front door assembly.
■ Make sure carry out the assembly adjustments during the dismantlement /installation of the front
door assembly.
■ After installation, re-coat some paint (the color of vehicle body) on the head of mounting bolt for
hinges.
■ Check the rotation parts of hinge for lubrication. Apply some “lubrication grease” when necessary.
■ This element is heavy, so two workers are needed for handling it.
■ After installation, check for normal open/close of the front door.
1. Replacement of Front Door
① Dismantle the clamping screws of front door Fig. 2.1.024

stopper.
② Dismantle the clamping screws of door assembly.

Fig. 2.1.025
226
Precautions:
■ The dismantlement of the screws should be carried out by several times. Please don’t loosen them
in one time.
■ The door should be dismantled from down to up.
■ Carry out the dismantlement steps with the help of the assistant.
③ Pull out the rubble sleeve of door wire Fig. 2.1.026

harness.
④ Cut off the door electrical connector.
⑤ Lift the door and place it on the proper place

with the help of the assistant. Fig. 2.1.027
① Move the door to the proper position with the help of the assistant.
② Connect the door electrical connector.
③ Reinstall the rubble sleeve of door wire harness.
④ Align to the mounting hole of clamping screw and mount the clamping screw of door assembly.
⑤ Mount the clamping screw of front door stopper.
Precautions:
■ Tighten the clamping screw of front door assembly, with the tightening torque: 25N·m.
■ Tighten the clamping screw of front door stopper, with the tightening torque: 5N·m.
227
■ The screws should be tightened by several times. Please don’t tighten them in one time.
■ Carry out the whole process with the help of the assistant.
2. Replacement of Outer Rear-view Mirror
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.028
③ Cut off the electrical connector of outer

Fig. 2.1.029
rear-view mirror.
④ Dismount the clamping screws on the outer

Fig. 2.1.030
rear-view mirror.
228
⑤ Take off the outer rear-view mirror. Fig. 2.1.031
① Align to the mounting hole for clamping screw and mount the rear-view mirror.
② Mount the clamping screw of outer rear-view mirror, with the tightening torque: 10 N·m.
③ Connect the electrical connector of outer rear-view mirror.
④ Align to the snap-in mounting hole and mount the inner trimming plate of rear-view mirror.
⑤ Reinstall the negative pole of storage battery.
3. Replacement of Inner Trimming Plate of Front Door
② Open the door and pry out the inner trimming plate of rear-view mirror with right-angled screwdriver.
Fig. 2.1.032
229
③ Cut off the electrical connector of outer Fig. 2.1.033

rear-view mirror.
④ Dismount the clamping screw on the inner

Fig. 2.1.034
door handle.
⑤ Pry out the wiredrawing of inner door handles Fig. 2.1.035

and take off the inner door handle.
230
⑥ Pry out the glass frame riser switch with Fig. 2.1.036
right-angled screwdriver.
⑦ Cut off the electrical connector of glass frame

Fig. 2.1.037
riser switch and take off that switch.
⑧ Dismantle the clamping screws on the inner

Fig. 2.1.038
trimming plate of the door.
231
⑨ Pry out that inner trimming plate.
Precaution:
■ During the dismantlement of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
Fig. 2.1.039
⑩ Cut off the electrical connector of front door Fig. 2.1.040

light
⑪ Take off the inner trimming plate of left front Fig. 2.1.041
door.
232
① Connect the electrical connector of front door light.
② Align to the snap-in mounting hole of front door inner trimming plate and mount the inner trimming
plate of left front door.
Precautions:
■ During the installation of inner trimming plate, please pay special attention to the snap-in, which
would easily cause the damage of the inner trimming plate.
③ Mount the clamping screw of front door inner trimming plate. Tightening torque: 2N•m.
④ Connect the electrical connector of glass frame riser.
⑤ Align to the right position and mount the glass frame riser switch.
⑥ Connect the pull rod of inner handle and mount the inner door handle.
⑦ Mount the clamping screws of inner door handle, with the tightening torque: 2N•m.
⑧ Connect the electrical connector of rear-view mirror.
⑨ Align to the snap-in mounting hole for the inner trimming plate of rear-view mirror and mount that
plate.
⑩ Reinstall the negative pole of storage battery.
4. Replacement of Waterproof Membrane of Front Door
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
2) Pry out the fixed snap-in of wire harness. Fig. 2.1.042
3) Disconnect and take off the waterproof Fig. 2.1.043

membrane.
233
4) Assemble in the reverse order with dismantlement..
Precautions:
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
■ Scale off the waterproof membrane with plastic knife.
■ Be careful to fetch the waterproof membrane in order not to damage it.
5 Replacement of Loudspeaker on Front Door
1) Dismount the door inner trimming plate. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
2) Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
3) Pull out the loudspeaker connector.
Fig. 2.1.044
4) Dismantle the clamping screw of loudspeaker

on front door. Fig. 2.1.045
234
5) Take off the front door loudspeaker.

Fig. 2.1.046
① Mount and tighten the clamping screw of loudspeaker on front door.
■ Tightening torque: 2N•m
② Connect the electrical connector of loudspeaker.
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
④ Mount inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of Front
Door”.
6. Replacement of Weather Seal on Front Window Glass
① Dismount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
Fig. 2. 1.047
③ Pry out an end of the weather seal with right-angled screwdriver and take off the inner side of the
seal slowly from that end.
235
④ Dismount the clamping screw at the outer side

Fig. 2.1.048
of the outer glass weather seal.
⑤ Take off the outer glass weather seal slowly from one end.
Precautions:
■ Don’t use too much force during dismantling, for too much force will cause the damage of the spare
parts.
■ Visually inspect the drip moulding after the dismantlement. Please replace it when distortion occurs.
① Align the mounting slot of outer glass weather seal to the vehicle body, and mount the seal to the
right position slowly from one end.
Fig. 2.1.049
② Tighten the outer clamping screw of outer glass weather seal, with the tightening torque: 2N • m.
③ Align the mounting slot of inner glass weather seal to the body, and mount the seal to the right
position slowly from one end.
④ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑤ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
236
7. Replacement of Front Window Glass
Front Door”.
Door”.
③ Dismount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
④ Reinstall the glass frame riser switch and regulate it to the proper position to facilitate the
dismantlement of the clamping screws of front window glass.
Fig. 2.1.050
⑤ Dismount the clamping screws of front window

Fig. 2.1.051
glass.
⑥ Take off the window glass.
① Reinstall the glass frame riser switch and regulate it to proper position to facilitate the installation of
the clamping screws of front window glass.
② Put the window glass into the door and align to the mounting hole.
③ Mount the clamping screws of front window glass, with the tightening torque: 7.5N•m.
237
④ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑤ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑥ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
8. Replacement of Glass Frame Riser of Front Window
Front Door”.
Door”.
Glass”.
④ Dismantle the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Dismount the fixed nuts of window glass support.
Fig. 2.1.052
⑥ Dismount the fixed nuts on the motor of glass Fig. 2.1.053

frame riser.
238
⑦ Cut off the electrical connector on the motor of Fig. 2.1.054

glass frame riser.
⑧ Take out the glass frame riser. Fig. 2.1.055
① Connect the glass frame riser connector of front window and put in the glass assembly.
② Mount the fixed nuts of front window glass support. Tightening torque: 7. 5N•m.
③ Mount the fixed nuts on the motor of front glass frame riser. Tightening torque: 7.5N•m.
④ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑤ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑦ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
9. Replacement of Lock Core of Front Door
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
Door”.
Glass”.
239
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.056
⑦ Dismount the clamping screws on mounting

Fig. 2.1.057
base support of the outer handle of the front
door.
⑧ Disconnect the outer handle from the fixed

Fig. 2.1.058
support for outer handle of the front door and
then take off the gasket.
240
⑨ Dismount the outer handle of the front door. Fig. 2.1.059
⑩ Dismount another screw on the mounting Fig. 2.1.060

support for outer handle of the front door.
⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.061
pull rod of the front door.
241
⑫ Take off the fixed support of the front door Fig. 2.1.062
handle.
⑬ Pry out the fixed snap-in of door lock core. Fig. 2.1.063
⑭ Replace the door lock core. Fig. 2.1.064
242
① Fix the door lock core on the fixed support of the door handle.
② Mount the fixed support of the front door handle.
③ Connect the outer handle pull rod and lock core pull rod of the front door.
④ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N•m.
Fig. 2.1.065
⑤ Mount the outer handle of the front door
⑥ Mount the gasket and connect the outer handle from the fixed support of outer handle.
Fig. 2.1.066
⑦ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑧ Mount the decorative cap of lock core of the outer handle of the front door.
⑨ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑩ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑪ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑫ Mount the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
10. Replacement of Front Door Lock Assembly
① Dismantle the inner trimming plate of the door, Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
243
Door”.
③ Dismantle the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window
Glass”.
⑤ Dismantle the glass frame riser. Refer to the “Replacement of Glass Frame Riser of Front Window”.
⑥ Pry out the decorative cap of lock core of the outer handle of the front door.
Fig. 2.1.067
⑦ Dismount the clamping screws on mounting

Fig. 2.1.068
support for the outer handle of the front door.
⑧ Disconnect the outer handle from the fixed

Fig. 2.1.069
support of outer handle of the front door and
then take off the gasket.
244
⑨ Dismount the outer handle of the front door.

Fig. 2.1.070
⑩ Dismount another screw on the mounting Fig. 2.1.071

support for outer handle of the front door.
⑪ Loosen the outer handle pull rod and lock core Fig. 2.1.072
pull rod of the front door.
245
⑫ Take off the fixed support of the front door Fig. 2.1.073
handle.
⑬ Dismount the clamping screw on the lock of Fig. 2.1.074

front door.
⑭ Cut off the connector and take out the door Fig. 2.1.074
lock assembly.
246
⑮ Dismount the lock and its pull rod.
Fig. 2.1.076
① Put in the front door lock and connect its pull rod.
② Connect the connector from the lock assembly and put the lock assembly into the door.
③ Mount the clamping screw on the lock of front door. Tightening torque: 5N·m.
④ Mount the mounting support of the front door handle.
⑤ Connect the outer handle pull rod and lock core pull rod of the front door.
⑥ Mount the clamping screw on the mounting support for the outer handle of the front door. Tightening
torque: 2.5N·m.
⑦ Mount the outer handle of the front door.
Fig. 2.1.077
247
⑧ Mount the gasket and connect the outer handle from the mounting support for the outer handle of
the front door.
Fig. 2.1.078
⑨ Mount the clamping screws on fixed support for the outer handle of the front door. Tightening torque:
2.5N•m.
⑩ Mount the decorative cap of lock core of the outer handle of the front door.
⑪ Mount the window glass. Refer to the “Replacement of Front Window Glass”.
⑫ Mount the glass weather seal. Refer to the “Replacement of Weather Seal on Front Window Glass”.
⑬ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Front
Door”.
⑭ Mount the inner trimming plate of the door. Refer to the “Replacement of Inner Trimming Plate of
Front Door”.
Precautions:
■ During the installation, the lock must be mounted as per the original position.
■ After installation, check for the normal open/close of the door; check for the firm locking. If not,
please carry out the re-installation or proper adjustment.
11. Replacement of Front Door Latch Fig. 2.1.079

248
① Mark the current position of the latch.
② Dismantle the clamping screw of latch.
③ Dismantle the latch.
④ Dismantle the washer as per the actual configuration.
① Mount the dismounted washer
② Mount the lock latch to the marked position.
③ Mount the screw. Tightening torque:25N•m.
④ Check the latch and the lock for being engaged. Refer to the “Replacement of Front Door Latch” if
some adjustments are needed.
12. Adjustment of Front Door Latch
1) Adjust the latch accordingly.
Fig. 2.1.080
① Loosen the latch screw.
② Move the latch to the required direction accordingly.
③ Fasten the screw to the tightening torque of 25N•m.
249
2) Adjust the latch frontward or rearward.
Fig. 2.1.081
① Apply some clay or joint sealer of vehicle body on the opening of door lock.
② Close the door from enough distance, enabling that the latch can press the joint sealer.
③ Leaving the door closed for a long time may cause the difficulty of removing the clay or joint sealer.
④ Open the door and check for the latch indentation being in the middle of the lock opening.
⑤ Carry out the following steps if adjustments are needed:
■ Dismount the latch.
■ Adjust and reinstall the latch.
■ Fasten the latch screw to the torque of 25Nm.
⑥ Apply paint on any exposed area and any area without paint after installing the latch.
Attention:
The replacements for the components of left or right front door are the same.
250
IV Replacement of Rear Door Assembly
1. Replacement of Inner Trimming Plate of Rear Door
① Dismantle the screw cover for the recessed frame of rear inner door handle.
Fig. 2.1.082
② Dismantle the screw cover for the trimming Fig. 2.1.083

plate of rear door.
③ Push the inner handle toward the direction of

hinge, pry out the pull rod and dismount the
inner handle of rear door.
④ Dismount the safety lock button. Fig. 2.1.084
251
⑤ Dismount the clamping screw for the switch of Fig. 2.1.085

rear glass frame riser.
⑥ Pry out the switch of rear glass frame riser.

Fig. 2.1.086
⑦ Cut off the switch connector of rear glass

Fig. 2.1.087
frame riser.
252
⑧ Dismount the clamping screw for inner

Fig. 2.1.088
trimming plate of rear door.
⑨ Pry out the snap-in for inner trimming plate of

Fig. 2.1.089
rear door.
Precautions:
would easily damage the inner trimming plate.
⑩ Take off the inner trimming plate of rear door.
图 2. 1.090
① Align to the snap-in mounting hole for inner trimming plate of rear door and mount the trimming
plate.
Precautions:
would easily damage the inner trimming plate.
253
② Mount the clamping screws of inner trimming plate of rear door. Tightening torque: 5N·m.
③ Connect the electrical connector for the switch of rear glass frame riser.
④ Align to the proper position and mount the switch of rear glass frame riser.
⑤ Mount the safety lock button of rear door.
⑥ Connect the pull rod for the inner handle of rear door and mount the handle.
⑦ Mount the clamping screw for inner handle of rear door. Tightening torque:
⑧ Mount the screw cover for the trimming plate of rear door.
⑨ Mount the screw cover for the recessed frame of rear inner door handle.
Precautions:
■ Before installing rear door trimmings, make sure the snaps-in are firmly installed into the plate hole
of the body, and then pressed the trimmings into the body.
2. Replacement of Waterproof Membrane of Rear Door
1) Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
2) Disconnect and take off the waterproof membrane.
Fig. 2.1.091
Precautions:
■ When installing the waterproof membrane, don’t let it cover the mounting hole for the cramp of
trimming plate.
■ Don’t touch the adhesive surface to avoid weakening the re-adhesive effect.
■ Scale off the waterproof membrane with plastic knife.
3. Replacement of Weather Seal on the Rear Window Glass
① Dismantle the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
254
② Dismantle the waterproof membrane. Refer to

Fig. 2.1.092
the “Replacement of Waterproof Membrane of
Rear Door”.
③ Take off the inner glass weather seal of rear

door.
④ Take off the outer glass weather seal of rear

Fig. 2.1.093
door.
① Align the mounting slot of outer glass weather seal to the body, and mount the seal into the right
Fig. 2.1.094
255
② Align the mounting slot of inner glass weather seal to the body, and mount the seal into the right
Fig. 2.1.095
③ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
④ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
4. Replacement of Rear Window Glass
of Rear Door”.
② Dismantle the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
③ Dismantle the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on
the Rear Window Glass”.
④ Connect the switch for rear glass frame riser and adjust rear window glass into the proper position.
Fig. 2.1.096
256
⑤ Dismount the weather seal for the upper part

Fig. 2.1.097
of rear window glass.
⑥ Dismount the clamping screw for locating slot

Fig. 2.1.098
of quarter window glass of rear door.
⑦ Dismount the locating slot of rear quarter

