V80 维修手册（OK Electrico Pag 3-20）技术指南左-英 15-6-15

Service Workbook
500
130
450
400
Technical Guide 110
350
90
3RZHUU (PS)
7RUTXHH (Nm)
300
250 70
200
50
150
30
100
50
1000
1500
2000
2500
3000
rpm
2015Year
WARNING
Warning: To reduce the possibility of personal injury and property damage, the following
instructions must be observed:
All six service workbooks provided by SMCV are dedicated for professional technicians. Trying to
do service or repair work without appropriate trainings, tools or equipments may cause injury to you or
others. It can also result in vehicle damage or abnormal operation.
Correct service and repair work is essential to personal safety of service technicians, as well as safe
and reliable operation of vehicles. If any part needs to be replaced, use the same part number or other
part number(s) specified by SMCV only. Never use any replacement part which is not approved by SMCV.
The repair instructions suggested and introduced in this workbook are beneficial for correct service
and repair. And sometimes special tools are required.
In this case, any use of the replacement parts, repair instructions or tools which are not suggested
or approved by SMCV should not be allowed until it is proved that this has no threat to the personal
safety or safe operation.
This workbook provides technical data, illustrations and function descriptions of all components on
MAXUS Datong PV, MPV and VAN models and not to any particular vehicle in model year - 2012.For the
specification of any particular vehicle, purchasers should consult their SMCV Distributor or Dealer.
Throughout this workbook, WARNINGS and CAUTIONS are included which should be strictly
observed for reducing personal injuries at the service and repair work. Any incorrect service or repair
will cause damage to the vehicle, left hidden dangers. However, these WARNINGS and CAUTIONS are not
complete. And it is impossible for SMCV to give warnings for all potential dangers resulting from
violation of these instructions.
In order to avoid accidental airbag deployment and relevant potential injury, it is recommended to
service the airbag first when both the airbag and other systems need to be repaired.
No part of this publication may be reproduced, stored in a retrieval system or transmitted, in any
form, whether electronic or mechanical, or by photocopying, recording or other means without prior
permission in writing of SMCV
Error and Advice Reporting
If any error is found in this service workbook, or any advice, you are encouraged to tell us.
You can send any advice via letter or fax to SMCV After Sales at
After Sales, SAIC Commercial Vehicle Co., Ltd
#2500, Jungong Road,
Shanghai City, China Postcode: 200438
The following information should be provided:
· Your name
·Authorized repair center
·Tel. and fax of the authorized repair center
·Model year and model
·VIN
·Description of your concern(s)
·Necessary relevant information (e.g. sample or marked page)
·Any applicable electronic information part identification number
SMCV will give relevant response in the following ways:
·Submitting your concern to relevant service engineer
·Consulting relevant service engineer
·Satisfying your concern within 10 working days.
Datong users are encouraged to send your concerns to SMCV Customer Support Center at: 400-081-2011.
Contents
Overview ......................................................................................................... 1-1
Vehicle Overview ............................................................................................................................................... 1-1
Technical Data ................................................................................................................................................... 1-2
Vehicle Dimension ............................................................................................................................................. 1-6
Vehicle Identification .......................................................................................................................................... 1-8
Maintenance Information................................................................................. 2-1

Lift Point ............................................................................................................................................................. 2-1
Maintenance & Service ...................................................................................................................................... 2-2
Lubrication & Sealing ......................................................................................................................................... 2-3
Description & Operation .................................................................................. 3-1

Engine Mechanical............................................................................................................................................. 3-1
Engine Electrics ............................................................................................................................................... 3-10
Engine Cooling................................................................................................................................................. 3-13
Engine Control ................................................................................................................................................. 3-17
Fuel system...................................................................................................................................................... 3-23
Air intake & Exhaust System............................................................................................................................ 3-26
Transmission.................................................................................................................................................... 3-30
Clutch............................................................................................................................................................... 3-33
Drive Shaft ....................................................................................................................................................... 3-35
Front suspension ............................................................................................................................................. 3-38
Exploded diagram of front shock absorber ...................................................................................................... 3-40
Rear suspension .............................................................................................................................................. 3-42
Steering............................................................................................................................................................ 3-46
Brakes system ................................................................................................................................................. 3-51
Windows .......................................................................................................................................................... 3-58
Wiper and Washer ........................................................................................................................................... 3-60
Exterior mirror .................................................................................................................................................. 3-63
Seat.................................................................................................................................................................. 3-66
Illumination....................................................................................................................................................... 3-68
Instruments ...................................................................................................................................................... 3-71
Immobiliser system .......................................................................................................................................... 3-80
Body control unit .............................................................................................................................................. 3-83
Vehicle entertainment system.......................................................................................................................... 3-87
Parking distance control................................................................................................................................... 3-91
Seat belt........................................................................................................................................................... 3-94
Airbag restraint system .................................................................................................................................... 3-96
Heating / Ventilation......................................................................................................................................... 3-99
Air conditioner ................................................................................................................................................ 3-102
ESP system ................................................................................................................................................... 3-107
ESP-HHC Function ........................................................................................................................................ 3-109
....................................................................................................................................................................... 3-110
....................................................................................................................................................................... 3-110
Contents
....................................................................................................................................................................... 3-110
Tyre pressure detection system ...................................................................... 4-1

Overview ............................................................................................................................................................ 4-1
Operation principle ............................................................................................................................................. 4-1
System structure: ............................................................................................................................................... 4-1
Instrument panel display .................................................................................................................................... 4-1
Tyre pressure warning alarm.............................................................................................................................. 4-1
Tyre critical alarm ............................................................................................................................................... 4-3
Signal transmission mode .................................................................................................................................. 4-3
Function description of component parts: .......................................................................................................... 4-4
Functions of hand-held learning diagnostic tool ................................................................................................. 4-4
Introduction of hand-held learning diagnostic tool.............................................................................................. 4-4
1、 Menu and button.......................................................................................................................................... 4-5
1、 Button definition ........................................................................................................................................... 4-5
2、 Activation picture ......................................................................................................................................... 4-5
2、 Learn binding ............................................................................................................................................... 4-5
3、 Delete mode ................................................................................................................................................ 4-6
4、 Tyre change-over mode............................................................................................................................... 4-7
5、 Diagnostic test functions.............................................................................................................................. 4-8
6、 Precautions................................................................................................................................................ 4-11
Overview
Overview
Vehicle Overview
A proven, durable 2.5 litre common rail diesel engine with turbocharger and intercooler is equipped
on V80 commercial vehicle. The engine is mounted transversely on the frame and provides the front
wheel drive by transaxle transmission. The engine employs a program control fuel injection system for
improved combustion efficiency, as well as low fuel consumption and low emission - Chinese Emission
Standard IV, hence an economical and environmental innovation. Combined with excellent performance
of SC25R Engine, 5MT is equipped on V80 commercial vehicle. The manual operated 5 Gear
Transmission can significantly improve the acceleration performance; and the reliable operation control
can ensure a stable and smooth driving.
V80 commercial vehicle is equipped with four-wheel disc brakes. Both on the front and rear wheels
are installed with ventilated disc brakes which have excellent heat dissipation and brake performance. In
addition, with the improved rigidness of the brake pedal, brake friction disk with high COF and advanced
tyres with strong adhesivity, outstanding brake performance can be ensured.
To prevent wheel locking when an emergency braking is applied, V80 commercial vehicle is installed
with Four-wheel Anti-lock Brake System (ABS). In this case, driving safety is guaranteed.
V80 commercial vehicle is equipped with SRS Dual Air Bags to sense, analyze and initiate relevant
program based on the crash condition. The initiator can, according to the crash severity, launch a short
interval explosion on the purpose of controlling the initiation of the air bags.
V80 commercial vehicle is installed with Front & Rear Air conditioning. Dedicated AC air outlet is
equipped in each row of seats. For the rear AC, hidden design is applied which locates the cool air outlet
on the top of the body. Both the temperature and air flow of rear AC can be adjusted by the control panel
in the middle left of the passenger compartment.
The very strong monocoque body shell encloses:
- Precise rack and pinion power steering.
- A well proven McPherson strut front suspension.
- A simple leaf spring rear suspension.
- Comprehensive electronic management system (EMS).
- Sophisticated vehicle security.
- In addition, a great range of features which include:
- Electric door locking and window operation.
- Cab door mirrors power operated and heated.
- Front passenger air bag & seat belt pre-tensioner.
- Pad wear audible indicators.
- Audible warning device.
1-1
Overview
Technical Data
Main Technical Data - Whole vehicle
SV61
SV80
short shaft long shaft lengthen shaft
Gross vehicle weight,kg 3200 3495 3800 3495 3800 4100
Gross train weight,kg 2185,2240 2240-2800 2185-2800 2280-2800 2530,2570,2610
Front/rear full axle load,kg 1360/1840 1550/1945 1760/2040 1550/1945 1760/2040 1870/2230
Number of Seats 2-13 2-16 10-19
Drive Type front driver
External Length 4950-5160 5700-5910 5990

Dimension Width 1998
（mm）
Height 2070-2345 2345-2552 （exceed low tip 2070）
Wheelbase （mm） 3100 3850 4175
Front Track （mm） 1734
Rear Track （mm） 1728
Front Suspension （mm） 865
Rear Suspension （mm） 985,1195
Approach Angle （°） 26
Departure Angle （°） 17 （without rear step）， 14 （with rear step）

Minimum Ground
157-200
Clearance （mm）
Fuel Tank Capacity （L） 80
To Speed （km/h） 150 140
Minimum Turning Radius

12.4 14.8 16.8
（m）
Fule consumption
oncomprehensive
8.3 9.1 8.5 9.1 9.6
operation modesper （L/
100km）
1-2
Overview
Main Technical Data - Engine
Model SC25R136Q4 SC25R120Q4
Type Inline 4-Cylinder CR, TCI Diesel
Number of Stroke 4
Bore (mm) 92.0 92.0
Stroke (mm) 94.0 94.0
Total Displacement (L) 2.499
Compression Ratio 17.5:1 17.5:1
Rater Power (kW/r/min) 100/3800 88/3800
Max. Torque (Nm/r/min) 330/1800 ～ 2600 300/1800 ～ 2600

Fuel Type Diesel
Cylinder Working Order 1-3-4-2
Weight (without starter and AC 230 230

compressor)(kg)
Emission Level Chinese Emission Standard Ⅳ /Chinese Emission Standard Ⅴ

Emission Device Catalytic Converter + Intercooler EGR
1-3
Overview
Main Data - Transmission
Model HTX-PVH
Type 5MT
1st C
2nd 2.105
Gear Ratio
3rd 1.300
4th 0.941
5th 0.750
Gear Ratio Rev 3.167
Final 4.188
Transmitted Torque (N.m) 330
Operation control Long distance cables
Front-wheel Alignment Data
Item Front-wheel Alignment Data
Wheel Camber 0.5 ± 1° (-0.5°～ 1.5°)

the difference between Left and right (-0.5°～ 0.3°)
Kingpin Castor 0.6 ± 0.9° (-0.3°～ 1.5°)
the difference between Left and right (-0.3°～ 0.3°)
Wheel Toe Individual wheel toe-in -0.11°～ 0.02°
Total toe-in -0.22°～ 0.04°
the absolute dispersion between Left and right ≤ 0.05
Kingpin Inclination 10 ± 2.5° (7.5°～ 12.5°)
Rear-wheel Alignment Data
Rear-wheel Alignment Data

Item
Left wheel (rear) Right wheel (rear)
Wheel Camber 0° 0°
Wheel Toe 0° 0°
Rear-wheel Thrust Angle 0 ± 0.25°
1-4
Overview
Suspension Date
Proof load (N) 13850 （free state）

Max. load (N) 9900 164 -6 4400 ～ 4700N
Static load (N) 6110 100 58 ± 5 60.5 ± 7%
Empty load (N) 4400 73 85 ± 5
No load (N) 0 0 158 ± 6
Load name Load N Deformation mm Camber mm Rigidity N/mm
Wheel & Tyre Data
Model SH6501、 SH 5040、 SH6571、 SH5041

Wheel Specification 16X6J
Tyre Specification 205/75R16C 215/75R16C
Tyre Pressures (kPa) (Front GVW=3.2t 380/420

Wheel / Rear Wheel)
GVW=3.5t 400/450
Available Body Colors
White Single white coat
Silver Galaxy silver
Grey Iron grey
Violet Water crystal violet
Brown Water brown metallic
1-5
Overview
Vehicle Dimension
1998
2345
2132
3100(SWB)
4950 1734
1998
1505
1728
1-6
Overview
1998
2552
2345
3850(LWB)
5700 1734
1998
1728
1728
1-7
Overview
Vehicle Identification
Vehicle Identification Number (VIN) :
VIN Example： - LSK G 4 G C 1 9 A A200000
LSK Identification code of the manufacturer
Vehicle Brand
G
Datong
4 = L<5.3 ; 5 = 5.3 < L < 6.0

4
Vehicle Length
Engine Type
G
G =60 ~ 149KWDiesel
PV Type and Steering Wheel Layout

C
C = Small PV(LEFT) ; L = Small PV (RIGHT)
Engine Layout
1
1 = Front-engine
9 Check digit
Model Year
A
A = 2010 年
Assembly Plant
A
A = Manufacturer
2 ××××× (6 Digits) Production Serial Number
VIN - Position
VIN is inside the engine compartment
1-8
Maintenance Information
Lift Point
Vehicle lifting illustration
CAUTION: Since there is no independent chassis, the lift should be operated at the pivot point specified
below to ensure no damage to the vehicle
S163035 S163035
2-1
Maintenance & Service
Maintenance & Service4
Item Service contents (requirements)
Engie oil change At first 5000km,then every 15000km
Renew oil filter At first 5000km,then every 15000km
Renew air cleaner element At first 10000km,then every 15000km
Renew fuel filter At first 10000km,then every 15000km
Power steering oil change Every 3 years(or every 80000km)
Renew timing belt Every 60000km or every 5 years
Renew engine coolant Every 2 years or every 60000km (Pay attention to coolant compositions)
Renew transmission oil At the first 10000km, then every 80000km
Renew brake fluid Every 2 years (or every 60000km)
Renew AC air cleaner element Every 1 year
2-2
Lubrication & Sealing

Fuel, Lubricants and Working Fluids
Fluid Name Fluid Type Fluid Amount Note
Engine oil CI-4 (or A3 /B4) -10W/40 6.5kg Already existed in the engine(EU4)
Engine oil CJ-4 5W/40 6.5kg Already existed in the engine(EU5)
Brake fluid DOT4 0.76L
Anti-freeze JFL-3 9L without rear Use only SMCV approved antifreeze

