Florid 2008

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PREFACE
GWFLORID will build 1.3L (GW413EF, GW4G13) or 1.5L (GW4G15) gasoline engines, in which the
GW4G13 and GW4G15 engines will both incorporate the newest VVT technology which meets the Euro IV
emission standards. GWFLORID features McPherson technology on its chassis system. With an ultra light
body made from structural steel and high-intensity front and rear fender impact beams as well as a collision
impact absorption system, it is able to maintain the cab's integrity and safety to greater extent. We wrote this
maintenance manual in order to meet the demand of Great Wall after-sales service technicians. This manual
mainly introduces the areas of importance in regard to maintenance and care, and removal and installation of
each system's assembly and maintenance technical parameters.
To reduce the possibility of injury or property damage, read and follow the instructions carefully:
This manual is provided by the Great Wall Motor Co., Ltd, and is written for the technician use. Any
maintenance or repair without proper prior training and tools or devices may result in personal injury of the
person performing the maintenance or others in the vicinity. It is also possible that damage to the vehicle will
occur or will lead to mechanical failure during normal operation.
Correct vehicle maintenance and repair is essential for the safety of the person performing regular
maintenance as well as the vehicle itself. If there is any component that needs to be replaced, use a
component with the same serial number or a serial number specified by the Great Wall Motor Co., Ltd. Never
use any part that has not been authorized by the Great Wall Motor Co., Ltd.
Any maintenance procedure introduced in this manual is effective for maintenance and repair. Some of
these procedures need specially designed tools.
Therefore, before using any vehicle part following any maintenance procedure or working with a tool
that has not been authorized by the Great Wall Motor Co., Ltd, check to make sure that none of the above
will endanger the safety of the person performing the work or the correct operation of the vehicle.
This manual includes multiple "Warnings" and "Cautions," which should be strictly followed, so as to
reduce the possibility of injury during maintenance or repair. Improper maintenance or repair of the vehicle
may cause potential safety hazards. These "Warnings" and "Cautions" are not exhaustive. It is impossible for
the Great Wall Motor Co., Ltd, to warn against all the potential dangers caused by not properly following the
instructions.
Please read carefully the "Areas of Importance" before carrying out any maintenance or repair on the
airbag system's components or its surrounding electrical components. Action contrary to any of the "Areas of
Importance" may lead to the deployment of the airbag, resulting in injury or unnecessary repair of the airbag.
To avoid accidental deployment of the airbag and its resulting injury, we suggest repairing the airbag
system before other vehicle systems if the airbag and the other vehicle systems both need repairing.
We have received generous support and help from many professional technicians during the preparation
of this manual. We would like to express our heartfelt gratitude to all of them.
Although we have tried our best to write this manual well, we do not guarantee that the entire content
in this manual is absolutely correct. Users may not make any legal claim against the Great Wall Motor Co.,
Ltd. in regards to this manual. Any loss caused by using this manual is not our responsibility. Because of
the writer's limited experience, there are likely mistakes in this manual, therefore we welcome any user
comments, suggestions, and corrections.
Great Wall Motor Co., Ltd. reserves the final right of explanation.
Editor
May 2008
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CONTENTS
Chapter One: Overview.................................................................................................................1
How to Use This Manual...............................................................................................2
Identifying Number Location.........................................................................................3
Comprehensive Repair Instructions..............................................................................4
General Repair Methods and Operations.....................................................................9
Chapter Two: Overall Parameters...............................................................................................10
Basic Parameters of the Overall Vehicle....................................................................11
Engine Technical Parameters.....................................................................................12
Chassis’ Main Assembly Technical Parameters..........................................................13
Vehicle Structure Type and Parameters.....................................................................15
Air Conditioning System Structure and Parameters...................................................16
Electrical System Structure and Parameters..............................................................16
Grade Specification and Filled Quantity of Each
Individual Functioning Component’s Working Agent...................................................18
Torque Specifications for Key Operational Bolts.........................................................18
Vehicle Body’s Basic Calibration Measurements . .....................................................22
Chapter Three: Fuel Supply and Exhaust System......................................................................29
Fuel Supply System....................................................................................................30
Components.............................................................................................................30
Fuel Tank Removal...................................................................................................31
Fuel Pump and Charcoal Canister Removal............................................................31
Fuel Filter Removal...................................................................................................31
Fuel Filler Pipe Assembly Removal..........................................................................32
Exhaust System..........................................................................................................33
Components.............................................................................................................33
Exhaust System Removal.........................................................................................34
Exhaust System Installation......................................................................................35
Chapter Four: Clutch Operational System..................................................................................36
Areas of Importance...................................................................................................37
Troubleshooting..........................................................................................................37
Clutch Operational System.........................................................................................38
Components.............................................................................................................38
Clutch Master Cylinder Removal..............................................................................38
Clutch Master Cylinder Installation...........................................................................40
Clutch Pedal Removal..............................................................................................40
Clutch Pedal Installation...........................................................................................40
Clutch Pedal Examination and Adjustment...............................................................41

Chapter Five: Transmission.........................................................................................................42
037A Transmission’s Overall External Schematics.....................................................43
Main Technical Parameters .......................................................................................43
Transmission’s Proper Use and Care.........................................................................44
Technical Specifications for Transmission Installation and Adjustment......................44
Areas of Importance...................................................................................................45
Troubleshooting..........................................................................................................46
037A Transmission Structural Schematics.................................................................47
Clutch..........................................................................................................................48
Gear Shift Fork and Fork Shaft...................................................................................49
Transmission Case.....................................................................................................50
Disassembling the Input Shaft Subassembly.............................................................56
Disassembling the Output Shaft Subassembly...........................................................60
Disassembling the Shift Cover Subassembly.............................................................64
Disassembling the Differential Subassembly..............................................................68
Chapter Six: Suspension System................................................................................................71
Suspension System Technical Parameters................................................................72
Front Suspension........................................................................................................73
Subframe and Front Stabilizer Bar.............................................................................77
Lower Swing Arm........................................................................................................80
Drive Shaft..................................................................................................................84
Rear Suspension........................................................................................................86
Wheel and Tire............................................................................................................89
Chapter Seven: Brake System....................................................................................................94
Brake System Components Arrangement Schematics...............................................95
Brake System Maintenance........................................................................................96
Brake Pedal................................................................................................................98
Parking Brake Control Mechanism Assembly...........................................................102
Vacuum Booster with Brake Cylinder Assembly.......................................................103
Anti-lock Brake System.............................................................................................107
ABS General Problem Maintenance and Areas of Importance.................................109
Steering Knuckle and Hub Brake Assembly.............................................................112
Front Brake Caliper...................................................................................................118
Rear Brake................................................................................................................124
Rear Support Axle.....................................................................................................131
Chapter Eight: Steering System................................................................................................134
Troubleshooting........................................................................................................135
Steering System Maintenance..................................................................................137
Power Steering Fluid Instructions.............................................................................141

Technical Requirements...........................................................................................141
Chapter Nine: Vehicle Body Electrical System..........................................................................142
Basic Information on the Electrical System..............................................................143
Fuse Box...................................................................................................................144
Overall Vehicle’s Grounding Point Schematics.........................................................150
Key Electrical Component’s Module Schematics for the Overall Vehicle.................151
Wire Harness Distribution Chart for the Overall Vehicle...........................................152
Wire Harness Relationship and Plug-in Connections Numbered Diagram...............155
Wire Harness Plug-in Connectors and Pin Function Diagram..................................156
Electrical Wiring Diagram for the Overall Vehicle.....................................................167
Chapter Ten: Electrical Accessories..........................................................................................177
Reverse Sensor........................................................................................................178
Combination Meter...................................................................................................180
Central Door Lock.....................................................................................................181
Power Windows........................................................................................................184
Immobilizer System..................................................................................................186
CD Player.................................................................................................................193
DVD Player...............................................................................................................195
Chapter Eleven: Air Conditioning System................................................................................202
Areas of Importance.................................................................................................203
Technical Parameters...............................................................................................203
Air Conditioning System’s Structure Diagram and Fundamentals............................207
Air Conditioning System Overview...........................................................................207
Air Conditioning System Terminal Definition.............................................................208
Compressor..............................................................................................................208
Electromagnetic Clutch.............................................................................................210
Vacuuming and Charging Refrigerant.......................................................................211
Filling Quantity and Method for Refrigerant Oil.........................................................212
Daily Maintenance of the Air Conditioning System ..................................................212
Chapter Twelve: Airbags............................................................................................................213
Airbag Electronic Control Unit...................................................................................214
Diagnostic Scanner...................................................................................................215
Vehicle Collision Diagnostics....................................................................................226
Removal Method for Individual Components............................................................227
Driver Side Airbag Module (DAB), Front Passenger Side
Airbag Module (PAB), Clock Spring, and Steering Wheel........................................228
Airbag Module Disposal............................................................................................230

Airbag’s Diagnostic Methods Without a Diagnostic Scanner....................................232
Chapter Thirteen: Vehicle Body.................................................................................................233
Front Door Lock Assembly........................................................................................234
Rear Door Lock Assembly........................................................................................237
Trunk Door Lock Assembly.......................................................................................239
Wiper Arm and Vent Panel Assembly.......................................................................240
Front & Rear Window Glasses.................................................................................241
Dashboard................................................................................................................242
Cooling Unit..............................................................................................................246
Front Door Assembly................................................................................................248
Rear Door Assembly.................................................................................................251
Trunk Door Assembly................................................................................................254
Front Bumper............................................................................................................256
Rear Bumper............................................................................................................259
Seat Belt...................................................................................................................262
Seats.........................................................................................................................266
Sunroof Assembly.....................................................................................................268

Overview 1
Overview
How to Use This Manual..................................................... 2

Identifying Number Location................................................ 3
Comprehensive Repair Instructions.................................... 4
General Repair Methods and Operations............................ 9

2 GWFLORID Maintenance Manual
How to Use This Manual

1. There is a content index on the first page of each
chapter. You can consult the index to see the items
needed for maintenance. In order to make searching
more convenient, the subject of each chapter has been
printed on the page header of each odd page.
2. There is a summary or caution item in the beginning of
each chapter. Please read this content carefully before
any maintenance is performed. Some systems include
a malfunction diagnostic table to help determine ve-
hicle failures and their causes.
3. Throughout the entire manual, each maintenance
step's corresponding specification is highlighted in bold,
so there should be no need to pause maintenance
work in order to find these specifications.
4. Warnings, Cautions & Notes
• Warnings are highlighted in bold, indicating the possibility
of causing injury to oneself or to others.
• Cautions are highlighted in bold, indicating the possibility
of damaging the part being repaired.
• Notes are listed separately from the instructions, not high-
lighted in bold. They are mainly used for additional expla-
nations in order to work more effectively.
5. Maintenance procedures:
Most of the maintenance procedures begin with a high-level
component schematic, which indicates individual vehicle
components and how they are assembled.
For example:
Front brake caliper assembly LH Copper washer
Hollow bolt
Left steering Q150B1235

100±10
Front brake disc knuckle
cover LH
Q1420612 Heavy duty spring washer Q40512
9±2
Q43082
Front hub bearing assembly
Front hub flange
Front brake disc
N·m : Specified torque

Disposable parts

Overview 3
The maintenance procedures are explained step by step:

• The schematics and diagrams illustrate how and where to
operate.
• The titles convey the maintenance content.
• Detailed instruction explains how to perform the maintenance,
as well as introduces other related matters, such as specifications,
warnings, and so on.
For example: Work Subject: What to do
4. Inspect the front brake disc thickness.
Standard thickness: 22.0 mm Specifications
Minimum thickness: 20.0 mm
The brake disc must be changed when its thickness falls be-
low the minimum level.
Illustration: How and where to operate.

Detailed Instruction: How to do it
Correct vehicle maintenance and repair is very important
to the safety of the maintenance person and the vehicle. If
any vehicle part change is necessary, please use a part with
the same part number or part number specified by the Great
Wall Motor Co., Ltd. Never use a part that has not been au-
thorized by the Great Wall Motor Co., Ltd.
Identifying Number Location

VIN
Vehicle Identification Number (VIN)
A Vehicle Identification Number is a unique serial number
consisting of 17 characters and used to identify individual
motor vehicles. This number is marked at three different
places: at the nameplate, at the upper-left side of the dash-
board, and at the cross member located under the front pas-
senger seat.
Vehicle Nameplate
Every vehicle has a vehicle nameplate, and this vehicle's
nameplate is located at the bottom of the right B-pillar.
Vehicle Nameplate
Engine Manufacturing Number

The engine manufacturing number is engraved on the left
side of the engine cylinder block.

Comprehensive Repair Instructions

1. Use the splasher, backing, and carpet to keep the vehicle
clean and to prevent damage.
2. While removing, mark all vehicle components or
place all the components in proper order to make re-
assembling more convenient.
3. Disposable parts:
(a) Always use new parts to replace cotter pins, gaskets, O-
rings, and oil seals.
(b) Disposable parts will be marked with a " " in the
components schematics section.
4. Precoated components.
The precoated components include bolts and nuts which
have been coated with locking sealant in the factory.
(a) If the precoated part is tightened, loosened, or moved
for certain reason, it must be coated with prescriptive
sealant again.
(b) When reused, the original sealant should first be
cleaned and dried using compressed air. Afterwards,
use the required locking sealant to coat the bolts, nuts,
or threads.
(c) Precoated parts are marked with " " in the components
schematics section.
5. All rules regarding a bolt's tightening torque must be
seriously obeyed, and a torque wrench must be used.
Torque wrench indication type
Torque wrench scale indication type
6. Be careful when using a jack to raise and support the

vehicle. Make sure to jack up and support the vehicle
at proper locations.
(a) To ensure safety, chock up the wheels of the opposite
side if the place to be jacked up is either the front or
back of the vehicle.
(b) After lifting the vehicle, make absolutely sure to
support it with a bracket. It's extremely dangerous to
Hydraulic jack Scissor type jack perform maintenance using merely a jack, even if to
finish the small matter quickly.