Fig. 2.1.099
window glass.
⑧ Dismount quarter window glass of rear door.
257
⑨ Connect the switch for rear glass frame riser

and adjust the rear window glass into the Fig. 2.1.100
proper position.
⑩ Dismount the clamping screw for rear window Fig. 2.1.101

glass.
■ Tightening torque: 7.5N•m.
⑪ Take off the rear window glass. Fig. 2.1.102
258
① Mount the switch for rear glass frame riser and adjust the rear window glass into the proper position
to facilitate the installation of clamping screw for rear window glass.
② Place the rear window glass into the door and align the glass to the mounting hole.
③ Mount and tighten the clamping screw for rear window glass
④ Reinstall the switch for rear glass frame riser and adjust the rear window glass into the proper
position to facilitate the installation of quarter window glass of rear door.
⑤ Mount the rear quarter window glass
⑥ Mount the locating slot of rear quarter window glass.
⑦ Mount and tighten the clamping screw for locating slot of rear quarter window glass.
⑧ Mount the weather seal for the upper part of rear window glass. Reinstall the switch for rear glass
frame riser and rise and lower the glass to check if the installation is qualified.
⑨ Mount the rear window glass. Refer to “Replacement of Weather Seal on the Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑪ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
5. Replacement of Glass Frame Riser of Rear Window
① Dismantle the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate
of Rear Door”.
Door”.
③ Mount the inner glass weather seal of rear door. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
259
⑤ Dismantle the fixed bolts for the support of Fig. 2.1.103

rear glass frame riser
⑥ Dismount the retaining nut for the motor of Fig. 2.1.104

rear glass frame riser.
⑦ Cut off the connector for rear glass frame riser Fig. 2.1.105
and take out the glass frame riser assembly.
260
① Connect the connector for rear glass frame riser and put in the glass frame riser assembly.
② Mount and tighten the retaining nut for the support of rear window glass.
③ Mount and tighten the retaining nut for the motor of rear glass frame riser.
④ Mount the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Mount the weather seal on the rear window glass. Refer to the “Replacement of Weather Seal on
⑥ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”.
⑦ Mount the inner trimming plate of rear door, Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
6. Replacement of Door Lock Assembly
of Rear Door”.
Door”.
③ Dismantle the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on
④ Dismantle the rear window glass. Refer to the “Replacement of Rear Window Glass”.
⑤ Dismantle the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑥ Dismantle the decorative cap on the outer handle of the rear door.
Fig. 2.1.106
261
⑦ Dismantle the clamping screw for outer handle and take the handle off.
Fig. 2.1.107
⑧ Dismantle the connecting pull rod for outer Fig. 2.1.108

handle.
⑨ Dismantle the mounting support for outer

handle of rear door.
⑩ Cut off the inner handle pull rod and the pull Fig. 2.1.109
rod of locking button.
⑪ Dismount the clamping screw for rear door lock.
262
⑫ Take out the rear door lock and cut off the electrical connector for the lock.
Fig. 2.1.110
① Put the door lock in and connect the electrical connector of it.
② Mount the clamping screw for rear door lock. Tightening torque: 7.5N•m.
③ Connect the inner handle pull rod and the pull rod of locking button.
④ Mount the mounting support for outer handle of rear door.
⑤ Mount the connecting pull rod for outer handle.
⑥ Mount the clamping screw for outer handle and mount the outer handle.
⑦ Mount the decorative cap on the outer handle of the rear door.
⑧ Mount the glass frame riser of rear window. Refer to the “Replacement of Glass Frame Riser of
Rear Window”.
⑨ Mount the weather seal on rear window glass. Refer to the “Replacement of Weather Seal on the
Rear Window Glass”.
⑩ Mount the waterproof membrane. Refer to the “Replacement of Waterproof Membrane of Rear
Door”
⑪ Mount the inner trimming plate of rear door. Refer to the “Replacement of Inner Trimming Plate of
Rear Door”.
Attention:
The replacements for the components of left and right rear door are the same.
263
V. Boot Cover
1. Replacement of Boot Cover Assembly
Precautions:
■ Two workers are needed for the handling of boot cover because of its heavy weight.
■ Don’t scratch the paint surface during the dismantlement or installation.
1) Assembly Breakdown Drawing
Breakdown Drawing of Boot Cover Assembly
1- Torsion bar of boot 2- Boot cover 3- Lock core of boot cover 4- Boot cover lock 5- Adjusting pad
of boot cover
6- Weather seal of boot 7- Boot cover Latch
264
① Dismantle the buffer stoppers on both side of the boot.
Fig. 2.1.111
② Dismantle the boot top trimming plate. Refer Fig. 2.1.112

to the “Replacement of Top Trimming Plate of
the Trunk”.
③ Cut off the wire harness connector of the boot Fig. 2.1.113
cover lock.
265
④ Dismantle the clamping screws on the boot cover with the help of the assistant.
Fig. 2.1.114
⑤ Lift the boot cover assembly down with the help of an assistant.
① Mount the boot cover assembly with the help of an assistant.
② Mount the clamping screws on the boot cover with the help of the assistant. Tightening torque:
25N•m.
③ Connect the wire harness of the boot cover lock.
④ Mount the boot top trimming plate. Refer to the “Replacement of Top Trimming Plate of the Trunk”.
⑤ Mount the buffer stoppers on both side of the boot.
2. Replacement of Weather Seal of the Boot Cover
① Pry out the weather seal with tools.
② Dismantle the weather seal slowly.
Fig. 2.1.115
Precautions:
■ Pull the weather seal moderately during the dismantlement.
■ Knock the weather seal moderately with the rubber hammer during the installation, to protect the
seal from being damaged.
266
① Mark the original mounting position of the weather seal and mount it according to that position.
② Fix manually the guide slot on the seal to the vehicle body.
③ Knock the weather seal into the required position with rubber hammer.
3. Check and Adjustment of Boot Cover
1) Check if there exists surface difference between the upper surface and the side walls of the boot
cover. If there exists, the surface difference can be eliminated by adjusting the height of buffer
stopper of boot cover.
Fig. 2.1.116
2) Check for uniform gap between the boot cover and side wall exterior panel.
Precautions:
■ If the gap is not uniform but just with little deviation, knock the boot cover latch with a little hammer
and close the cover to re-check the uniformity of the gap.
■ If the gap offtracks a lot, loosen the cover hinges and 4 clamping screws, and then move the cover
upward/downward or leftward/rightward to make the gap uniform; then pre-tighten the four screws
and tighten them until the boot cover has been adjusted to proper position.
■ Check for the flexibility of the opening/closing of the boot cover. If it is not flexible, adjust the latch
frontward/rearward or leftward/rightward to achieve the flexibility after loosening the clamping
screws of the latch.
267
4. Replacement of Spare Tire Cover Plate
Fig. 2.1.117
② Lift the spare tire cover plate and tow out two Fig. 2.1.118
right-angled grabs.
③ Take off the spare tire cover plate. Fig. 2.1.119
① Place the spare tire into the boot properly.
268
② Press the two right-angled grabs on the spare tire cover plate into the corresponding holes on the
boot door sill fender.
③ Close the boot cover.
5. Replacement of Spare Tire
① Dismantle the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
② Dismantle the fixture of spare tire.
Fig. 2.1.120
③ Take off the spare tire. Fig. 2.1.121
① Place the spare tire into the carriage without damaging other components.
② Mount the fixture of spare tire.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
6. Replacement of Coatrack
269
① Dismantle the clamping screws on the

Fig. 2.1.122
coatrack.
② Pry out the snaps-in on the coatrack. Fig. 2.1.123
③ Cut off the electrical connector for the high

Fig. 2.1.124
position brake lamp.
④ Take off the coatrack.
① Connect the electrical connector for the high position brake lamp.
② Mount the snaps-in on the coatrack.
③ Mount and tighten the clamping screws on the coatrack. Tightening torque: 2N•m,
270
7. Replacement of Front Trimming Plate
① Dismantle the coatrack. Refer to the “Replacement of Coatrack”.
② Pry out the fixed snaps-in on the front trimming plate.
Fig. 2.1.125
③ Take off the front trimming plate.
8. Replacement of Trunk Door Sill Fender
② Dismantle 3 outer fixed snaps-in on the door sill fender.
Fig. 2.1.126
③ Pry out 3 snaps-in on the back of the sill fender.
271
④ Take off the boot door sill fender.
Fig. 2.1.127
① Align to the mounting hole for snaps-in on the back of the door sill fender and mount the fender.
② Mount the outer fixed snaps-in on the door sill fender.
③ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
9. Replacement of Side Protecting Plate of the Trunk
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
③ Dismantle the protecting plate of rear tail lamp in the boot.
Fig. 2.1.128
272
④ Dismantle the clamping screws on the protecting plate of boot.
Fig. 2.1.129
⑤ Dismantle the snaps-in on that protecting

Fig. 2.1.130
plate by sequence.
① Put the boot protecting plate into the carriage and mount the fixed snaps-in on the plate by
sequence.
② Mount and tighten the clamping screws on the protecting plate by sequence. Tightening torque:
2N•m.
③ Mount the protecting plate of rear tail lamp in the boot.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
⑤ Mount the spare tire cover plate. Refer to the “Replacement of Spare Tire Cover Plate”.
273
10. Replacement of Top Trimming Plate of the Trunk
Fig. 2.1.131
② Pry out the fixed snaps-in on the trimming

Fig. 2.1.132
plate by sequence.
Place the plate properly; press the snaps-in of the trimming plate into the mounting hole and clamp
tightly.
274
VI. Oil Filler of Fuel Tank
1. Replacement of Oil Filler Door
① Open the oil filler door.
Fig. 2.1.133
② Dismount the connection between the cap and

Fig. 2.1.134
the oil filler door.
③ Dismantle the clamping screws for the oil filler Fig. 2.1.135
door.
275
④ Dismantle the oil filler door.

Fig. 2.1.136
① Align the oil filler door to the mounting hole.
② Mount the door to the side shroud with screws. Tightening torque: 0.6-1.0N•m.
③ Connect the wire between the oil filler cap and the oil filler door.
④ Close the oil filler door.
Fig. 2.1.137
2. Replacement of Oil Filler Cap Fig. 2.1.138

① Open the oil filler door.
276
② Dismantle the connection between the cap

Fig. 2.1.139
and the oil filler door.
③ Dismantle the oil filler cap.

Fig. 2.1.140
① Mount the oil filler cap.
② Mount the connection between the cap and the oil filler door.
③ Close the oil filler door.
277
VII. Replacement of Locking System Fig. 2.1.141

1 Replacement of Engine Hood Lock Body
② Dismantle the front bumper. Refer to the “Replacement of Front Bumper”.
③ Dismantle the bolts for the lock body.
Fig. 2.1.142
④ Cut off the lock body connecting wire and take Fig. 2.1.143
off the lock body of engine hood.
① Connect the lock body connecting wire and mount the lock body of engine hood.
278
② Mount and tighten the clamping screws for the lock body. Tightening torque: 5N•m.
③ Mount the front bumper. Refer to the “Replacement of Front Bumper”.
④ Close the engine hood.
2. Replacement of the Switch Handle of Engine Hood
① Dismantle the bottom part of the instrument panel at the driver’s side.
Fig. 2.1.144
② Dismantle the clamping screws for switch handle of engine hood.
Fig. 2.1.145
③ Cut off the wiredrawing for the engine hood Fig. 2.1.146
handle.
279
④ Take off the wiredrawing of the handle.
Fig. 2.1.147
① Connect the wiredrawing for the engine hood handle.
② Mount and tighten the clamping screws for switch handle of engine hood. Tightening torque: 2N•m.
③ Mount the bottom part of the instrument panel at the driver’s side.
3. Replacement of the Trunk Door Actuator
Fig. 2.1.148
① Open the boot door.
② Dismantle the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
280
③ Cut off the actuator connector. Fig. 2.1.149
④ Dismantle the clamping screws of actuator Fig. 2.1.150

with cross screwdriver.
⑤ Cut off the wiredrawing of actuator. Fig. 2.1.151
⑥ Take off the actuator.
281
① Connect the wiredrawing of actuator.
② Mount and tighten the clamping screws of actuator with cross screwdriver.
③ Connect the actuator connector.
④ Mount the door sill fender. Refer to the “Replacement of Trunk Door Sill Fender”.
⑤ Close the boot door.
Precautions:
■ Open the after-closed boot lock body check function after finishing the assembly
■ If the engagement between lock body and latch offtracks, loosen 2 fixed bolts of latch, and tighten
the bolts after adjusting the latch to the proper position.
4. Replacement of the Switch Handle of Trunk Lock
① Dismantle the clamping screws for the switch handle.
Fig. 2.1.152
② Cut off the connecting wire of switch handle.

Fig. 2.1.153
③ Dismantle the switch handle.
282
① Connect the connecting wire of switch handle.
② Mount the clamping screws for the switch handle.
5. Replacement of boot cover Lock Latch
Fig. 2.1.154
② Dismount the fixed bolts for boot cover lock latch.
■ Tightening torque: 5N•m.
Fig. 2.1.055
③ Pull out the latch and cut off the pull rod of boot cover lock latch.
① Connect the pull rod of boot cover to the latch.
② Pull out the latch and its pull rod of boot cover lock.
③ Mount and fasten the bolts for the boot cover latch.
④ Close the boot cover.
283
6. Replacement of Wire Harness of Boot Cover
① Dismantle the inner trimming plate of boot cover. Refer to the “Replacement of Inner Trimming Plate
of Boot Cover”.
② Cut off the electrical connector between the wire harness of rear body and the wire harness of boot
cover.
Fig. 2.1.156
③ Cut off the fastening band for wire harness of boot cover.
④ Pull out the clip.
⑤ Pull out the wire harness of boot cover from the vehicle body.
① Lay wire for the wire harness of rear boot from the door of the boot cover.
② Insert the clips to the hole on the body.
③ Fix the wire harness of boot cover with fastening band as per required.
④ Connect the electrical connector between the wire harness of rear body and the wire harness of
boot cover.
284
Section II Interior & Exterior Trimmings

I. Precautions
■ During dismantlement and installation of elements, use a cloth to protect the spare parts to be
dismounted from damage.
■ When dismounting the metal clip from trimmings, use a cloth to cover the blade of slotted screw
driver.
■ Don’t damage the elements of body.
■ When installing body trimmings, make sure the clip is firmly installed in the stamping hole of body
and then carefully press them in.
■ When it is impossible to dismantle and install some elements by one person, two people shall work
together to prevent the elements from falling.
■ When dismantling and installing some trimmings, please don’t press too hard as it may result in
II. Replacement of Front Bumper
Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
■ For the convenience of dismantlement and installation, put the vehicle on lifter to lift the vehicle at
any time.
1. Lift the vehicle to an appropriate height and dismount the clamping screw of front bumper base
board.
■ Tightening torque: 5 N.m
Fig. 2.2.001
285
2. Take off the snap fasteners at the two sides connecting the front bumper and mudguard.
Fig.2.2.002
3. Dismount the clamping screw connecting the rear end of front bumper and mudguard.
Fig. 2.2.003
4. Dismount the screw at the two sides connecting the front bumper and fender.
5. Dismount the screw connecting the front bumper and fender.
Fig. 2.2.004
286
6. Remove the front bumper and cut off the connectors of front fog lamp.
Fig. 2.2.005
7. Take off the front bumper and take out the percussion absorption pad.
Fig. 2.2.006
Fig. 2.2.007
Attention:
■ During assembly, don’t scratch the outside surface of bumper body.
■ After installation, check if it is installed properly and if the fitting clearance between other
components is right.
287
III. Replacement of Front Bumper Frame
1. Dismount the fixed nut of upper frame.
Fig. 2.2.008
2. Take off the upper frame.
3. Dismount the fixed nut of lower frame.
Fig. 2.2.009
4. Take off the lower frame.
Attention:
■ For the upper frame, fix the upper frame of front bumper to the body with 8 nuts. The tightening
torque is 12~15 N.m.
■ For the lower frame, take the projection welding nut in the center of body as locating hole. Use 5
nuts to fix the lower frame of front bumper to the body. The tightening torque is 5~6 N.m.
■ Finally, take the circular hole in the center of the upper frame of front bumper as datum hole. Align
the datum hole and set the front bumper percussion absorption pad to the upper frame of front
bumper.
288
Disassembly Diagram for Front Bumper
1-Datum hole for assembling percussion absorption pad 2-Upper frame 3-Lower frame
4-Percussion absorption pad 5-Datum hole for assembling lower frame
IV. Wheel Cover
1. Replacement of Front Wheel Cover
For the convenience of dismantlement, lift the vehicle up to dismount the tire.
1) Dismount the clamping screw at the outside of front wheel cover.
Fig. 2.2.010
2) Dismount the fixed snap-in and clamping screw of front wheel cover.
3) Screw off the fixed nut of front wheel cover.
4) Take off the front wheel cover and check it for crack. If any, replace it.