AC
10.5L with rear
AC
Power steering fluid ATF-DEXRON Ⅲ Type 0.96L
AC coolant R134a 600 ± 30g without rear AC
1450 ± 30g SWB with rear AC
1750 ± 30g LWB with rear AC
AC refrigerating oil PAG 0.3kg Loaded in the AC compressor
Transmission fluid 75W-85 2.3L
Fuel Diesel 80L Sulfur content of less than 50ppm of

the diesel
Windows washer fluid Universal lower freezing point 2.4L

washer fluid
Lithium grease NLGI 2 As required Hub bearing
Sealants / Thread locking adhesives
Loctite 601 Bowl plug
Loctite 510 Turbocharger fuel return pipe adapter
Molykote 111 'O' rings (crankshaft rear bearing, rear bearing seat)
Polymer 400 Cylinder liner 'O' ring
Loctite 222 Water temperature sensor
Screw plug
Engine support stud
Teflon grease Vacuum pump one-way valve
Oil pressure alarm switch
Molycote P – 1500 grease Fuel injector
Loctite 5900 Crankshaft rear bearing seat
Gear casing cover
2-3
CAUTION: It is essential that the correctly specified oil, grease, fluids etc. are used at all times.
2-4
Description & Operation
Engine Mechanical
Illustrations
Layout of block and cylinder power assembly
6
7
5 9
10 8
1 3
11
24
12
2
37
4
36
35
14 13
34
33 15
32 17
18
16
31
19
30 20
22 21
29 23
18 25
28
26
27
1 Cooling water pipe 10 Connection rod bush

2 Water pump 11 Connecting rod
3 Oil filter 12 Flywheel dust shield
4 Oil cooler 13 Rear main bearing seat
5 Fresh water pump inlet pipe and coolant inlet 14 Speed sensor
hose
15 Flywheel dust shield support
6 Piston ring
16 Crankshaft speed signal disc
7 Elastic retaining ring for holes
17 Connection rod bearing bush
8 Gudgeon pin
18 Main bearing seat
9 Piston
3-1
19 Flywheel 29 Main bearing bush
20 Starter ring gear 30 Crankshaft
21 Crankshaft rear oil seal 31 Vacuum pump
22 Crankshaft rear ring spacer block 32 Crankshaft pulley/damper
23 O seal ring 33 Oil pump drive gear
24 Cylinder liner 34 Vacuum pump/oil pump drive gear
25 Crankcase oil baffle plate 35 Oil pump
26 Oil pan pad 36 Crankcase
27 Oil pan 37 Oil pressure alarm switch
28 Oil strainer/pick-up pipe
3-2
Layout of cylinder head, air intake & exhaust and fuel system assembly
1 2
4
9
3 6 7
8 11 10
12
13
5
36
14
35
33 34 15
32 31
30
29
16
28
27 18
17
26
20
19 21
25
24
22
23
1 Fuel injector return pipe 9 Oil dipstick

2 High pressure fuel return pipe (fuel rail to fuel 10 Oil dipstick tube
injector)
11 Camshaft plug
3 Fuel rail
12 Air intake temperature & pressure sensor
4 Fuel injector
13 Cylinder upper head
5 Fuel rail pressure sensor
14 Cylinder upper head shim
6 Oil filler cap
15 Turbocharger air intake pipe
7 Oil/air separator
16 EGR air outlet pipe (EGR cooler to EGR valve)
8 Camshaft position sensor
17 Water temperature sensor
3-3
18 Cylinder head 27 Valve actuating system
19 Cylinder head shim 28 Engine lifting eye
20 Air intake pipe (EGR valve to cylinder upper 29 Exhaust pipe shim
head)
30 Exhaust pipe
21 Heater plug
31 Exhaust pipe heat shield
22 Vacuum pipe
32 Camshaft oil seal
23 Turbocharger oil return pipe
33 Camshaft retaining ring
24 Turbocharger oil pickup pipe
34 Inlet camshaft
25 Turbocharger
35 Exhaust camshaft
26 Thermostat and housing
36 Fuel rail oil return pipe
3-4
Layout of front end timing & accessories assembly
9
8
5 7
6
4
2
3
12
1 3 11 10
13
14
15
16
23 24
22 19
21
20 17
18
1 Engine front support 13 Crankshaft timing pulley

2 Front end timing protective cover 14 Power steering pump
3 Timing drive belt idler pulley 15 High pressure fuel pump
4 Timing drive belt 16 AC alternator mounting
5 Exhaust camshaft timing pulley 17 Alternator
6 Inlet camshaft timing pulley 18 AC compressor
7 Timing pulley case 19 Front end accessory drive belt
8 Timing pulley case bush 20 Front end accessory drive idler pulley
9 Timing pulley case damping pad 21 Front end accessory drive tension pulley
10 Timing pulley case shim 22 Timing pulley case damping pad
11 High pressure fuel pump pulley 23 Crankshaft front seal
12 Timing drive belt tension pulley 24 Gear casing cover
3-5
Layout of timing belt
1 2
3 3
6
5
1 Exhaust camshaft drive gear 5 Timing belt

2 Inlet camshaft drive gear 6 Crankshaft drive gear
3 Idler pulley 7 Belt tensioner
4 Fuel pump drive gear 8 Water pump
3-6
Description
Overview and cylinder head shim, the sealing of the cylinder head
SC25R engine is a small and medium power diesel will be influenced by the head gasket.
engine equipped with overhead camshaft, 16 valve direct
The aluminum thermal expansion piston is equipped
injection, turbocharger & intercooler and electronically
with a semi-floating gudgeon pin and applies an
controlled high pressure common rail. It boasts an
interference fit at the small end of connection rod.
international advanced level of energy-saving and high
efficient performance with a Chinese Emission Standard The crankshaft is supported by five bearing bushes
IV achieved by EGR. with eight balancing blocks. The upper half of connection
rod bearing bush is equipped with oil sump which is filled
The engine is mainly composed of aluminum
from the oil hole on the crankshaft to the bearing bush of
cylinder upper head & cylinder head, irony block and oil
connection rod big end.
pan made of composite steel plates. The aluminum
components ensure both the overall weight of the engine The installation holes of oil pump and vacuum pump
and outstanding heat dissipation. The irony components are located at the front end of the block.
ensure an excellent rigidity of the engine block. The oil
Lubrication System
pan made of composite steels ensures an anti-corrosion
The lubrication system is composed of oil pan, oil
property, as well as an excellent rigidity.
pump, oil filter, relief valve and oil sensor, etc. The main
Cylinder head parts function of lubrication system is to provide a certain
The cylinder head consists of cylinder head and amount of oil onto the friction surfaces on the purpose of
cylinder upper head with 16 valves, center located fuel lubricating, cooling, cleaning and sealing. The operation
injector and cold start heater plug. process is to pump the oil upward from oil pan to all oil
holes on the crankshaft and cylinder block through the oil
The hydraulic valve tappet is assembled at the head
filter. This engine
and directly driven by the camshaft located in the cylinder
upper head. ·Oil pan:
Oil pan is located at lower half of the crankcase,
Exhaust valve is used to prevent carbon deposit.
namely lower crankcase. Its purpose is to enclose the
The valve stem, the side surface of which is machined,
crankcase as the shell of oil sump, preventing the entry of
can remove the carbon deposit in the combustion
inclusions and collecting and storing engine oil returning
chamber and the valve guide end, so as to prevent the
from diesel engine friction surfaces.
valve sticking.
The stainless cylinder head gasket is used to seal ·Oil pump:

the surrounding of coolants, air vents and oil holes. Oil pump is used to raise oil pressure, ensure a
certain amount of oil and forces oil to every frication
The camshaft position sensor is installed at the top surface.
of the cylinder upper head.
·Oil filter:
Cylinder block parts
During the engine operation, metal debris, dusts,
The cylinder block is equipped with wet cylinder
carbon deposits oxidized at high temperature, gelatinous
liner. On the lower part of the wet cylinder liner are some
sludge and water are continuously mixed into the engine
steps to achieve the slide fit with the cylinder block. The
oil. Its purpose is to filter these mechanical inclusions and
liner steps are coated with a layer of sealant to keep the
gelatinous matters, ensuring the cleanliness of engine oil
cylinder liner within the block. Since the top of cylinder
and extending its lifetime.
liner is used as a section between combustion chamber
·Relief valve: Relief valves are installed at the main oil channel or
oil pump to prevent oil pressure too high in the lubrication
3-7
system which may result in increased engine power loss

and even oil leakage at the seal of oil gallery.
The purpose of relief valve is to limit the oil pressure

of the lubrication system not to exceed its specification.
·Oil sensor:
Oil sensor is used to measure the engine oil
pressure.
See the figure below for lubrication system oil

flow.
3-8
Illustration of lubrication system oil flow
15
14 4
5
13
12 6
11
7
10
8
9
1 Camshaft bearing 9 Oil strainer

2 Cylinder head 10 Oil pump
3 Piston cooling nozzle 11 Oil pressure regulating valve
4 Connection rod journal 12 Modularized oil cooler
5 Crankshaft main bearing 13 Oil filter
6 Crankshaft 14 Main oil gallery
7 Oil pan 15 Turbocharger
8 Vacuum pump
3-9
Engine Electrics
Illustrations
Layout of starting & charging devices
1
2
1 Alternator 2 Starter motor
3-10
Control chart of starting & charging devices
1 2
6 5 4
1 Alternator 6 Pre-fuse box

2 Starter motor 7 Instrument cluster
3 Relay 8 Ignition switch
4 Battery 9 Ignition key
5 Cabin fuse box
3-11
Description warning light remains on, check for any fault on the
Overview charging system or the battery will be damaged.
The start system is equipped with a 12V starter When the ignition switch is in the "ON" position, the
motor which drives the engine to start combustion to coils will provide power to make the pinion ring gear and
transform electric energy to mechanical energy. The flywheel ring gear coupled with each other. The pinion is
electric system must be able to provide enough energy to screw rotated on the motor shaft, ensuring a smooth
ensure that the crankshaft can be driven by starter motor. combination through the ring gear. On the starter motor,
The charging system is composed of one battery motor drives the pinion via reduction gear, not
pack and one alternator. The battery must be able to directly via the motor, proving a smooth combination
provide enough energy to drive starter motor and other between starter one-way clutch and flywheel ring gear.
electric systems. The alternator charges the battery when
the engine is in operation and when an increased output After the engine starts, when the ignition switch is
is required by the battery. released, the solenoid will provide enough energy to pull
the pinion from the ring gear.
The instrument cluster is installed with charging
warning light which is illuminated when the alternator has Battery:
no or low output electric energy. Battery is one of the most important parts on the
vehicle which provides electric energy to start the vehicle
This system mainly consists of starter, alternator, and adjusts the unbalance between the alternator output
battery, starter relay, starter switch and wiring harness, and load.
etc.
When the engine does not operate or operates at a
Charging system and starter motor: low speed, the battery will supply power to electric
The alternator uses self-excitation system where equipments; When the power consumption of any
LED provides partial current generated by the alternator electric equipment is above the alternator output power,
to the rotor. The alternator cannot provide initial current to the supply will supply power to the electric equipment
start the charging procedure. The initial current provides with the alternator; When the power consumption of any
and excites field winding with ignition switch on the electric equipment is lower the alternator output power,
battery input terminal to start charging procedure. the alternator will supply power both to the electric
equipment and the battery.
When the ignition switch turns on, the battery
voltage is also provided by the charging warning light and
grounded by alternator field winding to illuminate the LED
warning light.
When the engine starts, the rotor within the stator

rotates, generating 3-phase AC. When the rotation speed
of the rotor increases, the output voltage raises rapidly,
enlarging the potential difference at the field LED output
terminal. As the voltage rises, the charging warning light
is gradually dimmed.
When the alternator output voltage is equal to the

battery voltage, the warning light will light off. In this case,
alternator generates enough self-excited current from the
field LED to start charging for the battery. If the charging
3-12
Engine Cooling
Illustrations
Layout of cooling system
1
2
17 3
15
16
8
9 7
7
18
4
10
5
6
11
12
13
14
CS110007
1 Engine cooling module assembly 7 Radiator top seal

2 Air conditioning condenser assembly 8 Radiator upper mounting bracket
3 Intercooler assembly 9 Radiator upper rubber strip
4 Radiator 10 Main fan (30A)
5 Radiator bottom rubber strip 11 Auxiliary fan (30A)
6 Radiator bottom seal 12 Nut - engine cooling module installation
3-13
13 Big washer A level 16 Screw - radiator upper cross-member assembly
14 Bolt - engine cooling module installation 17 Bolt -radiator to body
15 Radiator upper cross-member assembly 18 Radiator upper cross-member mounting bracket

assembly
3-14
Description
Overview
The main function of cooling system is to ensure a
most suitable working temperature for the engine. The
cooling system used in this model is a pressurized water
forced circulation cooling which consists of cooling jacket,
radiator, expansion tank, water pump, thermostat, cooling
fan, water pipes, etc.
Operation principle
After absorbing heat in the jacket, the coolant is
pumped to the radiator where the coolant is cooled down
through the air flow from the cooling fan and driving. The
cooled coolant is then pumped back to the engine. After
the above circulation, the engine can be operated at a
suitable temperature.
Function description of component parts:

·Radiator
To provide a suitable engine operating temperature,
the radiator is used to adjust the temperature of coolant
flowing within the engine cooling circuit.
·Expansion tank
Since the coolant which flows within the engine
cooling circuit will expand as temperature raises, the
expansion tank is used to absorb these expansion.
·Water pump
The water pump is equipped to circulate the coolant
required by the engine.
·Thermostat
The thermostat is used to alter the coolant
circulation line to maintain a suitable coolant temperature.
·Cooling fan
The cooling fan is installed to reduce the coolant
temperature during the circulation to ensure a normal
operation. The cooling fan is mainly used for heat
radiation and temperature reduction.
·Water pipes
The water pipes in the engine cooling circuit are
used to absorbing engine vibration and reducing relevant
motion of radiator.
3-15
See the figure below for cooling system coolant flow:
B
1
A 2 3 C
J
6
F
5
D
E
3 E
3-16
Engine Control
Illustrations
Layout of engine management system
13
12 5
4 2
3
6
11
7
1
8 9 10
1 Speed sensor connector 8 High pressure pump

2 Camshaft position sensor connector 9 Water temperature sensor connector
3 Fuel injector 10 Air intake temperature & pressure sensor
connector
4 Wiring harness carrier
11 Fuel rail pressure sensor connector
5 Wiring harness assembly
12 Starter motor, EGR and TVA signal circuit
6 ECU connector
interfaces
7 Glow plug connector
13 Preheating power
3-17
Control chart of engine management system
1 1 1 1 2 3 4
11
5
10
12
9
8 7 6
1 3 5
2 4 R
1 Fuel injector 7 Water temperature sensor

2 Glow plug 8 Fuel rail parts
3 Speed sensor 9 Fascia
4 Camshaft position sensor 10 Fuel pump parts
5 Solenoid valve 11 Pre-heating relay
6 EGR Throttle control parts 12 Engine control unit (ECU)
3-18
Diagnosis plug
1 3 5
2 4 R
3-19
ECM IGN Switch EF3 30A
EF28 10A
Main Relay
FB10-02 FB10-01
G104 FB10-04 FB10-03 EF31 15A
FB10-06 FB10-05 EF20 30A
FB10-47
EF18 10A
FB10-87 FB10-65 FB10-46
FB10-66 FB10-88 Brake Switch EF29 10A
EF13 10A
FB10-38
FB10-78 EF28 10A
F13 10A
Glowplug Lamp
FB10-91
Cruise Lamp
BCM FB10-44 FB10-51
Clutch Switch FB10-41 Cruise Switch