Overview 5
7. Pay attention to the "Areas of Importance" below to

avoid damaging any part:
(a) Do not open the cover or case of the ECU (Electronic
Control Unit) unless it's absolutely necessary. (Touching
the pin of the IC (Integrated Circuit) may damage the
IC due to static electricity.)
(b) When unplugging the vacuum hose, make sure to pull
from the end of the hose but not the center.
Incorrect Correct
(c) To make hose reassembly more convenient, label the

unplugged portions for easier recognition later. After
The white side performing this task, check carefully to make sure the
hose is connected correctly.
(d) Be careful! Do not drop any electrical components (like
sensors or relay connectors). Replace them at once
if they have been dropped onto a hard surface. They
The black side cannot be used for the second time.
(e) When cleaning the engine with a steam, make sure to
properly protect the ignition coil and air filter as to
prevent water from seeping in.
(f) Do not forcefully try to connect a hose into an
oversized tube while using a vacuum gauge. Instead,
use a stepped connector. If the hose is stretched, it may
lead to leaking.
8. All resistors must be measured at below 20oC room
temperature unless special situations arise. This is
because resistance value measured under higher
temperature may exceed standard requirements, espe-
cially if measured after driving the vehicle. All measures
should be taken after the engine has cooled down.
Circuit Maintenance Instructions
1. Rules to be obeyed before a circuit is repaired:
(a) Make sure to disconnect the negative (-) cable from the
battery before electrical maintenance is performed.
(b) When inspection and maintenance work requires
disconnecting the battery, make absolutely sure to
disconnect the negative (-) cable of the battery and that
it is connected to the vehicle body as grounding.
(c) To prevent damaging the wiring terminal of the battery,
loosen the cable's fixing nut and lift up the cable, but
do not forcefully twist or press the cable.
(d) When cleaning up the battery's and the cable's connecting
terminals, make sure to use a special rag, and do not use a
file or other rough material to wipe them.
(e) While connecting the connecting terminals of the cable
and battery, loosen the nuts first, then tighten them
after installation. Do not hammer the cable's connecting
terminals into the battery with a hammer.
(f) If the battery's ground cable has not yet been
disconnected, please do not try to speed charge the
battery, as this could damage the alternator's diode.
(g) Should the battery's ground cable be disconnected,
please do not try to start the engine, as this could
seriously damage the wire.
(h) Make sure to properly cover the battery's positive (+)
end cover.

2.��
��
Inspection procedures for related fuses or fuses in re-
Same current rating lay boxes. Inspect the battery for damage, the battery's
charging state, cleanness, and tightening with the
connectors.
Before changing a fuse, make sure to check if the fuse's cur-
rent rating meets the required standards. You must not use a
fuse with a current rate that is higher or lower than required
standards.
3. Binding wire harness connectors.

(a) When disconnecting the connections, first press the two
ends of the connectors together, then loosen the lock
and press the lock pawl to release the connector.
(b) When disconnecting the connector, do not pull on its
wire harness. Grasp the joint directly.
(c) Check if the joint is deformed, damaged, or port lost
before connecting the connector.
Incorrect (d) The connector is not successfully connected until it
makes a click sound.
4. Wire harness connector inspection.

Loosen crimp
(a) Check while connecting the connectors.
Squeeze both ends of the connectors to make sure it is com-
Core pletely plugged in and tightly locked.
(b) Check when disconnecting the connectors.
Deformed terminal
Check by lightly pulling the wire harness behind the connec-
tor's joint. Look for any unconnected or dropped terminals,
loose clamps, or broken wires.
Pull lightly Visually inspect for instances of corrosion, metal fragments,
oddities, and water, as well as bending, rust, overheating,
pollution or deformed terminals, etc.
(c) Check the contact pressure of the terminals.

Prepare a plug that matches the connector's port, plug it into
the socket, then check for the proper rate of tension after
they are fully engaged.
The terminal is similar to a plug

Overview 7
5. ��
Maintenance methods��
for wire harness connector ter-
minals.
(a) Use an airgun or rag to clean the contact points if the
terminals become dusty. Do not use sandpaper to clean
it, as that could damage the electroplated layer.
(b) If the contact pressure seems unusual, change it to a
socket of the same type.
(c) Any terminal that has been damaged, deformed, or
Correct
corroded must be changed. If the terminal is not locked
Incorrect
to the case, then the case needs to be replaced too.
6. Clip removal and installation.

Methods for removal and installation of the vehicle's body part clips are shown in the table below.
Remark: If the clip is damaged during operation, it must be replaced with a new one.
Shape Removal / Installation
Vise
Clip extractor
Protection band
Screwdriver
Protection band
Screwdriver

Continued table
Shape Removal / Installation
Removal Installation
Screwdriver
Press
Clip extractor
Push out the king pin, remove it,

and pry the kingpin bush.
Screwdriver Press
Clip extractor
Screw off the king pin and pry the shell.
Press
Screwdriver
Clip extractor
Small clip extractor
Pry out the king pin, remove the rivet,

and then pry off the shell.

Overview 9
General Repair Methods and Operations

1. If a jack is needed, please kindly comply to the safety procedures listed below.
2. Park the vehicle on a flat surface, stablize the front and the back wheels using any fixed object or tool,
jack up the vehicle, support it with the chassis, and then start the maintenance.
3. Disconnect the battery's negative cable before maintenance, in order to reduce the possibility of
damaging and burning out the cable due to a short circuit.
4. Cover the vehicle body, seats, and floor to prevent them from being damaged and polluted.
5. Handle brake fluid and antifreeze fluid carefully, because it may damage the vehicle's surface paint
and its surroundings.
6. Using the proper tools or basic tools that have been recommended and are purchasable is very
important in guaranteeing an effective and reliable maintenance result.
7. Dispose the used dowel pins, gaskets, O-rings, oil seals, lock washers, and self-locking nuts. Prepare
new parts for installation. Normal functions are not guaranteed if these parts are reused.
8. Store the removed parts in order and in groups to make reassembly more convenient.
9. Store bolts and nuts separately, because their hardness levels and designs are different according to
the installation locations.
10. Clean parts before they are inspected or reassembled. In addition, parts that come in contact with
engine oil also need to be cleaned, as well as checked for blockage by using compressed air.
11. Before installation, use engine oil or grease to lubricate the rotating and sliding sides of the necessary
parts.
12. When necessary, use sealant on gaskets to avoid leakage.
13. Please carefully comply to all tightening torque specifications of bolts and nuts.
14. After maintenance, check to make sure whether the repairs were performed correctly and whether the
malfunctions have been fixed.
Vehicle Lifting/Lowering Procedures
When lifting the vehicle, the lifter must be placed at the indicated spots. Using these indicated spots
incorrrectly can lead to permanent deformation of the vehicle body. Many vehicle service stations
have autolifts that raise vehicles by supporting certain vehicle parts. If using other types of lifts, be
careful to prevent damages to the fuel tank, oil filler, or the base of the vehicle body.
Frame contact lifting device and basic hand jack

Floor arch jack
Lifting points (left/right) of central threshold

Overall Parameters
Basic Parameters of the Overall Vehicle............................. 11

Engine Technical Parameters.............................................. 12
Chassis' Main Assembly Technical Parameters.................. 13
Vehicle Structure Type and Parameters.............................. 15
Air Conditioning System Structure and Parameters............ 16
Electrical System Structure and Parameters....................... 16
Grade Specification and Filled Quantity of Each
Individual Functioning Component's Working Agent........... 18
Torque Specifications for Key Operational Bolts................. 18
Vehicle Body's Basic Calibration Measurements ............... 22

Overall Parameters 11
Basic Parameters of the Overall Vehicle

S08 S16 S12
Item
GW413EF GW4G15 YC4W75-31
Length 3907
Width 1694
Size Pa- Height 1521
rameters
Wheelbase 2368
(no load)
(mm) Tread: front/rear 1459/1430
Front suspension 813
Rear suspension 726
Load capacity (kg) 5 people × (68±7) kg/person
Curb weight (kg) 1135 1120 1118
Gross vehicle weight (kg) 1510 1495 1493
Quality
Unload axle load distribution: front/rear (kg) 646/434 669/451 689/429
Parameters
Unload centroid location (x, y, z) (mm) 951/27/285.9 954/27/285.9 909/27/285.9
Full load axle load distribution: front/rear (kg) 748/707 770/725 791/702
Full load centroid location (x, y, z) (mm) 1151/22/375.5 1148/22/375.5 1114/22/375.5
Minimum turning diameter (m) 11
Passing Minimum ground clearance (mm) 127 (full load)

Ability Approach angle (°) 17 (full load)
Parameters Departure angle (°) 20 (full load)
Breakover angle (°) 16 (full load)
Minimum stable speed of the direct gear (km/h) ≤25
Direct drive 25 km/h - 100 km/h acceleration
≤32
time (s)
Dynamic
Acceleration time from standstill with the first
Performance ≤19
gear to shifting gears until reaching 100 km/h (s)
Maximum speed (km/h) 162 178 152
Maximum climbing capacity (%) 30.6 34 34.3
Sliding distance (m) of 50 km/h initial speed ≥500
Fuel consumption of 90 km/h speed with
5.79 6.1 4.25
constant velocity (L/100 km)
Economy Fuel consumption of 120 km/h speed with
≤8.5
constant velocity (L/100 km)
Under the urban and suburb driving cycle
≤7.5 ≤8.1 ≤7.5
simulation (L/100 km)
Service braking distance (m) of 50 km/h initial
19.0≤ (no load) ≤ 20 (full load)
braking speed
Braking
Emergency braking distance (m) of 50 km/h
Performance ≤38
initial braking speed
Grade braking (%) ≥18
Maximum angle of rolling stability when empty
≥35
Stability or inactive (°)
Handling stability (min) Nan≥60 and NZ≥60

Outter acceleration noise dB (A) ≤74 ≤75

Ride
60 km/h constant velocity interior noise dB (A) ≤65 ≤65
Performance
Driver operating noise dB (A) ≤90 ≤90
CO emission (g/km) ≤2.30 ≤1.00 ≤0.64
HC emission (g/km) ≤0.20 ≤0.10 /
Emission NOx emission (g/km) ≤0.15 ≤0.08 ≤0.5
Particle emission (g/km) / / ≤0.05
Smoke density / / ≤4.0
Engine Technical Parameters

Item Unit Specifications and Parameters
Model number GW413EF GW4G15 YC4W75-31
Inline four cylinder, 4-stroke, water cooling, dual Inline four cylinder,
overhead camshaft, petrol engine 4-stroke, water cooled,
Model
dual overhead camshaft,
diesel engine
High pressure electronic
Fuel supply type Electronic controlled, multi-points ordinal injection controlled common-rail
fuel injection
Cylinder bore ×
mm × mm 78.7 × 69.0 75 × 84.7 71.0 × 77.0
stroke
Displacement L 1.342 1.497 1.219
Compression ratio 9.3:1 10.5: 1 18.5:1
Number of valves/
16/4
cylinder
Lowest rate of fuel
g/(kW·h) <260 ≤260 215
consumption
Maximum power/
kW/(r/m) 65/6000 77/6000 50/4200
rotation speed
Max. torque/
rotation N·m/(r/m) 115/4400-5200 138/4200 153/2000-2400
speed
Total net weight kg 115 96 142±2
Idle speed r/min 800±50 800 750±50
Fuel type and
RON/MON Unleaded gasoline, #93 Euro diesel fuel
grade
Forced water circulation Forced water circulation Forced water circulation
cooling, the opening cooling, the opening cooling, the thermostat
temperature of the temperature of the starts to open at 75oC and
thermostat is 82±2 C, the thermostat is 82±2 C, the is fully open at 85oC, the
o o
Cooling style and water temperature under water temperature under opening pressure of the
performance normal working condition normal working condition coolant compensation
parameters is 90-100oC, the opening is 80-90oC, the opening box's pressure limiting
pressure of the coolant pressure of the coolant valve is 108±14.7 kpa
compensation box's compensation box’s
pressure limiting valve is pressure limiting valve is
108±14.7 kpa 108±15 kpa
Starting style and Motor starting, starting performance complies with GB18297
performance requirements 8.1.2 and 8.1.3
Lubricating
Pressure and splash combination
method

Chassis' Main Assembly Technical Parameters
Item Specifications
Model number GW413EF GW4G15 YC4W75-31
Single chip, dry type,
Single chip, dry type, diaphragm spring
diaphragm spring
Driven disc diameter: Clutch disc diameter: Driven disc diameter:
Clutch type
Clutch 200 mm 213 mm 212 mm
Separating stroke:
Maximum stroke: 9 mm, separating stroke: 7.5 mm
7.5 mm
Clutch hydraulic pressure
Clutch pedal total stroke: 116.5mm
control system
Transmission
037A CC0011A ZM007Q ZM007W
model number
Transmission type Mechanical 5-gear manual transmission
Main speed
3.944 4.3125 4.267 3.937
reduction ratio
1st gear 3.545 3.545 3.364 3.182
2nd gear 1.913 1.905 1.895 1.895
Transmission Gear 3rd gear 1.310 1.310 1.286 1.25

transmission 4th gear 0.973 0.970 0.969 0.91
ratio
5th gear 0.804 0.816 0.800 0.703
Reverse
3.214 3.250 3.214 3.08
gear
Maximum bearing
130 160 153 153
torque (N·m)
Maximum input speed
6000
(r/min)
The input end of the propeller shaft adopts a widely used, near constant
Propeller shaft velocity, retractable spherical roller wheel joint. The output end adopts a
Rzeppa joint.
Air intake system Dry air filter, paper filtering element.
Equipped with GW413EF engine, two grade muffler with two grade three-
way catalytic converter. Front/rear oxygen sensors.
Exhaust system
Equipped with YC4W75-31 engine, two grade muffler with one grade three-
way catalytic converter and oxygen sensor.
Equipped with GW413EF engine. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister. An electronic accelerator pedal
controls the fuel supply. The fuel evaporation control system controls the
charcoal canister through a solenoid valve
Fuel supply system
Equipped with the YC4W75-31 engine. High pressure electronic common-
rail fuel injection and dual fuel pipeline. The 45L metal fuel tank includes an
electronic fuel pump and a charcoal canister, electronic accelerator pedal, a
fuel line is connected with the fuel-water separator and diesel fuel filter.
The cooling system uses the enclosed forced water circulation cooling
system, the heat dissipating electronic fan uses a two level speed controller.
Cooling system The electronic fan and overflow tank are combined in one. The radiator is
equipped with upper and lower water chamber aluminum pipe. The system
pressure is 90 kPa.