289
Attention:
■ Before installation, check if there is defects such as crack of front wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the fender and front bumper.
Align the hole and tighten the screw.
2. Replacement of Right Rear Wheel Cover
1) Dismount the 3 snap fasteners fixing the rear wheel cover in turn.
Fig. 2.2.011
2) Dismount the fixed nut of rear wheel cover.
Fig. 2.2.012
3) Dismount the clamping screw of rear wheel cover.
4) Take off the rear wheel cover.
Fig. 2.2.013
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Attention:
■ Before installation, check if there is defects such as crack of rear wheel cover and omission of fixed
snap-in of wheel cover.
■ After installation, make sure the wheel cover is fitting properly with the body and rear bumper. Align
the hole and tighten the screw.
V. Replacement of Ceiling Stripe
1) Pry out the ceiling stripe at the welding part of car roof with plastic flat-edge tools.
2) Dismount the ceiling stripe from the guide slot of car roof.
Attention:
■ Don’t damage the clip on the ceiling stripe. Otherwise, it is required to replace it.
Fig. 2.2.014
1) Align the front end of the stripe with the fixed snap-in at the front end of guide slot.
2) Set the stripe in properly.
3) Use the rear end of stripe to cover the weather seal of rear window.
Fig. 2.2.015
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VI. Replacement of Rear Bumper
Attention:
■ The trimming plate of bumper is made from resin material. Please don’t apply great force on it and
keep it away from oil.
■ When dismantling the trimming plate of bumper, it is necessary to operate by two people to prevent
it from falling.
■ Before dismantlement, dismount the rear tail lamp first.
■ During installation, don’t scratch the outside surface of bumper.
1. Dismount the rear wheel cover. Refer to “Replacement of Rear Wheel Cover”.
Fig. 2.2.016
2. Put the vehicle on the lifter and lift it to an appropriate height. Dismount the clamping screws at the
lower part of rear bumper in turn.
3. Dismount the screw, at the left and right sides, connecting the rear bumper and fender.
Fig. 2.2.017
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4. Dismount the clamping screw at the upper part of rear bumper in turn.
Fig. 2.2.018
5. Cut off the electric connectors of sensors of auxiliary parking system.
Fig. 2.2.019
6. Take off the rear bumper.

VII. Replacement of Rear Bumper Frame
Disassembly Diagram for Rear Bumper

1-Frame 2-Percussion absorption pad
3-Datum hole for assembling percussion absorption pad 4-Body
293
1. Take off the percussion absorption pad.
2. Pry out the wiring clip fixing the wire harness on the rear bumper frame.
Fig. 2.2.020
3. Dismount the nuts fixing the lower frame and body in turn.
Fig. 2.2.021
4. Take off the frame and re-install the nut.

5. Dismount the clamping screw on the left and right connection supports at the lower part of rear
bumper.
The left and right connection

supports at the lower part
Diagram for Left and Right Connection Supports at the Lower Part

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VIII. Replacement of Sun Visor
1. Dismount the clamping screw on the sun visor.
■ Tightening torque: 1.4 N.m
Fig. 2.2.022
2. Take off the sun visor.
3. Dismount the screw on the hook of sun visor with cross screw driver.
Fig. 2.2.023
4. Install in the reverse order with dismantlement of sun visor.
Note: The replacement steps for left and right sun visors are the same.
295
IX. Replacement of A-pillar Trim Board
1. Pry out the fixed snap-in of A-pillar trim board with slotted screw driver.
Attention:
■ Don’t scratch the trim board.
Fig. 2.2.024
2. Dismount the A-pillar trim board.
Fig. 2.2.025
3. During installation, align the snap-in of trim board with hole, press it in with force and make it seized.
X. Replacement of Front Door Pedal
1. Use a slotted screw driver to pry out the metal fixed snap-in of front door.
Attention:
Fig. 2.2.026
■ Don’t scratch the pedal.
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2. Dismount the front door pedal.
3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
XI. Replacement of A-pillar Lower Trim board
1) Dismount the front door pedal at first. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.027
2) Hold the A-pillar lower trim board and pull it out, disconnect the snap-in and dismount the lower trim
board.
Fig. 2.2.028
3) Install in the reverse order with dismantlement. During installation, align the snap-in of trim board
with hole, press it in with force and make it seized.
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XII Replacement of Rear Door Pedal
1. Screw off the clamping screw of rear door pedal.
■ Tightening torque: 1.4 N•m
Fig. 2.2.029
2. Use slotted screw driver to pry out the rear door pedal.
Attention:
■ Don’t scratch the pedal.
Fig. 2.2.030
3. During installation, align the snap-in of pedal with hole, press it in with force and make it seized.
Then tighten the clamping screw.
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XIII. Replacement of B-pillar Trim board
1) Adjust the front seat to an appropriate position.
Fig. 2.2.031
2) Dismount the front door pedal. Refer to “Replacement of Front Door Pedal”.
Fig. 2.2.032
3) Dismount and replace the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
Fig. 2.2.033
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4) Dismantle the trim strip of door edge at both

Fig. 2.2.034
sides of B pillar.
5) Dismount the fixed bolt at the bottom of safety

Fig. 2.2.035
belt.
6) Pry out the fixed snap-in of B-pillar lower trim

Fig. 2.2.036
board.
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7) Take off the B-pillar lower trim board.

Fig. 2.2.037
8) Pry out the anchor seat cover of front safety

Fig. 2.2.038
belt.
9) Dismount the clamping screw of anchor seat

Fig. 2.2.039
of front safety belt.
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10) Dismount the clamping screw of B-pillar upper trim board.
Fig. 2.2.040
11) Take off the B-pillar upper trim board.
1) Install the B-pillar upper trim board and tighten its clamping screw.
2) Install the clamping screw of anchor seat of front safety belt.
3) Install the anchor seat cover of front safety belt.
4) Align the installation hole and fix the B-pillar lower trim board properly.
5) Install the clamping screw at the rear end of safety belt.
6) Install the rubber strip of door edge at both sides of B pillar.
7) Install the rear door pedal. Refer to “Replacement of Rear Door Pedal”.
8) Install the front door pedal. Refer to “Replacement of Front Door Pedal”.
9) Adjust the front seat to an appropriate position.
Attention:
■ Before installation, check if there is damage or omission of snap-in.
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
■ As the snap-in is fragile, please don’t install it forcibly.
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XIV. Replacement of C-pillar Trim board
1) Dismount rear seat. Refer to “Replacement of Rear Seat”.
2) Dismount rear door pedal. Refer to “Replacement of Rear Door Pedal”.
3) Dismount the trim strip of rear door.
Fig. 2.2.041
4) Screw off the fixed bolt at the rear end of safety belt of rear seat.
Fig. 2.2.042
5) Pry out the guider cover of safety belt on the

Fig. 2.2.043
C-pillar upper trim board.
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6) Pry out the fixed snap-in of C-pillar upper trim board.
Fig. 2.2.044
7) Take off the C-pillar upper trim board.

Fig. 2.2.045
8) Dismount the coatrack. Refer to “Replacement

Fig. 2.2.046
of Coatrack”.
9) Dismount the clamping screw of C-pillar lower

trim board.
10) Pry out the fixed snap-in of C-pillar lower trim board.
11) Dismount the C-pillar lower trim board.
304
Attention:
■ Before installation, check if there is damage or omission of snap-in.
■ Align the snap-in of trim board with hole, press it in with force and make it seized.
■ As the snap-in is fragile, please don’t install it forcibly.
XV. Replacement of Auxiliary Handle
1. Use slotted screw driver to pry out the screw decorative cap of auxiliary handle.
Fig. 2.2.047
2. Use cross screw driver to dismount the

Fig. 2.2.048
clamping screw of auxiliary handle.
3. Take off the auxiliary handle.

Fig. 2.2.049
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XVI. Replacement of Ceiling
1. Dismantlement Steps:
Fig. 2.2.050
1) Dismantle the sun visor. Refer to “Replacement of Sun Visor”.
2) Dismantle the reading light. Refer to “Replacement of Reading Light”.
3) Dismantle the auxiliary handle. Refer to “Replacement of Auxiliary Handle”.
4) Dismantle the A-pillar trim board. Refer to “Replacement of A-pillar Trim Board”.
5) Dismantle the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
6) Dismantle the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
7) For the convenience of removing ceiling, rotate the right front seat backrest to horizontal position.
8) Dismantle the fixed snap-in at the back of ceiling interior trimming with special tools.
Fig. 2.2.051
9) Dismantle the ceiling interior trimming from the weather seal of door.
10) Remove the ceiling interior trimming from right front door.
2. Installation Steps:
1) Put the ceiling interior trimming in from right front door.
2) Install the ceiling interior trimming from the weather seal of door.
3) Install the fixed snap-in at the back of ceiling interior trimming.
306
4) Adjust the right front seat backrest to the original position.
5) Install the C-pillar trim board. Refer to "Replacement of C-pillar Trim Board".
6) Install the B-pillar trim board. Refer to "Replacement of B-pillar Trim Board".
7) Install the A-pillar trim board. Refer to "Replacement of A-pillar Trim Board".
8) Install the reading light. Refer to “Replacement of Reading Light”.
9) Install the auxiliary handle. Refer to “Replacement of Auxiliary Handle”.
10) Install the sun visor. Refer to “Replacement of Sun Visor”.
Attention:
■ During installation, don’t bend the ceiling interior trimming too much.
■ When installing ceiling interior trimming, align the holes of sun visor on the ceiling interior trimming
and the two holes at the back of ceiling interior trimming with the correspondent holes on the body.
XVII. Replacement of Carpet
Attention:
■ The carpet is a single layer of molded carpet covering the front/rear floor. Replace the carpet
according to the following steps:
1) Dismantle the rear seat backrest. Refer to “Replacement of Rear Seat”.
2) Dismantle the rear seat cushion. Refer to “Replacement of Rear Seat”.
3) Dismantle the front seat. Refer to “Replacement of Front Seat”.
4) Screw off the fixed bolt of front seat safety belt retractor.
5) Dismantle the front and rear door pedals.
7) Dismantle the central console of front floor.
8) Dismantle the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
9) Dismantle the console. Refer to “Replacement of Console”.
10) Dismantle the sub-assembly of ECU.
11) Screw off the sub-assembly of carpet clamp holder.
12) Dismantle the carpet of carriage.
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1) Put a carriage carpet.
2) Install the sub-assembly of carpet clamp holder.
3) Install the sub-assembly of ECU. Refer to “Replacement of ECU”.
4) Install the console. Refer to “Replacement of Console”.
5) Install the central console of front floor.
6) Install the auxiliary facia console assembly. Refer to “Replacement of Auxiliary Facia Console”.
7) Install the A-pillar lower trim board. Refer to "Replacement of A-pillar Lower Trim Board”.
8) Install the front and rear door pedals.
9) Tighten the fixed bolt of retractor of front seat safety belt.
10) Install the front seat. Refer to “Replacement of Front Seat”.
11) Install the rear seat backrest. Refer to “Replacement of Rear Seat”.
12) Install the rear seat cushion. Refer to “Replacement of Rear Seat”.
XVIII. Replacement of Front Trimming Plate of Coatrack
1. Dismount coatrack. Refer to “Replacement of Coatrack”.
2. Pry out the fixed snap-in on the front trimming plate.
Fig. 2.2.052
3. Take off the front trimming plate.
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XIX. Replacement of Protecting Plate of Rear Boot Cover

Attention:
■ Fix the protecting plate to the outer panel of rear boot cover with 5 plastic snap-ins and 5
self-tapping screws.
■ During dismantlement, screw off the self-tapping screws in turn and take off the protecting plate of
rear boot cover.
■ During dismantlement, don’t scratch the outside surface of the protecting plate of rear boot cover.
1. Dismount the fixed self-tapping screws on the protecting plate of rear boot cover in turn.
Fig. 2.2.053
2. Take off the protecting plate of rear boot cover.

Disassembly Diagram for Protecting Plate of Rear Boot Cover

1-Plastic snap-in (5 pcs) 2-Fixed hole of rear boot cover (5 pcs) 3-Outer panel of rear boot cover
4-Self-tapping screw (5 psc) 5-Protecting plate of rear boot cover
Attention:
■ Before installation, check if there is any defect affecting appearance, such as scratch, shrinkage,
uneven gloss, etc.
■ Check if the 5 plastic snap-ins are firmly set to the outer panel of rear boot cover and if there is any
omission.
■ After installation, make sure the protecting plate of rear boot cover is fitting well with the edge of
outer panel.
■ During installation, don’t scratch the outside surface of protecting plate of rear boot cover.
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XX. Replacement of Front Seat
1) Adjust the seat to an appropriate position to dismantle the clamping screw at the front end of seat.
Fig. 2.2.054
2) Dismount the clamping screw at the front end

Fig. 2.2.055
of seat.
3) Adjust the seat to an appropriate position

Fig. 2.2.056
again to dismantle the clamping screw at the
rear end of seat.
4) Dismount the clamping screw at the rear end

Fig. 2.2.057
of seat.
310
5) Adjust the seat backrest to an appropriate position to move it out.
Attention:
■ When moving the seat, pay attention to prevent the paint from scratch.
Fig. 2.2.058
6) Move the seat out and re-install the screws.
1) Adjust the seat backrest to an appropriate position to put the seat in.
2) Put the seat in.
3) Install the clamping screw at the rear end of seat. Tightening torque: 35~55 N•m.
4) Adjust the seat to an appropriate position again to install the clamping screw at the front end of seat.
5) Install the clamping screw at the front end of seat. Tightening torque: 35~55 N•m.
6) At last, adjust the seat backrest to an appropriate position.
XXI. Replacement of Rear Seat
1. Pull the fixed snap-in of rear seat cushion outwards.
Fig. 2.2.059
311
2. Lift the seat cushion and disconnect the snap-in.
Fig. 2.2.060
3. Take the seat cushion out.

Fig. 2.2.061
4. Press the switch of backrest latch and put the

Fig. 2.2.062
left rear seat backrest to an appropriate
position.
5. Dismount the left rear seat backrest.

Fig. 2.2.063
312
6. Press the switch of backrest latch and put the

Fig. 2.2.064
right rear seat backrest to an appropriate
position.
7. Slightly tilt the backrest and take it out.