G203 FB10-55 FB10-74
A/C Press Switch

Instrument FB10-19 FB10-75
FB10-48
ABS FB10-43 FB10-37
FB10-42
Glowplug Relay EF1 60A
Instrument FB10-68
FB10-90
C/Fan Relay-3
M
G102
Accelerator
M
FB10-28
C/Fan Relay-1 EF5 40A
FB10-81
FB10-67 FB10-92
FB10-22
C/Fan Relay-2 EF6 40A
FB10-60
FB10-58 FB10-93
Engine Error Lamp

FB10-70
Air Flow Sensor
FB10-12
FB10-20
FB10-63
FB10-21
WIF Sensor
FB10-77
G105
WIF Lamp
FB10-73
OBD Lamp
FB10-71
EF7 30A
FB10-29
Fuel Heater Relay
Starter Relay EF2 40A

EN01-03
EN01-22
Starter
M A/C Compressor Relay EF14 10A
Crank Shaft Position Sensor

EN01-20
EN01-13
EN01-14
EN01-56
Camshaft Position Sensor

EN01-08
EN01-57
EN01-35
ECT
EN01-44
Boost Pressure Sensor With Temp Sensor
EN01-07
EN01-54
EGR
EN01-28 EN01-29
EN01-53
Rail Pressure Sensor

High Pressure Pump
EN01-06 EN01-60
EN01-52 EN01-16
Injector 1
EN01-40 EN01-47
EN01-17
Injector 4
EN01-33
Coolant Temp Sensor

EN01-37 EN01-01
Injector 3
EN01-50 EN01-46
EN01-02
Injector 2
EN01-31
3-20
3-21
Description
This system is composed of ECU, various sensors,

wiring hardness assembly and actuating system,
etc.(See table below).
A series of sensors supply a constant flow of

information to the Electronic Control Module (ECM)
which allow it to control injector timing.
Sensors Location Function
Engine speed sensor (CKP) Crankcase side To determine crankshaft phase and
engine speed
Camshaft position sensor (CPS) On cylinder upper head To determine camshaft phase
Air intake temperature & Upper surface of cylinder upper head To measure air intake temperature and
pressure sensor (MAP) pressure
Coolant temperature sensor Cylinder head air intake side, 4th cylinder To measure coolant temperature
Fuel temperature sensor (FTS) Filter head To measure fuel pick-up temperature
Fuel rail pressure sensor End face of fuel rail To measure fuel pressure in the fuel rail
Mass air flow (MAF) Air intake pipe behind air filter To measure air flow
3-22
Fuel system
Illustrations
Layout of fuel system
11
10
8
7
2
5 1
6
1 Fuel tank assembly 8 Oil return pipe interior tube assembly

2 Fuel level sensor seal 9 Oil filter mount
3 Feed pipe assembly 10 Oil filter
4 Feed pipe cover 11 Oil pick-up pipe front tube assembly
5 Front fuel tank clamp
6 Rear fuel tank clamp
7 Oil pick-up pipe interior tube assembly
3-23
Description
Overview 1 2
The diesel fuel system is the core of the diesel
engine which has a decisive influence on engine's
12
dynamics, economy, emission, noises, operation
10 11
reliability and durability. The system is used to inject finely 9 4
3
atomized and well distributed diesel into the combustion 8
chamber at a fixed time and amount according to engine 7

5
operation requirements and to mix with air for a sufficient

6
combustion. V80 is equipped with common rail fuel
injection system.
The fuel system is composed of (injection pump, fuel

1 Fuel metering unit 8 Fuel filter
injector, high pressure fuel pipes, pump injector) fuel tank,
2 Injector 9 Primer pump
canister, fuel filter and fuel pump, etc.
3 Common rail 10 Fuel heater
Operation principle: 4 Fuel rail pressure 11 High pressure fuel
See right for operation principle of fuel system. High sensor pump
pressure fuel pump (12) draws fuel from the tank (7) and 5 One-way valve 12 Fuel pump
through the filter (9) where the primer pump (10) directs it 6 Fuel tank
to common rail (4) via fuel pipes for injection to the engine 7 Water in fuel
block. Components (1), (3) and (5) is used respectively sensor
for fuel metering, pressure control and fuel rail pressure
sensing, etc. The excess fuel is piped back through the ECM receives information from various other
one-way valve (6) to the fuel tank. The common rail sensors (e.g. accelerator pedal position, road speed etc.)
allows the highly pressurized fuel to be 'stored', ready for and decides on the fuel pressure requirement for any
delivery to the injector as required. The common rail given road speed/load condition. Then ECM delivers the
contains a pressure control valve (3) and a rail pressure signal to metering unit and pressure control valve to
sensor (5).The rail pressure sensor sends fuel pressure adjust the common rail pressure and satisfy fuel pressure
information to the ECM. requirements.
The injector is located at the center position of the

cylinder. They are opened electrically and the timing of
this 'open' period is controlled precisely by the ECM. The
high pressure in the common rail ensures finely atomized
fuel at the injectors for clean combustion and high power.
Electronic control of injector opening time ensures

optimum fuel economy and performance.
Parts function presentation

The figure of common rail system as shown:
3-24
·Advantages:
·Overall optimized fuel spray.
·Improved combustion efficiency.
·Reduced emission.
·Reduced wall impingement.
·Reduced thermal loading.
·Chinese Emission Standard IV.
S163035 WARNINGS: Do not work on any part of the fuel

system when the engine is running. Diesel fuel is
1 Rail pressure sensor delivered under extreme pressure in the fuel
2 Fuel pressure control valve pipes from the injection pump to the injectors.
This may be as high as 1600 bar. Use extreme
System properties:
caution when inspecting for leaks as fuel under
- Electronically controlled fuel metering unit. that pressure can penetrate skin causing injury or
- Flexible injection pressure control range: 250 Pa to death therefore any contact with fuel spray must
1600 Pa. be avoided. Inspect for fuel leaks using thick
card. Wear safety goggles and adequate
- Injection pressure control independent from engine protective clothing when serving the fuel system.
speed and load. Do not smoke or allow open flame of any type
- Injection control. when working on or near any fuel related
components. Fuel vapor can ignite and cause
3 stages Pilot injection/Main injection/Post injection damage and/or personal injury.
Advantages: ·Fuel filter:

Fuel filter is used to remove solid impurities, such as
- High pressure management independent from
ferric oxides and dusts in the fuel, so as to prevent
engine rpm and load.
blockage of fuel system (especially the injectors).In this
- Improved combustion efficiency case, the mechanical wear can be reduced to ensure a
stable and reliable engine operation.
- Improved emission control
·Fuel pump:
- Overall advantage of fuel consumption.
The fuel pump draws fuel from the tank and delivers
- Pilot injection it into the fuel pipes after pressurized to build a certain
- Gradual heat release fuel pressure with the fuel pressure regulator. The fuel
pump delivers high pressure fuel to distribution pipes to
- Significant noise reduction ensure a continuous fuel supply to injectors.
- Improved cold starting
- Simple operating system
·Injectors:
Vertical direct injection, located at center of valve .
3-25
Air intake & Exhaust System
Illustrations
Layout of exhaust system
1 Catalytic converter 4 Exhaust tail pipe assembly

2 Exhaust silencer front pipe
3 Exhaust silencer assembly
3-26
Description vacuum pump on the engine front and the EGR vacuum
Overview regulator on the body.
The component parts picking up air and mixture gas Exhaust System:
into the engine cylinders are assembled as the engine air The exhaust system is composed of a series of steel
intake system. components. The exhaust pipe front contains a DOC
(Diesel Oxidation Catalytic Converter) which is
The component parts discharging exhaust gas out
connected with engine exhaust manifold with 3 bolts and
of the engine cylinders are assembled as the engine
1 shim. In the front of DOC there is an exhaust pipe
exhaust system.
carrier to fix its front section onto the engine. At the tail of
Air intake & breathing system: the exhaust pipe front assembly there is a hook to
The air intake & breathing system is composed of air connect the body floor via a rubber hook. The silencer is
flow sensor, air filter, turbocharger, intercooler, PCV connected with the exhaust pipe front assembly with a
valve, EGR vale and breathing pipes, etc. clamp. At each side of the tail there is a hook to connect
the body floor via a rubber hook. Exhaust tail pipe (LWB
Air enters through the air filter and the air pipe to the
or SWB) is also connected with the silencer with a clamp.
turbocharger. Then the high temperature & pressure air
At the tail there is also a hook to connect the body floor
is forced through the intercooler and the air pipe to the air
via a rubber hook.
intake pipe.
The basis of a catalytic converter is a ceramic
The air filter consists of upper/lower seals, filter
honeycomb structure coated with catalytic material which
element and bottom/side gaiters to provide the engine
includes valuable metals such as platinum or palladium.
with clean air.
The catalytic converter converts nitrogen oxide, carbon
The intercooler aims at cooling down the high monoxide and hydrocarbons into the less dangerous
temperature/pressure air forced by the turbocharger to nitrogen, carbon dioxide and water. A catalytic converter
prevent any knocking due to fuel precombustion. In only works efficiently at high temperatures, and the
addition, the cooling operation for the inlet air can reason it is located close to the engine is so it can benefit
increase air density and charging efficiency on the from the engine's diffused heat.
purpose of improved engine power and reduced
The exhaust silencer is installed with baffles and
emission.
noise absorbing devices. On the one hand, through
PCV valve is installed on the cylinder upper head. friction on noise absorbing devices such as glass fibers,
When the crankcase pressure is too high, it causes the steel fibers , the energy of exhaust gas is decreased; on
diaphragm in the PCV valve to open against the spring, the other hand, after repeatedly reflections, collisions,
and allows crankcase ventilation to take place via the air expansions in pipes of various shapes and in the
vent hose. It also separates the oil from the crankcase air resonant cavity, the exhaust vibration and noise are
and returns it to the crankcase. significantly reduced. After the treatment of catalytic
converter and exhaust silencer, the exhaust gas finally
Air intake pipe is a kind of round aluminum
reaches the atmosphere.
component secured on the cylinder upper head with 4
studs and nuts. A shim is installed between the air intake Function description of component parts:
pipe and the cylinder upper head for sealing purpose. Air ·Throttle body:
intake pipe is installed with EGR and sealed with a shim. The throttle body is the valve controlling the air
The digital control EGR valve accurately controls the intake of the engine. The throttle body is basically divided
exhausted air entering into the air intake pipe to control into three parts: The actuator, throttle blade and throttle
the cylinder temperature and NOX emissions. The position sensor which are usually encapsulated as an
vacuum required by EGR valve is controlled by the integral.
3-27
·Air filter:
It is a device to remove particle impurities in the air.
The air filter consists of filter element and filter housing.
The correct air filter should have high filter efficiency, low
flow resistance and a long service time.
·Silencer:
The silencer is a component to prevent sound
transmission and to allow air flow which is essential to
remove air power noise.
·Catalytic converter
It is the most important outer purifier installed in the
exhaust system which can convert discharged CO, HC
and NOx and other harmful gas into harmless CO2 and
H2O by oxidation and reduction.
3-28
Operation principle:
See the figure below for air intake & exhaust system
operation principle.
3
4
2 5
10
8 9
7 6
1 PCV valve 5 Hose

diaphragm 6 Turbocharger
2 Spring 7 Air hose
3 Positive Crankcase 8 Air filter
Ventilation (PCV) 9 Hose
valve
10 Intercooler
4 Intake air vent hose
Air enters through the air filter (8) and clean air hose
(7) to the turbocharger (6).From the turbocharger it is
forced via hose (9) to the intercooler (10), and from there
into the engine air intake pipe via hose (5).
Engine breathing is controlled by the Positive

Crankcase Ventilation (PCV) valve (3) fitted to the
cylinder upper head. When pressure builds up in the
crankcase it causes the diaphragm (1) in the valve to
open against a spring (2), and allows crankcase
ventilation to take place via the intake air vent hose
(4).Any oil in the crankcase air which reaches the PCV
valve is separated out and returns to the crankcase.
3-29
Transmission
Illustrations
Sectional view of transmission
3-30
Description transmitted to the driven shaft via the engagement

Overview between the drive shaft reverse gear (integrated with the
drive shaft) and the driven shaft reverse gear and to the
The transmission is used to alter engine torque and
transmission shaft via the engagement between the
engine speed to satisfy different requirements for driving
driven shaft final drive gear and the differential final drive
wheel traction and road speed in different driving
driven gear and finally to the wheel for reverse operation.
conditions, such as starting, accelerating, driving and
Note that the rotation of the drive shaft reverse gear is
overcoming various obstacles.
different from 1/2/3/4/5 gear.
V80 manual transmission (HTX-PVH) is a 5MT
Gear selector control
which allows a maximum transmitted torque of 330N.m.
This 5MT is designed special for Front-engine Front-drive When 1st gear speed output is required, shift the
(FF) vehicle. This transmission has 6 gears, namely 1st gear lever to the "1st" position and the torque will be
gear, 2nd gear, 3rd gear, 4th gear, 5th gear and the transmitted to the gear selection assembly via cables.
reverse gear. The 1st and 2nd are low speed gears, The selection rocker pulls the gear selector shaft out
suitable for engine start or driving on rugged mountains through the torque rotation of cables and the gear
or steep slopes. The 3rd and 4th are intermediated selector shifting block on the shaft will move out
speed gears, suitable for driving on relatively smooth accordingly to the groove position on 1/2 gear fork. At this
urban roads. The 5th is the top speed gear, suitable for moment, the selector shifting block should be separated
driving on motorways and in good road conditions. from the groove of 3/4 gear shifting block. One foot of the
Interlock ring seizes the 3/4 and 5/R gear fork groove, the
Transmission box other foot fully separates from the 1/2 gear fork groove.
The transmission box contains input shafts which Then the selection rocker drives the rotation of gear
transmit the engine power to the powertrain. The selector shaft through the cable torque. The gear selector
powertrain can alter the speed and rotation direction shifting block rotates with the selector shaft and its one
through gear engagement between the drive shaft and side initiates 1/2 gear fork to drive 1/2 gear synchromesh
driven shaft to generate five different forward gears and for gear selection. The selections on other gears are
one reverse gear. similar.
The powertrain transmits the power to the differential Reverse block control
via the final drive driven gear and then to output via LH The reverse block is used to: prevent direct shift
and RH drive shafts. from 5th gear to the reverse gear. Control principle:
Power transmission When 5th gear is selected, the reverse gear fork on the
reverse block pushes one foot against the exterior of the
When 1st gear is selected, the 1st synchromesh
reverse block washer (the torsion spring is producing
gear ring of the drive shaft will engage with 1st gear ring
torques); when 5th gear is shifted into, the foot releases
via the synchromesh sleeve. While due to the rolling
from the exterior of the reverse block washer and returns
bearing, other gears will not rotate and the input power
to normal with the torques provided by the torsion spring
will be transmitted to the driven shaft via the gear
(the foot has entered into the other side of the reverse
engagement between the drive shaft and the driven shaft
block washer); when attempting a direct shift from 5th
and to the transmission shaft via the engagement
gear to the reverse gear, the other foot of the reverse
between the driven shaft final drive gear and differential
gear fork will tend to rotate accordingly due to the rotation
final drive driven gear and finally to the wheel. The
alternation, however, it will no longer rotate as soon as it
transmission principles of 2nd, 3rd, 4th and 5th gears are
hit the edge of the reverse block washer so as to prevent
similar to this and will not be discussed in detail.
reverse gear engaging initiated by the gear selector
When the reverse gear is selected, the driven shaft shifting block..
reverse synchromesh gear ring will engage with the
driven shaft reverse gear ring. The power will be
3-31
Power interruption
When the release rocker is at free state, the clutch
drive plate contacts tightly with engine flywheel and the
power is transmitted to the transmission via the input
shaft. As the release rocker rotates, the release fork is
driven to force the release bearing axially moves against
the diaphragm spring of the clutch disc so that the drive
plate is separated from the flywheel and there is no
power transmission through the input shaft, resulting in
transmission operation interruption.
3-32
Clutch
Illustrations
Layout of clutch pedal and master cylinder
2
6
1
1 Clutch disc 4 Master cylinder

2 Drive plate 5 Slave cylinder and release mechanism
3 Release bearing 6 Clutch pedal
3-33
Description
Overview
Clutch is a powertrain component directly
connecting with the engine and its function is to: ensure a
stable combination or temporary separation between the
engine power and the driving units and a reliable engine
torque transmission for correct starting, parking or gear
changing operations.
V80 uses a push-type dry diaphragm spring clutch (

￠258mm) which is equipped with hydraulic clutch
release mechanism. It is powered by two sealing
systems - pre-filled master cylinder and slave cylinder.
The clutch does not need any adjustment if worn.
The clutch is composed of clutch drive plate

assembly, clutch disc assembly, release bearing and
release fork, etc.