Chassis' Main Assembly Technical Parameters (Continued)

Item Specifications
Wheel specifications Standard 15 × 6J rim, offset distance: 40 mm
Wheel and Tire specifications Standard tire selection 185/65 R15 88H
tire Spare tire
Spare tire 185/65 R15 88H, T125/70R16 96M J16 × 4T
specifications
Rack and pinion hydraulic power steering gear, with drive ratio of 19.03,
Steering gear
power steering pump rate of flow is 6.7-8.9 L/min
Safe, energy absorbing, angle-adjustable steering column, with an adjustable
Steering column
range of 3.6°.
A three stage softening type with airbag, diameter of 370 mm, and maximum
Steering wheel
steering circle number of 3.08.
Front wheel camber/rear wheel camber -0° 43′ ± 30′ /-0° 43' ± 30'
Steering Kingpin angle +10°21′ ± 30′
system
Kingpin caster +1°49′ ± 30′
Main technical Front wheel toe-in/rear wheel toe-in -0° 01′ ± 15′ /+0° 14' ± 15'
parameters Inside wheel steering angle (°) 32°-37°
Outer wheel steering angle (°) 28°-30°
Steering wheel rotation number (n) 3.08
Steering system angle ratio (i0ω) 19.03
The service brake system adopts a hydraulic vacuum power-assisted type.
The front/rear brakes are disc and drum brakes respectively. The front brake
Service brake type uses a ventilated disc, and the brake pedal is a suspended pedal with vacuum
booster. Brake line is in a dual-circuit diagonal (X type) arrangement,
adopting a ABS + EBD anti-lock and braking force distribution system.
Service brake booster Single stage Φ9inch vacuum booster, series dual-chamber brake master
and master cylinder cylinder, cylinder bore Φ22.22 mm, stroke 32 mm
Shares with the clutch master cylinder reservoir and installed with a brake
Brake reservoir
fluid level alarm.
Brake pedal stroke Free play: 6-9 mm, working stroke: 37-40 mm.
Brake Brake pedal pressure <380 N (no load) <480 N (full load)
system The parking brake system uses a mechanical remote ratchet cable control
Parking brake mechanism to control the rear wheel drum brake. Brake lever's functional
stroke is 5-8 gearteeth.
Wheel cylinder
Φ54 mm
diameter
Front wheel Floating caliper disc brake
Brake disc
Φ255 mm
diameter
Brake parameters
Wheel cylinder
Φ19.05 mm
Leading trailing shoe drum diameter
Rear wheel
brake Drum brake
Φ200 mm
diameter

Vehicle Structure Type and Parameters

Item Structural parameters & performance descriptions
Body type All-metal closed hard surface bearing body.
Body in white Pressed and welded, all-metal enclosed structure.
Framed door with four-door impact beam, hinged sliding open door, trunk door
Door assembly
opens upwards, front/rear doors are installed with auto window regulator.
Body Engine hood Opens up/downwards using a single arm hinge.
Front door opening Engine hood
35°/60° 74.5°
Closure part angle opening angle
parameters Rear door opening Trunk door max.
36°/64° 96°
angle opening angle
Satisfies ergonomic and comfort requirements. Fire resistance complies to regulatory
Interior
requirements.
Uses an injected molding structure with brace reinforcement, built in multifunctional
combination meter, knob plus button-press air conditioning controller, CD player
Dashboard
(DVD and GPS LCD are optional), and auxiliary facia console which adopts a gear
shift control mechanism.
A, B, C, and D
pillars and door's Uses injected molding and front door guard plates equipped with package tray, four-
inner decoration door guard plates are all installed with window regulator switches.
board
Automobile Windshield is laminated glass, front and rear door glass is tempered glass, trunk door
glass glass is heating & defrosting tempered glass with resistance wire.
Elite type: electrically actuated convertible body and electronically controlled mirror
with defroster.
Outer rearview
Luxury type: manually folded body and electronically controlled mirror without
mirror
defroster.
Comfort type: manually folded body and manually adjusted mirror without defroster.
Vehicle
Inner rearview
interior/ Flexible with anti-glare function
mirror
exterior and
accessories Driver & front passenger seats, independent seats. For front and rear seats, backrest
angle and seat headrest are both manually adjustable. Second row seats use a three-
Seats seat arrangement. The seats' front and back positions and backrest angles are
nonadjustable. Seat headrests are both manually adjustable, back of the seat can be
folded forward, and the middle seat includes a child seat belt.
The front seat has two kinds of seat belts, complex equipment type being an
electronic preload three-point seat belt, and simple equipment type a non-preload
Seat belt three-point seat belt. Advanced configuration uses the electronic preload three-point
seat belt, while simple configuration uses the non-preloaded three-point seat belt.
The rear seat belt uses a normal three-point seat belt.
Left and right sun visors both have cosmetic mirrors, and the sun visors can be
Sun visor rotated up and down and from side to side, the up and down rotation can be held at
any position.
Front and rear
Bumper assembly can withstand collision speeds of 8 km/h.
bumper
Equipped with front and rear wiper, one 5th gear thrust washer reservoir, two motors,
Washer two sets of pipelines in the front and rear, two washing nozzles with one in the front,
and the other in the back.

Air Conditioning System Structure and Parameters

Item Structure and parameters
Structure type Vapor compression refrigeration, water warmer, and water heater
Air conditioner refrigerating capacity is 5 kW. Blower's air volume is 450 m 3/h. Air
Performance parameters
conditioner heating capacity is 4.5 kW.
Control panel knob, button, manual shift lever control, position gate and temperature
threshold cable drive, new damper micro-motor drive, able to select and adjust air
Controls
outlet position, heating/cooling mode, air inner/outer circulation mode and wind speed,
temperature, and more advanced selections and adjustables.
Refrigerant R134a, 510±10g
Compressor Model number: JSS-96TV4-4
Advective and subcooling structure with flat tube thickness of 16 mm and dry reservoir
Condenser
Φ34 mm × L280 mm.
Heating, Ventilating and Air Conditioning (HVAC): Of a three-box type consisting of
Heating, Ventilating
a layered evaporator, advective heater, H-shaped expansion valve, centrifugal blower,
and Air Conditioning
and air outlet distributing box. Contains cooling, heating, defrosting and air freshening
(HVAC)
functions, and operated by a link mechanism driving air valve.
Refrigeration line & Refrigeration line: a compound structure using a rubber cooling pipe and an aluminum
water heating tube pipe. Water heating pipe: molded rubber pipe.
Sensors Evaporator temperature sensor
Pressure switch High/Mid/Low three position pressure switch
Electrical System Structure and Parameters

Power, start Circuit Single wire system, voltage of DC12 V, negative ground
up, and Battery 12 V/60 Ah, maintenance-free battery
electronic
charging Starter 1.2 kW
system Alternator 14 V/90 A
2 white (high beam 55 W, low beam 60 W) H4, height is electrically
Headlight
adjustable.
Parking lamp 2 front parking lamp: white, 5 W. 2 rear parking lamp: red, 5W
Amber colored. 21W, 2 in the front and 21W, 2 in the back. Turn signal
Turn signal lamp
lamps: 0.3W, 4 LED.
Fog lamp 2 front fog lamps: 55W. 2 rear fog lamps: 7.5 W
Brake lamp 2 red 21 W. high mounted brake lamps 3 W
Lighting and License plate lamp 2 white 5 W
signaling Reverse lamp 2 white 21 W
system
Hazard warning signal
All turn signal lamps and switch controls
lamp
Rear reflectors Red and non-triangular, inside the rear combination lamps.
Front reading lamp: one white 10 W or one white 10 W, two 5 W (with
Front reading lamp &
sunroof).
interior dome lamp
Interior dome lamp: White, 10 W.
Cigarette lighter
Blue, 3 W, one
lighting

Electrical System Structure and Parameters (Continued)

Speedometer, tachometer, odometer, fuel gauge, LCD (electronic clock &
Combination meter
reserved automatic gear indication).
Driver's seat belt unfastened warning lamp, charging indicator lamp, low
oil pressure warning lamp, service engine light, ABS malfunction indicator
Dashboard lamp, EBD indicator lamp, EOBD indicator lamp, door unlock warning
system lamp, SRS malfunction indicator lamp, high beam indicator lamp, left
Indicator lamp turn signal lamp, right turn signal lamp, parking brake indicator lamp,
brake malfunction warning indicator lamp, front fog lamp indicator, back
fog lamp indicator, fuel warning lamp, engine cooling water high/low
temperature indicator lamp, engine preheating indicator lamp, oil/water
separator indicator lamp, O/D indicator lamp.
Overhead antenna & interior lighting adjustment switch control.
Front wiper: inching, high speed, low speed, and clearance gear with time
Windshield system slot adjustment, with reset.
Rear wiper: normal gear with reset.
Defog & defrost device Rear wiper uses an electrical heated tempered glass with switch control.
Driver's side has the master control, other doors and windows are
Power window
independent (left and right front doors are both with door lock controlling
regulator
switches), with anti-pinch and automatic closing.
Remote central door lock (controlled from the front left door), rear doors
Central door lock
Auxiliary containing children protector.
electrical Backup power supply 12 V, 120 W, one
system Single CD, audio input interface
Multidisc DVD (optional)
Stereo equipment
There are 4 speakers in the standard configuration, 6 in the luxury and elite
configuration.
Cigarette lighter 12 V, 120 W, with lighting, one
Horn High/low disc type horn
Comfort type uses a driver side electronic airbag
Airbag Luxury type and elite type uses driver and front passenger electronic
double airbags
Engine With immobilizer system

Grade Specification and Filled Quantity of Each Individual Functioning

Component's Working Agent
Functioning Quantity
No. Specifications
component GW413EF GW4G15
#93 and above high quality unleaded gasoline (GW413EF,
1 Engine fuel 45L GW4G15 engine)
#-10 light diesel fuel (YC4W75-31 engine)
SJ 15W-40/SJ 10W-30
GW413EF (For China domestic model)
Engine SL 5W-30 (For alpine region model)
2 3.25±0.25 L 3.5L
lubricant SJ 20W-40/SJ 10W-30 (For domestic &
GW4G15 exported high-temperature region model)
SL 10W-30 (For alpine region model)
Ethylene-Glycol-35oC antifreeze fluid
(For China domestic model)
3 Coolant 5.5±0.5 L 5.4±0.5 L
Ethylene-Glycol-45oC antifreeze fluid
(For alpine region model)
4 Clutch fluid 0.49±0.02 L 0.72±0.02 L DOT4 synthetic brake fluid
GL-4 80W-90 (For China domestic model)
Transmission
5 1.9±0.1 L 1.8L GL-4 75W-90 (For alpine region model)
lubricant
GL-5 140 (For high-temperature region model)
Power steering
6 0.65±0.02 L 0.75±0.02 L ATF DEXRONⅢ Mobil fluid
fluid
7 Brake fluid 0.49±0.02 L DOT4 synthetic brake fluid
Battery
8 1.0 g Industrial vaseline
terminal
Room temperature: use clean water with a hardness less
Windshield than 205g/1000 kg.
9 2.8±0.1 L
washer fluid Low temperature (-18 oC±3 oC): use methanol-water
solution concentration of 50%.
Air conditioner
10 510±10 g R134a
refrigerant
Torque Specifications for Key Operational Bolts

Any part that has a tightening torque requirement for fastening piece connections should be fastened according
to specifications, the tightening torque of fastening pieces that have no tightening torque specification should
satisfy the QC/T 518—1999 regulations.
Tightening torque for key operational bolts are shown in the table below.
Tightening
Fastening piece name
No. Important fastening piece locations Quantity torque
and model number
(N·m)
1 Chassis
Left mount & left side member Hexagon bolt for flange face 1 112±10
1.01
Left mount & left mounting bracket Hexagon bolt for flange face 2 64±5
Left mounting bracket & transmission Hexagon bolt for flange face 3 64±5
1.02
Right mount & engine Hexagon nut for flange face 1 41±4
Right mount & engine Hexagon bolt for flange face 2 64±5
1.03
Right mount & vehicle body Hexagon bolt for flange face 2 64±5

Tightening
and model number
(N·m)
Right mount & vehicle body Hexagon bolt for flange face 1 64±5
1.04
Right mount & transmission Hexagon bolt for flange face 1 64±5
Right mount & transmission Hexagon bolt for flange face 2 64±5
1.05
Rear mount & rear mounting bracket Hexagon bolt for flange face 1 64±5
Hexagon bolt for flange face
1.06 Rear mount & subframe 1 64±5
(M10 × 1.25 × 70)
1.07 Rear mount & subframe Hexagon nut for flange face (M10 × 1.25) 2 64±5
Hexagon head bolt and flat washer
1.08 Fuel tank & rail 4 35±3
subassembly
Hexagon head bolt, spring washer and flat
1.09 Fuel filler pipe & vehicle body 1 47±3
washer subassembly
1.10 Accelerator pedal & vehicle body Hexagon nut for flange face 3 9±2
1.11 Fuel filter bracket & tank 3 9±2
subassembly
1.12 Fuel pump install panel & tank 8 4±1
subassembly
Fuel filler pipe assembly & vehicle Hexagon head bolt and spring washer
1.13 1 9±2
body subassembly
Hexagon head bolt and spring washer
1.14 Air filter bracket & vehicle body 2 9±2
subassembly
1.15 Air filter & air filter bracket 3 9±2
subassembly
1.16 Exhaust pipe rear protection support Hexagon bolt for flange face 2 23±3
Between the front muffler and catalytic
1.17 Hexagon bolt for flange face 2 64±5
convertor
Connections between the front exhaust
1.18 pipe and catalytic convertor, front & Bolt (M10 × 1.25) 4 64±5
rear muffler flanges
Connections between the front exhaust
1.19 Air intake and exhaust nut components 2 64±5
pipe & engine exhaust manifold
1.20 Front, central, and rear heat shield 5 9±2
washer subassembly
1.21 Front heat shield Hexagon nut for flange face 1 9±2
1.22 Fan with overflow tank assembly 3 9±2
subassembly
1.23 Clutch pedal & clutch master cylinder Nut (M8) 2 21±5
1.24 Clutch pedal & beam Hexagon bolt for flange face 1 23±3
Mounting bolts on the bracket connected
1.25 the rigid pipe of the clutch master cylinder 1 9±2
subassembly
and hose
Connected the rigid pipe bracket of
1.26 Hexagon head bolt 3 23±3
clutch slave cylinders & bolts
Transmission control mechanism Hexagon head bolt and flat washer
1.27 4 20±2
assembly & floor subassembly
Transmission control cable assembly Hexagon head bolt and flat washer
1.28 1 9±2
bracket mounting bolt subassembly
Transmission control cable fixed plate Hexagon head bolt and flat washer
1.29 2 9±2
mounting bolt subassembly
Transmission control cable assembly
1.30 Hexagon nut for flange face 1 9±2
bracket & vehicle body