Fig. 2.2.065
Attention:
■ When dismantling backrest, do dismantle from left to right.
■ Don’t get the seat dirty during dismantlement and installation.
313
XXII. Replacement of Name Plate
1) Before dismantlement, heat the name plate

in circle at 152 mm away from the surface
for approximately 30 s.
Fig. 2.2.066
Fig. 2.2.067
Fig. 2.2.068
2) Use tape to protect the installation surface.
314
3) Use plastic flat-edge tool to pry out or dismantle the name plate from the surface of panel.
Fig. 2.2.069
Fig. 2.2.070
Attention
■ Don’t damage the paint of body.
1) Clean the area on which the name plate is about to be installed and make the area completely dry.
2) Mark the tape with the dimension when the nameplate is located correctly.
3) Heat the installation surface to around 27~41℃.
4) Stick the adhesive foam tape to the back side of name plate and press the name plate to the correct
position.
Attention:
■ Try to stick the name plate in an environment without dust. Dust or other foreign substances may
lead to improper stickup.
5) Remove the protective tape from the installation surface.
315
XXIII. Replacement of Front Windshield
1) Open the engine hood.
2) Cover the surrounding area of front windshield to protect the paint and the interior ceiling lining.
3) Dismantle the wiper arm and wiper blade of front windshield. Refer to “Replacement of Wiper Arm”
in “Wiper and Wiper Cleaner System”.
4) Dismantle the air inlet grid. Refer to “Replacement of Front Wiper Driving Components”.
5) Dismantle the inside rear-view mirror. Refer to “Replacement of Inside Rear-view Mirror”.
7) Dismantle the stripe ornament of front windshield.
① Hold the lower corner of stripe ornament of windshield and slowly pull it out.
② If the stripe ornament of windshield is too tight, cut it along the windshield with multi-purpose knife to
dismantle it.
Attention:
■ When dismantling windshield, the only proper lubricant is clean water.
8) Use tools for dismantling glass sealing layer or static window glass to dismantle the windshield.
Diagram 1 for Dismantlement and Installation Methods of Windshield
9) Dismantle the front windshield from the vehicle with the help of assistant.
316
10) Check the following components which may lead to breakage of windshield:
① The edge of windshield frame.
② Stripe ornament of windshield.
③ Windshield.
11) Check the status of windshield frame and flanging of adhesive.
12) Clear all broken glass from the front cover plate, seat, floor and the duct of defroster.
13) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
After treating the windshield frame according to the requirement, conduct the following operations:
1) Shake the hold-down welding primer for at least 1 min.
2) Use new coating tools to coat the surface of binding part (1) with hold-down welding primer.
317
3) Wait for the primer to be dry for around 10 min. Make sure all the scratch and rubbing marks are
covered.
4) Install washer and filling strip of VIN plate.
5) Install stripe ornament of window at the edge of windshield. If the original stripe ornament of window
is damaged, replace it.
318
6) With the help of an assistant, fit the windshield and frame to confirm the correct way to locate the
front windshield in the frame.
7) Use tape (1) to mark the location of windshield in the frame.
8) Cut off the tape at the top edge of windshield.
9) With the help of an assistant, dismantle the windshield from frame with suction cup.
10) Put the windshield on a clean and safe surface, making the inside face upwards.
11) For using the original windshield repeatedly, get rid of all carbamate adhesive from the surface of
windshield with multi-purpose knife or shaver blade. However, leave a layer of film there.
319
12) Moisten a lint-free cloth with solution mixed by isopropyl alcohol and water (the volume ratio is 50/50)
to clean the edge of windshield’s inner surface.
Attention:
■ Don’t get rid of all marks of adhesive. Just get rid of all accumulated or scattered chips of carbamate
adhesive.
13) For long-term usage, get rig of all adhesive at the flanging of hold-down welding. However, leave
about 2 mm of adhesive there.
14) Shake the hold-down welding primer for at least 1 min.
15) Use new coating tools to coat the surface of the flanging of hold-down welding with primer.
16) Dry the clamping welding primer for around 10 min.
Attention:
■ Please take care when adding glass protective agent (transparent) to windshield. This primer may
become dry immediately. If coating unevenly, the visible area on windshield may be polluted.
17) Use new coating tools to coat along the edge of inside surface of window with 10~16 mm of glass
protective agent.
18) Coat the same position on the glass with a second layer of glass protective agent.
19) Use a clean lint-free cloth to wipe the position, coated with primer, clean immediately.
20) Shake the glass protective agent for at least 1 min.
21) Use new coating tools to coat the glass primer on the same place coated with glass protective agent.
The glass primer may be used in 8 hours after coating. The surface of glass for primer coating must
be clean.
320
22) Wait the glass primer to be dry for at least 10 min.
23) Cut out the coater nozzle to form a 6.0 mm of flanging.
321
24) Use barrel-type caulking gun to coat the flanging of glass glue evenly and continuously.
25) Coat glass glue on the existing glass glue of body.
26) With the help of an assistant, install the windshield in the frame with suction cup.
322
27) Align the windshield with the tape line (1) on the body.
28) Press the windshield properly.
29) Use tape to stick the windshield to the body to reduce moving until the glass glue is solidified.
30) Clear the remaining glass glue on the body.
Attention:
■ Don’t directly spray high pressure water on the glass glue which is just coated.
31) Conduct water-tightness test to windshield by moderate-pressure warm water jet.
32) Check if there is leakage of windshield.
33) If there is leakage, use plastic scraper to coat more glass glue at the leaking position.
34) When the glass glue is solidified, check for leakage of windshield again.
Caution:
■ It takes 24 h for the maintenance material to be solidified completely. Don’t interfere with the
maintenance part before it is completely solidified. Otherwise, the passenger without any protective
measures will fall out from the vehicle and get hurt.
35) Dismount the protective tape and covering from windshield area.
■ Replace the rear windshield according to the above steps.
323
Section III Console
I. Precautions
may be caused.
Dismount the negative pole of storage battery and wait for at least 1 min before dismounting the
II. Replacement of Driver Airbag Module
Refer to “Safety Airbag System”.
III. Replacement of Steering Wheel
1) Dismount the negative pole of storage battery.
Fig. 2. 3.001
2) Turn the ignition switch to “OFF”.
324
3) Dismantle the clamping screw of airbag module. Rotate the steering wheel along its central position
so as to take off the second screw.
Fig. 2. 3.002
4) Move away the driver airbag module and cut off the connector of airbag module at the driver’s side.
Fig. 2. 3.003
5) Cut off the connector of horn button and dismantle the clamping screw of horn switch.
Fig. 2. 3.004
6) Take off the horn switch assembly.
7) Mark out a location mark on the steering wheel hub and align this mark with the notch on steering
shaft.
325
8) Unscrew the steering wheel nut.
Fig. 2. 3.005
9) Use special tools to dismount the steering wheel from steering shaft.
Fig. 2. 3.006
10) Dismantle the steering shaft nut.
11) Remove the wiring of airbag module connector from the steering wheel.
2. Installation steps
1) Arrange the wiring of airbag module connector through steering wheel.
2) Align the mark on steering wheel with the notch on steering shaft.
3) Install the steering wheel.
4) Install the steering shaft nut.
■ Tightening torque: 41N.m.
326
5) Install the clamping screw of horn switch and connect the connector of horn switch.
Fig. 2. 3.007
6) Place the driver airbag module on steering wheel, connect the connector of driver airbag module
and ensure that the circuit is correctly and firmly installed during installation.
7) Install the clamping screw of airbag module.
Fig. 2. 3.008
8) Check if the operations of the following components are correct or not:
■ Horn
■ Steering wheel
■ Safety Airbag System
327
IV. Replacement of Trimming Cover of Steering Column
Fig. 2. 3.009
2. Dismount the steering wheel assembly. Refer to “Replacement of Steering Wheel”.
3. Dismount the clamping screw of lower cover of steering column.
Fig. 2. 3.010
4. Dismount the upper/lower trimming cover of steering column.
Fig. 2. 3.011
5. Install with the reverse order. Notice that the steering column should be placed at central position
and install the clamping screw of left lower protective cover of console.
■ Tightening torque: 1.4 N.m.
328
V. Replacement of Clock Spring of Safety Airbag
Refer to “Safety Airbag System”.
VI. Replacement of Lower Protective Cover of Console at Driver’s Side
1. Dismount the bottom cover of lower protective cover of console at driver’s side.
Fig. 2. 3.012
2. Dismount the handle of engine hood.
Fig. 2. 3.013
3. Cut off every connector seat connected with the lower protective cover of console at driver’s side.
Fig. 2. 3.014
329
VII. Replacement of Ignition Switch
Fig. 2. 3.015
2. Dismantle the driver airbag module. Refer to “Replacement of Driver Airbag Module”.
3. Dismantle the steering wheel. Refer to “Replacement of Steering Wheel”.
4. Dismantle the upper/lower protective cover. Refer to “Replacement of Trimming Cover of Steering
Column”.
5. Dismantle the clock spring of airbag. Refer to “Replacement of Clock Spring of Airbag”.
6. Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
Protective Cover of Console at Driver’s Side”.
7. Dismantle the combined switch. Refer to “Replacement of Combined Switch”.
8. Dismount the connector from the ignition lock module assembly.
Fig. 2. 3.016
9. Dismantle the assembling bolt of ignition

switch and key alarm switch assembly from Fig. 2. 3.017
ignition switch and key alarm switch assembly.
330
Fig. 2. 3.018
10. Dismantle the ignition switch and key alarm switch assembly from ignition lock module assembly.
Figure of Ignition Switch and Key Alarm Switch Assembly
11. Install in reverse order with dismantlement; ensure that the circuit is correctly and firmly installed
during installation.
VIII. Replacement of Glove Box
1. Dismount the two left/right bolts of glove box.
Fig. 2. 3.019
331
2. Pull out the glove box from the console opening.
Fig. 2. 3.020
3. Install in reverse order with dismantlement.
IX. Replacement of Auxiliary Fascia Console
1) Dismantle the lower protective cover of console at driver’s side. Refer to “Replacement of Lower
2) Dismantle the glove box. Refer to “Replacement of Glove Box”.
3) Dismantle the clamping screw of left/right trimming plate of auxiliary fascia console and slightly pull
out the trimming plate outward.
Fig. 2. 3.021
4) Dismantle the screw of front part assembly of

auxiliary fascia console. Fig. 2. 3.022
332
5) Dismount the protective sleeve of control lever.
Fig. 2. 3.023
6) Dismount the control lever housing.

Fig. 2. 3.024
7) Dismount the ash tray.

Fig. 2. 3.025
8) Dismantle the middle fastening bolt of front

Fig. 2. 3.026
part assembly of auxiliary fascia console.
333
9) Dismount the cigarette lighter assembly.
10) Dismantle the front part assembly of auxiliary fascia console.
11) Take off the rear fixed cup holder pad.
12) Dismantle the front/rear fastening bolt of rear part assembly of auxiliary fascia console and then
slightly pull out the rear part assembly of auxiliary fascia console forward.
Location Plan of Front/Rear Fastening Bolt of Auxiliary Fascia Console
2. Installation steps
1) Install the rear part assembly of auxiliary fascia console to the vehicle and fasten the front/rear
fastening bolt of auxiliary fascia console.
■ Tightening torque: 9N.m
2) Install the rear fixed cup holder pad.
3) Install the front part assembly of auxiliary fascia console.
4) Install the cigarette lighter assembly.
5) Install the middle fastening bolt of front part assembly of auxiliary fascia console.
Fig. 2. 3.027
334
6) Mount the ash tray.
Fig. 2. 3.028
7) Install the control lever housing.

Fig. 2. 3.029
8) Install the protective sleeve of control lever.
9) Install the screw of front part assembly of auxiliary Fig. 2. 3.030

fascia console.
10) Slightly insert left/right trimming plate of auxiliary

fascia console inward and fasten the bolt.
11) Install the glove box.

Fig. 2. 3.031
Refer to “Replacement of Glove Box”.
12) Install the lower protective cover of console at

driver’s side.
Refer to “Replacement of Lower Protective Cover of

Console at Driver’s Side”.
335
X. Replacement of Steering Column
1. Dismantle the negative pole of storage battery.
2. Dismount the steering wheel. Refer to “Replacement of Steering Wheel”.
3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Airbag”.
6. Dismantle the combined switch assembly. Refer to “Replacement of Combined Switch”.
7. Dismantle the ignition switch assembly. Refer to “Replacement of Ignition Switch”.
8. Dismount the fastening bolt connected with intermediate steering shaft and steering gear.
Fig. 2. 3.032
9. Dismantle the upper/lower fastening bolt of

Fig. 2. 3.033
steering column and take off the steering
column assembly.

Fig. 2. 3.034
■ Tightening torque of bolt connected with
intermediate steering shaft and steering gear:
25 N.m.
■ Tightening torque of upper/lower assembling

bolt of steering column: 35 N.m.
336
XI. Replacement of Combined Device
1. Dismantle the negative pole of storage battery.
Fig. 2. 3.035
2. Dismantle the clamping screw of outer cover Fig. 2. 3.036

plate of combined device.
■ Tightening torque: 1.4N.m.
3. Carefully take off the outer cover plate of Fig. 2. 3.037

combined device.
4. Dismount the clamping screw of combined

device.
■ Tightening torque: 1.4N.m.
337
5. Cut off the connector of combined device and dismount the combined device.
Fig. 2. 3.038
XII. Replacement of Control Panel of Air Conditioner

Fig. 2. 3.039
2. Dismount the cover plate of central control

Fig. 2. 3.040
panel group.
338
3. Dismount the glove box.
Fig. 2. 3.041
4. Unscrew the clamping screw of control panel Fig. 2. 3.042

of air conditioner.
5. Pull out the control panel of air conditioner

Fig. 2. 3.043
forward, cut off the relevant connector and
take off the control panel of air conditioner.
7. Check if the air conditioner system is normal or not.
339
XIII. Replacement of Console
Fig. 2. 3.044
2. Dismount the steering wheel assembly. Refer to “Replacement of Steering Wheel”.
3. Dismount the trimming cover of steering column. Refer to “Replacement of Trimming Cover of
Steering Column”.
4. Dismantle the clock spring of Airbag. Refer to “Replacement of Clock Spring of Safety Airbag”.
Protective cover of Console at Driver’s Side”.
6. Dismantle the combined switch assembly. Refer to “Replacement of Combined Switch”.
7. Dismantle the ignition switch assembly. Refer to “Replacement of Ignition Switch”.
8. Dismantle the steering column assembly. Refer to “Replacement of Steering Column”.
9. Dismantle the lamp of glove box. Refer to “Replacement of Glove Box Lamp”.
Fig. 2. 3.045
10. Dismantle the glove box. Refer to “Replacement of Glove Box”.
11. Dismantle the passenger airbag module.
12. Dismantle the ash tray.
13. Dismantle the auxiliary fascia console assembly. Refer to “Replacement of Auxiliary Fascia
Console”.
340
14. Dismantle the combined device assembly. Refer to “Replacement of Combined Device”.
15. Dismount the cover plate of central control panel group.
Fig. 2. 3.046
16. Dismount the clamping screw of glove box Fig. 2. 3.047

and take off its element.
17. Dismount the control panel assembly of air Fig. 2. 3.048

conditioner. Refer to “Replacement of Control
Panel of Air Conditioner”.
18. Dismount the main frame of audio. Refer to

Fig. 2. 3.049
“Replacement of Main Frame of Audio”.
341
19. Dismantle the air conditioner’s internal

Fig. 2. 3.050
circulation switch and rear window glass
defrosting switch assembly.
20. Dismantle the hazard lamp switch assembly.

Fig. 2. 3.051
21. If the vehicle is equipped with automatic lamp,

Fig. 2. 3.052
dismantle the solar sensor.
22. Dismount the left/right pedal of front door.
23. Dismount the left/right trim strip of front door.

Fig. 2. 3.053
342
24. Dismantle the left/right pedal.

Fig. 2. 3.054
25. Dismantle the left/right trimming plate of pillar
A.
26. Dismantle the side trimming plate of console.