·Flywheel:
The flywheel stores partial power transmitted to the
crankshaft at the power stroke to overcome resistance at
other strokes, in order to drive crank link mechanism to
travel over the top dead centre (TDC) and the bottom
dead centre (BDC), ensuring that the crank angular
velocity and torque are as even as possible, and making
it possible for the engine to overcome a short period
overload. The flywheel transmits power to the
transmission via the clutch. There are 6 threaded holes
on the flywheel to position the disc into place.
3-34
Drive Shaft
Illustrations
Layout of drive shaft
1 2
3
5
4
21
1 Retaining nut 4 Drive shaft (RH)

2 Hub washer 5 Bearing plate
3 Drive shaft (LH)
3-35
Exploded diagram of drive shaft
1
3
5
4
7
6
7
3
1 Left drive shaft 5 Tripod universal joint (LH)

2 Right drive shaft 6 Tripod universal joint (RH)
3 CV joint 7 Tripod universal joint gaiter
4 CV joint gaiter
3-36
Description
V80 model uses drive shafts with an equal length to

transmit the power from the transaxle to drive wheels.
The drive shaft consists of 2 permanent universal

joints, 1 moveable universal joint and 1 intermediate
shaft. External CV ball joint is composed of ball shell,
retainer, starlike inner race and steel ball, etc. The starlink
inner race splines are connected with the drive shaft.
There are six grooves on the external surface for inner
race and relevant grooves on the ball shell internal
surface for outer race. Six steel balls run in each groove
at the same plane sustained by the retainer. The three
tripod universal joints are at the same plane as 120o.
Their axes intersect at a certain point on the output shaft.
3-37
Front suspension
Illustrations
Layout of front suspension
1 1
3 3
4 4
1 Front strut and spring assembly 4 Control arm sub assembly

2 Front suspension anti roll bar
3 Anti roll bar link assembly
3-38
Exploded diagram of front suspension
2
3
1
1 Anti-roll bar 4 Anti-roll bar link

2 Anti-roll bar clamp support 5 Control arm assembly
3 Clamp bush 6 Control arm rear pivot
3-39
Exploded diagram of front shock absorber
2 5
6
1
1 Strut sub assembly 5 Bump stop

2 Bolt spring 6 Bearing
3 Gaiter front spring retaining ring 7 Shock absorber support
4 Upper spring seat assembly
3-40
Description Screw spring:

Overview Screw spring is a kind of buffer elements. When the
The suspension is the connection mechanism impact force from the road to the wheel transmits to the
assembly between the frame (or the body) and wheel screw spring; the spring will be deformed to absorb and
axle (or the wheel).Its function is to transmit the wheel transform the wheel KE to spring's energy of position
force and torque applied by road to the frame (or the which will effectively reduce the affect by the impact force
body) to ensure a normal driving. from the road to the body.
V80 is equipped with a Macphersan independent Front anti-roll bar:

front suspension which is composed of the spring and When the body swaps, the suspension on two sides
the shock absorber assembly with race ball bearing at will have different deformation. While the anti-roll bar will
the top. The lower part of the strut is installed on the act as a lever to uniform the spring deformations on both
knuckle with a lower ball joint. The ball joint is connected sides as close as possible, so as to reduce body sway
with the lower control arm on the large rubber bush, able and vibration and to increase driving stability.
to rotating upward and downward on the sub-frame.
This system consists of spring elements, shock

absorber and guide mechanism, etc. The front
suspension is composed of screw spring, front strut,
bearing and upper spring seat, etc. and is connected with
the body and the knuckle. Anti-roll bar, anti-roll bar link
and control bar components are connected with the
knuckle.

·Front shock absorber:
To change the disturbing forces of vibration source
and system transmission properties so as to achieve
vibration reduction. See the exploded diagram of the front
shock absorber.
3-41
Rear suspension
Illustrations
Layout of rear suspension
1 2
4
5
6
7
CS220000
1 Rear steel leaf spring assembly 6 Rear spring upper cover

2 Rear shock absorber assembly 7 Rear axle assembly
3 Rear steel leaf spring bump stop 8 Rear shock absorber to rear axle bolt
4 Rear suspension bump stop bolt 9 Rear steel leaf spring U bolt to rear axle nut
5 Rear steel leaf spring U bolt
3-42
Exploded diagram of rear suspension
11
7
10
8 8 3
7 3
6
5 9
13
1
12
2
4
CS220001
1 Rear steel leaf spring assembly 8 Rear steel leaf spring U bolt
2 Rear steel leaf spring eye rear bush 9 Rear steel leaf spring upper cover
3 Rear steel leaf spring eye front bush 10 Rear suspension bump stop attaching bolt
4 Rear steel leaf spring shackle assembly 11 Rear steel leaf spring bump stop
5 Rear steel leaf spring shackle bush 12 Rear steel leaf spring U bolt to rear axle nut
6 Steel leaf spring shackle cover 13 Rear steel leaf spring front attaching bolt4
7 Rear steel leaf spring shackle nut
3-43
Exploded diagram of rear damper
2
1
1 Bolt (rear suspension shock absorber to body) 3 Shock absorber assembly

2 Nut (rear suspension shock absorber to body) 4 Bolt (rear shock absorber to rear axle)
3-44
Description
Overview
V80 uses transversal leaf spring dependant
suspension. The leaf spring is a two-stage taper leaf
spring with a spring span of 1450mm.
It is composed of two leaf springs, the middle of

which is fixed on the axle with two 'U' bolts. The leaf
spring and front bracket are connected by the front spring
eye using bolts; while the leaf spring and rear bracket are
connected by the rear spring eye using lifting eyes.

·Rear leaf spring assembly:
The leaf spring is the most widely used spring
element for vehicle suspension. It is a kind of spring
beam made up of several alloy spring pieces with the
same width and different length (thickness can be the
same or not) and its rigidity is almost the same as the
individual piece.
3-45
Steering
Illustrations
Layout of steering column and power steering
1 8
2 9
1 Steering wheel 6 Steering fluid reservoir

2 Steering column 7 Steering oil pipe assembly
3 Steering intermediate shaft 8 Fluid reservoir to steering pump oil pickup pipe
4 Steering gear assembly 9 Steering oil pump
5 Steering oil reservoir assembly
3-46
Exploded diagram of steering column
4 2
1 Steering column 4 Pinch bolt

2 Nut 5 Coupling shaft
3 Screw
3-47
Exploded diagram of power steering
2
4
1 6
5 3
1 Steering gear assembly 4 Gaiter assembly

2 Steering tie rod inner ball joint 5 Steering tie rod outer ball joint
3 Lock nut
3-48
Layout of power steering hydraulic system
2 4
3
5
8
9
1 Anti-roll bar clamping bracket 4 Anti-roll bar link

2 Anti-roll bar rubber bush 5 Steering gear assembly
3 Anti-roll bar 6 Sub-frame assembly
3-49
Description
Steering is the dedicated system to alter driving

directions.
Power steering is equipped with additional hydraulic

servo to the original mechanical steering. The hydraulic
power steering includes steering wheel, steering column,
power steering gear, steering oil pump, oil reservoir and
oil galleries, etc. The outer joint is connected with the
knuckle. The toe out can be adjusted by slackening
steering gear lock nut and turning steering tie rod.
This model is equipped with front-wheel steering

and pinion & rack hydraulic power steering gear. The
steering wheel is constructed with metallic framework
coated with foamed plastic; the diameter is 380mm.
Steering gear ratio is 47mm/r; rack travel is 168mm.
The power steering pump is mounted externally on

the engine and is driven by the front end auxiliary drive
(FEAD) belt. Each side of the steering tie rod includes
two components. The outer rods (with ball joints) are a
fixed length, and tracking adjustment is made at the inner
rods, which must be adjusted to an equal length.
3-50
Brakes system
Illustrations
Layout of brake hydraulic system
3-51
Exploded diagram of front brakes
1
2
3
4
12
13 5
3
11
10
9
8
1 Brake caliper 8 Guide pin bush

2 Brake slipper 9 Guide pin
3 Piston 10 Pin gaiter
4 Rectangle seal 11 Pin shaft bolt
5 Piston gaiter 12 Bleed screw head
6 Setting pin 13 Bleed screw
7 Support
3-52
Exploded diagram of rear brakes
1
3
2 4
15
5
6
14 7 8
10
9
13
11
12
1 Guide pin 9 Guide pin rubber bush

2 Bleed screw head 10 Support
3 Bleed screw 11 Guide pin gaiter
4 Brake caliper 12 Brake slipper snap spring
5 Rectangle seal 13 Brake slipper
6 Piston 14 Mud flap
7 Piston gaiter 15 Bolt
8 Guide pin gaiter
3-53
Layout of handbrake system
1
10 11
4 2
7 5
8
9 6 12
1 Handbrake rear cable assembly 7 Handbrake cable tensioner

2 Handbrake rear cable conduit 8 Handbrake front cable
3 Handbrake adjuster 9 Handbrake adjusting nut
4 Rear brake shoes 10 Handbrake lever assembly
5 Rear brake drum tensioner 11 Handbrake warning switch
6 Rear brake plate assembly 12 Rear shaft power bumper
3-54
Control chart of brake system
8 1 1
7
2 2
6
5 9
1 Front ABS sensor 6 Ignition power fuse 27 (5A) - Cabin fuse box
2 Rear ABS sensor 7 Battery fuse 5 (40A) - Engine compartment fuse
box
3 Instrument cluster
8 Battery fuse 8 (50A) - Engine compartment fuse
4 Diagnostic connector
box
5 Brake light switch
9 DSC adjuster
3-55
Description · When braking is applied, ABS will not perform an

Overview anti-lock brake pressure adjustment until the
controlled wheel is to be locked. If the controlled
The brakes consist of all brake and deceleration
wheel is not to be locked, this brake operation will
systems installed on the vehicle to decelerate or stop the
be exactly same with the normal brake operations.
driving car or keep the parked vehicle motionless.
· ABS is equipped with self-diagnosis functions
V80 brake system applies brake calipers (disc
which are able to monitor the system operation
brakes, with floating calipers) at both the front and the
state and shut down ABS automatically if a fault
rear. Handbrake is equipped with brake drum which is
which has an effect on the system normal
combined with the rear brake. The former is hydraulic
operation is detected and illuminate ABS warning
controlled, while the latter is mechanically controlled by
light to send a driving warning signal. However,
handbrake cables. The front & rear hydraulic brake
this brake system can still perform the same brake
actuating mechanism is composed of brake pedal, push
operations as normal brake systems.
rod, vacuum servo, fluid reservoir, brake wheel cylinder
ABS usage:
and pipes, etc.
· When braking on the road with low adhesion
The brake system consists of brakes and brake coefficient, brake pedal should be applied to the
controls. The brakes generates the brake effect; the end.
brake actuating mechanism controls the brakes
· The vehicle can be stopped at a shortest brake
operation; the front & rear brake calipers axially moves
distance.
relatively to brake disc through connection with knuckle
and rear axle with bolts. The brake caliper is equipped · When braking is applied, high direction stability
with oil cylinder only on the internal of cylinder disc and can still be ensured.
the external brake slipper is attached only to the caliper. Operation principle of ABS:
ABS monitors and effectively controls the braking
When braking is applied, hydraulic oil flows into the
state via its controls and continuously adjusts the braking
brake cylinder through the inlet to drive the piston and the
force in the braking system, so as to build a most suitable
attached slipper moving to left and pressing on the brake
condition for wheels to ensure an outstanding anti-
disc and even making the cylinder and the caliper moving
sideslip ability, a shortest brake distance and an excellent
along the guide pin to right until the friction block on the
driving safety.
left of brake disc also presses on and holds the disc to
make a brake operation. When braking is applied, the CAUTION
brake pedal is pressed and the master cylinder piston · In addition to the scheduled brake fluid change,
moves after the powering supplied by the servo to pump periodic inspection of brake components is
the brake fluid out of the master cylinder and piped into recommended. As the vehicle ages, and as a
front and rear wheel cylinders to shift the wheel pistons. precaution against the effects of wear and
When braking is released, the brake pedal is released deterioration, it is necessary to make a more
and the wheel cylinder piston returns with the return searching inspection and renew parts as
spring to release the braking operation. necessary.
ABS： · Use the recommended brake fluid.