Tightening
and model number
(N·m)
1.31 Propeller shaft assembly Front drive shaft nut (M22 × 1.5) 2 240±20
Hexagon bolt for flange face and flat
1.32 Subframe & vehicle body (rear) 2 116±10
washer subassembly
Hexagon bolt for flange face and flat
1.33 Subframe & vehicle body (front) 2 70±5
washer subassembly
1.34 Subframe strut bar & vehicle body 4 47±5
subassembly
1.35 Swing arm & steering knuckle Swing arm ball end nut (M12 × 1.25) 2 98±10
1.36 Swing arm & subframe Hexagon nut for flange face (M12 × 1.25) 2 \
1.37 Swing arm & subframe 2 136±10
subassembly
1.38 Swing arm & subframe 2 107±10
subassembly
1.39 Front shock absorber & vehicle body Hexagon nut for flange face (M8) 6 39±4
1.40 Front shock absorber & steering knuckle Hexagon bolt for flange face (M14 × 1.5) 4 \
1.41 Front shock absorber & steering knuckle Hexagon nut for flange face 4 132±10
1.42 Front stablizer bar bracket & frame 4 23±3
subassembly
1.43 Hanger rod, swing arm & stablizer bar Type 2 non-metal insert lock nut 2 23±3
1.44 Trailing arm spindle sleeve assembly 2 82±5
subassembly
1.45 Rear shock absorber support shaft Hexagon nut for flange face 2 49±5
1.46 Rear shock absorber components I type hexagon nut 4 64±5
1.47 Hub Wheel nut (M12 × 1.25) 16 103±10
Steering wheel & steering column
1.48 Hexagon nut for flange face 1 50±4
mounting nut
1.49 Steering column & beam mounting bolt Hexagon bolt for flange face 1 23±3
1.50 Steering column & beam mounting bolt 2 23±3
subassembly
Steering pump adjustable bracket &
engine mounting bolt
Powr steering pump & bracket mounting
bolt
Steering pump mounting bracket
&engine mounting bolt
Steering gear & subframe mounting Hexagon head bolt and flat washer
1.54 2 107±7
bolt subassembly (M12 × 1.25 × 80)
Steering gear & subframe mounting Hexagon head bolt and flat washer
1.55 2 107±7
bolt subassembly (M13 × 1.25 × 100)
Steering gear & steering knuckle
1.56 Hexagon castle thin-nut 2 50±10
mounting nut
Steering protection plate & subframe
mounting bolt
1.58 ABS sensor & steering knackle 2 9±2
subassembly
1.59 Rear brake & rear axle Bolt: for installing brake 8 50±5
1.60 Brake pedal & booster Nut 4 23±3

Tightening
and model number
(N·m)
ABS sensor front wire harness & front Hexagon head bolt and flat washer
1.61 2 23±3
shock absorber subassembly
1.62 ABS & vehicle body 3 23±2
subassembly
1.63 Parking brake cable & vehicle body 6 9±2
subassembly
1.64 Parking brake cable & rear brake 2 9±2
subassembly
ABS sensor rear wire harness, vehicle Hexagon head bolt and spring washer
1.65 6 9±2
body & rear brake subassembly
Parking brake fixed cable braket & Hexagon head bolt and spring washer
1.66 1 9±2
vehicle body subassembly
ABS sensor front wire harness & vehicle Hexagon head bolt, spring washer and flat
1.67 2 9±2
body washer subassembly
1.68 Parking brake control mechanism 2 23±3
washer subassembly
Rear brake pipe connector & vehicle
body
1.70 Seven-hole tube clamp & vehicle body Hexagon bolt for flange face 1 9±2
1.71 Brake pedal & vehicle body Hexagon bolt for flange face 1 23±3
1.72 Brake cable & rear axle Hexagon nut for flange face 2 9±2
1.73 All of the brake line connectors M10 16±2
1.74 All of the brake line connectors M12 16±2
2 Vehicle body
2.1 Connected seat belt Front seat belt upper mounting bolt (7/16) 2 42±5
2.2 Connected seat belt Seat belt lower mounting bolt (7/16) 4 38±5
2.3 Connected seat belt retractor Front seat belt retractor lower bolt (7/16) 2 38±5
2.4 Connected seat belt retractor Hexagon bolt for flange face 2 9±3
2.5 Connected seat belt Rear seat belt upper mounting bolt (7/16) 2 38±5
2.6 Connected seat belt retractor Rear seat belt retractor bolt (7/16) 2 38±5
Mounting bolts on the middle seat belt
2.7 Connected seat belt 1 38±5
(7/16)
2.8 Connected front seat belt mortise lock Front seat belt mortise lock bolt (7/16) 2 60±5
2.9 Connected rear seat belt lock Rear seat belt lock bolt (7/16) 2 38±5
3 Air conditioner
Hexagon bolt for flange face Q1841030FD
3.1 Compressor bracket & engine 4 64±5
(M10 × 1.25)
Hexagon bolt for flange face-oversize
3.2 Comperssor bracket & compressor 4 23±3
Q1860890FD
3.3 Condensor fan mounting bolt 1 9±2
subassembly Q1400630 (Q402) F32
3.4 Condensor mounting bolt Hexagon bolt for flange face 2 23±3
Compressor suction hose & HVAC
3.5 Hexagon bolt for flange face Q1460640F32 1 9±2
refrigeration line port
Air conditioner hose, compressor, and
3.6 Hexagon bolt for flange face Q1840625F32 4 9±2
condenser coupling bolt
3.7 Expansion valve & HVAC refrigeration line port Hexagon bolt for flange face Q1840630F32 2 9±2

Vehicle Body's Basic Calibration Measurements

This section shows the basic parameters of the overall vehicle. Please refer to this section when servicing or
repairing.
• All figures used to express measurements are actual figures.
• Measuring points are taken from the center of the mounting holes.
• When using the gauge, adjust the two measuring needles until they reach an equal length, then check
the measuring needle and the gauge itself to ensure there are no gaps.
• When using measuring tape, make sure not to stretch, twist, or bend it.
• The asterisk (*) symbol after a numerical measurement value indicates that the other side's
symmetrical position is of equal value.
• Coordinates of the measuring points refer to the distances measured between the point and "X", "Y",
and "Z" standard lines.
• The left & right symmetry points of a measuring point's coordinate represent a coordinate point on the
left side, and that the right and left side are symmetrical.
Imaginary
reference line
Vehicle center line
Front wheel center line
"Z" represents the imaginary

reference line [below reference
line ("OZ" line of the design
diagram) 400 mm]

Engine Compartment
Mark Axis (X, Y, Z) Diameter (mm) Mark Axis (X, Y, Z) Diameter (mm)
A (115.2, 0.4, 701.5) Ф10 B (-461.2, -447.6, 627.7) Ф8
C (56.5, -520.3, 698.8) Ф11 D (-143.9, -645.9, 690.9) Ф8
E (-506.2, -45.0, 679.1) Ф9 F (-52.3, -681.0, 725.3) Ф10
G (-606.8, -464.3, 290.6) Ф8.5 H (-548.7, -403.6, 359.8) Ф8
J (-188.4, 467.5, 387.9) Ф13 K (-319.0, -425.0, 327.5) Ф14

Chassis
LH
side
Upper Lower
Front
Front
Unit: mm

Chassis (Continued)
Axis Axis
Ф
LH
side
Ф
Ф
Ф
Front
Unit: mm

Subframe
1195±1.5 ( Distance between the center points of both shaft's end surfaces )
1381±0.5 ( Distance between points P and Q )
Unit: mm

Left side panel
Mark Name Diameter (mm) Mark Name Diameter (mm)

A Front door lower hinge mounting via hole Φ13 E Process cut
B Rear door upper hinge mounting via hole Φ15 F Process cut
C Front door upper hinge mounting via hole Φ13 G Process cut
D Front door contact switch via hole Φ19 H Process cut
I Rear door lower hinge mounting via hole Φ15 J Rear door contact switch via hole (location Φ19
hole)
Right side panel

A Front door wire harness via hole (location Φ38 E Process cut
hole)
B Rear door lower hinge mounting via hole Φ15 F Process cut
C Front door upper hinge mounting via hole Φ13 G Rear door lower hinge mounting via hole Φ15
D Front door contact switch via hole Φ19 H Rear door contact switch via hole (location Φ19
hole)
I Process cut J Process cut

Windshield

A Central defroster air duct mounting holes Φ11 B Process cut Oblong hole 7×12
C Central defroster air duct mounting holes Φ8 D Process cut Oblong hole 7×12
Trunk door frame

A Left D column inner decoration board B Right D column inner decoration board
laps over R angle laps over R angle
C Left combination taillight install panel D Right combination taillight install panel
connecting plate laps over R angle connecting plate laps over R angle

Fuel Supply and Exhaust System 29
Fuel Supply and Exhaust System
Fuel Supply System............................................................ 30

Components...................................................................... 30
Fuel Tank Removal............................................................ 31
Fuel Pump and Charcoal Canister Removal..................... 31
Fuel Filter Removal........................................................... 31
Fuel Filler Pipe Assembly Removal................................... 32
Exhaust System.................................................................. 33
Components...................................................................... 33
Exhaust System Removal................................................. 34
Exhaust System Installation.............................................. 35

Fuel Supply System

Components
Single-hole clamp Desorption hose III

Fuel filler hose III
Canister solenoid valve
Canister solenoid valve installation sheath
Canister solenoid valve mounting bracket assembly
Desorption hose II
Fuel hose sheath
Fuel filler hose

Desorption fuel hose
Desorption hose I
Fuel filler hose II Three-hole

clamp I
Fuel filter mounting bracket
assembly
Fuel filter
Fuel filler cap Electronic fuel pump Electronic fuel pump install panel
Single-hole clamp
Charcoal canister
Fuel filler hose I
Fuel filler pipe sleeve

Absorption hose
Fuel filler pipe assembly
Strengthening cushion
Fuel filler pipe Fuel tank assembly

connecting hose
Fuel tank heat shield

assembly
Air return hose Charcoal canister air pipe
Rear install buckle of fuel tank's heat shield

Fuel tank assembly Fuel Tank Removal

Special note: When maintenance of the fuel supply
Strengthening system requires removal of the fuel line, the pressure
cushion of the fuel system should first be released, so as to
Q1400835FD
avoid the spraying of high-pressure fuel.
Heat shield
(Q402) front install 1. Pull out the electrical connector of the fuel pump on the
buckle top of the fuel tank.
Heat shield rear
install buckle 2. Pull out the quick connectors of fuel filler hose II and
Fuel tank heat the inlet rigid pipe, as well as desorption hose I and
shield assembly the desorption rigid pipe. Afterwards, use a cotton cloth
to block the mouthpiece to avoid the spraying of high-
pressure fuel.
3. Remove the fuel filler pipe connecting hose, air pipe,
Q673B20 Q673B20 and air return hose (two attachment clips and one
Fuel filler pipe
connecting hose clamp) at the rear of the fuel tank.
4. Use specified torque of 26±3 N·m to remove the four
bolts and the strengthening cushion.
Q1461025
Q67639 Q67639
Fuel filler pipe
assembly Air return hose
Fuel Pump and Charcoal Canister Removal

1. Assembly removal
(a) Remove the pipeline connected to the fuel pump.
(b) Clean any accumulated dirt from the flange of the fuel
pump.
(c) Starting diagonally, use a wrench to successively
remove the small bolts on the install panel of the fuel
pump in diagnostic mode.
(d) Pay careful attention not to damage the fuel level
sensor when taking the assembly out from the fuel
tank.
2. Assembly installation
Desorption hose II Q1400508F3 (a) Carefully install the fuel pump and charcoal canister
assembly, as well as the oil level sensor, ensuring they
will not be damaged.
(b) Ensure that the port of the pipeline between the fuel
Fuel filler hose II pump and charcoal canister is correct.
Charcoal (c) Install the weatherstrip and install panel using specified
canister torque of 3-4 N·m to tighten the bolts.
Fuel filler hose I
Fuel pump and oil level
sensor assembly
Fuel filler hose I Fuel Filter Removal

1400616F3
1. Pull out the two quick connectors which connect to the
fuel filter.
2. Loosen the bolts on the fuel filter mounting bracket in
order to take out the filter. The entire filter should be
1400616F3 replaced.
Fuel filter
Fuel filler hose II
Fuel filter mounting
bracket assembly

Fuel Filler Pipe Assembly Removal

Fuel filler cap
1. Remove the oil filler cap.
2. Screw off the fixed bolts connecting the fuel filler pipe
assembly bracket and vehicle body.
Fuel filler pipe sleeve
3. Remove the attachment clips and clamps from the

Q673B20 Q673B20 fuel filler pipe connecting hose, air return hose, and air
Fuel filler pipe pipe.
connecting hose 4. Remove the fuel filler pipe sleeve.
Q1461025
Q67639 Q67639
Air return hose

Exhaust System
Components
Exhaust manifold
Gasket I
Exhaust pipe front joint
Front heat shield
Sealing
Air intake and exhaust ring
nut components
Bolt
Q1460612
Spring
Hexagon flange nut
Rear three-way catalytic Gasket II

converter assembly
Hexagon flange bolt
Middle heat shield
Q1460612 Spring bolt
Front exhaust hanger
Exhaust pipe rear

protection support
Sub-muffler assembly
Q1840816
Rear heat shield
Rear exhaust hanger
Q1460612
Main muffler assembly

Exhaust System Removal

Caution: Wait at least 30 minutes between the engine
being turned off and the actual removal of any component
of the exhaust system, as to avoid personnel injury due to
hot components.
1. Main muffler assembly removal
(a) First use a No. 13 wrench (open), sleeve, or ratchet
spanner to remove the connecting spring bolt between
the front flange of the main muffler assembly and the
rear flange of the sub-muffler. Then take out the gasket
between the flanges.
(b) Remove the two rubber hangers on the main muffler.
(c) Take down the main muffler assembly.
Caution: The sealing ring between the front flange of
the main muffler assembly and the rear flange of the
sub-muffler is used only for sealing. If reused, it may
cause large deformations and result in a poor sealing
effect. Accordingly, it is suggested not to use a sealing
ring repeatedly. If necessary, only one repetition should
be allowed.
Warning: While performing this kind of maintenance
work, a person should be present to support the main
muffler to avoid injury in case the muffler falls.
2. Sub-muffler assembly removal

(a) Use a No. 14 wrench (open), sleeve, or ratchet wrench
to remove the connecting bolt between the front flange
of the sub-muffler assembly and the rear flange of the
catalyst assembly.
(b) Remove the support of the sub-muffler plate bracket.
(c) Remove the two two-hole rubber hangers between the
sub-muffler and the frame.
(d) Take down the sub-muffler assembly.
Caution: The sealing ring between the front flange of
the sub-muffler and the rear flange of the catalyst as-
sembly is used only for sealing. If reused, it may cause
large deformations and result in a poor sealing effect.
Accordingly, it is suggested not to use a sealing ring
repeatedly. If necessary, only one repetition should be
allowed.
Warning: While performing this kind of maintenance
work, a person should be present to support the sub-
muffler to avoid injury in case the muffler falls.
3. Rear catalytic assembly removal

(a) Remove the connecting spring bolt between the front
flange of the sub-muffler assembly and the rear flange
of the rear catalytic assembly. Then take out the sealing
ring between the flanges.
(b) Take off the rear catalytic assembly.