Fig. 2. 3.055
27. Dismount the clamping screw at the left side

Fig. 2. 3.056
of console.
28. Dismount the clamping screw at the right side

Fig. 2. 3.057
of console.
343
29. Cut off all electric connecting connectors.
30. Take down the console with the aid of the assistant.
XIV. Replacement of Console Support
1. Dismantle the console assembly. Refer to “Replacement of Console Assembly”.
2. Dismantle all of electrical appliances connected with console support.
3. Dismantle the wire harness of the console.
4. Dismantle the fastening bolt at the left side of console support.
Fig. 2. 3.058
5. Dismantle the fastening bolt at the right side of console support.
Fig. 2. 3.059
6. Take down the console support with the aid of the assistant.
344
Maintenance Manual of Tojoy Sedan
Circuit Overhaul Manual
Preface Contents
This Maintenance Manual of Tojoy Sedan Contents

has been prepared to help the technical
service personnel to know and become
familiar with JAC sedans so that they can
repair and maintain the cars in a fast and How to Use This Manual
reasonable way. This Manual is composed of
the engine volume, the chassis volume, the
electrical appliance & structure volume of
vehicle body, and circuit overhaul volume. Circuit Diagram
The circuit overhaul volume provides the
detailed circuit schematic diagrams and wire
harness diagrams for complete Tojoy sedan.
Component Position
It also includes the descriptions and the
illustrations for the positions of the electrical
components and sensors on the complete
vehicle, which are helpful for the service
Wire Harness Layout
personnel to find out the circuit fault of the car
quickly.
Without written permission, no part of this

Manual may be reproduced or utilized in any
form or by any means.
All rights reserved.

Contents for How to Use This Manual

Introduction...............................................................................................................................................1
Expression................................................................................................................................................6
Fault Detection Guide.............................................................................................................................13
Maintenance Manual of Tojoy Sedan How to Use This Manual
Introduction
This Manual covers the following four main tools to detect and eliminate the circuit fault.
● Circuit diagram
● Component position index
● Component position diagram
● Wire harness layout diagram
The shapes of the lead wire connectors are included in the circuit diagrams.
Circuit Diagram
The description of each system starts with its circuit diagrams. The circuit diagrams depict all the
working paths of each component, such as the power supply and the negative ground of the electrical
loads, the positions of the lead wire connectors as well as the relevant fuses, switches and so on
constituting the circuit. To diagnose and eliminate the fault, it is essential to fully understand the
circuit diagrams first.
Engine ECM system 5 - stepper motor D-5
Stepper motor
M18 Combination M19 Combination

M17 Combination
E39 Stepper motor instrument B (black) instrument C E47 Speed sensor
instrument A
1
Component Position Index

To position the component shown in a schematic diagram on the vehicle, refer to the component position
index following the schematic diagram. The component position index lists the main components and
ground as well as the reference pages for the diagrams indicating their specific positions.
ABS N-3
Component Position Index
Component Code Component Name
E04 ABS module
F04 Left rear wheel speed sensor
F10 Right rear wheel speed sensor
E05 Left front wheel speed sensor
E06 Right front wheel speed sensor
F02 Left rear combination light
Component Position Diagram

On a component position diagram, it is easy to find the mounting positions of the fittings, the lead wire
connectors, etc. shown in a component position index.
MF03 MF05 Connector of right

Left A pillar
MF02 Connector
Connector of left of left body wire rear door wire harness
body wire harness harness
MF01 Connector of left body

wire harness
2
Lead Wire Connector Shape

This section shows the shape of each lead wire connector shown in the circuit diagrams, and provides
the diagrams indicating the specific position for each lead wire on the connector, as determined by its
color and terminal. The lead wire connector shape diagram helps to find the position to be inspected.
The way to read the shape diagram is as follows: when the lead wire connector is not detached, the
direction from the wire harness side of the female lead wire connector to the male lead wire connector
shall face the front; when the lead wire connector is detached, the component side or the male lead wire
connector shall face the front. If the wirings on a lead wire connector are used by multiple systems, it
indicates that this connector is the common lead wire connector.
M23 ETACS A White M14 Rear fog light
M24 ETACS B Grey Rear fog light relay M21 Combination light switch
switch
MR01 Connector of
M23 ETACS A White M24 ETACS B Grey main wire harness R03 Ceiling
F24 Boot F23 Boot light M32 Key lighting
and ceiling wire
switch lighting
harness
E13 Right
E17 Left turn light E16 Right turn light E21 Left headlamp M13 Combination light switch
headlamp
3
Lead Wire Connector Shape Diagram and Terminal No. Sequence

1. Lead Wire Connector Shape Diagram
Socket Plug Description

Locking point
The sockets and the plugs
Actual Diagram are differentiated by the
terminals rather than the
Terminal Terminal
Protecting
sleeve
Protecting sleeve openings of the protective
sleeves.
To number the connectors,
Diagram in This Manual
refer to the table below.
2. Terminal No. Sequence
Numbering Sequence Description
Number from the upper right to the

Socket
lower left
Number from the upper left to the

Plug
lower right
4
Wire Harness Layout

The wire harness layout diagrams depict the mounting and fixing positions of the main wire harnesses
and the lead wire connectors as well as the routes of the main harnesses. These diagrams make the
circuit service easier.
5
Expression
In this Manual, the following electrical expressions, electrical symbols and abbreviations are used.
Expression on Circuit Diagram
Component Diode
The solid line means that the It means that in the diode, the current
entire component is visible. can flow only in the direction of the
arrow.
The dotted line means that only Fuse and Fusible Wire
part of the component is visible.
It means that power is supplied
at the “ON” position.
Fuse box
Stop The name of the component is on

lamp It means that the short terminal is
the upper right corner of it.
switch connected with another fuse.
(closed
when
the Fuse No.
brake
It means that the fuse protects the loop
pedal is The description of the
depres under allowable current.
sed)
component’s functions follows its
name.
Normally-ON
Engine cabin relay box
Connectors
Plug
Connector No. Fusible link B 30A

Socket
No. of terminal inside connector
It means that the connector is

connected directly with the
component.
Circuit Breaker
It means that the connector is
connected with the component via a The circuit breaker is reusable. When
wire or wires. there is a current overload, the circuit
breaker will cut off due to overheating.
Some circuit breakers can be
automatically reset after being cooled
while others must be reset manually.
It means the terminal of the

screw.
6
Power is supplied
The wave line means that the at the “ON” Fuse box
line seems broken, but actually
it is not.
The lead wire is indicated by a

yellow line with a red line on it.
See the power distribution on
page SD-15.
The circuit is interconnected on two

pages with the arrow indicating the
current direction. “A” can be found at The branch circuit shows only the
the position marked. connecting points. For the details of the
subsidiary wire, refer to the marked
circuit.
A lead wire connecting arrow

Connecting Point
points into another circuit.
Connecting point no.

Circuit name
The line break means that part of the

circuit is shown. Refer to the circuits The connecting points are
listed in the component schematic indicated with dots. Their
diagrams. exact positions vary from
vehicle to vehicle.
See the grounding distribution
on page SD-23.
Ground “G”
The different selection of lines is This symbol means that the
indicated with the selection bracket end of the lead wire is
in the following diagram. connected to the body
metal.
A/T M/T
This grounding mark (one

point above three lines)
means that the component
housing is connected to the
body metal.
The dotted line means that both the Shielding Wire

red line and the yellow blue line are
on the E35 connector.
It means that, to prevent

the radio interference, the
lead wire is wrapped with a
shielding layer, which is
always grounded.
7
Switch Connector
This type of switches moves with one

another. The dotted line means that It shows that multiple power
they are connected by way of cords are connected.
mechanical devices.
Relay Indicator
It means that the seat belt

It shows the condition of the relay warning light is connected
when there is no current through with other indicator lights in
the coil. Once the current passes, the combination instrument.
the contact will shift.
Indicator
light
Seat belt
warning lamp The indicator light is indicated
N/O contact by the lighted symbol.
N/C contact
8
Electrical Symbol on Circuit Diagram

Electrical
Symbol Description Symbol Description
Symbol
● Produce electricity by chemical ● Produce heat from electricity.
action.
● Supply electricity directly to the Electric heating
Battery circuit.
● Connect the wire harness to the body ● Produce heat from electricity. It can
ground point and direct the current to also be used as on-board power
Wire the battery negative pole to form a supply.
harness circuit. Cigarette lighter
ground point ● Distribute power to
● If the rated current is exceeded, the externally-connected electric
fusible wire will blow and the current appliances with compliant rated
Slow-blow will be shut off immediately. voltage.
Vehicle power
device ● Warning: When the fuse protector is
replaced, the rated current shall not ● Produce a sound by way of
be exceeded. electricity.
Fuse link
Horn
Fuse link
Slow-blow device
● When the current flows through the
filament, the light will be emitted with
heat produced.
Lighting
Loudspeaker
● It is mainly used in a serial circuit to
protect electrical parts within limited ● Open or close a circuit to allow or
rated voltage. block the current flow.
Resistor
Switch
● Convert electric energy into
mechanical energy. ● Allow current to flow in only one
direction.
Diode
Motor
● Emit light when current passes.
● Draw and discharge gas or liquid by ● Unlike ordinary bulbs, LED
motor action. produces no heat when emitting
Light-emitting
light.
diode (LED)
Pump
9
Electrical
Symbol Description Electrical Symbol Symbol Description
Symbol
Sensor ● Its resistance value varies with the ● Cool the engine.
temperature.
(Thermistor Fan
type)
Sensor ● Its resistance value varies with the
component position.
Circuit ● The above diagram represents that

(Slide interconnection circuit C-D is interconnected with
resistor type) circuit A-B.
● Produce magnetic force through the coil to
engage the relay contacts so that current
passes.
No current passing through coil Current passing through coil
N/O relay
No current With current
● Produce magnetic force through coil to engage

relay contact so that current passes.
No current passing through coil Current passing through coil
N/C relay With current No current
10
Description of Lead Wire Color

Wire Color Code Wire Color Code
Black B Orange O
Blue L Pink P
Brown Br Red R
Green G Violet V
Grey Gr Yellow Y
Light green Lg White W
Wire Harness Identification Mark
The wire harnesses are classified into the following The circuits of complete vehicle are differentiated
types in accordance with the positions of the lead with following paging codes by system function:
wires:
Wire Harness Name Connector Code System Function Paging Code

Main wire harness M Power distribution system A
Airbag wire harness, ABS module wire Starting and charging system B
harness and air conditioner wire A Window elevating and horn part K
harness Engine ECM system D
Engine cabin wire harness and power Reversing radar E
E
supply wire harness ACC system F
Control wire harness E Lighting G
Frame wire harness F BCM system H
Left/right front door wire harnesses D Power rear-view mirror I
Left/right rear door wire harnesses D Sunroof system J
Tail door wire harness R Combined switch and wiper K
Ceiling wire harness R Airbag L
Radar sensor wire harness F Diagnostic system M
Rear defrost wire harness R ABS N
Air conditioning system O
Instrument system P
Anti-theft system Q
11
Lead Wire Connector Identification Code

A lead wire connector identification code consists of a wire harness position identification code and a
lead wire connector identification code. For the position of the lead wire connector, refer to the wire
harness layout diagrams.
Example:
It indicates the main number (serial no.) of the lead wire

connector
It indicates the wire harness position code (engine wire
harness)
Attention
A lead wire connector between wire harnesses is indicated with a code as below.
Example:
It indicates the main number (serial no.) of the lead wire

connector
Rear wire harness
Main wire harness
Relay Identification
A relay identification code consists of the abbreviation and the main number (serial no.) of the relay.
Example:
It indicates the main number (serial no.) of the relay
It indicates the abbreviation of the relay
12
Fault Detection Guide

Fault Detection Procedure
The detection involves the following five phases. Fault Diagnosis Devices
1. Verify Customer’s Complaint Voltmeter and Test Lamp
To properly repair a faulty circuit, inspect its Use a test lamp or a voltmeter to inspect the
components first and maintain a record. No condition of the circuit and use a test lamp to check
disassembly is allowed until the cause of the fault whether a voltage exists across the circuit. A test
has been ascertained. lamp includes a pair of lead wires and a 12V bulb.
2. Read and Analyze Circuit Diagram During the inspection, ground one lead wire and
Analyze the entire circuit of the faulty component, connect the other to a certain point to be
ranging from the power supply to the ground, in measured. If the lamp lights, it indicates that this
accordance with the circuit diagram of the point is supplied with power.
component, before determining the operation Attention
method. If the operation method cannot be To measure the voltage of an electronic control
determined, refer to reference books on how the module, such as the voltage across the circuit of
circuit works. Inspect other circuits common with the ECM (engine control module) used by an
the faulty circuit too. For example, refer to the electronically controlled fuel injection engine, do
circuit diagrams to inspect the common circuits of use a digital voltmeter with a resistance of 10M or
the components such as the fuses and the ground. higher. If a test lamp is used to inspect the circuit of
Inspect the common circuits not covered in the first the module, the internal circuit may be damaged.
phase too. If the common circuits work normally, Therefore, never use a test lamp to inspect an
the fault lies in the faulty circuit itself. If all the electronic circuit.
circuits work abnormally, the fault may lie in the The voltmeter and the test lamp are used in
fuses or the ground. basically the same way. The difference is that the
3. Inspect Circuit and Component test lamp can only inspect whether power is
Use a tester for the second-phase detection. An supplied while the voltmeter can also display the
effective fault diagnosis must be a logic and simple voltage.
process. Determine the cause of the fault using the
fault diagnosis procedure or the fault diagnosis
table. In addition, detection shall start from the
most possible cause and the position that is the
easiest to detect. Test lamp
4. Repair Fault
Find out the fault and make necessary repairs.
5. Confirm Working of Circuit
After the repairs have been completed, inspect the
circuit again to confirm that the fault has been Self-powered Test Lamp and Ohmmeter
eliminated. If the fault lies in a blown fuse, inspect Use a self-powered test lamp or an ohmmeter to
all the circuits that use this fuse.
13
inspect the continuity of a circuit. A self-powered Caution

test lamp consists of a bulb, a battery and two lead To protect the circuit to be inspected, do not
wires. When the two wires are connected, the bulb use a fused jumper with a capacity greater than
lights. Before the inspection, disconnect the the rated capacity of the circuit. Furthermore,
battery negative wire and pull out the fuses of the do not use jumpers in place of the output or
circuit. input signals if ECM, TCM and other control
Attention: modules are connected.
If a self-powered test lamp is used to inspect
the circuit of a module, the internal circuit may
be damaged. Therefore, never use a
self-powered test lamp to inspect an electronic
circuit.
The ohmmeter and the self-powered test lamp are
used in basically the same way. But the ohmmeter
can also display the resistance. A low resistance
indicates good continuity.
Semiconductor elements shall be inspected by a Short-circuit Detector
digital multimeter with a resistance of 10M or more. With a short-circuit detector, the position of the
When using a digital multimeter to measure the short circuit can be found. When a short-circuit
resistance, disconnect the battery negative wire, or detector is used to inspect the shorted circuit, a
a wrong reading will result. When an ohmmeter is pulse magnetic force will be produced so that the
used to measure the resistance, the diodes or the short circuited position can be found.
semiconductor elements in a circuit may affect the Fault Detection
measured value. To inspect whether a component 1. Voltage Detection
affects the measured value, take one value first This involves detecting whether there is voltage
and then reverse the polarity to take another value. across a certain point. When a terminal of the lead
If the values obtained from the two measurements wire connector is detected, it is permissible to test
differ, it indicates that the semiconductor elements from the back of the connector rather than
affect the measured value. disassembling the wire connection.
① To use a test lamp or a voltmeter to measure
the voltage, connect the negative pole of the
tester with the negative pole of the battery
Self-powered test first.
lamp ② Then connect the other lead wire of the test
lamp or the voltmeter to the position to be
detected.
③ If a test lamp is used and it lights, it indicates
that the detected position is supplied with
Fused Jumper
power. If a voltmeter is used and it displays a
Use jumpers to inspect an open loop circuit. value over 1V lower than the specified value, it
A jumper is an inspection tool in series with the indicates that the circuit is faulty.
tested lead wire. It can be used with most lead wire
connectors without damaging them.
14
3. Short-circuit Test
Normally-ON ① Disconnect the negative pole of the battery.