ABS is usually composed of wheel speed sensor, · Never leave fluid in unsealed containers. They can
brake pressure adjuster, electronic controls and ABS rapidly absorb water in the air, so it is dangerous
warning lights. ABS is featured in following aspects: to use them in the brake system.
· ABS will not perform an anti-lock brake pressure

adjustment until vehicle speed is over a specified
value (e.g. 5km/h or 8km/h).
3-56
· Fluid drained from the system or used for bleeding

must not be re-used, and must be disposed of in
an approved manner.
Advices
· Disc brake pads, drum brake linings, hoses and
pipes should be examined at intervals no greater
than those laid down in Scheduled Maintenance.
· It is recommended that all flexible hoses should be
renewed every 4 years or at the Scheduled
Service nearest to 160, 000 miles (whichever
occurs first).At the same time all hydraulic
components should be thoroughly checked for
leaks, damage etc., and new parts fitted where
necessary.
3-57
Windows
Control chart of window regulator
1 1
3
2
5 6
1 Electric window switch 4 Relay

2 Cabin electrical box 5 Electric window regulator of front left door
3 Battery 6 Electric window regulator of front right door
3-58
Description
Overview
Most electric windows consist of motor, speed
reducer, guide rope, guide plate and glass mounting
bracket. The windows are used for day lighting,
transparency, separation and ventilation. Driver's master
control switch assembly can control all electric window
motors. Electric window switch is controlled by control
unit of multiplex control system.
Speed reducer:
It is an enclosed actuator between prime motor and
working machine, which is used to reduce rotational
speed and increase torque to meet working
requirements.
3-59
Wiper and Washer
Illustrations
Layout of wiper and washer
3-60
Control chart of wiper and washe
1 2 3
15
8
1 Wiper motor 5 Ignition switch

2 Connector of wiper motor 6 Cabin fuse box
3 Wiping / washing rod switch 7 Engine compartment fuse
4 Front window washer pump 8 Body control unit (BCU)
3-61
Description · High speed wipe

Overview When the switch is on and locked in high speed
Wiper of vehicle windscreen is to remove fog, frost, position, the wiper will wipe continuously with high speed.
rain, snow, dust, dirt and other stains on the windscreen, When the switch is moved to stop position, the wiper will
providing the driver with clear view to ensure safe driving. come back to stop automatically.
Wiper and washer system starts to work after BCM · Intermittent wipe
receives command from the driver. All functions of wiper Intermittent wipe function is controlled by BCM and
are controlled by multi-functional wiper rod switch when the switch is in intermittent position, BCM will
installed on driver's right side. measure the position of corresponding rotary switch and
vehicle speed position and timer corresponding to the
Wiper and washer system includes:
vehicle speed. When BCM timer reaches to latency,
- Wiper motor wiper will operate one complete wipe with low speed and
stops in stop position. Then BCM will start the timer for
- Wiper link mechanism
another selected latency before starting wiper again.
- Two wiper arms and blades
· Intermittent delay adjustment
- Two washer jets If a long latency is selected for intermittent functions,
- Washer and washer pump it will be applied in the next wipe operation. If a shorter
one is selected, then wipe operation will be carried out
- Wiping and washing rod immediately after this selection. Four intervals are
available for this switch.
Functions of wiper are available when ignition switch
is in 'IGN' position.
Functions of wiper
Wiper system supports:
- Inching wash and wipe
- Low speed wipe
- High speed wipe
- Intermittent wipe
- Intermittent delay adjustment
· Inching wash and wipe

When non-self-locking switch is pressed down
650ms above, washer pump will immediately jet out
water to front window until washer switch released and
front wiper will start to work at the same time. Wiper will
operate three complete wipes with low speed until motor
stops.
· Low speed wipe

When the switch is on and locked in low speed
position, the wiper will wipe continuously with low speed.
When the switch is moved to stop position, the wiper will
come back to stop automatically.
3-62
Exterior mirror
Illustrations
Layout of exterior mirror
3-63
Control chart of exterior mirror
4
3
1 Cabin fuse box 3 Right exterior mirror

2 Driver door module (DDM) 4 Left exterior mirror
3-64
Description When exterior mirror has reached to max

All models are equipped with exterior mirrors, adjustment position in certain axial direction, a sliding
among which minibus Standard, kombi and van are clutch mechanism can protect exterior mirror. Housing,
equipped with manual exterior mirrors and minibus mirror ring, base plate, support, support shield, rotate
Luxury is equipped with heated electric exterior mirror pivot, glass regulator, direction indicator etc are non-
while minibus Standard can be equipped with heated maintenance parts and must be changed as assembly.
electric exterior mirror as option. Right-hand drive vehicle Only main glass and auxiliary glass are repairable parts.
is equipped with electric exterior mirror. Every kind of When disassembling main and auxiliary glasses,
exterior mirror only has leather-like part and integrates slightly press the glass until one side tilting up and pry it
with direction indicator. Electric exterior mirror is off glass regulator. Glass of heated electric exterior mirror
controlled by a four-direction switch on front door at can be heated electrically to prevent fogging. Heater
driver's side and two left / right select switch. The heating band is glued behind the glass and starts to work with
function of heated electric exterior mirror is controlled by normal operation temperature of 70 ℃ when ignition
combination switch on centre console. The mirror surface switch is in 'IGN' position. Two terminals on the heater
angle of manual exterior mirror can be adjusted manually band can connect the heater band and door harness and
and direction indicator is controlled by BCM through when disassembling glass, harness connector should be
switch on steering wheel. pulled out of the terminal.
Every kind of exterior mirror is manually assembled Exterior mirror housing can be manually folded
with same basic construction: main glass, auxiliary glass, inward or outward to let the vehicle pass narrow area.
housing, mirror ring, base plate, support, support shield, Main and auxiliary glasses can be adjusted 8° upward,
rotate pivot, glass regulator, direction indicator etc, downward, leftward or rightward and electric mirror can
among which, main glass of heated electric exterior be adjusted by a four-direction switch on the front side
mirror has heater band. door and two left / right select switches.
There are three bolts fixed on every exterior mirror
support and when assembling, the three bolts pass the
holes on inside and outside metal plates of the front side
door and secure the support on front side door with three
nuts. These nuts can be assembled and removed after
removing interior trim of inside plate of front side door.
Exterior mirror housing is secured on the base plate with
four screws and the base plate is installed on the support
by rotate pivot. This rotate pivot allows exterior mirror to
rotate in two directions and to be folded manually or
folded in any direction when obstructed. Exterior mirror
housing is a molded plastic part, in which main and
auxiliary glass regulators (main glass regulator has
electric adjustment and manual adjustment while
auxiliary only has manual adjustment) and main and
auxiliary glasses. Mirror ring is installed on the mirror
housing for sealing and decoration.
3-65
Seat
Layout
Layout of vehicle seats
SWB Luxury of 7 seats SWB Luxury of 9 seats LWB Luxury of 9 seats LWB Luxury of 11 seats
A1 C1 A1 C1 A1 C1 A1 C1
L L L L L L
L L L
H L
H L
H
H
LWB Standard of 14 seats LWB Standard of 15 seats

LWB Standard of 11 seats LWB Standard of 15 seats LWB Standard of 16 seats
A1 C1 A2 C2 A2 J A2 C2 A2 J
L L K K K K
L L
D E D E D E D E
L L
D E D E D E D E
H
N G H G F F F F
SWB Standard of 11 seats SWB Standard of 12 seats

SWB Standard of 9 seats SWB Standard of 12 seats SWB Standard of 13 seats
A1 C1 A2 C2 A2 J A2 C2 A2 J
L L K K K K
L L D D D D
E E E E
H
M G M G F F F F
LWB / SWB Logistics of 5 seats LWB Logistics of 8 seats LWB / SWB Van of 2 seats
A2 C2 A2 J A2 C2 A2 J A2 C2 A2 J
I I I I
J J
LWB /SWB Logistics of 6 seats LWB Logistics of 9 seats LWB / SWB Van of 3 seats
3-66
Description ·"Rear backrest unadjustable single-passenger

seat
Overview
V80 has many types of vehicle seats and the Cushion inclination is 7° and initial backrest angle
material has cotton flannel and knitted fabric. is 18°;Headrest can be adjusted for height with three
levels.
·"Rear foldable three-passenger seat
·Driver's seat is 8-direction manual adjustable
seat Seat backrest angle is 18°;Backrest can be folded
forward and headrest can be adjusted for height without
Initial backrest angle is 18°. Backrest angle can be
armrest. Fixed points of seat belt are arranged on the
adjusted 15° forward or 55° backward. Angle
seat. Segregate backrest and integral cushion.
adjustment mechanism is single side locking and
headrest can be adjusted for height. Cushion inclination ·"Front dual-passenger seat
is 7° and can go up or down forward or backward. Seat Cushion inclination is 7° and initial backrest angle
can be moved forward or backward. There is a fixed point is 13°/ 18°;Headrest can be adjusted for height
of seat belt on right side. without armrest. Two fixed points of seat belt of seat next
to the door are on B post. Segregate backrest and
·"Front single-passenger seat
integral cushion.
Cushion inclination is 7° and initial backrest angle
is 18°; Backrest angle can be adjusted 15° forward or ·"Rear backrest adjustable three-passenger seat
55° backward. Angle adjustment mechanism is single Cushion inclination is 7° and initial backrest angle
side locking. Headrest can be adjusted for height with is 18°;Backrest angle can be adjusted 15° forward or
three levels. There is a fixed point of seat belt on left side. 22° backward; Headrest can be adjusted for height with
three levels. Segregate backrest and integral cushion.
·"Rear backrest adjustable dual-passenger seat
Cushion inclination is 7° and initial backrest angle ·"Rear backrest unadjustable dual-passenger
is 18°;Backrest angle can be adjusted 15° forward or seat
22° backward. Angle adjustment mechanism is single Cushion inclination is 7° and initial backrest angle
side locking. Headrest can be adjusted for height with is 15°;Headrest can be adjusted for height with three
three levels. Segregate backrest and integral cushion. levels. Segregate backrest and integral cushion.
·"Rear backrest adjustable single-passenger ·"Rear single-passenger wide seat

seat
Initial angle of seat backrest is 18°;Backrest angle
Cushion inclination is 7° and initial backrest angle can be adjusted 15° forward or 55° backward;
is 18°;Backrest angle can be adjusted 15° forward or Headrest can be adjusted for height with three levels.
22° backward. Angle adjustment mechanism is single Armrests are installed on both sides. Fixed points of seat
side locking. Headrest can be adjusted for height with belt are arranged on the seat.
three levels.
·"Rear backrest unadjustable dual-passenger

seat
Cushion inclination is 7° and initial backrest angle
is 15°;Headrest can be adjusted for height without
armrest. Segregate backrest and integral cushion.
3-67
Illumination
Illustrations
Layout of external illumination
1
2
3
8
9
10
11
7
1 Front direction indicator 7 Reflectors

2 Main beam and dipped beam 8 Brake lamp and position lamp
3 Position lamp 9 Rear direction indicator
4 Front fog light 10 Reverse light
5 Center high mount stop lamp (CHMSL) 11 Rear fog light
6 Rear number plate light
3-68
Layout of internal illumination
1 Step well light 3 Rear roof internal vanity light

2 Front roof internal vanity light
3-69
Description ·Reflector
External illumination: It can reflect the light from external light source.
Many external illumination and signal devices
Internal illumination
installed on the vehicle can provide vehicle user with
Vehicle internal lights consist of front roof internal
good view to ensure safety driving at night, in tunnel or
vanity light and rear roof internal vanity light and they are
foggy days.
primarily used for internal illumination.
The system consists of external illumination devices
and external signal devices.
External illumination devices are: Headlamp, front

fog light and number plate light etc.
External signal devices are: Rear fog light, brake

lamp, parking light, direction indicator tell-tale and
reflector etc.
·Headlamps
They are also called headlights and installed on both
sides of vehicle head, illuminating the road when driving
at night. Light color is white or yellow.
·Front fog light

Fog light is used to make the vehicle visible to other
vehicles during foggy days or rainy days when visibility is
significantly affected. Light color is white or yellow.
·Number plate light

Number plate light is used to illuminate rear number
plate at night. Usually bulb is used as number plate light
and the light color is white.
·Rear fog light

Rear fog light is used to indicate the existence of the
vehicle to users of other road behind the vehicle. It is
installed in the lower rear of vehicle and the light color is
red.
·Brake lamp
Brake lamps are used to indicate the vehicle is
slowing down or braking to users of other road behind the
vehicle. They are installed on both sides of vehicle rear.
The light source shall be striking red light that can be
recognized clearly in day or at night to prevent rear-end
collision.
3-70
Instruments
Illustrations
Layout of instrument cluster
3-71
Description
Overview:
The vehicle instrument system is driven by Driving mode of pointer Stepping motor
electronic stepping motor and consists of speedometer, Speed gear ratio 2360 pulses / km (Option
tachometer, fuel gauge, thermometer, alarm icons, dot- 2320 pulses / km)
array LCD clock, sub-total, grand total and tyre pressure Pulse number 4 pulses / turn
information.
Signal source Sensors
Response time of pointer 3 to 4 seconds
·LCD display
LCD interface displays clock, subtotal and grand
60
80 100
120 2
3
4 total of mileage (hereinafter referred as main interface),
40 140
F 1 5 H
20 160
E 0 180 0 6 c
km/h 1000r/mmin

·Speedometer
80 100
60 120
40 140
20 160
0 180
km/h
Basic requirements of speedometer
Pointer indication range 0 ～ 180km/h

Minimum division value 10km/h
Speed gear ratio 1：590

（Option 1:580）
Type of input signal Square wave (collector）
High level Instrument power voltage
Max. low level 1V
Signal duty cycle (%) 30% ～ 70%
3-72
tyre pressure, temperature and tyre pressure alarm and grand total remain unchanged and clock
LCD display mode is switched by buttons. times.
- Main interface c. Subtotal displays o and grand total

remains unchanged after battery and
- Tyre pressure interface ignition switch disconnected and then
reconnected. Clock displays 12：00. Time
a. Normal tyre pressure format is 24-hour.
b. Normal temperature ·Tachometer
- LCD display overview
3
LCD display LCD
2 4
Operating temperature -30 ℃～ + ６ 5 ℃ 1 5
LCD presentation mode White on black
0 6
LCD driving mode Driven by microprocessor 1000r/mmin
LCD display mode Negative
LCD backlight White
LCD display format Dot array

Basic requirements of tachometer
- Mileage range
Pointer indication range 0 ～ 6000r/min
Parameters Subtotal Grand total Alarm range 4000 ～ 6000 r/min
mileage mileage
Max. low level 1V
Indication range 0 ～ 1999.9km 0 ～ 999999km
Minimum division value 500r/min
Display digits 4 digits 6 digits
Driving mode of pointer Stepping motor
Min. display unit 0.1km 1km
Response time of pointer 3 to 4 seconds
Display leading N/A N/A
Signal source ECM
NOTE: Output pulse of sensor 2 pulses

(signal source)
Subtotal mileage: Subtotal mileage
automatically returns to zero after reaching max Min. high level 8V
reading (1999.9km).
Signal duty cycle (%) ３ 0% ～７ 0%
Grand total mileage: Grand total mileage Max. rotational speed 6000rpm
remains unchanged after adding up to max
reading (999999km).
- Requirements of LCD work mode:

a. LCD lights on after battery reconnected
and reignited.
b. LCD does not display after ignition off

when battery connected. Subtotal and
3-73
·Fuel gauge Data and indication angle of fuel gauge
Indication Input Indication Indication

point resistance error (°) angle (°)
(Ω)
E 300 -5 ～ 0 0
F Alarm 265.6 -3 ～ +3 13
1/4 246.5 -3 ～ +3 26
1/2 170 -3 ～ +3 52
E 3/4 93.5 -4 ～ +4 78
F 40 -5 ～ +5 104
·Temperature gauge
Basic requirements of fuel gauge
Pointer indication range E～F

Minimum division value 1/8(E ～ F)
Singal source Fuel sensor
H
Input resistance range 300 Ω～ 40 Ω
Driving mode of pointer Fuel sensor Stepping
motor c
Response time of pointer See notes for detail
NOTE:
Response time of pointer: Basic requirements of thermometer