4. Front exhaust pipe removal

(a) Use a No. 14 wrench (open), sleeve, or ratchet wrench
to remove the connecting nut between the front flange
of the front exhaust pipe assembly and the flange of the
exhaust manifold. Then take out the gasket between the
flanges.
(b) Carefully remove the front exhaust pipe from the
subframe.
Caution: The gasket between the front flange of the
front exhaust pipe and the flange of the exhaust
manifold are used only for sealing. If reused, they may
cause large deformations and result in a poor sealing
effect. Accordingly, it is suggested not to use the
sealing ring repeatedly.
Exhaust System Installation

1. The clearance between the exhaust pipe assembly and
both sides of the individual components should be no
less than 15 mm.
2. Before installing rubber hangers, coat a proper amount
of silicon oil in holes. After installation, even force
should be applied.
3. After installing the center exhaust pipe with the three-
way catalytic converter assembly, ensure the plug of
the oxygen sensor is well connected.

Clutch Operational System
Areas of Importance............................................................ 37
Troubleshooting................................................................... 37
Clutch Operational System.................................................. 38
Components...................................................................... 38
Clutch Master Cylinder Removal....................................... 38
Clutch Master Cylinder Installation.................................... 40
Clutch Pedal Removal....................................................... 40
Clutch Pedal Installation.................................................... 40
Clutch Pedal Examination and Adjustment....................... 41

Clutch Operational System 37
Areas of Importance
1. Clutch Rigid Pipe Installation
Before installing, check to make sure that the rigid pipe flare contact area is in good condition, the pipeline is
clean, and that there is no foreign materials.
2. Clutch Hose Installation
Check the surface of the clutch hose to make sure that there is no scuffing and that the pipeline is clean.
3. Coat grease on the U-joint of the pedal and the master cylinder.
4. Strictly adhere to the set torque guidelines when tightening the pipe fittings.
Rigid pipe and the master cylinder: M10 16±2 N·m
Clutch rigid pipe and hose: M10 16±2 N·m
5. While the clutch system is undergoing the exhausting process, make sure that all the air bubbles in
the pipeline are cleared out. Then check the brake fluid level in the reservoir, it should be between
MIN and MAX.
Troubleshooting
The numbers in the table represent the order of the possible malfunction causes, so be sure to check each part in
turn. If necessary, replace the part.
Symptoms Possible Causes

Clutch vibration 1. Engine mounting bracket (loose)
2. Clutch plate (axial runout is too much)
3. Clutch plate (oil build-up)
4. Clutch plate (polished)
5. Clutch plate (hardened)
6. Diaphragm spring (damaged)
Clutch pedal is spongy 1. Clutch pipeline (air entering)
2. Clutch master cylinder cup (damaged)
3. Clutch slave cylinder cup (damaged)
Clutch makes abnormal noise 1. Clutch release bearing (wear and tear, dirty or damaged)
2. Driven plate torsion damper (damaged)
Clutch slips 1. Clutch pedal (free play is out of alignment)
3. Clutch plate (polished)
4. Diaphragm spring (damaged)
5. Pressure plate (deformed)
6. Flywheel (deformed)
Clutch cannot be disengaged 1. Clutch pedal (free play out of alignment)
2. Clutch pipeline (air entering)
3. Clutch master cylinder cup (damaged)
4. Clutch slave cylinder cup (damaged)
5. Clutch plate (axial runout is too much)
6. Clutch plate (wear out from friction)
7. Clutch plate (dirty or burnt)
9. Clutch plate (lack of grease on the spline)

Clutch Operational System

Components
Reservoir
Clutch discharge pipe
Clutch feed connecting hose
Steel band elastic hoop
Limit adjusting bolt
Clutch master cylinder
Return spring
Lock nut
Clutch Master Cylinder Removal

Steel band elastic hoop 1. Use a combination plier to loosen the steel band elastic
hoop, and to remove the clutch feed connecting hose.
Caution: Release the brake fluid in the reservoir before
disconnecting the hose.
Clutch feed connecting hose

2. Remove the driven clutch discharge pipe with a M10

open-end wrench.
Clutch discharge pipe
3. Remove the pedal lock pin.
Pedal lock pin
4. Remove the return spring and the connecting pin.
Connecting pin Return spring
5. Remove the lock nuts of the clutch pedal with a M13

sleeve and an extension bar.
Lock nut
6. Remove the clutch master cylinder.
Clutch master cylinder

Bleed screw
Clutch Master Cylinder Installation
Installation of clutch system is reverse to its removal, but
since the whole clutch system uses hydraulic assistance,
make sure to air bleed it after the installation is completed.
Detailed steps as follows:
(a) Plug one end of the long transparent connection hose
(about 0.5 m long) into the bottom of bleed screw, and
the other end into a fixed container.
(b) Loosen the bleed screw via the open end of the M8,
meanwhile ask the assistant to step on the clutch pedal
repeatedly until no air bubbles can be seen in the hose.
Remark: Residual air in the clutch system has been
completely exhausted.
(c) Lastly, lock the bleed screw.
Caution: Refilling the brake fluid reservoir should be
performed while air bleeding the clutch.
Clutch Pedal Removal

1. Remove the battery's negative cable.
2. Remove the glove box at the left of the dashboard.
3. Remove the cotter pin at the U-joint of the clutch
master cylinder, and separate the center pin and the
pedal lever.
4. Remove the clutch pedal bracket from the cowl.
5. Remove the clutch pedal.
(a) Move the clutch pedal to the maximum stroke position.
(b) Take down the return spring.
(c) Remove the bolts and nuts.
(d) Take the pedal lever down from the pedal bracket.
Clutch Pedal Installation

1. Install the clutch pedal.
(a) Install the return spring.
(b) Install the clutch pedal lever.
(c) Install the bolts and nuts.
Tightening torque: 30 N·m
(d) Put the pedal lever at the maximum stroke position and
connect it with the spring, in order to set the pedal to its
initial position.
2. Install the clutch pedal onto the 2 studs of the clutch
master cylinder.
Use a M13 wrench to tighten the clutch pedal brackets with
two M8 nuts.
Tightening torque: 23±3 N·m
3. Install the clutch master cylinder push rod with the U-
joint.
(a) Coat the contact areas between the center pin and the
U-joint pedal connector with multi-functional grease.
(b) In succession, join the U-joint (pedal connector) and
the clutch pedal lever with a cotter pin.
Caution: Insert the center pin into the pedal lever from
the left side of vehicle.
(c) Install the cotter pin onto the center pin.
4. Check and adjust the clutch pedal.
5. Connect the negative cable of the battery.

Clutch Pedal Examination and Adjustment

1. Check if the pedal height is correct.
Height from the carpet: 100-110 mm
Pedal height
2. Adjust the pedal height.

Loosen the lock nut and adjust the clutch pedal limit adjust-
Limit adjusting bolt ing bolt until its height is correct, and then tighten the lock
nut.
Lock nut
3. Check if the pedal free play is correct.

Step on the pedal until one can feel the resistance.
Pedal free play: 13.7 mm
Free play
4. Adjust the free play.

(a) Loosen the lock nuts of the clutch master cylinder and
rotate the push rod until the pedal reaches the correct
free play.
(b) Tighten the lock nuts.
(c) Recheck the clutch pedal height.
Lock nut

Transmission
037A Transmission’s Overall External Schematics............. 43

Main Technical Parameters ................................................ 43
Transmission's Proper Use and Care.................................. 44
Technical Specifications for Transmission Installation
and Adjustment.................................................................... 44
037A Transmission Structural Schematics.......................... 47
Clutch.................................................................................. 48
Gear Shift Fork and Fork Shaft........................................... 49
Transmission Case.............................................................. 50
Disassembling the Input Shaft Subassembly...................... 56
Disassembling the Output Shaft Subassembly................... 60
Disassembling the Shift Cover Subassembly...................... 64
Disassembling the Differential Subassembly...................... 68

Transmission 43
037A Transmission’s Overall External Schematics

The 037A transmission is a step mechanical transmission with differential, two-shaft front wheel drive
application. The forward gear has adopted the inertia synchronizer gear-shifting mechanism, which offers
smooth and easy gear shifting, reduces noise dramatically, and improves the service life of the gear - important
in achieving the overall economical efficiency. Regarding its control mechanism, the set steel ball and spring
allow the shifting gear to be quick, accurate with solid handling. The 5th gear transmission is equipped with an
interlocking mechanism to prevent accidental switching to reverse, to improve driving comfort and reliability.
Main Technical Parameters

Basic parameters of the 037A transmission
Max. input torque 115 N·m/4400-5200 rpm
Speed ratio for each gear
3.545 1.913 1.310 0.973 0.804 3.214
Main deceleration ratio 3.944
Odometer speed ratio 31/35 (currently no driven gear)
Center distance (mm) 65
Lubricant capacity (L) 1.8
Control method Remote cable control
Netweight (kg) 28
Match engine GW413EF

Transmission's Proper Use and Care

1. Transmission's proper operation
1.1 Shift the gear gently, not excessively.
1.2 Do not start with high speed.
1.3 To avoid premature abrasion of the gear shift fork, do not rest your hand on the gear lever while driving.
2. Model number of the lubricant to be used:
GL-4 80W-90 (For China domestic model)
GL-4 75W-90 (For alpine region model)
GL-5 140 (For high-temperature region model)
Caution: Please only use the lubricant with model numbers specified by the Great Wall Motor Co., Ltd.
Do not mix lubricants with different model numbers. Only fill with clean lubricant.
3. Areas of importance for new vehicle usage:
3.1 Before using a new vehicle, be sure to check the transmission and all exposed connectors and fastening
pieces, so as to avoid failure due to faulty installation or loose connections.
3.2 Since the new vehicle is still in the run-in period, the transmission's lubricant should be replaced after 5000 km
distance.
4. Transmission three-level maintenance:
4.1 Transmission level-one maintenance: During the first level of maintenance, the liquid level of the lubricant
should be checked to ensure that it is up to the oil-filling mouth. Add more if insufficient. Excessive low
oil level can lead to ineffective lubrication, as well as burning of the bearings and gears. Excessive high oil
level, however, can overheat the transmission or cause oil to leak. In addition, during the first level of main-
tenance, the breather plug should be checked and cleaned. If the breather plug is clogged, internal pressure
will build up and oil will leak from the transmission.
4.2 Transmission level-two maintenance: The transmission's lubricant should be replaced the first time that the
vehicle undergoes the second level of maintenance. Clean the transmission with kerosene. The quality of the
lubricant should be inspected during the future second level of maintenance practises. The lubricant should
be replaced if diluted, gummy, or dirty.
4.3 Transmission level-three maintenance: During the third level of maintenance, it should be removed for in-
spection, cleaning, and oil changing.
Technical Specifications for Transmission Installation and Adjustment
Inspect the axial play (δ) between the synchronizer ring and the gear shaft
Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7 0.7-1.7
Check the axial play (δ) between each gear

Gear (δ1) (δ2) (δ3) (δ4) (δ5)
Standard axial play (mm) 0.1-0.4 0.1-0.6 0.1-0.4 0.1-0.6 0.1-0.55

Transmission 45
Thread fastening piece tightening torque table

Tighten-
Use parts Bolt code Specifications Quantity ing torque
(N·m)
Differential case × differential ring gear 037-2303309 M12 × 1.0 6 123.6
Clutch housing × reverse gear arm
037-1702073 M8 × 1.25 2 17.2
bracket subassembly
No. 1 gear shift fork shaft × No. 1 gear
037-1702056 M6 × 0.75 1 15.7
shift fork
No. 2 gear shift fork shaft × No. 2 gear
037-1702056 M6 × 0.75 1 15.7
shift fork
Transmission case × clutch housing 037-1701012 M8 × 1.25 13 29.4
Transmission case × manipulation lid
037-1702051 M8 × 1.25 4 12.0
subassembly
Transmission case × position mechanism
037-1702042 M18 × 1.5 1 36.8
component
Transmission case × reverse gear idler
037-1701404 M8 × 1.25 1 29.4
shaft × sealing ring
Transmission case × hexagon head plug 037-1701016 M18 × 1.5 2 39.2
Transmission case × reverse gear switch
037-1701022 M18 × 1.5 1 40.2
subassembly
Transmission case × cable bracket 037-1701019 M8 × 1.25 4 11.3
Clutch housing × clutch slave cylinder
037-1601019 M8 × 1.25 2 11.3
subassembly
Select lever assembly × gear shifting
037-1702027 M8 × 1.25 1 38.0
block
Clutch housing × release fork support
037-1601011 M10 × 1.25 1 36.8
nail
Counterweight component × shift lever
037-1702030 M8 × 1.25 2 20.0
component
Release fork support nail 1 29.4
Areas of Importance
Removal
During removal, all components should be gently handled to avoid knocking, especially the joint surface.
All components should be placed in the proper order to avoid misplacing and mistaking.
Installation
1. Clean all parts before installation (except rubber pieces and gaskets).
2. All oil seals, shaft retainers, and elastic pins should not be reused.
3. All rubbing surfaces should be coated with lubricant, and the lips of all oil seals should be coated with
grease.
4. During installation of the bearings, do not use any kind of rolling element to transmit pressure, and
make sure not to tilt it.
5. During the installation of synchronizer components, the two sides of the spring piston's openings
should alternate.
6. When the transmission is operating under normal working conditions, there should be no lubricant
leakage from any of the parts.
Transportation and storage
1. When transporting a transmission, make sure the conditions are dustproof and rainproof, as well as
take proper care not to damage it due to jolting, shaking, removal, or installation.
2. Transmission assembly should be stored in a ventilated, dustproof, and dry place.
3. Users with special transportation or storage requirements should have another discussion to reach an
agreement on this matter in the supply contract.