Instrument fuse
box ② Connect one lead wire of a self-powered test
lamp or an ohmmeter with one terminal of the
fuse.
③ Ground the other lead wire of the self-powered

test lamp or the ohmmeter.
Switch
④ Inspect the wire harnesses one by one,
starting from the harness closest to the fuse
box. Repeat this procedure until there is a
Test lamp distance of about 15cm from the self-powered
or voltmeter test lamp or the ohmmeter.
Coil
⑤ If the self-powered test lamp lights or the

ohmmeter has an indication, it shows that the
circuit from this position to the ground is
shorted.
2. Power-on Test
① Disconnect the negative pole of the battery. Disconnect battery

Fuse box
② Connect one lead wire of a self-powered test (with fuses
removed)
lamp or an ohmmeter to the position to be
inspected. To use an ohmmeter, first short
Short-circuit
connect its two lead wires and then zero it with
a zero setter.
③ Connect the other lead wire of the tester with Switch

Self-powered
the other terminal of the load to be inspected. test lamp or
ohmmeter
④ If the self-powered test lamp lights, it indicates
continuity. If an ohmmeter is used and it
displays a resistance that is very low or Disconnect load
nearing 0, it indicates good continuity.
Coil
Self-powered test Brake light

lamp or ohmmeter switch
15
4. Detect with Short-circuit Detector
① Pull out the blown fuse and disconnect the

negative pole of the battery.
② Connect the short-circuit detector with the

fuse terminal.
③ Turn on the switch to inspect the circuit.
④ When the short-circuit detector moves to the

position of the short circuit, a pulse magnetic
force will be produced between the fuse and
this position.
⑤ Move the short-circuit detector slowly along

the lead wire from the fuse box. As long as the
detector is between the fuse and the short
circuit, its pointer will move as the pulse
current changes. Once the detector passes
the position of the short circuit, its pointer will
stop moving.
Disconnect battery
Fuse box
(with fuses removed)
Short-circuit
detector
Pulse magnetic filed
Instrument Switch
Move the Pulse magnetic filed

instrument
along circuit
Short-circuit
Coil
Point where
pointer stops
moving
16
Contents for Circuit Diagram

Electrical Distribution System - A..............................................................................................................1
Outdoor Fuse Box ....................................................................................................................................1
Indoor Fuse Box .......................................................................................................................................3
Starting and Charging System - B ............................................................................................................6
ECM System of Engine - D.......................................................................................................................9
Front/Rear Oxygen Sensor.....................................................................................................................12
Ingnition Coil, Spray Nozzle....................................................................................................................10
Air Throttle Position, Water Temperature, Crankshaft Position, Camshaft position sensors................... 11
Air Intake Pressure, Knock Senor, Carbon Canister Control Valve.........................................................12
Stepper Motor.........................................................................................................................................13
Reversing System - E.............................................................................................................................17
ACC Hi-fi - F ...........................................................................................................................................19
Light Illumination - G ..............................................................................................................................21
Small Light..............................................................................................................................................28
Turn Light, Danger Alarm Light...............................................................................................................24
Front Fog Lamp......................................................................................................................................27
Rear Fog Lamp ......................................................................................................................................28
BCM System - H.....................................................................................................................................30
Rear Defrosting Relay ............................................................................................................................43
Rear Defrosting Switch...........................................................................................................................31
Door Light and Door Light Switch...........................................................................................................32
Ceiling Light, Key Insertion Illumination, Boot Illumination .....................................................................33
Anti-theft relay, Mortise Lock of Safety Belt ............................................................................................34
Relay of Small Light ...............................................................................................................................35
Fastener System ....................................................................................................................................37
Electric Back Mirror System - I ...............................................................................................................39
Sun Roof System - J ..............................................................................................................................41
Electric Door and Window System - K....................................................................................................43
Airbag System - L...................................................................................................................................48
Diagnosis System - M.............................................................................................................................50
ABS Brake System - N ...........................................................................................................................52
Air Conditioning System - O ...................................................................................................................55
Combination Instrument - P....................................................................................................................60
Maintenance Manual of Tojoy Sedan Circuit Diagram
Power Distribution System - 1 Outdoor Fuse Box A-1
Outdoor electric box
Fuse
puller
R/L1 Relay of electric horn F3 BCM

R/L2 Relay of condenser fan 2# F4 Blower fuse
R/L3 Starting relay F5 Fuse of ABS and starting relay
R/L4 Low beam relay F6 Starting relay
R/L5 High beam relay F7 Fuse of air conditioner, oil pump and fan relay
R/L6 Relay of condenser fan 1# F8 Fuse of blower relay
R/L7 Relay of oil pump F9 Fuse of Radiator fan
R/L8 Main relay F10 Fuse of condenser fan
S/B-1 ABS slow blow device F11 High beam fuse
S/B-2 ABS slow blow device F12 Low beam fuse
S/B-3 Main relay slow blow device F13 Relay of air conditioner
S/B-4 Vacant F14 Vacant
S/B-5 Ignition switch slow blow device F15 Vacant
S/B-6 Vacant F16 Oil pump
F1 Fuse of rear wiper motor
F2 Fuse of bass horn
1
Power Distribution System - Outdoor Fuse Box A-2
Outdoor
Outdoor Outdoor Outdoor
fuse box fuse box fuse box
fuse box
Outdoor
Storage Outdoor electric
box
battery fuse box
Main relay Ignition
switch
Relay of air
conditioner
Outdoor Outdoor Outdoor Outdoor Outdoor Outdoor

fuse box fuse fuse box fuse box fuse fuse box
box box
Relay of Relay of Fuel pump relay High beam relay Low beam relay Electric horn
condenser fan Radiator fan
2
Power Distribution System - 2 Indoor Fuse Box A-3
Indoor electric box
Flasher
relay
Danger alarm
relay
Anti-theft
alarm relay
R/L1 Relay of small light F3 CD player fuse, cigarette lighter fuse

R/L2 Relay of A/C compressor F4 Vacant
R/L3 Relay of rear wiper F5 Back mirror fuse
R/L4 Relay of front wiper F6 Front wiper fuse
R/L5 Anti-theft alarm relay F7 Fuse of body control 1
R/L6 Rear defrosting relay F8 Fuse of sun roof 1
R/L7 Flasher relay F9 Fuse of warning lamp 1
R/L8 Danger alarm relay F10 Fuse of instrument 1
R/L9 Relay of rear fog lamp F11 Fuse of reversing lamp
R/L10 Relay of electric door and window F12 Fuse of airbag
R/L11 Blower relay F13 Fuse of rear fog lamp
R/L12 Relay of front fog lamp F14 Fuse of front fog lamp
F1 Fuse of rear wiper motor F15 Fuse of automatic door lock
F2 Fuse of small light F16 Fuse of sun roof 2
F17 Fuse of instrument 2
F18 Fuse of body control 2
F19 Fuse of stop lamp
F20 Fuse of electric door and window
F21 Rear defrosting fuse
F22 Fuse of warning lamp 2
3
Power Distribution System - Indoor Fuse Box
A-4
Terminal Ignition switch Key insertion Ignition switch

switch illumination
Position Key
Pull out
Ignition switch
Insert
into
Indoor Indoor Indoor Indoor

fuse fuse fuse fuse box Start-1
box box box
Indoor Indoor
fuse fuse
box box
Indoor Indoor Indoor

Airbag Instrument 1 Reversing fuse fuse
fuse
box box box
CD player
Back mirror
Warning Body control Blower

lamp 1 1 motor
Indoor
fuse box
Rear fog lamp

Indoor Indoor Indoor
fuse fuse fuse
box box box
Rear wiper Rear wiper Front wiper
4
Power Distribution System - Indoor Fuse Box
A-5
Indoor Indoor Indoor Indoor Indoor Indoor Indoor

fuse fuse fuse fuse fuse fuse fuse
box box box box box box box
Rear defrosting Relay of small Automatic Electric door and Waning lamp 2 Front fog
relay light door lock window lamp
Outdoor Indoor Indoor electric

electric electric box
box box
Blower relay Brake Instrument 3
5
Starting and Charging System B-1
Terminal
Ignition switch Key insertion Ignition switch
switch illumination
Position Key
Pull
out
Insert
into
Anti-theft alarming
M32 Key insertion illumination M31 Ignition lock
6
Stating and Charging System
B-2
Outdoor fuse box
Outdoor fuse box R/L5
Anti-theft alarm relay
Storage Starter
battery
Outdoor fuse box R/L3

Electric generator
Staring relay
Ground
M26 Key insertion M25 Ignition lock E20 Electric generator excitation
illumination
7
Starting and Charging System B-3
Index of element position
Element code Element name

M32 Key insertion illumination
M31 Ignition lock
M25 Ignition lock
Connector
EE01
EE02
EE03
Ground point
01
8
ECM System 1 of Engine - Front/Rear Oxygen Sensor D-1
Rear oxygen sensor Front oxygen sensor
Live
Outdoor Outdoor
electric box electric box
E44 Front oxygen sensor (white) E22 Rear oxygen sensor (black) ECM
Pin
hole
9
ECM System 2 of Engine - Ignition Coil, Spray Nozzle D-2
Fuel injector 4#
Fuel injector 1#
Fuel injector 2#
Ignition coil Ignition coil

1#, 4# 2#, 3#
Fuel injector 3#
E34, E32 Ignition coil E50, E51, E52, E53 Spray

nozzle
10
ECM System 3 of Engine - Air Throttle Position, Water Temperature, Crankshaft Position, Camshaft
Position Sensors D-3
Crankshaft position
sensor Camshaft position sensor
Air throttle position

sensor
Water temperature sensor
E46 Crankshaft position sensor E41 Camshaft position E45 Water temperature E40 Air throttle position
sensor sensor sensor
11
ECM System 4 of Engine - Intake Air Pressure, Knock Sensor and Carbon Canister Control Valve D-4
Carbon canister
control valve
Knock sensor
Intake air temperature and

pressure sensor
E33 Intake air pressure sensor E38 Carbon canister control valve E49 Knock sensor
12
ECM System of Engine 5 - Stepper Motor D-5
Outdoor fuse box
Stepper motor
E39 Stepper motor M18 Combination instrument B M17 Combination E47 Speed sensor
(black) M19 Combination instrument A
instrument C
13
ECM System of Engine 6 D-6
Outdoor fuse box
Outdoor fuse box
Outdoor
R/L6
Outdoor R/L2
Relay of Relay of
condenser condenser
fan 1# fan 2#
Indoor R/L2
Condenser
Air fan
conditioner
relay
A/C compressor
Three-way
pressure
switch
Outdoor electric box
Outdoor R/L8
Main relay
E18 Connector of
A/C compressor
①
E37 Three-way Outdoor R/L8 Indoor R/L2 Indoor R/L6 Outdoor R/L2
pressure switch
14
ECM System of Engine
D-7
Outdoor fuse box Outdoor fuse box
Outdoor fuse
box F9 30A Outdoor R/L7
Relay of fuel pump
Relay of Radiator
fan M23
Radiator fan
Fuel pump
R/L7 Outdoor M23 Relay of E07 Radiator fan E08 Condenser F26 Fuel pump
radiator fan (beside fan
BCM controller)
15
ECM System of Engine D-8

E44 Front oxygen sensor
E22 Rear oxygen sensor
E27 ECM
E34, E32 Ignition coil
E50, E51, E52, E53 Spray nozzle
E46 Crankshaft position sensor
E41 Camshaft position sensor
E45 Water temperature sensor
E40 Air throttle position sensor
E33 Intake air pressure sensor
E38 Carbon canister control valve
E49 Knock sensor
E39 Steeper motor
M18 Combination instrument B
M19 Combination instrument C
M17 Combination instrument A
M17 Speed sensor
E37 Three-way pressure switch
E07 Radiator fan
E08 Condenser fan
F26 Fuel pump
Connector
EE02
ME02
ME03
Ground point
08
01
09
16
Reversing System E-1
Indoor electric box
Reversing light switch
Buzzer
Left reversing light
Right reversing
Reversing radar controller
light
Left probe Middle probe Right probe
C18 F12 Reversing F13 (Left) F14 M12 F02 Left rear F03 Right rear
Reversing radar controller (Right) F15 Buzzer combination combination
light switch (Middle) light light
17
Reversing System E-2

C18 Reversing light switch
F12 Reversing radar controller
F13, F14, F15 Reversing radar sensor
M21 Buzzer lock
F03 Right rear combination light
Connector
MF04
ME03
Ground point
09
02
18
ACC Hi-fi F-1
Indoor fuse box
CD player
amplifier
Antenna
Right Right
high door
pitch loudspe
loudspe aker
aker
Right
Left rear
Left high door Left loudsp
pitch loudspe rear eaker
loudspe aker loud
aker spea
ker
M08 Antenna amplifier D06 Left door loudspeaker F5, F6 Rear F07 CD player
D07 Left door high pitch loudspeaker
loudspeaker
D08 Right door high pitch
loudspeaker
D09 Right door loudspeaker
19
ACC Hi-fi F-2

M08 Antenna amplifier
D6 Left door loudspeaker
D7 Left door high pitch loudspeaker
D8 Right door high pitch loudspeaker
D9 Right door loudspeaker
F05 Left rear loudspeaker
F06 Right rear loudspeaker
M28 CD player
Connector
MF01
MD02
MD03
Ground point
07
20
Light Illumination - Small Light G-1
Left license Left rear Right rear Right front

position Right Left front
light position license light combination
light combination
light light
light
F20 Left rear license light F02 Left rear combination light E21 Left front combination light
F21 Right rear license light F03 Right rear combination light E13 Right front combination light
21
Illumination
light of
cigarette
lighter
Light of
miscellaneous Cigarette
lighter
articles Illumination
compartment of glass
frame riser
switch
Illumination switch of miscellaneous
articles compartment
Note: Light switch of miscellaneous articles M01 Cigarette lighter

compartment, light of miscellaneous articles
compartment and illumination light of cigarette lighter
are connected by separate plugs.
22
Alarm light Combination Hi-fi switch

switch instrument A/C control Illumination Air
Rear fog Front fog
module of rear conditioner
lamp switch lamp switch
defrosting switch
switch
Dimming switch
M34 Dimming
switch
23
Light Illumination - Turn Light, Danger Alarm Light G-4
Indoor fuse box
Live
Terminal
Position Warning light Indoor fuse box
switch
Relay of danger
alarm light R/L8
Flasher relay of indoor
fuse box R/L7
R/L7 Flasher relay
R/L7 Flasher relay M28 Warning light R/L8 Relay of danger

(black) switch alarm light
24
Light Illumination - Turn Light, Danger Alarm Light 2 G-5
Terminal
Switch
Left Headlight combination

light switch
Right
Right
rear turn
light
Right front Right Left rear
turn light Left front Left turn
turn light turn light turn light light

E17 Left turn light E16 Right turn E21 Left headlight E13 Right M13 Combination
light headlight light switch
25
Light Illumination Live Live ON

G-6
Outdoor fuse box Outdoor fuse box

Indoor fuse box
Outdoor electric
box
Relay of low
Relay of high beam light R/L4
beam light R/L5
Left combination Right combination

High beam Small light
headlight headlight
Overtaking Headlight
R/L4, R/L5 Relay of high beam

light and low beam light
E21 Left combination headlight M13 Combination light switch M18, M19 Combination instrument
E13 Right combination headlight
26
Light Illumination - Front Fog Lamp G-7
Indoor fuse box
Live
Relay of front fog

lamp
Left front fog Right front

lamp fog lamp Front fog lamp
switch
E11 Left front fog lamp E26 Right front fog lamp M25 Front fog lamp switch
27
Light Illumination - Rear Fog Lamp G-8

Indoor fuse box
Indoor fuse box
Relay of rear fog

lamp R/L9
Left rear fog Right rear fog

lamp lamp Rear fog lamp switch
M14 Rear fog lamp switch Power supply of connector On Connector grounded On the
M03 Front fog lamp switch the main harness main harness
28
Light Illumination G-9