(1) IGN OFF ─ > ON :Response time: The time required
Pointer indication range C～H
for pointer moving from initial position to 90% of total
scale is 3 seconds max. Minimum division value 1/8 of total radian
Max. low level 1V

(2) IGN ON (no speed):Response time: Fuel gauge
pointer 1s/1°. Driving mode of pointer Stepping motor
Signal source ECM

(3) IGN ON (with speed):Response time: Fuel gauge
pointer 30s/1°. Input PWM range 2% ～ 96%
PWM frequency 50Hz
(4) IGN OFF: Pointer back to stop position.
Response time of pointer See notes for detail
·Low fuel level alarm
In the direction where resistance increases,
resistance of fuel sensor ≥ 265.6 Ω , alarm indicator on;
In the direction where resistance reduces,resistance

of fuel sensor ≤ 260.6 Ω , alarm indicator off;
3-74
NOTE:
Response time of pointer:
(1) IGN OFF ─ > ON :Response time: The time required

for pointer moving from initial position to 90% of total
scale is 3 seconds max.
(2) IGN ON (vehicle driving):Response time:

Thermometer pointer 0.5s/1°.
(3) IGN OFF: Pointer back to stop position.
Data and indication angle of thermometer
Indicatio tempera Duty Indicatio Indicatio

n point ture ℃ cycle 1) n error n angle
(%) (°) (°)
C 50 ５ 0 0
1/4 70 20.7 -3 ～ +3 26
1/2 80 42 -3 ～ +3 52
3/4 90 53.2 -3 ～ +3 78
Alarm 115 85.4 -3 ～ +3 91

(red
sector)
H 120 93.4 -3 ～ +3 104
1) Duty cycle - high level is valid.
If water temperature equal to or below 50 ℃ , the pointer

stays at point C .
If water temperature equal to or above 120 ℃, the pointer

stays at point H
·High water temperature alarm

In the direction where water increases, duty cycle of
water temperature ≥ 85.4％, alarm indicator on;
In the direction where water reduces, duty cycle of

water temperature ≤ 69％, alarm indicator off;
NOTE:
Temperature of high water temperature alarm

sensor sent to ECU shall be identified based on
summer test and temperature range of water
temperature sensor is from -40 ℃ to 140 ℃ . Duty
cycle above shall prevail temporarily as the
vehicle manufacturer cannot provide.
3-75
·"Alarm requirements of bleeper

Sound pressure level (SPL): (at 2048Hz, 12Vp-p,
Square wave) : >
98 ± 3 dB
Frequency：:2048Hz
Alarm type Sound condition Connection Sound mode

mode of port
Ignition key in Alarm signal BCM sent to Battery =ON Continuous alarm
switch alarm / instrument =ON (low level signal Signal port of ( External BCM signal
headlamp on is valid) (Note: These two alarm alarm sound =ON 1) Headlamp on alarm: with ignition switch
alarm signals are controlled by BCM (low level signal is switching from KL.15 to OFF, BCM instructs
and outputted by the same pin） valid) bleeper to sound alarm when dipped beam
switch turned on.
2) Key in switch alarm: 1. key turns to OFF
with driver side door open.
2. When key stays in any position of ignition
switch, bleeper sounds alarm with RKE
locking or driver's side key locking.
Bleeper sounds with the cycle of 3S audible
alarm and 1.5S stop)
Seat belt alarm 1. When speed >0 and seat belt Battery = ON Continues alarm (constant sound)
unfastened (seat belt signal Ignition = ON
=OFF), bleeper sounds. Seat belt signal =
2. During driving: When the state OFF (lights on by
of seat belt switch changes, earthling)
above judgment condition is to
be initiated again.
3. When speed =0, seat belt
=ON or =OFF, bleeper turns off.
Danger warning Danger warning signal (left and Battery = ON Continuous alarm Bleeper frequency
alarm right turn =ON) Ignition = OFF 1600HZ_6ms_800HZ_8ms (325ms on,
Left turn = ON 325ms off (1.54HZ).This value can not be
right turn ＝ ON changed through diagnostic apparatus.)
(Whether to ignite is controlled by BCM)
Left and right Left turn =ON or right turn =ON Battery = ON Continuous alarm Bleeper frequency
turn alarm Ignition = ON 1600HZ _6ms_800HZ_8ms (When direction
Left turn = ON indicator works, it flashes with frequency of
(right turn =ON) 75 flashes per minute (1.25HZ), but it is
default value and can be changed by
diagnostic apparatus. Frequency set by
diagnostic apparatus will be observed to
flash after change.
TMPS bleeper Tyre fast air leakage alarm, low Battery = ON

critical alarm pressure alarm, high pressure Ignition = ON
alarm, high temperature alarm Tyre pressure =
ON (normal input)
TMPS bleeper Low sensor battery, malfunction Battery = ON

warning alarm of TPMS system Ignition = ON
Tyre pressure =
ON (normal input)
3-76
Priority order
1） Danger warning alarm

2） TPMS critical alarm
3） TPMS warning alarm
4） Driver's seat belt untied alarm
5） Left and right turn audible indication
6） Ignition key in switch alarm
·Requirements of tyre pressure

TPMS pressure sensors are directly installed on the
hub of each tyre and suitable for tyres without inner tube.
The sensor can detect tyre pressure and temperature
and transmit the data to receiver through wireless radio
frequency. Receiver judges pressure and temperature
values from sensor and low / high tyre pressure alarm or
high tyre pressure alarm occurs, corresponding TPMS
warning lights on.
User can switch display mode to TPMS normal

display mode by button on instrument panel to display
current tyre pressure or temperature on LCD at real time
(alternative display).
- Normal interface that displays tyre pressure is as

below:
- Normal interface that displays tyre temperature is

as below:
If the tyre is not learned, in information frame sent by

TPMS to the instrument, high four-digit of tyre position
means whether corresponding tyre position has been
learned, if not, high four-digit is 0000 and instrument
panel displays "ns" for corresponding tyre position and
follow-up information does not need to be handled; If high
four-digit is 1111, it means the tyre has been learned and
the instrument panel needs to handle information of
corresponding tyre. If high four-digit is 0000 in one piece
of tyre position information, corresponding position
displays "NS" and "wait for learning" beside.
3-77
·"Illumination and alarm indicators

Illumination and alarm indicators list
No. Function Icon Color Control mode
Lights on when
1 Left turn Green connected with
battery +
Lights on when
2 Right left Green connected with
battery +
Lights on when
3 Main beam Blue connected with
battery +
Lights on when
4 Front fog light Green connected with
battery +
Lights on when
5 Rear fog light Yellow connected with
battery +
6 Low fuel level warning Yellow Controlled by SCM
High engine cooling water

7 Red Controlled by SCM
temperature warning
Lights on by
8 Water in fuel warning Yellow
earthing
Lights on by
9 Low oil pressure warning Red
earthing
Lights on by
10 Red
Brake System Warning earthing
Lights on by
11 Power system fault Yellow
earthing
warning
Lights on by
12 OBD Yellow
earthing
Lights on when
connected with
power supply + or
13 Yellow
ABS fault warning untouched and off
when connected
with low level
3-78
Lights on by
14 Airbag fault warning Red
earthing
Lights on by
15 Seat belt warning Red
earthing
Lights on by
16 Cruise control indicator Green
earthing
17 TPMS warning Yellow Controlled by SCM
Lights on by
18 Glow plug indicator Yellow
earthing
Lights on by
19 Door open warning Red
earthing
Lights on by
Alternator charging
20 Red earthing, exciting
warning
current 300mA
Lights on by
21 IMMO warning Yellow
earthing
Transmission box fault Lights on by

22 Yellow
warning earthing
Lights on by
23 ESP fault warning Yellow
ESP earthing
Lights on by
24 Trailer light fault warning Green
earthing
Lights on when
connected with
power supply + or
25 EBD Red
EBD untouched and off
when connected
with low level
Signal requirements of alarm indicator:

High level within ９ V-16V and low level within 0-
0.05V.
3-79
Immobiliser system
Illustrations
Immobiliser system layout
7
9
8
4
1
1. Information display 6. Keys
2. Instrument Cluster 7. Reader coil
4. Starter motor 8. Engine management system (EMS)
5. Horn 9. Body control module (BCM)
3-80
Control chart of immobilizer system
5 4
1 Reader coil 5 Diagnostic connection

2 Keys 6 Engine control module (ECM)
3 Ignition switch 7 Starter motor
4 Instrument cluster 8 Body control unit (BCU)
3-81
Description
Overview
Targeted to engine security directly, immobiliser
system combines keys, electronic immobiliser, and
engine control unit into an organized security system
through perfect security strategy, greatly enhancing the
overall vehicle safety. This immobilizer system is
equipped with combined ECU and aerial installed on
ignition switch core. Immobiliser system only accepts
programmed ignition keys. If invalid key is used, start
system and engine management system are
unavailable.
Immobiliser system consists of immobiliser, coil and

transmitter. Covering the ignition switch core, the coil is
connected to immobiliser by wiring. Transmitter is
mounted in the handle of key.
Operation principle
Non-contact radio sensing technology is used for
password transmission, calculation and certification.
·Keys:
The keys are primarily for activating the engine's
immobiliser and starting systems, but will also lock /
unlock the driver's door and rear door. Use of a key in
either of these doors will lock/unlock that door only. The
keys will also lock/unlock the fuel filler cap.
·Plip:
control part of central door locking system used to
lock / unlock all vehicle doors .
·Plip learning
Refer to instructions of diagnostic apparatus.
·Immobiliser system matching

Refer to instructions of diagnostic apparatus.
3-82
Body control unit
Illustrations
Layout of body control unit
4 3
1 Body control module (BCM) 4 Connector

2 Connector 5 Connector
3 Connector
3-83
Control chart of body control unit
1
2
9
3
10
7 6
1 Cabin fuse 7 Rear right door lock

2 Engine compartment fuse 8 Rear left door lock
3 Central door locking switch 9 Load space lid lock
4 Wireless remote controlled receiver 10 Body control unit (BCU)
5 Front passenger side door lock
6 Driver side door lock
3-84
Rear Courtesy Roof Lamp
Z
BCM $
Z
$ IP08-4
$ IP07-11 Z
Batt $ IP08-1 IP07-6

Timed Relay
$ IP07-5 Z
Tailgate Solenoid
IP07-4
Tailgate Lock
Relay 0
Power manage Tailgate Unlock IP07-3
IP08-11 Relay Passenger Door Left Sliding Door
IP08-3 Driver Door Right Sliding Door
５Ｖ Lock Relay
Output 0 0 0
relay

0
Unlock Relay
IP08-10
control signal LH 55w
IP05-1 $
RKE Circuit Relaydrive
Matching $
IP05-18 Dipped Beam IP08-2
OUT
IMMO DATA Lamps
Station IP05-19 RH55w
IMMO DATA SCK
IP05-39
Diagnosis Switch K line Batt LH 55w
$
circuit drive
IP05-40
IGN
ECM IP05-32 5 /LQH
IP06-5 RH 55w
SRS IP05-17 Front Fog

Light
Vehicle speed signal IP05-14

IPK
IP05-37
Engine running status
Batt $ /('

IP05-21 Security IP06-26
$ Lamp Batt
IP05-22
IP05-2 Batt
HRW&Heater IP06-3
Mirror $
High side signal
IP08-5
$
Front Fog Switch IP05-7
KEY IP05-4
DriverDoor Open Status Switch IP05-15
Low side
Low side
Right Sliding Door Open Status SW IP05-9 output drive
IP06-16 $
Left Sliding Door Open Status SW IP05-33 circuit Alarm
Tailgate Open Status SW
Front Passenger Door Status SW
IP05-34
IP05-13
MCU
LH60w $
Main Beam Lamps Relay
Batt
$
RH60w Batt
Side IP05-12 Main Bean IP06-2
Lamps
Fault
)73
feedback Batt
/R IP05-24 RH Front 5W
+,
IP05-10 Signal Low side signal IP06-17 $
Position NO.Plate Lamps 5W
FTP Beam
manage Lamps RH
LH 5W
Rear 5W
$
IP05-29
Rear Fog Light Switch
LH DI Switch IP05-31
Rear 5W
RH DI Switch IP05-11 IP08-9
Audible Waming
Hazard Warning Switch IP05-30 IP06-12 IPK
Lock Status LED Facial Illumination
Driver Door Key Unlock Switch IP05-35

IGN IGN
Driver Door Key Lock Switch IP05-16 IP06-18 $
Front Wiper

Rear Courtesy Lamp Switch IP05-6 Batt
0

HRW&Heated Mirror Switch IP05-27
Master Lock Switch Simulate signal Front Wiper
Lock IP05-8
Master Unlock Switch
Unlock IP05-28
High side
output Batt
Front Courtesy Roof Lamp
0
Washer Motor
2 )) Map Lamp RH 5W
,17
/2:
+,*
IP08-7
Ourtesy Roof
IGN 2 ))
,17
Wiper SW IP05-20 Lamps
/2: Map Lamp LH 5W
+,*
Interval
High side
Front Wiper Delay IP06-14 Fault drive
IP06-19 feedback
circuit Footwell Lamps 5W LH 21W
IGN IP07-2
Rear Fog
Wash IP05-23 Lamps
RH 21W
IP07-1 Front 24W
RHDI Lamps
Rear 21W Side 5W
IP08-6 Front 24W

LHDI Lamps
Rear 21W Side 5W
3-85
Description
Body control unit (BCU) is located behind glove box

of front passenger side. BCU is secured on cross-beam
of instrument panel framework with two bolts and
accessible after removing the glove box. BCU is in
charge of a series of functions and communicates with
other electronic monitoring element through K bus.
BCU directly controls vehicle functions below:

- Front / rear electric window;
- Central door locking;
- Wipers and washers;
- Alarming and wireless receiving system;
- Electric control air conditioning system;
- Vehicle interior illumination;
- Heated rear windows;
- Power load management;
- Flameout under unloading status;
- Faults record and diagnosis
3-86
Vehicle entertainment system
Illustrations
Layout of vehicle entertainment system
1 2
4
3
7
6
9
1 DVD+ navigator (if fitted) 6 Rear right speaker

2 FM+MP3 player 7 GPS aerial (if fitted)
3 Instrument desk left side speaker 8 AM/FM aerial
4 Instrument desk right side speaker 9 Roof aerial connecting line assembly
5 Rear left speaker
3-87
3-88
Control chart of vehicle entertainment system
1
2
6
3
4
1 Front speaker (left) 4 Rear speaker (right)

2 Front speaker (right) 5 Cabin fuse box
3 Rear speaker (left) 6 Radio (with MP3 function)
3-89
Description
Two audio units are available for V80 to install.
Standard feature is MP3 player with FM and AM

radio functions and USB MP3 playing functions.
Luxurious feature is GPS navigated MP5 player with

GPS navigation function, FM and AM radio functions as
well as streaming media functions of playing RM, RMVB,
MPEG 1-4, avi, wmv and ASF format read by SD card
and USB.
Audio unit is located on central instrument panel with

double DIN dimensions and body shortened. Depth is
reduced to 70mm. A 16 - pin connector located under the
unit provides various control signals required by audio
input of power speaker. A separate aerial coaxial-cable
socket located under the unit provides AM / FM signal. A
10A fuse protects against power overload.
The system consists of: ICE system audio unit \ 4

speakers in the front, rear, left and right (2 coaxial
speakers and 2 woofer speakers) \ overhead FM/AM
aerial.
3-90
Parking distance control
Illustrations
Layout of parking sensor control system
2
3
1 PDC ECU 4 PDC sensor
5 Jacket
3-91
Control chart of parking sensor
2 3
4
1 Cabin fuse 3 Parking distance control ECU

2 Parking distance control sensor 4 Non-neutral start switch
3-92
Description
Overview
The full name of parking sensor is "reverse anti-
collision sensor" or "parking aids", consisting of ultrasonic
sensor (nicknamed probe), controller and display (or
bleeper).