Troubleshooting
Common problems Possible causes Solving methods
Difficult gear Not applying clutch Use correct driving methods
engagement Insufficient clutch separation Inspection & adjustment
Serious abrasion of the synchronizer ring Replace component
Positioning spring is too hard Replace component
Noise is too loud or Oil level is too low Fill oil to the specified level
abnormal Lubricant is of poor quality Replace the specified oil
Untimely oil changes Replace oil and damaged part
Improper gear axial position and clearance Inspect and adjust
Damaged bearing Replace component

Gear has a burr or has been knocked Repair or replace gear
Oil leakage Too much oil is added, oil level too high. Fill the oil level to the specified position.
Reassemble and screw in according to regu-
Bolt loose or missing
lations.
Breather plug fails Replace
Damaged seal Replace
Synchronizer is damaged Excessive gear shifting force Replace synchronizer
Not applying clutch Use correct driving methods
Synchronizer's spring expan-
Replace
sion ring is damaged
Gear disengagement Control mechanism malfunction Inspect and adjust
Retaining spring or steel ball missing Additional assembly
Retaining spring malfunction Replace
Fork groove of the gear sleeve is worn out Replace
Shifting fork is worn out. Replace
Bearing and gear are burnt Oil level is too low Replace part and fill oil
Lubricant is of poor quality. Replace part and lubricant
Untimely oil replacement causes
Replace part and lubricant
the oil to be too dirty
Mixed use of different oils
Replace part and lubricant
or use of additives
Difficulty shifting gears Synchronizer spring malfunction Replace
The internal groove of the syn-
Replace
chronizer ring is worn out
The synchronizer ring is seized
Replace
into the conical surface
Deformed shifting fork or
Replace
shifting fork shaft
Shifting fork is worn out Replace

Transmission 47
037A Transmission Structural Schematics
1
2
3
4
5 9
6 10
7 11
8 12
76 13
75 14
74 15
73 16
17
72 18
71 19
70 20
21
22
69 23
68 24
67 25
66 26
65
64
63
27
28
29
62 30
31
61 32
60 33
59
58
57
56
55 34
54 35
53 36
52 37
38
51 39
50 40
49 41
48 42
47 46
45
44
43
1. No. 2 gear sleeve 2. Shaft retainer 3. No. 2 Slider (3) 4. Spring expansion ring (2) 5. No. 2 gear hub 6. 3rd gear synchronizer ring
7. 3rd gear gear assembly 8. Needle bearing 9. With washer bolt 10. Clutch slave cylinder subassembly 11. Release fork protective
cover 12. Release fork spring 13. Bolt for flange face (3) 14. Release fork 15. Clutch housing 16. Release fork support nail 17. Ball
bearing 18. 2nd gear synchronizer ring 19. T oil seal 20. No. 1 gear sleeve 21. No. 1 Slider 22. 1st gear synchronizer ring 23. 1st gear
gear components 24. Needle bearing 25. Release bearing subassembly 26. Tapered roller bearing 27. Guide nozzle 28. 2nd gear gear
assembly 29. No. 1 gear hub 30. Spring expansion ring (2) 31. Bolt for flange face (6) 32. Straight pin 33. Odometer driver 34. T oil
seal 35. Tapered roller bearing 36. Adjusting shim (2) 37. Axle shaft gear (2) 38. Planetary gear (2) 39. Gasket (2) 40. Differential
case 41. Planetary gear shaft 42. Differential ring gear 43. Bolt for flange face (8) 44. Tapered roller bearing 45. Adjusting shim 46.
T oil seal 47. Shaft retainer 48. Retaining ring 49. Needle bearing 50. 3rd driven gear 51. Spacer 52. 4th driven gear 53. 5th driven
gear 54. Shaft retainers 55. Tapered roller bearing 56. Adjusting shim 57. Output shaft 58. 5th gear gear assembly 59. Shaft retainer
60. Retaining ring 61. Spring expansion ring (2) 62. Needle bearing 63. Input shaft 64. Adjusting shim 65. Ball bearing 66. 3rd gear
gear hub 67. 3rd gear Slider (3) 68. 3rd gear gear sleeve 69. 5th gear synchronizer ring 70. Steel ball 71. 5th gear thrust washer 72.
Needle bearing 73. 4th gear components 74. Retaining ring 75. 4th gear synchronizer ring 76. Transmission case

Clutch
Components
Release bearing
Cable bracket
Release fork
Bolts with
washer
×5
11.3
Cable bracket
Release fork support nail
29.4
Bolts with washer

11.3
Release fork dust cover
Differential assembly
Clutch housing Magnetic body
Guide nozzle
Tapered roller
bearings
T oil seal
Output shaft assembly
Input shaft assembly

Transmission 49
Gear Shift Fork and Fork Shaft

Components
Clutch housing
No. 1 gear shift fork shaft
Shaft retainers
Set bolt 15.7
Elastic
cylindrical pin
No. 1 gear shift fork

Shaft
retainers
Elastic
cylindrical pin
Lock pin No. 1
guide block
Pressure spring
No. 3 gear shift
Reverse gear fork shaft
gear shift fork No. 3 guide block Lock pin
No. 2 gear shift fork shaft
No. 3 gear shift fork
Shaft retainers Set bolt
Bracket bolt 15.7

17.2
Shaft retainers
Reverse gear arm No. 2 gear shift fork

bracket assembly
Reverse gear
idler assembly
Reverse gear
idler shaft Output shaft assembly
Bolt for flange face
29.4
Gasket
Input shaft assembly

Transmission Case
Components
Bolt for flange face 12.0
Clip
Clip
Clip
Shift lever assembly Reverse gear

switch subassembly
Pressure torsion spring Washer
Oil drain slot
Tapered roller bearings

Bush
Adjusting shim
Adjusting shim Transmission case
Position mechanism
assembly
36.8 39.2
Hexagon head plug
Hexagon head plug

39.2 Washer Washer
Bolt for flange face ×8

N·m : Specified torque 29.4

Transmission 51
Shift System Removal

1. Remove 4 bolts for flange face from the manipulation
lid.
2. Remove the set bolts from the sides of the transmis-

sion case.
3. Separate the clutch housing and the transmission

case.
(a) Remove 8 bolts for flange face from the transmission
case and clutch housing.
(b) Remove 5 bolts for flange face from the clutch housing
and transmission case.
(c) Pound the housing's protruding parts with a soft ham-
mer to remove the transmission case.
4. Remove the reverse gear idler shaft and the reverse

gear idler assembly.

5. Remove the reverse gear arm bracket assembly.
6. Remove the No. 1 gear shift fork shaft and the set
bolts.
7. Remove the elastic cylindrical pin from the No. 1 guide

block.
8. Remove the No. 1 gear shift fork, No. 1 gear shift fork
shaft, and No. 1 guide block.

Transmission 53
9. Remove the elastic cylindrical pin from the No. 3 gear

shift fork.
10. Remove the elastic cylindrical pin from the No. 3 guide
block.
11. Remove the No. 3 gear shift fork, compression spring,

and No. 3 guide block.
12. Remove the set bolts from the No. 2 gear shift fork
shaft.

13. Remove the No. 2 gear shift fork shaft, No. 2 gear shift
fork, and No. 2 guide block.
14. Remove the input and output shaft subassembly.
15. Remove the differential subassembly.
16. Remove the magnetic body from the inside of the

clutch housing.

Transmission 55
17. Remove the oil drain slot from the inside of the transmis-
sion case.
18. Remove the T oil seal with a screwdriver from the

clutch housing.
19. Remove the release fork and the release bearing from
the clutch housing.
20. Remove the set bolts of the release fork from the
clutch housing.

Disassembling the Input Shaft Subassembly

Components
Needle bearing 4th gear subassembly
Rear ball bearing 4th gear synchronizer ring
Retaining ring
Spring expansion
ring Shaft retainer
Spring expansion ring

No. 3 Slider
No. 3 gear sleeve/
No. 3 gear hub
No. 2 gear sleeve/No. 2
gear hub
5th gear
synchronizer ring No. 2 Slider
Spring expansion
ring
5th gear gear
subassembly Needle bearing 3rd gear
synchronizer ring
Retaining ring
3rd gear gear subassembly

Shaft retainer
Input shaft Needle bearing
Steel ball
Front ball bearing
5th gear thrust washer
1. Remove the input shaft's ball bearing.

Transmission 57
2. Remove each component from the 3rd synchronizer.
3. Remove the 5th gear needle bearing.
4. Remove the retaining ring.
5. Remove the shaft retainer.

6. Remove the input shaft's 5th gear thrust washer.
7. Remove the steel balls from the 5th gear thrust washer
of the input shaft.
8. Remove the 4th gear subassembly, 4th gear needle

bearing, 4th gear synchronizer ring, and the 4th gear
bearing washer (4 types of part).
9. Remove the shaft retainer from the input shaft's No. 2

synchronizer gear hub.

Transmission 59
10. Remove each component of the input shaft's No.2 syn-

chronizer.
11. Remove the input shaft's 3rd gear synchronizer ring

and the 3rd gear subassembly.
12. Remove the needle bearing from the 3rd gear of input
shaft.

Disassembling the Output Shaft Subassembly

Components
Rear tapered
1st gear roller bearing
synchronizer ring
Shaft retainer
5th driven gear

1st gear gear
subassembly
4th driven gear
Needle bearing
Spacer
3rd driven gear
Retaining ring
Shaft retainer
Needle bearing
Output shaft
2nd gear gear subassembly
2nd gear synchronizer ring

No. 1 Slider
No. 1 gear sleeve/No. 1

Front tapered gear hub
roller bearing
1. Remove the output shaft's rear tapered roller bearing.

Transmission 61
2. Remove the output shaft's 5th driven gear shaft retainer.
3. Remove together the output shaft's 5th and 4th gear

driven gear.
4. Remove the output shaft spacer.
5. Remove the output shaft's 3rd driven gear and the 2nd
gear subassembly spacer.

6. Remove the output shaft's 2nd gear synchronizer ring,

2nd gear needle bearing, and the 2nd gear subassem-
bly retaining ring.
7. Remove the shaft retainer from the No. 1 synchronizer

gear hub of the output shaft.
8. Remove the output shaft's No. 1 synchronizer compo-

nents and the 1st driven gear.
9. Remove the needle bearing from the output shaft's 1st

driven gear subassembly.

Transmission 63
10. Remove each component of output shaft's No. 1 syn-

chronizer.
11. Remove the front tapered roller bearing.

Disassembling the Shift Cover Subassembly

Components
Gear shifting block

Shift lever assembly
Dust cover
T oil seal
38.0 Set bolt
No. 2 spring seat
Pressure spring
Manipulation lid
Shaft retainer
T oil seal
Select lever subassembly
Shift guide block

Gasket
Lock plate Shaft retainer

Elastic cylindrical pin
1. Remove the shift lever's elastic cylindrical pin.

Transmission 65
2. Remove the shaft retainer on the shift lever and the se-
lect lever.
3. Remove the lock plate.
4. Remove the pressure torsion spring.
5. Remove the No. 2 spring seat.

6. Remove the set bolts and the select lever assembly.
7. Remove the select lever subassembly.
8. Remove the shaft retainer on the shift shaft and the se-
lect lever.
Caution: Use a cord to fasten the shift lever in order to
Cord make the operation convenient.
9. Remove the shift shaft and the shift shaft dust cover.

Transmission 67
10. Remove the shaft retainer from the shift shaft.
11. Remove the shift shaft T oil seal from the manipulation
lid.
12. Remove the T oil seal from the manipulation lid.

Disassembling the Differential Subassembly

Components
T oil seal
Clutch housing
Elastic cylindrical pin Differential case
Odometer drive gear
Gasket
Planetary gear
Adjusting shim Differential ring gear
Axle shaft gear

Axle shaft gear
Planetary gear shaft Bolt for flange face
Adjusting shim
Planetary gear 123.6
Gasket
T oil seal
Adjusting shim
Transmission case

Transmission 69
1. Remove the tapered roller bearings of the left differen-

tial.
2. Remove the odometer drive gear from the differential.
3. Remove the tapered roller bearings of the right differen-

tial.
4. Remove the bolts for flange face of the differential ring

gear and the differential case.

5. After removing bolts for flange face from the differential

ring gear and the differential case, gently pound to re-
move the differential ring gear with a soft hammer.
6. Remove the elastic cylindrical pins from the differential

case and the gear shaft.
7. Remove 2 planetary gears, 2 axle shaft gears, 2 ad-

justing shims, and 2 gaskets from the inside of the dif-
ferential case.