F20 Left rear license light
F21 Right rear license light
E21 Left front combination light
E13 Right front combination light
M01 Cigarette lighter
M34 Dimming switch
M28 Warning light switch
E17 Left turn light
E16 Right turn light
M13 Combination light switch
M18, M19 Combination instrument
E11 Left front fog lamp
E26 Right front fog lamp
E25 Front fog lamp switch
M14 Rear fog lamp switch
Connector
MF01
MF02
ME03
ME01
ME02
Ground point
09
02
01
07
06
29
BCM System - Rear Defrosting Relay H-1
Indoor electric box
Live
Rear
defrosting
relay R/L6
M23 ETACS A white R/L6 Rear defrosting F29 Power supply end F22 Ground end of rear
relay of rear windscreen windscreen heating
heating
30
BCM System - Rear Defrosting Switch H-2
Rear
defrosting
switch
M24 ETACS B grey M11 Rear defrosting switch

(grey)
31
BCM System - Door Light and Door Light Switch H-3
Contact switch of
right rear door
Contact switch of
left rear door
Contact switch of
left front door
Right front
Left front
door light
door light
Contact switch of
right front door
D25 Left front door F16 Contact switch of right front

M23 ETACS A white M24 ETACS B grey M18 Instrument B light door
D24 Right front door F17 Contact switch of left front door
light F18 Contact switch of left rear door
F19 Contact switch of right rear
door
32
BCM System - Ceiling Light, Key Insertion Illumination, Boot Illumination H-4
Indoor fuse box Remote control receiver

antenna (on left A pillar)
Live
Indoor fuse box
Live
Ceiling light Boot Key insertion

illumination illumination
Boot
switch
M23 ETACS A white M24 ETACS B grey F24 Boot MR01 Connector of F23 Boot R03 Ceiling M32 Key
switch main harness and illumination light insertion
ceiling harness illumination
① ①
33
BCM System - Anti-theft Relay, Mortise Lock of Safety Belt H-5
M23 ETACS A white M24 ETACS B grey F01 Lock of A01 Airbag ECU
safety belt
34
BCM System - Relay of Small Light H-6
Indoor fuse box
Live
Indoor fuse box
Relay of small light

R/L1
M23 ETACS A white Relay of rear fog lamp M14 Rear fog lamp M21 Combination
M24 ETACS B grey switch light switch
35
BCM System H-7
M23 ETACS A white M24 ETACS B grey Relay of electric door and window M05 Wiper
Relay of electric door and
Relay of front fog lamp
window washing switch
Blower relay
Relay of rear fog lamp
36
BCM System of Engine - Fastener System H-8

Indoor fuse box
automatic door
Unfastening Fastening
Relay of
lock
Left front
door lock
door lock
Left rear
Right rear
door lock
Right front
door lock
M23 ETACS A (white) M24 ETACS B (grey) M21 Relay of automatic D20, D21, D22, D23
door Fastener
37
BCM System H-9

M23 ETACS A (white)
F29 Power supply end of rear windscreen heating
F22 Ground end of rear windscreen heating
M24 ETACS B (grey)
M11 Rear defrosting switch (yellow)
M18 Instrument B
D25 Left front door light
D24 Right front door light
F16 Contact switch of right front door
F17 Contact switch of left front door
F18 Contact switch of left rear door
F19 Contact switch of right rear door
F24 Boot switch
F23 Boot illumination
R03 Ceiling light
F01 Lock of safety belt
A01 Airbag ECU
M14 Rear fog lamp switch
M21 Combination light switch
M05 Wiper washing switch
M21 Lock of safety belt
D21, D22, D23, D24 Fastener
Connector
MF01
MF02
ME03
ME01
ME02
Ground point
09
02
01
07
06
38
Electric Back Mirror System I-1
Indoor fuse box
ACC power supply
Regulating switch of electric back mirror
Left outdoor back mirror Right outdoor back mirror

motor motor
D03 Left back mirror motor D02 Regulating switch of back

D05 Right back mirror motor mirror
39
Electric Back Mirror System I-2

D3 Left back mirror motor
D5 Right back mirror motor
D2 Regulating switch of back mirror
Connector
MD02
MD03
Ground point
06
40
Sun Roof System J-1

IG2 power supply control
Live switch
Ignition lock
Electric sun
roof
Relay of sun roof
Ceiling
light
Stop
Off Sun roof Carriage
Open switch ceiling
light
Relay
control Off Open
Limit switch
Sun roof motor
R01 Sun roof switch R02 Ceiling light (with sun roof) R03 Ceiling light (without sun
roof)
41
Sun Roof System J-2

R01 Sun roof switch
R02 Ceiling light (with sun roof)
R03 Ceiling light (without sun roof)
Ground point
G
42
Electric Door and Window System K-1

Indoor fuse box
lighter relay
Cigarette
Main switch of window

elevating system
Left front motor Right front motor Left rear motor Right rear motor
Right front glass Left rear glass Right rear glass

elevating switch elevating switch elevating switch
Relay of electric door and widow D15 Glass elevating switch of D10 Main switch of window D11 Left front glass
Relay of electric right front door elevating system elevating motor
door and window D12 Glass elevating switch of D16 Right front glass
left rear door elevating motor
D17 Glass elevating switch of D13 Left rear glass
right rear door elevating motor
D18 Right rear glass
Relay of Blower relay Relay of elevating motor
front fog rear fog
lamp lamp
43
Horn K-2
Outdoor fuse box

Live
Outdoor fuse box
Relay of electric horn

R/L1
High pitch electric

horn
Horn
button
E19 Horn M19 Horn switch R/L1 Relay of electric horn
44
Wiper Washing Switch, Front Wiper Motor K-3
Indoor fuse box
Wiper
Indoor fuse box intermittent
relay
Front
Front washing
wiper motor
motor
Wiper washing
switch
Pin
Function
Intermittent
Low speed
High speed
Front washing
Intermittent
time
Rear washing
Rear wiper on
Rear wiper off
M05 Wiper switch E31 Rear washing motor E28 Front washing motor E36 Front wiper motor
45
Wiper Washing Switch, Rear Wiper Motor K-4
Indoor fuse box Outdoor fuse box
Indoor fuse box

Rear
Relay of rear wiper wiper
R/L3 motor
Rear
washing
motor E31
Wiper washing switch
Pin
Function
Intermittent
Low speed
High speed
Front washing
Intermittent
time
Rear washing
Rear wiper on
Rear wiper off
M05 Wiper switch E31 Rear washing E28 Front washing M24 ETACS B M23
motor motor ETACS A
46
Electric Door and Window, Horn, Wiper Washing switch and Wiper Motor K-5

D10 Main switch of window elevating system
M19 Horn switch
E31 Rear washing motor
E28 Front washing motor
M05 Wiper motor
E19 Horn
D15 Glass elevating switch of right front door
D12 Glass elevating switch of left rear door
D17 Glass elevating switch of right rear door
D11 Glass elevating switch of left front door
D16 Glass elevating switch of right front door
D13 Glass elevating switch of left rear door
D18 Glass elevating switch of right rear door
E36 Front wiper motor
R/L1 Relay of electric horn
M24 ETACS B
M23 ETACS A
Connector
MD01
MD02
MD03
FD04
FD05
MF04
ME01
ME02
MF02
ME01
Ground point
G01
G07
G06
47
Airbag System L-1

Indoor fuse box
Airbag of driver’s seat

Airbag of passenger seat
Pre-tensioner of Pre-tensioner of
safety belt of safety belt of
driver’s seat passenger seat
Airbag ECU
M24 ETACS B grey A02 Airbag of A03 Airbag of A04 Pre-tensioner of F01 Mortise lock of
driver’s seat passenger seat left safety belt safety belt
A05 Pre-tensioner of
right safety belt
MA01 MA02 M02 Diagnostic connector
48
Airbag System L-2

M24 ETACS B grey
A02 Airbag of driver’s seat
A03 Airbag of passenger seat
A04 Pre-tensioner of left safety belt
A05 Pre-tensioner of right safety belt
F01 Mortise lock of safety belt
M02 Diagnostic connector
Connector
MA01
MA02
Ground point
10
49
Diagnostic System M-1
Diagnostic connector
A01 Airbag ECU
E04 ABS M02 Diagnostic connector M23 ETACS A white
50
Diagnostic System M-2

M02 Diagnostic connector
Ground point
G06
G07
51
ABS N-1
Outdoor fuse Outdoor fuse Outdoor fuse
box box box
ON Live Live
Left rear wheel Right rear
speed sensor wheel speed
sensor
Left front wheel Right front

speed sensor wheel speed
sensor
Outdoor fuse box
Starting relay
ABS controller
E05 Left front wheel speed

sensor
M27 Brake M17 Instrument A M18 Instrument B M19 Instrument C
E06 Right front wheel switch
speed sensor
F04 Left rear wheel speed
sensor
F10 Right rear wheel speed
sensor
52
ABS N-2
Indoor fuse box

Live
Stop lamp switch

High position brake lamp
Right stop lamp

Left stop lamp
M27 Stop lamp switch F02 Left rear stop lamp F03 Right rear stop F11 High position stop
lamp lamp
53
ABS N-3

E04 ABS module
F04 Left rear wheel speed sensor
F10 Right rear wheel speed sensor
E05 Left front wheel speed sensor
E06 Right front wheel speed sensor
F11 High position stop lamp
M27 Stop lamp switch
Connector
MF01
ME01
ME02
MF04
Ground point
G01
G02
G09
54
Air Conditioning System 0-1
Air conditioner controller
Out
Ground
Air door mode motor Temperature mode motor
AA01 A16 Air door mode motor A104 Temperature mode M12 Evaporator surface
motor temperature sensor
MA04 HVAC connector 1 M33 Internal and M06 Air conditioning control panel MA03 HVAC
external air connector 2
change-over switch
55
Internal and external

circulation motor
Internal and external air
change-over switch
A13 Internal and external

circulation motor
MA04 HVAC connector 1 M33 Internal and M06 Air conditioning control panel MA03 HVAC connector 2
external air
change-over switch
56

Outdoor electric Outdoor electric
box box
Live
Blower relay
Blower
motor
MA04 HVAC connector M33 Internal and M06 Air conditioning control panel MA03 HVAC
1 external air connector 2
change-over switch
57
Speed adjusting resistor
Blower switch
A09 Speed adjusting

resistor
MA04 HVAC connector 1 M10 Blower switch M06 Air conditioning control MA03 HVAC
panel connector 2
58

M06 Air conditioning panel
A16 Air door mode motor
A14 Temperature mode motor
M12 Evaporator surface temperature sensor
M33 Internal and external air change-over switch
A13 Internal and external air circulation motor
M10 Blower switch
A09 Speed adjusting resistor
Connector
MA03
MA04
AA01
Ground point
G07
59
Combination Instrument P-1
Combination instrument
Fuel pump
connector
Connecting
with end 87 of
fuel pump relay
M23 ETACS A white F26 Fuel pump C15 Speed sensor E43 Water temperature
M24 ETACS B grey connector gauge
M17 Combination instrument A
60
Indoor fuse
box
level sensor
Brake fluid
Hand
brake
switch
M17 Combination M18 Combination instrument B M23 ETACS A white E30 Brake fluid E27 Hand
instrument A (white) (black) sensor brake switch
M19 Combination instrument C
(white)
61
Instrument A
Engine oil
pressure
switch
Live
M17 Combination M14 Rear fog lamp M02 Diagnostic C30 Engine oil
instrument A switch connector pressure switch
62
High beam indication
M24 ETACS B grey M28 Warning light M34 Dimming switch F24 Contact switch of
switch boot
M18 Combination instrument B black M17 Combination instrument A

M19 Combination instrument C white
63

E30 Brake fluid level sensor
E27 Hand brake switch
C15 Wheel speed sensor
F26 Fuel pump connector
M17 Combination instrument A (white)
M18 Combination instrument B (black)
M19 Combination instrument C (white)
C30 Engine oil pressure sensor
E43 Water temperature gauge
M34 Dimming switch
Connector
ME04
ME02
MF02
ME03
EE01
Ground point
G09
G01
G07
64
Contents for Component Position
Main Wire Harness ...................................................................................................................................1

Engine Compartment Wire Harness I .......................................................................................................6
Engine Compartment Wire Harness II ......................................................................................................7
Controller Wire Harness .........................................................................................................................12
Right Chassis Wire Harness...................................................................................................................15
Left Chassis Wire Harness .....................................................................................................................17
Left Front Door Wire Harness.................................................................................................................21
Right Front Door Wire Harness ..............................................................................................................22
Left Rear Door Wire Harness .................................................................................................................24
Right Rear Door Wire Harness...............................................................................................................25
Ceiling Wire Harness..............................................................................................................................26
Ground Wire Harness.............................................................................................................................27
Airbag Wire Harness ..............................................................................................................................29
Air Conditioner Wire Harness .................................................................................................................30
0
Maintenance Manual of Tojoy Sedan Component Position
Main Wire Harness
Main wire harness (1)
M02 Diagnostic
connector
MF02 Connector of MF03 Connector

Left A pillar
left body wire harness of left body wire Left A pillar
harness
ME04 Connector of engine wire harness

wire harness
ME02 Connector-2 ME03 Connector-3

of instrument wire of instrument wire
Left A pillar harness harness
Right A pillar
MF04 Connector of right body

wire harness
ME01
Connector of G07 Ground
engine wire
harness
1
M25 Connector
of front fog lamp
switch
M14 Connector
of rear fog lamp
Left A pillar
switch
M12 Buzzer connector
Left A pillar
MD02
Connector of left
door wire G06 Ground
harness
Left A pillar
MR01 Connector of ceiling wire

harness
M17 M19
Combined Combined
M27 Stop lamp switch device A device C
M18
Combined
device B
2
Steering
column
M05 Wiper
washing switch
M13 Combination light
switch
M23 ETACS A connector
Steering
column
ETACS module
M32 Insert-key illumination
M31 Ignition lock switch
M24 ETACS B connector
M07 CD connector
M28 Alarm
light switch
3
M33 Internal and M11 Rear

M06 Connector external circulation defrosting switch
of air conditioning switch
M10 control panel
Connector of
blower switch
M08 Antenna
connector
M01 Connector
of cigarette
lighter wire
harness
Instrument
framework/right
MA03 Connector 1 of air

conditioner
Blower
MD03 Connector
of right front door
wire harness
MA04 Connector 2 of air

conditioner
4
A03 Ballonet connector
MA01 Connector A
of airbag wire
harness
MA02 Connector B
of airbag wire
harness
5
Engine Compartment Wire Harness I
Engine compartment wire harness I (1)
Rear end of
EE01 Connector of engine wire cylinder body
harness
C30 Engine oil pressure sensor
E24 Starter switch
G03 Starter ground
E21 Starter power supply
E25 Electric generator

power supply
E20 Electric generator excitation

connector
6
Engine compartment wire harness I (2)
G04 Storage battery

ground
7
Engine Compartment Wire Harness II
Engine compartment wire harness II (1)
ME02 Connector ME03 Connector