· Ultrasonic sensor:
Transmit and receive ultrasonic signal and used to
measure distance.
· Host machine:
Transmit sine wave pulse to ultrasonic sensor and
handle received signal to calculate distance value before
communicating the data to display.
· Display or bleeper:
Receive data from the host machine and display
distance value based on distance and provide alarm
sound for different level.
3-93
Seat belt
Illustrations
3-94
Description · 3-point emergency locking retractor (ELR) of

passenger seat
Overview
To ensure occupant security, seat belt, as one of Front dual seat and rear seat are equipped with 3-
restraint systems, can protect the occupants against high point emergency locking retractor (ELR) seat belt as
deceleration during vehicle collision or overturn accident standard feature. ELR seat belt has emergency locking
and restrain the occupants to avoid the second impact, retractor mode. Generally, seat belt is in ELR mode for
playing an important role in reducing personal injury. free activities of passengers during non-emergency
situations.
A seat belt pre-tensioner is fitted to the driver's side
on this vehicle. Its purpose is to apply additional tension · Others
on the seat belt upon impact, and assist in holding the Electronic controlled pre-tensioner is controlled by
driver in the seat. SRS ECU that located under centre console beneath
airbag. SRS ECU senses the impact and decides
This system consists of belt, buckle lock, guide part
whether it is serious enough to deploy, and if so, times
and retractor.
the deployment so that the pre-tensioner operates just
Function description of component parts: ahead of the air bag(s).
· Belt
Refers to the flexible belt that can restrain occupant
and pass force to fixed points of seat belt in seat belt
assembly.
· Buckle lock
Buckle for short, refers to the connection
mechanism that can not only restrain occupant in seat
belt but also release quickly.
· Guide part
Refers to the part that is easy to arrange seat belt
retractor and used to change the direction of belt to make
the belt closely restrain the body effectively and improve
the comfortability for occupants wearing seat belt.
·Retractor
Refers to the device that used to retract and store
part or all belt and plays specific role after adding some
mechanism.
· Seat belt pre-tensioner of front seat

Seat belt pre-tensioner of front driver's seat is
standard feature. It contains pyrotechnic retractor of
mechanical control and will be triggered upon front
collision or fore-end collision of certain angle to reduce
looseness of seat belt. Seat belt pre-tensioner of front
seat shall be replaced after triggered due to accident.
3-95
Airbag restraint system
Illustrations
Layout of airbag restraint system
1 Clock spring 3 Airbag ECU
3-96
Control chart of airbag restraint system
7
8
4
9
1 Front airbag module of front passenger side 6 Ignition switch

2 Front airbag module of driver side 7 Restraint system warning light in instrument
cluster
3 Rotary coupler
8 Diagnostic connector
4 Cabin fuse
9 Battery
5 Restraint system diagnostic and control unit
(DCU)
3-97
Description
Overview
When the vehicle suffers front impact of adequate
strength, supplementary restraint system (SRS) will be
activated to protect the driver and front passenger. Main
circuit of SRS module senses the strength of impact force
and ignites gas generator in the airbag assembly for gas
charging when necessary to deploy airbag. If battery
voltage is low or power supply is disconnected for
collision, voltage regulator and spare supply circuit will
keep constant voltage.
The system consists of gas bag, gas generator,

ECU and harness.
ECU triggers gas generator after receiving trigger
signal to release gas to fill up gas bag quickly. Under
normal operation and storage conditions, the deployment
of this vehicle airbag is controlled by SRS ECU located
under centre console beneath airbag. If front collision
occurs during normal vehicle driving, SRS ECU can
detect collision information and decide whether it is
serious enough to deploy airbag, and meanwhile, sends
collision information to seat belt pre-tensioner of driver's
seat for tension while deploying airbag.
CAUTION:
When collision occurs with collision surface angle

beyond 30 degree of vehicle driving direction, airbag isn't
sure to deploy.
3-98
Heating / Ventilation
Illustrations
Layout of heating and ventilation
2
3
1 Ventilation pipe assembly 4 Front defogging air duct

2 Side defogging air duct 5 Front heating control
3 Central ventilation grille assembly
3-99
Control chart of blower
1 2 3
7 6
1 Fresh / circulating air switch 5 Blower switch

2 Body control switch 6 Blower
3 Fresh / circulating air servo motor 7 Blower relay R5
4 Resistor assembly
3-100
Description
Overview
Heating and ventilation system can control vehicle
internal temperature and provide internal air distribution
to the vehicle. This system consists of filter assembly,
heater core assembly, distributing pipe, control panel,
cool and warm door, servo motor and blower.
Heating is to take advantage of the heat of engine
cooling water and transfer the heat to the vehicle by
heater core to keep comfortable temperature. Electric
water valve controls hot water volume that enters into
heating system to adjust temperature in vehicle.
Operation principle chart of heating and ventilation system
Heat release
Heat absorption
Heating
Engine device
M
Cab
3-101
Air conditioner
Illustrations
Layout of air conditioner refrigerating system
Evaporator (low temperature

and pressure gas)
(liquidˉˉgas), heat absorption
Expansion valve (low temperature and pressure fog)
ntermediate temperature and

high pressure gas
Drier
Condenser (gasˉˉliquid), heat rele
Low temperature and pressure gas
High temperature and pressure gas
Compressor
3-102
Control chart of compressor and fan
1 2
3
10
9 12
11
7 6
5
1 Temperature sensor of evaporator 7 AC compressor

2 Body control unit (BCU) 8 Clutch relay of AC compressor
3 Air conditioner switch (Electronic controlled air 9 Main relay
conditioning system)
10 Control panel of air conditioning system
4 Relay fuse of cooling fan
11 ECM
5 Relay module of cooling fan
12 Pressure sensor
6 Cooling fan
3-103
Description
Overview
Air conditioning system could create a comfortable
vehicle space with fresh air and comfortable temperature
for driver and passengers. As there is great disparity of
temperature range between various areas, thus greater
refrigerating capacity, heating capacity and ventilation
volume are required for vehicle air conditioning system.
Air conditioning system applied in this vehicle can
refrigerate quickly and meet user's requirements.
Air conditioning system consists of compressor,

condenser, expansion valve, evaporator, receiver drier
assembly and pipeline assembly.
Operation principle
The circulation of refrigerant can reduce air
temperature and remove water vapor in air by absorbing
the heat in air to realize temperature reduction and
moisture preservation. Meanwhile, cold and warm air
drawn in by air conditioning system can remove frost and
fog on windscreen and side windows.
3-104
Operation principle chart of air conditioning
Gas
High pressure
and temperature
Low temperature and pressure
High temperature
and pressure gas Compressor
Gas
Compress Evaporator
Condenser Evaporate
Condense
Heat absorption
Liquid Heat release Expand Expansion valve
Fluid (High-pressure)
1 After the vehicle started, compressor, driven by 5 Fog refrigerant of low temperature and pressure
engine, starts to work and propel refrigerant comes into evaporator immediately to absorb air
(HFC-134a) circularly flows in sealed air heat from evaporator, thus reducing air
conditioning system to compress gaseous temperature and blowing out cool wind to realize
refrigerant to refrigerant gas of high temperature refrigeration. Refrigerant evaporates into
and pressure before expelling the refrigerant. gaseous refrigerant of low temperature and
pressure due to heat absorption. (In refrigeration
2 After refrigerant gas of high temperature and
technique, evaporation is a heat absorption
pressure flows to condenser through pipelines,
process where liquid changes to gas under
liquid refrigerant of intermediate temperature and
simmer state by absorbing outside heat).
high pressure flows out with heat release and
temperature reduction in condenser. (Condense 6 Gaseous refrigerant of low temperature and
is a heat release process where vapor is cooled pressure is drawn into compressor again for
to temperature equal to or below its saturation compressing and preparing next circulation. As
temperature to change gas to liquid by releasing long as compressor works continuously,
heat). refrigerant will circulate in air conditioning
system to realize refrigeration. If compressor
3 Liquid refrigerant of intermediate temperature
stops working, refrigerant will not flow anymore
and high pressure flows into receiver drier
and no refrigeration available.
through pipeline for drying and filtration before
flowing to expansion valve.
4 After liquid refrigerant of intermediate

temperature and high pressure throttled by
expansion valve, it will change its state quickly,
becoming fog refrigerant of low temperature and
pressure.
3-105
· Compressor:
It can compress low temperature and pressure gas
into high temperature and pressure gas. It is located
between evaporator and condenser and driven by
vehicle engine.
· Condenser:
It can change gaseous refrigerant into liquid
refrigerant. It is located between compressor and
receiver drier.
· Receiver drier:
It can store liquid refrigerant from condenser
temporarily. It can filter foreign objects and absorb
moisture in refrigerant. It is equipped with pressure switch
for system protection and sight glass for maintenance.
· Expansion valve:
It is a flow restriction device that separates system
high pressure side and low pressure side. High pressure
liquid refrigerant changes into mixing fog of low pressure
and temperature gas and liquid that can absorb heat after
throttled. It can measure the quantity of liquid refrigerant
that enters into evaporator by detecting the temperature
of evaporator outlet and adjust inlet clearance depending
on situations. It can adjust refrigerant flow automatically
based on thermal load to ensure that the evaporator
works safely and effectively.
· Evaporator:
It can absorb heat from external air to heat and
evaporate refrigerant from expansion valve into low
temperature and pressure gas. At this moment, air
around evaporator is cooled and cool wind is obtained by
blower. The gas is sent back to compressor again for
next circulation and new cooling work.
3-106
ESP system
ESP is a function extension of ABS (antilock braking
system) system. ESP system consists of a control unit
and a steering sensor (monitor steer wheel angle), wheel
sensors (monitor rotational speed of each wheel), Yaw-
rate acceleration sensor (monitor the vehicle body state
rotated about a vertical axis), a lateral acceleration
sensor (monitoring the centrifugal force of the vehicle
when the vehicle is turning) and others. The control unit
according the signals of these sensors to determine the
running state of the vehicle, and then issue control
instructions. The difference between ESP and ABS is
that ABS is only passively respond to control signal, but
ESP is able to detect and analyze the driving condition
and correct errors before they occur. ESP is sensitive to
over steer or under steer. When the car turn left too fast,
slippery drift to the right will produce. When the sensors
detect the sliding, the control unit will issue signal to brake
the right front wheel. The torque reverse to the sliding
direction occur, so the car could remain in the original
lane. Of course, everything has a degree range, If the
driver driving too fast, Any safety devices are difficult to
guarantee safety.
3-107
Illustrations
2
3
2 4
1 2
1 Hydraulic modulator with attached ECU 4 Yaw-rate and lateral acceleration sensor
2 Wneel-speed sensors 5 Communication with engine management
3 Steering-angle sensor
3-108
ESP-HHC Function
ESP-HHC Structure and Principle
HHC-S-Sensors ECU Hydraulic Digram

Brake master
cylinder pressure HHC_S-Logic
Brake light
switch
wheel speed
HSV USV
Parking- W W
ESP-Logic
brake
Slope sensor
EV
W W
Reverse Gear AV
Switch R
Clutch
Switch Safety-Logic
3-109
Standstill 2 Start
1
4
3 t
HHC-S Start
Slow Down
About 1.5 Seconds
3-110
ESP-HHC Function Description

1 When the car is driven uphill, HHC-S prevents
the car from rolling backwards after the brake
pedal is released by the driver.
2 The driver has up to 1.5s time to move from the
brake pedal to the accelerator pedal to make a
hill-start.
Hill Hold Control(HHC)

1 The brake pressure which was applied by the
driver stops the car and keeps it standstill.
2 The driver releases the brake pedal to make a
hill-start.
3 Maintain the braking pressure to prevent the car

from rolling backwards during the period that the
driver moves his feet from the accelerator pedal
to the brake pedal.
4 When the car is started, the brake pressure is

released.
3-111
3-112
Tyre pressure detection system
System structure:
Overview
Tyre pressure monitor system (TPMS) can monitor tyre
internal pressure, temperature, battery voltage, tyre
Tyre pressure Tyre pressure
information etc. at real time. It can raise alarm when sensor 1 sensor 2
vehicle tyre pressure and temperature is abnormal or

Tyre pressure Tyre pressure
sensor 3 sensor 4
sensor battery voltage is below certain value, monitor
and warn abnormal tyre situations and system faults
TPMS receiver
such as slow air leakage (reaching specified value), fast Data transmission
through serial port
air leakage, perforation etc. and point out tyre fault

location.
Display pressure and
temperature data
TPMS sensor is installed on each hub and suitable for
tyres without inner tube to monitor air pressure and
temperature of tyre or slow air leakage at real time before Display section is transmitted to instrument panel through
sending a frame of corresponding data through wireless serial port and when tyre pressure or temperature is
(433.92MHZ). It consists of pressure sensor, temperature abnormal, alarm is to be raised with alarm icon ISO 2575
sensor, and acceleration sensor, MCU, RF transmitting displayed on instrument panel. TPMS at real time collects
chip, battery, LF receiving circuit and aerial. The sensor pressure, temperature, sensor battery voltage signal to
can receive 125kHz LF waking signal and transmitter transmit to the receiver by wireless way before the
switches between sleep mode and work mode to reduce receiver sending to instrument panel for display through
power consumption based on LF waking signal or serial port (RS232) When sensor battery voltage is
acceleration sensor signal. abnormal, receiver sends various alert data through
serial port and instrument panel gives out audible and
TPMS receiver sends pressure, temperature, battery visual alarms to warn the user.
voltage from transmitter to instrument panel through
RS232 and when tyre pressure or temperature is Instrument panel display
abnormal, receiver sends various alert data through The user can switch between TPMS and other LCD
serial port to instrument panel for audible and visual display with buttons on instrument panel. If TPMS detects
alarms to warn the user. system faults, TPMS alarm LED lamp on instrument
cluster lights on (ISO2575 alarm icon) and when critical
Operation principle
alarm has occurred, LCD automatically switches to alarm
TPMS at real time collects pressure, temperature, sensor mode for words alarm and bleeper audible alarm.
battery voltage signal to transmit to receiver by wireless
way before the receiver sending to instrument panel for Normal pressure or temperature display:
display through serial port (RS232). When pressure, User can switch display mode to TPMS normal display
temperature, or sensor battery voltage is abnormal, mode by button on instrument panel to display current
receiver sends various alert data through serial port to tyre pressure or temperature on LCD at real time
instrument panel for audible and visual alarms to warn (alternative display).
the user.
Tyre pressure warning alarm
Low sensor battery, system failure, tyre high temperature;
For tyre warning alarm, bleeper sounds with the cycle of
0.5 second audible alarm and 1 second stop until the
user annually press left button briefly to switch to alert
mode. Instrument alarm indicator lights on until the alarm
is disarmed, but LCD display still remains alarm display
(user can short press left button to switch to other display
4-1
and if TPMS alarm is disarmed, it will automatically below under TPMS display modes with corresponding
switch to TPMS alarm display after 20 seconds). tyre flashing and TPMS warning indicator on.
Cycles with 0.5 second audible