Suspension System 71
Suspension System
Suspension System Technical Parameters......................... 72

Front Suspension................................................................ 73
Subframe and Front Stabilizer Bar...................................... 77
Lower Swing Arm................................................................ 80
Drive Shaft........................................................................... 84
Rear Suspension................................................................. 86
Wheel and Tire.................................................................... 89

Suspension System Technical Parameters

Main technical parameters
Front suspension type McPherson independent suspension
Coil spring, hydraulic telescopic shock absorber, stabilizer bar, lower swing
Suspension type and Front suspension components arm
composition
Rear suspension type Compound trailing arm semi-independent suspension
Rear suspension components Coil spring, hydraulic cylinder damper, & twist beam welded components
Front wheel camber -0° 43′ ±30′
Front wheel kingpin angle +10° 21′ ±30′
Wheel positional Front wheel kingpin caster +1° 49′ ±30′
parameters
(no load) Front wheel toe-in -0° 01′ ±15′
Rear wheel camber -0° 43′ ±30′
Rear wheel toe-in +0° 14′ ±15′
Tightening torque
Tightening
Assembly locations for
Part Code torque Quantity Glue Grade
standard components
(N·m)
Q1861455TF2
(M14×1.5) + Q402 Subframe & vehicle body (rear) 145±15 2 Red glue 10.9
(d2=32 t=5) FD
Q1861275TF2
(M12×1.25) + Q402 Subframe & vehicle body (front) 120±10 2 Red glue 10.9
(d2=32) FD
Q1401020 (M10×1.25) FD Subframe strut bar mounting bolt 49±5 4 Red glue 10.9
2904011-S08 Swing arm & steering knuckle 98±10 2 Red glue
Front Q1401495 (t=4)
Swing arm & subframe (front) 180±10 2 Red glue 10.9
suspen- (M14×1.5) FD
sion Q1401280 (M12×1.25) FD Swing arm & subframe (rear) 120±10 2 Red glue 10.9
2904013-S08 Swing arm & subframe (rear) / 2
Front shock upper assembly loca-
2905011-S08 40±5 6
tion
Front shock lower assembly loca-
Q32014 (M14×1.5) FD 132±10 4 Red glue 10.9
tion
Front stabilizer bar mounting
Q1400830 (d2=13.5) 37±4 4 Red glue
bracket
Q32608 Front stabilizer bar hanger rod 16±2 4
Q151B12110TF2+Q402 10.9 grade

Twist beam & vehicle body 80±10 2 Red glue
(d2=35 t=5) FD with guide
Rear sus-
Q32012T13F2
pension Rear shock absorber & twist beam 120±10 2 Red glue 10 grade
(M12×1.25) FD
Rear shock absorber & vehicle
Q341C10 64±5 4
body
3101014-K00 Wheel nut (M12×1.25) 110±10 16
Wheel
Q30612FD (M12×1.25) Wheel nut cone nut 110±10 16
Wheel and tire parameters

Tire specifications: 15 × 6J (For 185/65R15 tires), 16 × 4T (For T125/70R16 tires)
Tire specification: 185/65 R15 88H
Spare tire specification: T125/70R16 96M
Tire pressure must be gauged when the tire is cool: Tire inflation pressure: 200±10 KPa
Spare tir e inflation pressure: 420±10 KPa

Front Suspension
Components
Press plate on the front shock

absorber column
Front shock absorber with

coil spring assembly
Front stabilizer bar mounting bracket
Front stabilizer bar bushing
Front stabilizer bar

hanger rod subassembly
Lower swing arm

assembly RH
Front stabilizer bar
Subframe assembly
Lower swing arm
assembly LH
Subframe strut bar
Insert into this hole Steering knuckle assembly removal

1. Preparation
First, remove the front wheel, the front shock absorber with
coil spring assembly, and the steering knuckle coupling
bolt in turn. For detailed steps, please refer to the removal
of the wheel and the front shock absorber with coil spring
assembly.
2. Remove propeller shaft nuts
(a) First, pry the flattened areas of the propeller shaft's nuts
into a circle with a chisel.
(b) Half-insert a long bolt or metal bar into the brake disc
holes to loosen the nuts (shown on the left).
(c) Pull out the mount point on the steering knuckle to
separate it from the mounting bracket under the front
shock absorber. Prop a wood stick or metal bar against
the propeller shaft's outer end, and then hammer the
stick or metal bar to get the propeller shaft out of the
hub (shown on the left).
Caution: When hammering, prop it up against the shaft
end's location holes (middle recess). Be sure not to
damage the thread.

3. Remove the wheel speed sensor and the brake hose

Remove the wheel speed sensor's mounting bolts with a M10
sleeve to take off the wheel speed sensor. Remove the front
brake hose's mounting bolts with a M18 sleeve, and then
take off the brake hose.
Front brake hose
Caution: When removing the brake hose, brake fluid
mounting bolt may flow out, catch the fluid with a container. Also,
because the brake fluid is corrosive, please pay
Wheel speed sensor attention to personal protection.
mounting bolts
Lightly hammer here 4. Remove the cotter pins and lock nuts of the steering tie
rod and the lower swing arm
Because the ball stud and steering knuckle act in conjunction
with the tapered bore, they can not yet be removed after re-
moving the nuts. Pound the steering knuckle arm (unfinished
surface) with a hammer. Positions are shown on the left.
Shake to loosen.
Caution:
1. To avoid separating the ball studs, do not pound the
tie rod and the lower swing arm with a hammer.
2. To avoid damaging the thread, do not hammer the
ball stud's head.

Front shock absorber with coil spring assembly (Image)
Front bumper
Press plate on the front

shock absorber column
Dust cover on the front shock absorber
Hexagon flange nut

Erection support under
the front shock absorber
Front shock absorber assembly
Erection support under

the front coil spring
Dust cover
Front coil spring Erection support on the front coil spring
Erection support on the front shock absorber column
Front shock absorber with coil spring assem-

bly removal and installation
1. Hoist up the vehicle so that the front suspension is in a
free suspension state.
Brake hose 2. Remove the wheel speed sensor and the brake hose.
Remove the wheels and take out the brake hose from the
Wheel speed sensor shock absorber bracket. Then remove the wheel speed sensor
wire harness
wire harness (shown on the left) from the steering knuckle.
3. Remove the coupling bolt between the front shock

absorber and steering knuckle and the brake hub
assembly.
Front
4. Loosen the mounting nuts of the front shock absorber

and remove the front shock absorber with coil spring
assembly (shown on the left).
5. Installation of the front shock absorber with coil spring
assembly.
Installation follows the reverse order of removal, but
please pay attention to the areas of importance below:
(a) The Insertion direction of the bolts should be consistent
with direction shown in the image. Insertion order is
from up to down. After inserting, tighten them one by
one as required.

(b) All of the fastening pieces must be tightened to the

required torque, and comply to the standard gluing re-
quirements in this chapter.
Front shock absorber with coil spring assem-

bly disassembly and installation
1. Compression spring
Use SST to grasp the spring, separated by adhesive tape
at the contact area. Alternately rotate the bolts on the SST
until there is no tension on the spring seat from the spring.
The front coil spring rotating means that the spring has been
compressed (shown on the left).
2. Disassemble the front shock absorber with coil spring

assembly
Remove the dust cover of the front shock absorber. Remove
the nuts on top using a ratchet wrench and M21 sleeve. Re-
move the erection support on the front shock absorber col-
umn, support bearing, the front coil spring's erection support,
front coil spring, dust cover, and the bumper in turn.
Tightening torque: 40-60 N·m
3. Retracting spring
Alternately reversing, rotate the bolts on the SST until all the
spring tension is released, then remove the tool.
4. Change any component that needs to be replaced
5. Installation of the front shock absorber with coil spring
assembly
Installation is in the reverse order of disassembly,
please pay attention to items below:
(a) Use SST to compact the spring.
(b) Steps for the installation of each component of the
front shock absorber with coil spring assembly is the
opposite of the steps for its disassembly.
(c) Pull up the strut piston rod as hard as possible and
make sure not to let it draw back into the strut.

Subframe and Front Stabilizer Bar

Components
Stabilizer bar bracket

Front stabilizer bar Stabilizer bar bushing
Lower swing
arm RH
Subframe
Subframe strut bar
Lower swing arm LH
Subframe removal and installation

1. Remove the engine's rear suspension bolts, coupling
bolts between steering propeller shaft and column,
and the steering fuel hose. Disconnect the connection
between the steering knuckle, swing arm, and steering
tie rod. For detailed steps, please refer to the removal
of the engine, steering system, and the steering
Q1401020 knuckle assembly.
2. Remove the strut bar.
Screw off the subframe strut bar mounting bolts Q1401020
(M10×1.25) FD with a sleeve, and remove the strut bar. As
shown on the left: There are four bolts, two on the left and
two on the right.
Caution: When removing the steering fuel hose, power
steering fluid may flow out, so collect the fluid in a
container.
3. Remove subframe.
Remove the subframe's front mounting bolt Q1861275TF2
(M12×1.25) + Q402 (d2=32) FD with a M18 sleeve (needs
a extension bar). Remove the subframe's rear mounting bolt
Q1861455TF2 (M14×1.5) + Q402 (d2=32 t=5) FD with the
same tool. (shown on the left).
Caution: Lift the subframe when removing to avoid
operator injury due to it falling off.
4. Remove the front stabilizer bar, steering gear, and
Q1861275TF2 lower swing arm. For detailed steps, please refer to the
Q1861455TF2 removal and installation of the stabilizer bar, steering
gear, and lower swing arm.

Remark: When removing the subframe's front mounting bolt,

Insert extension bar an extension bar should be inserted through the lower swing
through this hole arm's hole. Positions shown on the left.
5. Subframe installation.
Installation follows the reverse removal steps.
Caution: Fix the position of the subframe with the
position pin, to avoid influencing the four wheels'
positioning. Location hole is shown on the left: a total
of two, one on the left and one on the right.
This is the subframe

location hole
Stabilizer bar removal and installation

1. Remove the hanger rod.
Use a M10 open-end wrench to lock the sliding side of the
hanger rod (slightly higher than center position), screw off
the hanger rod lock nuts, and remove the hanger rod.
Caution: These are non-metal insert lock nuts, and
cannot be reused. So please replace them with new
ones after removal.
2. Remove the stabilizer bar arm.

Q1400830
Remove the stabilizer bar bracket mounting bolts Q1400830
(d2=13.5), and take down the bracket and bushing. As shown
on the left: There are four bolts, two on the left and two on
the right.
3. Stabilizer bar installation.

Install it by reversing the removal steps, but please pay
attention to the areas of importance below:
(a) During removal, please remember the installation order
Hanger Washer
Bushing rod of each of the hanger rod's components, so as to avoid
improper installation.
Shaft sleeve
Bushing Washer

(b) The sliding side of the hanger rod should face upward,
Correct Incorrect so as to make the operation more convenient.

Lower Swing Arm

Components
Lower swing arm
Q1401495
Subframe
Q1401280
Swing arm removal and installation

1. First, remove the steering knuckle, subframe, and
stabilizer bar hanger rod. For detailed steps, please
refer to the removal of the steering knuckle, subframe,
and stabilizer bar.
2. Screw off the lower swing arm's front mounting bolt

Q1401495 (t=4) (M14×1.5) FD with a sleeve.
Q1401495
3. Screw off the lower swing arm's rear mounting bolt

Q1401280 (M12×1.25) FD with a sleeve.
Caution: The nuts here are designed to prevent sliding.
When installing or removing, please do not tighten or
loosen this part, a sleeve needs to be used to apply
force onto the bolt.
Q1401280

4. Remove the lower swing arm.

Swing the lower swing arm up and down, and pull it out at
Rear the same time. Force F shown as in the picture. Pull the front
mount point of the swing arm from the subframe, and then
take down the lower swing arm.
5. Lower swing arm installation.
Install it by reversing the removal steps.
Front
F
Lower swing arm assembly inspection

1. Lower swing arm ball stud inspection.
(a) Check that the ball stud's swing angle is within 50°,
swings flexibly, and clamping free.
(b) Check to see if the ball stud is damaged.
(c) Check to see if the ball stud dust cover is damaged and
replace it if needed.
Caution: Do not take apart the lower swing arm weld as-
sembly and the lower swing arm ball stud. If the rotation is
not flexible or if the ball stud is damaged, the entire lower
swing arm with ball stud assembly must be replaced.
2. Ball stud dust cover replacement.

Rotate and remove the fastened ball stud dust cover clasp
with SST, and replace the ball stud dust cover. You can
reattach the clasp with the same tool.
SST
3. Inspect the lower swing arm's large and small shaft sleeve
for signs of wear.
Clean the large and small shaft sleeve of the lower swing
arm with water, and inspect for damage, wear, cracks, and
similar flaws. Replace with new ones if needed.
4. Lower swing arm's large shaft sleeve removal, replace-

ment, and press fitting.
(a) Before removing, mark two lines on the lower swing
arm according to the shaft sleeve location, so as to refer
to the proper location during press fitting.

(b) On the press, press out the lower swing arm's large
F
shaft sleeve with SST (Special Service Tools), and re-
place it with a new one.
SST
(c) Check that the mounting holes of the lower swing arm's
large shaft sleeve are Φ55-0.2
-0.3 , measure for inaccurate di-
mensions, replace the lower swing arm's weld assembly if

inaccurate.
SST
(d) Before press fitting, mark the same position on the

new lower swing arm's large shaft sleeve, so as to
correspond to the mark on the lower swing arm, and
thus ensure angle alignment.
(e) On the press, use SST (Special Service Tools) to press

F the new lower swing arm's large shaft sleeve into the
correct position.
SST
SST
5. Lower swing arm's small shaft sleeve removal, replace-

ment, and press fitting.
Sanding spots (a) Use a sander to smooth level the rubber flange on the
lower swing arm's small shaft sleeve.
Caution: When using the sander, be very careful not to
damage the lower swing arm.
Sanding spots
F
(b) On the press, use SST (Special Service Tools) to press
out the lower swing arm's small shaft sleeve, and re-
SST place it with a new one.
(c) Check that the lower swing arm's small shaft sleeve's
mounting hole dimensions are Φ31+0.05
0 .
SST Caution: Measure for inaccurate dimensions, replace
the lower swing arm's weld assembly if inaccurate.

F (d) On the press, use SST (Special Service Tools) to press

the new lower swing arm's small shaft sleeve into the
SST
correct position.
SST

Drive Shaft
Components
Front shock absorber with

coil spring assembly LH
Front drive
shaft nut LH Front drive shaft
assembly LH Transmission assembly
Wheel assembly
Drive shaft removal

1. First use a M32 sleeve, ratchet wrench, and extension
bar, to remove front drive shaft nut LH. Then, according
to the wheel and front suspension disassembly
specifications, remove the Front suspension system
LH and wheel.
2. Then use a pry bar to forcefully pry the connection

between the differential and the drive shaft until the
drive shaft obviously moves towards the outside. Do
not damage the drive shaft's dust cover.

Drive shaft installation

1. Insert the drive shaft.
First, align the inner end of the drive shaft and differential
spline. Keep the drive shaft axes and the differential axes
bases uniform, then hammer towards the direction of the
differential drive shaft's outer end until a clear and sharp
clicking sound is heard. Here, the drive shaft and the
transmission should have a clearance of about 1 mm.
2. According to the front suspension and wheel assembly

installation specifications, properly install the front
shock absorber with coil spring assembly LH and
wheel.
3. Use an M32 sleeve, ratchet wrench, and extension bar
to tighten front drive shaft nut LH.

Rear Suspension
Components
Upper mounting rubber cushion

for the rear coil spring Rear shock absorber subassembly
Rear coil spring
Lower mounting rubber cushion

for the rear coil spring
Hexagon bolt for flange face
Rear twist beam assembly Hexagon nut for flange face

Large washer
Rear shock absorber and

rear coil spring removal
1. Hoist the vehicle with a jack, then remove the left and
right rear wheels.
2. During the removal of the rear twist beam, use SST (Special
Service Tools) to clamp the coil spring, so that it does not
pop out and cause injury.
3. Compression spring.
Hold up the rear twist beam upwards with a lift, compressing
the rear coil spring and damper.