2 of main wire EE02 Connector of engine controller wire
3 of main wire harness
Left A pillar
harness harness
ME01 Connector
1 of instrument
wire harness Engine control module
Left front E17 Left turn light

wheel arch
E05 Connector of left front wheel speed

sensor
Carbon Left front

canister combination light
E11 Connector of left front fog

lamp E21 Connector of left front combination
light wire harness
8
E30 Connector of
brake fluid level
sensor
E04 ABS ECU
connector
EE01 Connector of engine wire

harness
E19 Horn connector
E07
Radiator
connector
9
E18 Connector of air-conditioned

compressor
E08
Connector of
cooling fan
Right front
combination light
E37 Connector
of three-way
pressure switch
E13 Connector of right front

combination light wire harness
E28 Wiper washing motor

E26 Connector of right front
fog lamp
10
Right front E16 Right turn light

wheel arch
E06 Connector of right front wheel

speed sensor
G02 Body ground
G01 Body ground
11
Controller Wire Harness
Controller wire harness (1)
EE02 Connector of engine controller wire

harness
E27
Engine
ECU
connector
Engine control module
E36 Connector of wiper

Left A motor
pillar
ME04 Connector of engine wire

harness
E38 Connector of carbon E34 Ignition coil

canister solenoid valve
E49 Connector of knock

sensor
12
E50 Nozzle 1 E51 Nozzle 2 E52 Nozzle 3 E53 Nozzle 4
E33 Connector of intake air temperature and E32 Connector of ignition

pressure sensor coil
E40
Connector
of air throttle
position
sensor
E39 Connector of stepper

motor
13
E46
Connector of
crankshaft
position
sensor
E47
Connector of E45 Connector
of engine coolant
speed sensor
temperature
sensor
C18 Connector of reversing

light switch
E41 Connector of camshaft position

sensor
E22 Connector of rear oxygen

sensor
E43 Connector of
water
E44 Connector of front oxygen
thermometer sensor
14
Right Chassis Wire Harness
Right chassis wire harness (1)
Right A pillar
FD05 Connector
of right rear door
MF02 Connector of main wire harness
wire harness
F19 Contact
switch of right
rear door
F16 Contact
switch of right
front door
Right rear C
pillar
Right C pillar upper
trimming plate
F10 Connector of right rear wheel F22 Connector of rear defrosting

speed sensor switch
15
Right chassis wire harness (2)
G05 Body ground
16
Left Chassis Wire Harness
Left chassis wire harness (1)
MF02 Connector of MF03 Connector

Left A pillar
left body wire harness of left body wire Driver’s seat

harness
F01 Switch for

mortise lock of
safety belt

wire harness
F17 Contact
switch of left
front door
F27 Parking switch
F18 Contact switch of left rear

door
F26 Connector of fuel pump
wire harness
17
Left rear C pillar Boot

F04 Connector of
left rear wheel
speed sensor
F12 Reversing radar controller
FD04 Connector
of left rear door
wire harness
F02 Left rear

combination
light
F24 Contact
switch of
liftgate
F03 Right
rear
combination
light
Locking piece of
boot
18
Left C pillar upper

trimming plate
F05 Left rear

loudspeaker
F29 Connector of rear
defrosting switch
F23 Boot illumination
F11 Connector of high position

brake lamp
F20 Left rear license light
F06 Right rear

loudspeaker
19
F21 Right rear license

light F15 Connector of
center reversing
radar sensor
F13 Connector of F14 Connector of

left reversing radar right reversing
sensor radar sensor
Left C pillar
G09 Ground
20
Left Front Door Wire Harness
MD01 Connector of instrument

wire harness
D03 Connector
of left electric
back mirror
D11
Connector of
left front door
glass
elevating
motor
D07
Connector D06 Connector of
of left front left front door bass
door high horn
pitch horn
D02 Connector of electric back mirror D21 Connector of

switch
left front door
fastener
D07 Connector for D25 Connector

main switch of window of left front
elevating system
door lamp
21
Right Front Door Wire Harness
Right front door wire harness (1)
MD03 Connector of main

wire harness
Right front fender
D05 Connector
of electric back
mirror
D16 Connector of right

front door glass
elevating motor
D08 Connector of
right front door high
pitch horn
D09 Connector of
right front door bass
horn
D15 Connector of
right front door glass
elevating switch
22
Right front door wire harness (2)
D24 Connector
of right front
door lamp
D20 Connector of
right front door
fastener
23
Left Rear Door Wire Harness
FD04 Connector
of left body wire
harness
D13 Connector of left

rear door glass
elevating motor
D12 Connector of left

rear door glass
elevating switch
D23 Connector of
left rear door
fastener
24
Right Rear Door Wire Harness
FD05 Connector
of right rear door
wire harness

rear door glass
elevating motor

rear door glass
elevating switch
D22 Connector
of right rear door
fastener
25
Ceiling Wire Harness
R03 Connector of
reading light
MR01 Connector of main wire (connector of dome
harness lamp)
26
Ground Wire Harness
Ground wire harness (1)
G08 ECU ground
G04 Storage battery

ground
Left A
pillar
G02 Body ground
G01 Body ground
G06 Ground
Right A pillar
Left A pillar
G07 Ground
27
Ground wire harness (2)
Left C pillar G05 Body ground
G09 Ground
G03 Gearbox ground
28
Airbag Wire Harness
Right B
pillar
MA01 Connector A
of airbag wire
harness
MA02 Connector B
of airbag wire A05 Wire harness
of right safety belt
harness pretensioner
A03 Connector of airbag on

passenger seat
Left B pillar
A04 Wire harness

of left safety belt
pretensioner
29
Air Conditioner Wire Harness
A13 Connector of
MA03 Connector 1 internal and external
of instrument wire mode motor
harness Blower
Right A
pillar
MA04 Connector 2
of instrument wire
harness
Evaporator
Heater
A12 Connector of A16 Connector of

evaporator surface air door motor
temperature sensor
A14 Thermostatic
air door motor
Right A
pillar
A09 Connector of
blower
30
Contents for Wire Harness Layout
Main Wire Harness ...................................................................................................................................1

Engine Compartment Wire Harness I .......................................................................................................3
Engine Compartment Wire Harness II ......................................................................................................5
Controller Wire Harness ...........................................................................................................................7
Right Chassis Wire Harness.....................................................................................................................9
Left Chassis Wire Harness .....................................................................................................................11
Left Front Door Wire Harness.................................................................................................................13
Right Front Door Wire Harness ..............................................................................................................14
Left Rear Door Wire Harness .................................................................................................................15
Right Rear Door Wire Harness...............................................................................................................16
Ceiling Wire Harness..............................................................................................................................17
Airbag Wire Harness ..............................................................................................................................18
Air Conditioner Wire Harness .................................................................................................................19
0
Maintenance Manual of Tojoy Sedan Wire Harness Layout
Main Wire Harness
1
Illustration of Main Wire Harness

M01 Connector of cigarette lighter wire harness M33 Internal and external circulation switch
M02 Diagnostic connector M34 Dimmer switch
M05 Combined switch (washing) A02 Connector for wire harness of airbag on
M06 Air conditioning control panel drivers seat
M07 CD player A03 Connector for wire harness of airbag on
M08 Antenna passenger seat
M10 Blower switch MA01 Connector A of airbag wire harness
M11 Rear defrosting switch MA02 Connector B of airbag wire harness
M12 Buzzer MA03 Connector 1 of air conditioner wire
M13 Combined switch (lamp) harness
M14 Rear fog lamp switch MA04 Connector 2 of air conditioner wire
M17 Combined device A harness
M18 Combined device B (blue) MD01 Connector of left front door wire harness
M19 Combined device C MD02 Connector of left front door wire harness
M23 ETACS A MD03 Connector of right front door wire harness
M24 ETACS B ME01 Connector 01 of engine wire harness
M25 Front fog lamp switch ME02 Connector 02 of engine wire harness
M28 Alarm light switch ME03 Connector 03 of engine wire harness
M31 Ignition lock ME04 Connector of engine controller wire
M32 Insert-key illumination harness
MF01 Connector of left body wire harness
MR01 Connector of ceiling wire harness
G06 Ground of main wire harness
G07 Ground
2
Engine Compartment Wire Harness I
3
Illustration of Engine Compartment Wire Harness I
C04 Engine oil pressure sensor E24 Starter switch

E01 Positive pole of storage battery E25 Electric generator power supply
E02 Negative pole of storage battery EE01 Connector of engine wire harness
E20 Engine excitation connector G03 Starter ground
E21 Starter power supply G04 Storage battery ground
4
Engine Compartment Wire Harness II
5
Illustration of Engine Compartment Wire Harness II

E03 Connector for the positive pole of power supply
E04 ABS ECU connector
E05 Connector of left front wheel speed sensor
E06 Connector of right front wheel speed sensor
E07 Connector of radiator fan
E11 Connector of left front fog lamp
E13 Right front combination light
E16 Right turn light
E17 Left turn light
E18 Connector of air-conditioned compressor
E19 Connector of high pitch horn
E21 Left front combination light
E26 Connector of right front fog lamp
E28 Connector of washing solution motor
E30 Brake fluid level sensor
E31 Connector of rear washing solution motor
E37 Connector of three-way pressure switch
EE01 Connector of engine wire harness
EE02 Connector of engine controller wire harness
ME01 Connector 01 of engine wire harness
G01 Body ground
G02 Body ground
6
Controller Wire Harness
7
Illustration of Engine Controller Wire Harness

E22 Connector of rear oxygen sensor E46 Connector of crankshaft position sensor
E27 Engine ECU connector E47 Connector of speed sensor
E32 Ignition coil (Cylinder II, III) E49 Connector of knock sensor
E33 Connector of intake air pressure and E50 Nozzle 1
temperature sensor E51 Nozzle 2
E34 Ignition coil (Cylinder I, IV) E52 Nozzle 3
E36 Connector of wiper motor E53 Nozzle 4
E38 Carbon canister solenoid valve EE02 Connector 01 of engine wire harness
E39 Connector of stepper motor ME04 Connector 04 of instrument wire harness
E40 Connector of air throttle position sensor G08 ECU ground
E41 Connector of camshaft position sensor
E43 Connector of water thermometer
E44 Connector of front oxygen sensor
8
Right Chassis Wire Harness
9
Illustration of Right Chassis Wire Harness

MF04 Connector of right body wire harness
FD05 Connector of right rear door wire harness
F10 Connector of right rear wheel speed sensor
F16 Contact switch of right front door
F19 Contact switch of right rear door
F22 Rear defrosting connector
G05 Body ground
10
Left Chassis Wire Harness
11
Illustration of Left Chassis Wire Harness

F01 Switch for mortise lock of safety belt F20 Left license light
F02 Left rear combination light F21 Right license light
F03 Right rear combination light F23 Boot illumination
F04 Left rear wheel speed sensor F24 Boot contact switch
F05 Left rear loudspeaker F25 Fuel filter ground
F06 Right rear loudspeaker F26 Fuel pump
F11 High position brake lamp F27 Parking switch
F12 Reversing radar controller F29 Rear defrosting connector
F13 Left reversing radar sensor MF01 Connector 01 of left body wire harness
F14 Right reversing radar sensor MF02 Connector 02 of left body wire harness
F15 Center reversing radar sensor MF03 Connector 03 of left body wire harness
F17 Contact switch of left front door FD04 Connector of left rear door wire harness
F18 Contact switch of left rear door G09 Ground
12
Left Front Door Wire Harness
Illustration of Left Front Door Wire Harness

D02 Back mirror switch
D03 Connector of electric back mirror
D06 Connector of left front door bass horn
D07 Connector of left front door high pitch horn
D10 Main switch of window elevating system
D11 Connector of left front door glass elevating motor
D21 Connector of left front door fastener
D25 Connector of left front door lamp
MD01 Connector 01 of left front door wire harness
MD02 Connector 02 of left front door wire harness
13
Right Front Door Wire Harness
Illustration of Right Front Door Wire Harness

D05 Electric back mirror
D08 Connector of right front door bass horn
D09 Connector of right front door high pitch horn
D15 Connector of right front door glass elevating switch
D16 Connector of right front door glass elevating motor
D24 Connector of right front door lamp
D20 Connector of right front door fastener
MD03 Connector of instrument wire harness
14
Left Rear Door Wire Harness
Illustration of Left Rear Door Wire Harness

D12 Connector of left rear door glass elevating switch
D13 Connector of left rear door glass elevating motor
D23 Connector of left rear door fastener
FD04 Connector of left body wire harness
15
Right Rear Door Wire Harness
Illustration of Right Rear Door Wire Harness

D17 Connector of right rear door glass elevating switch
D18 Connector of right rear door glass elevating motor
D22 Connector of right rear door fastener
FD05 Connector of right body wire harness
16
Ceiling Wire Harness
Illustration of Ceiling Wire Harness

R01 Connector of electric sun roof
R03 Connector of dome lamp
MR01 Connector of main wire harness
17
Airbag Wire Harness
Illustration of Airbag Wire Harness

MA01 Connector 01 of instrument wire harness
A01 Airbag ECU
A04 Left safety belt pretensioner
A05 Right safety belt pretensioner
G11 Ground
18
Air Conditioner Wire Harness
Illustration of Air Conditioner Wire Harness

A09 Connector of blower motor
A11 Power amplifier
A12 Connector of evaporator surface temperature sensor
A13 Connector of internal and external mode motor
A14 Connector of temperature mode motor
A16 Connector of air door motor
19

A-Car Workshop Manual

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Maintenance Manual of Tojoy Sedan Contents

I. General Precautions ....................................................................................................1

Section II Engine Lubrication System ...........................................................................................64

Section III Cooling System of Engine............................................................................................75

Section IV Fuel Supply System of Engine ....................................................................................91

I. General Precautions ..................................................................................................91

VI. Fuel Pump Assembly .................................................................................................99

Section V Emission Control System of Engine ...........................................................................107

I. Fuel Evaporation System.........................................................................................107

Chapter 2 Electrical Part of Engine ........................................................................... 114

Section 2 Starting and Charging System ....................................................................................118

I. Basic Diagram of Starting and Charging System.....................................................118

Chapter III Electronic Control System of Engine......................................................135

I. Precautions of Supplement Restraint System (SRS) ...............................................135

Section II Structural Principle and Overhaul of Engine Control System ......................................139

I. System Illustration ...................................................................................................139

Section III Structural Principle and Overhaul of Engine Electronic Elements..............................153

I. Intake Manifold Absolute Pressure (MAP) Sensor...................................................153

XI. Carbon Canister Solenoid Valve..............................................................................168

Section IV Trouble Diagnosis Procedures for Engine Control System........................................177

I. Diagnosis by Trouble Code......................................................................................177

Chapter 1 Mechanical Part of Engine

6. Parts Needed to Be Screwed Up with Specified Angle

- Cylinder cover bolt

- Bolt of main bearing cap

- Connecting rod nut

II. Precautions on Sealant

After dismounting the fixing nuts and bolts, use the

■ Do not damage the matching faces.

■ Insert the scraper, and then knock its side to

■ For the positions where it is difficult to use the

2. Application Steps of Sealant

1) Use a scraper to remove the attached old

■ Thoroughly remove the old sealant from the

3) Put the sealant (with the specified size) in the

■ Put the sealant into the groove for it, if any.

■ Generally, the sealant is put inside the bolt Fig.1.1.004 Inner

■ Install the matching elements within 5minutes

■ Eliminate the dirt from the sealant, if any.

■ Do not re-screw down the nuts or bolts after

■ Add the engine oil and the engine coolant

■ Conduct the operation in accordance with the

List of Special Tools

Installer for rear Used to install

2. List of Auxiliary Materials for Assembling Engine

List of Auxiliary Materials for Assembling Engine

No. Name Application Specification and Grade

3. List of Auxiliary Materials for Assembling Cylinder Cover

List of Auxiliary Materials for Assembling Cylinder Cover

No. Name Present Material and Model Assembly Position

IV. Engine Assembly

■ Air duct and air cleaner assembly. See “Air Duct”.

■ Radiator assembly and radiator fan. See “Radiator”.

3. Dismantlement of Relevant Elements inside Engine Compartment

① Disconnect the following pipelines and put them aside.

Use plugs to prevent leakage when disconnecting the pipelines.

■ Inlet pipe of oil injector. See “Oil Injector”.

■ PVC hose. See “Fuel Evaporation Control System”.

■ Oil inlet pipe joint of clutch. See “Hydraulic Pipeline of Clutch”.

■ Low and high-pressure pipes at air compressor. See “air compressor”.

② Dismount the throttle wiredrawing. See “Throttle Wiredrawing”.

③ Dismount the steering fluid reservoir.

■ Engine coolant temperature sensor