Normal driving Critical alarm
alarm and 1 second stop
Press
left button
LCD is alarm display and
TPMS alarm indicator Alert mode
constant on When alarms for various tyres have occurred at the same
time, LCD is to be switched to various alarm interfaces in
accordance with priority.
For tyre high temperature alarm when tyre temperature is

above 80 ℃ , temperature sensor sends temperature
information to TPMS receiver before TPMS sending
alarm signal to instrument to switch to LCD display
interface as below first with corresponding tyre flashing
and TPMS warning indicator on.
As for sensor low battery alarm when sensor battery

below threshold value, sensor is to give out low battery
alarm information before TPMS sending alarm
information to instrument for LCD display interface as
below with corresponding tyre flashing and TPMS
warning indicator on.
As for system failure alarm when remind system that

reminds sensor lost fails, instrument LCD displays as
4-2
recommended tyre pressure value), pressure sensor is to

Tyre critical alarm
transmit pressure information to TPMS receiver before
When fast air leakage alarm, low voltage alarm, high
TPMS sending alarm signal to instrument to switch to
pressure alarm, tyre ultra-high temperature alarm sound,
LCD display interface as below first with corresponding
it shows that the tyre has been in critical alarm mode and
tyre flashing and TPMS warning indicator on.
necessary measures shall be taken to remove faults as
there are hidden dangers if driving continued. When
system is in critical alarm mode, bleeper is to sound with
the cycle of 1 second audible alarm and 1 second stop
until the user annually press left button briefly to switch to
alert mode. Instrument alarm indicator lights on until
alarm disarmed, but LCD display still remains alarm
display (user can short press left button to switch to other
display and if TPMS alarm is disarmed, it will
As for low tyre pressure when tyre pressure is 25% below
automatically switch to TPMS alarm display after 20
standard pressure value (manufacturer recommended
seconds).
tyre pressure value), pressure sensor transmits pressure
information to TPMS receiver before TPMS sending
alarm signal to instrument to switch to LCD display
interface as below first with corresponding tyre flashing
and TPMS warning indicator on.
Cycles with 1 second audible
Normal driving Critical alarm
alarm and 1 second stop
Press
left button
LCD is alarm display and
TPMS alarm indicator Alert mode
constant on
For tyre ultra-high temperature alarm when tyre

As for tyre fast air leakage alarm when tyre pressure temperature is above 80 ℃ , temperature sensor sends
changes beyond 10kPa in one minute, system is to temperature information to TPMS receiver before TPMS
immediately raise air leakage alarm and pressure sensor sending alarm signal to instrument to switch to LCD
is to quickly send change signal to TPMS receiver before display interface as below first with corresponding tyre
TPMS sending air leakage signal to instrument to switch flashing and TPMS warning indicator on.
to LCD display interface as below first with corresponding
tyre flashing and TPMS warning indicator on.
Signal transmission mode

Pressure sensor sends pressure and temperature
As for high tyre pressure when tyre pressure is 40%
information to TPMS receiver by wireless radio
above standard pressure value (manufacturer
4-3
frequency. TPMS receiver sends to instrument by wiring

Introduction of hand-held learning
harness for display with dot-array LCD.
diagnostic tool
Sensor: collecting relative air pressure and temperature
of tyre and sending with RF wireless. 1
3 6 8
Tyre pressure monitor: can be used as electronic clock
with accuracy reaching up to ± 1 minute; Monitor tyre
PWR
ENT
pressure; receive dada from sensors and display tyre
LF
pressure, temperature sensor battery. When tyre
ESC
PWR
pressure or temperature beyond limits (pressure too high
or too low, temperature too high), the system sounds
7
alarm with corresponding tyre position indicator flashing. 2
4 5
Meanwhile, pressure or temperature value is displayed.
Functions of hand-held learning diagnostic

tool ① LCD display
Hand-held learning diagnostic tool mainly activates ② LF transmission telltale, illuminated after activation
sensor by transmitting LF (125kHz) signal of certain function selected
power and timing sequence before receiving sensor ID
③ Power light, constant on while battery low
and current tyre temperature and pressure value to learn
tyre position binding, tyre rotation and sensor ④ ESC, escape from current menu command
replacement as required. After activation, receiver store
⑤ ENTER, enter current menu command
such sensor ID to tyre position that corresponds with the
receiver to achieve several tyres' ID binding for the ⑥ up, menu selection
system to learn vehicle assembly, wheel change over
and sensor replacement. ⑦ down, menu selection
Major functions of hand-held learning diagnostic tool: ⑧ power off / on, turned on after pressing 5 seconds
· After all assembly finished, hand-held tool can
be used to read every sensor ID installed in tyre
to realize sensor and receiver binding. No
programming button required on receiving
controller;
· Check pressure and temperature value of any

tyre at any time;
· Exchange tyre position and reset sensor without

sensor removal;
· Replace sensor separately for any tyre position

and send sensor information to receiver for new
correspondence.
· Sensor activation, learning sensor binding,

sensor delete, sensor change over and
downstream function detection
4-4
1、 Menu and button 2、 Learn binding

1、 Button definition 1 Select main menu mode and press △ up button
ESC:escape button. Press this button to escape from or ▽ down button to switch learn binding mode
current menu and back to previous menu interface
Function display interface of learn binding is as below
△ : Up button. Press this button to increase value
▽ : Down button. Press this button to reduce value and

enter next interface.
ENT: enter button. Press this button to enter next menu

and confirm next menu
① Learning mode
PWR: power off / on, turned on after pressing 5 seconds Front left Front right
Rear left Rear right
2、 Activation picture Back OK
2 Press ENT button to enter next menu and default

select learning front left tyre binding or press up
button or down button to switch between four
tyres or switch to different positions for system
learning binding
If front left tyre is selected for learning binding, function

display interface is as below:
Note：Put the cutivator 10cm upper away from the

edge of air core outward tyre.
Front left learning Front right learning

→ Front left Front right Front left → Front right
Rear left Rear right Rear left Rear right
Back Activate Back Activate
4-5
3 Press ENT button to enter next menu and if

activation of front left tyre is required, approach 3、 Delete mode
tyre pressure sensor and press activation button 1 Select main menu mode and press △ up button
to wait until tyre ID and pressure and
or ▽ down button in main menu to switch to
temperature information displayed within 10
delete mode interface
seconds maximum. If data shown in the right
figure below does not appear, reactivation is Delete mode interface is as below
required. NOTE: Bleeper sounds three tick - tick
- ticks after successful activation
②Delete mode
Front left Front right
Front left learning ID information
Front left learning Rear left Rear right
ID ? updated after ID 3662512
Back OK
Pr ? TR ? sensor activated Pr 250kPa Tr28
Back Learning Back Learning

select front left tyre position delete or press up
4 Press ENT button to let tyre start to learn binding button or down button to switch between four
of tyre pressure sensor ID. For example: If front tyre positions or switch to different position for
left tyre is learned successfully, display is as system delete
below:
If front left tyre delete is selected, function display
interface is as below
Front left learning

Front left tyre learning
OK Front left delete Front right delete
Back Learning → Front left Front right Front left → Front right
Back Delete Back Delete
5 Observe such binding learning procedures for

activation of other tyres and back to second step
for reselection of tyre positions for learning
binding after learning finished.
4-6

delete of front left tyre is required, press delete 4、 Tyre change-over mode
button 1 Select main menu mode and press △ up button
or ▽ down button in main menu to switch to tyre
change-over mode interface
Tyre change-over mode interface is as below
Front left delete
Completed
Back OK
ĸChange over
Back OK
CAUTION:If certain tyre is to be deleted, the tyre

should be activated first for hand-held tool to
obtain current tyre ID, otherwise the sensor
cannot be deleted.
If front left tyre is not activated, ID cannot be received and
select front left and front right tyre change-over
interface below is to appear when deleting front left tyre: or press up button or down button to switch
between four tyre positions or select two different
tyre positions for exchange
If exchange between front left and front right tyres is

selected, function display interface is as below
Front left delete
Can not complete

Back OK
Front left and front right Front left and front right
exchange exchange
→ Front left → Front right → Front left Front right
Rear left Rear right → Rear left Rear right
Back Exchange Back Exchange

exchange between front left and front right
4-7
positions is required, press change-over button

and display below is to appear 5、 Diagnostic test functions
1 Select main menu mode and press △ up button

or ▽ down button in main menu to switch to
diagnostic test mode
Diagnostic test function interface is as below
Front left and front right

exchange
Exchange successfully
Back OK
ĺ Diagnostic test mode
Back OK
CAUTION:If certain two tyres are to be
exchanged, one of the tyres should be activated
first for hand-held tool to obtain current tyre ID,
otherwise the sensor position can not be
exchanged.
If front left tyre is not activated, ID cannot be received and select diagnostic test of front left tyre or press up
interface below is to appear when exchanging front left button or down button to switch between four
and front right tyres: tyre positions or switch to different positions for
system diagnostic test
If diagnostic test of front left tyre is selected, function

display interface is as below
Front left and front right

exchange
Can not exchange
Back OK
Front left test Front right test
→ Front left Front right Front left → Front right
Back OK Back OK
3 After selecting relative position for test, press

ENT button to enter next menu and if front left
test is selected currently, press OK to enter
selected position and select corresponding
4-8
alarm. If front left tyre is selected for simulation 8 Simulate texting the alarm function of sensor in
test, function display interface is as below low power situation
Press △ up button or ▽ down button to switch between

several alarms of selected tyres, switchable alarms are:
1 Simulation test of low pressure alarm function

Front left test Front left test
2 Simulation test of under-inflation alarm function ENT
ʽTest finished
Tyre high pressure alarm Tyre high pressure alarm
3 Simulation test of fast air leakage alarm function ESC
Back OK Back OK
4 Simulation test of high pressure alarm function
5 Simulation test of high temperature alarm

function
6 Simulation test of ultra-high temperature alarm

function
7 Simulation test of sensor low battery alarm

function
Front left test ENT Front left test

ʽTest finished
Tyre low pressure alarm Tyre low pressure alarm
ESC
Back OK Back OK
Front left test ENT Front left test

ʽTest finished
Tyre under-inflation alarm Tyre under-inflation alarm
ESC
Back OK Back OK
4-9
Front left test ENT

Front left test
ʽTest finished
Tyre ultra-high Tyre ultra-high
temperature alarm temperature alarm Front left test ENT
Front left test
ESC
Back OK Back OK ʽTest finishe
Fast air leakage alarm Fast air leakage alarm
ESC
Back OK Back OK
Front left test ENT

Front left test
ʽTest finished
Tyre high temperature alarm Tyre high temperature alarm
ESC
Back OK Back OK
Front left test ENT

Front left test
ʽTest finished
Low battery alarm Low battery alarm
ESC
Back OK Back OK
4-10
6、 Precautions
1 If a tyre is to be deleted, the tyre should be

activated first for obtaining corresponding tyre ID
before deleting the tyre under delete mode. If
front right tyre is to be deleted, front right tyre
should be activated under learning mode first to
receive tyre ID before entering front right mode
to delete front right tyre.
2 Never freely change the position of the tyre
where sensor is installed or delete programmed
sensor and if above operations are performed
carelessly, the sensor should be reprogrammed
under the guidance of instruction book or
professional staff.
3 As multi-functional diagnostic test tool is

supplied by battery, power supply of the tool
should be turn off when not in use or charged in
time when red light illuminates to show low
system voltage.
4-11

V80 维修手册（OK Electrico Pag 3-20）技术指南 左-英 15-6-15

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V80 维修手册（OK Electrico Pag 3-20）技术指南 左-英 15-6-15

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Service Workbook

After Sales, SAIC Commercial Vehicle Co., Ltd

#2500, Jungong Road,

Shanghai City, China Postcode: 200438

The following information should be provided:

·Authorized repair center

·Tel. and fax of the authorized repair center

·Model year and model

·Description of your concern(s)

·Necessary relevant information (e.g. sample or marked page)

·Any applicable electronic information part identification number

SMCV will give relevant response in the following ways:

·Submitting your concern to relevant service engineer

·Consulting relevant service engineer

·Satisfying your concern within 10 working days.

Maintenance Information................................................................................. 2-1

Description & Operation .................................................................................. 3-1

Tyre pressure detection system ...................................................................... 4-1

The very strong monocoque body shell encloses:

- Precise rack and pinion power steering.

- A well proven McPherson strut front suspension.

- A simple leaf spring rear suspension.

- Comprehensive electronic management system (EMS).

- Sophisticated vehicle security.

- In addition, a great range of features which include:

- Electric door locking and window operation.

- Cab door mirrors power operated and heated.

- Front passenger air bag & seat belt pre-tensioner.

- Pad wear audible indicators.

- Audible warning device.

Gross vehicle weight,kg 3200 3495 3800 3495 3800 4100

Gross train weight,kg 2185,2240 2240-2800 2185-2800 2280-2800 2530,2570,2610

Drive Type front driver

External Length 4950-5160 5700-5910 5990

Wheelbase （mm） 3100 3850 4175

Front Track （mm） 1734

Rear Track （mm） 1728

Front Suspension （mm） 865

Rear Suspension （mm） 985,1195

Approach Angle （°） 26

Departure Angle （°） 17 （without rear step）， 14 （with rear step）

Fuel Tank Capacity （L） 80

To Speed （km/h） 150 140

Minimum Turning Radius

Main Technical Data - Engine

Model SC25R136Q4 SC25R120Q4

Type Inline 4-Cylinder CR, TCI Diesel

Bore (mm) 92.0 92.0

Stroke (mm) 94.0 94.0

Total Displacement (L) 2.499

Compression Ratio 17.5:1 17.5:1

Rater Power (kW/r/min) 100/3800 88/3800

Max. Torque (Nm/r/min) 330/1800 ～ 2600 300/1800 ～ 2600

Cylinder Working Order 1-3-4-2

Weight (without starter and AC 230 230

Emission Level Chinese Emission Standard Ⅳ /Chinese Emission Standard Ⅴ

Main Data - Transmission

Gear Ratio Rev 3.167

Transmitted Torque (N.m) 330

Operation control Long distance cables

Front-wheel Alignment Data

Item Front-wheel Alignment Data

Wheel Camber 0.5 ± 1° (-0.5°～ 1.5°)

Rear-wheel Alignment Data

V80 维修手册（OK Electrico Pag 3-20）技术指南左-英 15-6-15

V80 维修手册（OK Electrico Pag 3-20）技术指南左-英 15-6-15