4. Remove the rear shock absorber.

Screw down the hexagon nut for flange face Q32012T13F2
Rear shock absorber (M12×1.25) FD linking the rear shock absorber and rear
twist beam, and remove the rear shock absorber. Make sure
the rear twist beam is firmly supported meanwhile.
Hexagon nut for 5. Remove the coil spring.
flange face Slowly release the firmly supported rear twist beam, at
Large washer the same time support the coil spring, until the coil spring
loosens, then take it down.
Rear twist beam assembly removal

1. Hold up the rear twist beam assembly with a lift, and
remove the rear shock absorber and rear coil spring.
For detailed steps, refer to the rear shock absorber and
coil spring removal.
2. Remove the hexagon bolt for flange face
Q151B12110TF2 + Q402 (d2=35 t=5) FD, and slowly
set down the twist beam (as shown on the left).
When removing bolts, check and ensure that the rear
twist beam is reliably supported, to avoid injury from it
falling.
Inspection, installation, and removal of the

trailing arm spindle sleeve assembly
1. Trailing arm spindle sleeve inspection.
(a) Inspect the trailing arm spindle sleeve for deformities,
shifting, partial or serious cracks, or loosening.
(b) If any existing damage of the trailing arm spindle
sleeve is not clearly seen, take the following steps:
Wash the trailing arm spindle sleeve's rubber areas with
clean water. Rub it clean with cotton meanwhile (shown
on the left). Check and make sure the rubber surface has
none of the previously mentioned flaws. If it does, re-
place with a new trailing arm spindle sleeve assembly.
2. Trailing arm spindle sleeve removal.

(a) Use a white paint pen to mark, and remember the trail-
ing arm spindle sleeve assembly direction.
(b) The trailing arm spindle sleeve is disposable. If
damaged, first use a pry bar to lift up the edge of the
trailing arm spindle sleeve's outer tube in order to
install the SST (Special Service Tools).

(c) Use SST (Special Service Tools) to clog the shaft

SST sleeve's installation tube. Tighten the two adjusting
bolts, use a wrench to twist the middle long bolt, and
push out the shaft sleeve.
3. Install the new trailing arm spindle sleeve assembly.

SST (a) Before installing the new trailing arm spindle sleeve
assembly, first to distinguish the installation direction
for the trailing arm spindle sleeve's nylon bushing as-
sembly.
(b) Use SST (Special Service Tools) to clog the shaft
sleeve's installation tube. Tighten the two adjusting
bolts, twist the middle long bolt with a wrench, and
push in the shaft sleeve.

Wheel and Tire

Tire
Remark
This vehicle's tire is of the tubeless type. The optimal design condition is met when the inflation pressure is at
the recommended value, and the tire is under full load. Maintaining suitable tire pressure and proper driving
habits greatly influence the tire's use life. For the vehicle, it improves riding comfort, stability, and handling. For
the tire, it reduces tread wear, damage to the tire and extends tire life. Overloading, speeding, and unnecessary
emergency braking will all add to the tire's wear and tear.
Tire pressure measurements should be taken under normal temperature. If the tire pressure rises due to motion
generated heat when driving, cooling it will return to the normal temperature. Therefore, do not deflate the tire
when the air pressure has risen to this point. The tire's air pressure will naturally and slowly decrease when used
under normal conditions. Hence please inspect the air pressure regularly (suggested once a month). The spare
tire should be kept in a useable condition at all times.
Inspect the tire pressure when it is cool monthly or before a long drive. Adjust the tire pressure to the recom-
mended level. The air pressure will normally rise because the tire warms up due to movement. Therefore, after
driving, you absolutely must not deflate or reduce the tire's air pressure, as deflating could reduce the cool tire's
air pressure.
Tire inflation
During a new tire's initial stage of use, warning due to bending motions will cause the tire to swell, and thus
reduce the corresponding air pressure. After 24 hours or 2000-3000 km worth of drive, charge the air pressure.
After inflating, check if the air nozzle core is leaking air with soapy water, then lock on the cap.
Possible problems caused by tire pressure

Exceeding the recommended air Below the recommended air pressure Same vehicle axle, different
pressure air pressure
Possible problems it 1. Bumpy ride 1. Noisy turns 1. Uneven braking
can create 2. The tear or rupturing of the tire 2. Uneasy turns 2. Over steering
3. Rapid wear of the tire tread's center 3. Tread edge wear is accelerated and uneven 3. Steering failure
4. The tire's rim is damaged or ruptured 4. Deviation while accelerating
5. The tire cord ruptures
6. High tire temperature
7. Steering failure
8. Large oil consumption
Tire and wheel (steel wheel) installation instructions

When installing the tire and wheel, the tire's radial hardware components, also called "high spot", should be at
the same level of the wheel's minimum radius or so called "low spot".
The "high spot" of the tire is initially marked by the paint spot on the side of the tire's surface. This paint will
eventually be washed away.
The "low spot" of the wheel is initially marked by a paint spot on the wheel flange. Whenever the tire is
removed from the wheel, the tire and wheel need re-balancing to make sure the vehicle runs smoothly. If no
paint spot is found on the tire, draw a line on the tire and the wheel before they are removed, in order to make
sure that the tire and the wheel will be re-assembled at the same place.
Tire replacement
When a tire needs to be replaced, make sure to use a tire with the same specification as the original one. A new
tire used for replacement must be of the same dimension, load area, and structure as the original one. Using tires
that are different in dimension or type will influence the vehicle's riding comfort, handling, speedometer and
odometer calibration, vehicle ground clearance, and the clearance between the tire or the tire's snow chain and
the vehicle body or chassis.
It is suggested to use a new pair of tires on the same axle. If only one tire is needed to be replaced, make sure to
use a tire with a tread most similar to the original, so as to keep brake power and traction balanced.
Warning: Do not mix radial tires, bias tires, bias belted tires, etc., which are of different structure on the
same vehicle unless it is an emergency. Mixing different tires would seriously influence the vehicle's
handling and stability, and even possibly lead to losing control of the vehicle.

Tire's abnormal wear and tear

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

Here the sway means the vehicle's front or rear part shakes
from side to side, together or individually. Tire sway is
caused by the steel wire belt inside the tire not being straight.
The sway is the most obvious when the vehicle runs at the
speed of 8-48 km/h.
Road tests can help finding malfunctioning tires. If the
malfunction is with the rear tires, then left and right shaking
or "swaying" would take place at the back of the vehicle.
Here the driver of the vehicle would feel as if someone were
pushing from one side of the vehicle.
If the malfunction is with the front tires, swaying would be
even more obvious. The metal plate in the front may seem
moving back and forth, and the driver feels as if he/she were
at the vehicle's center of rotation.
Vehicle road test methods

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

Tire rotation
For equal wear or tear for the tires, please rotate the tire
positions timely. Swapping principle shown on the left.
Radial tires should be regularly switched, and add pressure
according to the regulations.
Front Rear Caution:
Due to structural reasons, radial tires usually quickly
receive most of its wear on the shoulders, especially
the front tires. Do a tire rotation per 8000-12000 km,
and the tire life can increase by 20%. This makes
regular tire rotation especially useful.
Deviation judging methods
"Deviation" means that, when no one is in control of the steering, the vehicle does not move in a straight line
while driving on a straight and leveled surface.
Adjust the tire pressure to

the recommended level
Test by driving back and forth

on a straight and leveled road
After swapping the right and left front

tires, perform the above test again
Tends to lean After solving, if working, Tends to

in the same switch the tires again lean in the
direction other direction
Return the tires to their Replace one of the

initial positions and inspect front side tires with
the front wheel alignment a "good tire"
If the problem is not

After solving,
yet solved, replace the
switch the tires again
other side's front tire
with a "good tire"
After solving,
If the problem is not yet
switch the tires again
solved, it means the "good
tire" is in fact not good
Deviation causes:
• Incorrect tire and front wheel alignment,
• Braking force is not even,
• Tire structure problems.
Tire production and manufacturing methods can also lead to vehicle deviation. For example, the arrangement of
the tires inner steel wire belt. A steel wire belt which is inside the radial tire deviating from the tires centerline
can create lateral force when the tires are rolling in a straight line. If one of the tire's diameter is larger than the
other, the tire will tend to roll to that side, this also creates lateral force (a tapering effect) leading to vehicle
deviation. When the front wheel alignment is found to be correct and in proper order, the above process is also
applicable in judging tire deviation. Rear tires cannot cause deviation.

Tire installation and removal

• Install or remove tires with a tire changer. When operating machinery, make sure to comply to the machine
manufacturers operation manual. Please do not change tires merely with manual hand tools or tire installation
crowbars. This will damage the tire chafer or the vehicle wheel's rim.
• Use a wire brush or coarse steel wool to clean off grease and old rubber, as well as light rust or corrosion from
the rim tire bead's tire chafer seat. Before tire installation or removal, first use the indicated tire lubricant to
thoroughly lube the tire chafer portions one time.
• After installing the tire, inflate it to the specified pressure and make sure the tire bead is properly seated.
Warning: Do not over-inflate the tire. If the tire bead severally expands and exceeds the safety limit,
it may burst and cause serious personal injury. While inflating, do not exceed the specified pressure.
If the specified pressure does not allow the tire bead to sit properly, deflate the tire, re-lubricate, and
then re-inflate.
Spare tire usage
• Spare tire standard inflation pressure: 420 kPa.
• Spare tire pressure measurements should be taken under normal temperature conditions.
• After inflating the spare tire, soapy water should be used to check if the air nozzles core is leaking air, then
lock on the air nozzle cap.
• The spare tire should always be kept in a useable state. Check the air pressure at least once a month.
• When the spare tire's working limit, indicated by the remaining pattern's depth, reaches 1.6 mm (and its pat-
tern groove bottom protrudes to the same level), for your safety, please stop using the spare tire.
Caution:
• The " " symbol on the tire bead of the spare tire in-
dicates the set position of the wear index (shown on
the left).
• The spare tire's maximum driven speed is 80 km/h,
and maximum distance 200 km per trip.
• Each vehicle is allowed to use only one spare tire.
• The spare tire is only used as a temporary backup.
Please go to a professional service station immediately
to get the initial tire repaired or replaced.
Wheel
General tire balancing procedures
Clean out the accumulated dirt and debris from the inside of the rim.
Warning:
The gravel on the tread must be eliminated to avoid flying out and injuring the operator when
undergoing rotational balancing. This is also a good way to acquire better balance. First thoroughly
inspect the tire's damaged condition, then according to the balancing device manufacture's
recommendations, carry out the balancing operation.
Off-vehicle balancing
Most off-vehicle balancers are more accurate and convenient than on-vehicle rotational balancers. They are
also able to perform dynamic (two sided) balancing. Although it does not correct drum brake and brake disc
imbalance like on-vehicle balancing, it achieves the same effect based on its accuracy.
On-vehicle balancing
On-vehicle balancing is different based on equipment and tool manufacturer. Therefore, when performing
balancing operations, be sure to comply to each manufacturer's operating instructions.
Warning: Control the wheel rotation speed to make sure the speedometer stays within 55 km/h.
This restriction is necessary because when a driven wheel slides while the other one stays still, the
speedometer will display only half of the actual wheel speed. When a wheel is sliding, be extremely
careful, because sliding wheels can reach very high speeds. This may lead to the tire rubber peeling
or differential damage, which may cause serious personal injury, or damage to the vehicle.

Dynamic balance and static balance

[A] [B] 2 There are two types of wheel balance: static and dynamic.
Picture 1 shows static balance. Picture 2 shows dynamic
balance.
Static balance means that the weight distribution around the
wheel is equal. If the wheel is static and unbalanced, violent
vibrations may be created, called jump vibration.This kind
3 of situation can ultimately lead to the uneven wear and tear
1 of the tires. Shown in diagram 1.
Diagram 1
1. Wheel hop important points [A]: Counterweight not yet added
2. Locations to add counterweight [B]: Counterweight added
3. Axis
[C] [D] Dynamic balance means that the weight distribution on the
2
two sides of the medium plane of the wheel is equal, so
during the rotation process, the tire assembly cannot create a
tendency for the medium plane of the wheel to shift from one
side to the other. If the wheel is dynamic and unbalanced, it
can create a shimmying effect. Shown in diagram 2.
1. Wheel shimmy important points [C]: Counterweight not yet added
2. Locations to add counterweight [D]: Counterweight added
3
3. Axis
1 Diagram 2
Wheel maintenance
Do not use welding, heating, or hammering to repair wheels. All damaged wheels must be replaced.
If the vehicle's wheel is twisted or deformed, sunken or depressed, having too much horizontal or radial hop,
leaking air from the welded parts, stretched out at the bolt holes , having flimsy nut bolt lock, or severely rusty,
the wheel must be replaced. When the wheel is hopping too much, it will lead to undesirable vibrations.
When replacing the tire, be sure that the load capacity, diameter, rim width, offset distance, and the installation
structure of it, are equal to the settings of original wheel. If the wheel dimensions are not appropriate, this will
influence the wheel and bearing's life, brake cooling effect, speedometer and odometer calibration, vehicle
ground clearance, as well as the clearance between the tire and the vehicle body, and the tire and vehicle chassis.
Wheel (steel wheel) removal
1. Remove the wheelhouse and loosen the nuts, 1-2 turns is
enough.
2. Hoist the vehicle.
3. Screw off the nuts and remove the wheel.
Nut tightening torque: 110±10 N·m
Caution: Heating methods absolutely must not be used
to loosen tightened wheels, otherwise the heat will
reduce its use life and damage the hub bearing.
Wheel (steel wheel) installation

Installation according to the reversed instructions used for
removal, and pay attention to the following requirements:
B A Wheel nuts must be tightened in proper order and according to
the specified torque, as to avoid wheel or brake disc deformity.
When installing the wheel house, be sure to line up the wheel
housing notch locations with the inflation nozzle.
Tightening sequence: A – C – B – D
Caution: Before installing the wheel, first clean off the
corrosion on the wheel's mounting surface and drum
C D brake or brake disc's installation surface with a wire
brush, in order to make the wheel installing easier by
making the space between its metal firmly connect
to the mounting surface, otherwise it may lead to the
wheel nuts loosening to the extent that the vehicle's
wheel may come off while driving some day.

Brake System
Brake System Components Arrangement Schematics....... 95

Brake System Maintenance................................................ 96
Brake Pedal......................................................................... 98
Parking Brake Control Mechanism Assembly................... 102
Vacuum Booster with Brake Cylinder Assembly................ 103
Anti-lock Brake System..................................................... 107
ABS General Problem Maintenance and
Areas of Importance.......................................................... 109
Steering Knuckle and Hub Brake Assembly...................... 112
Front Brake Caliper........................................................... 118
Rear Brake........................................................................ 124
Rear Support Axle............................................................. 131

Brake System 95
Brake System Components Arrangement Schematics

Left steering knuckle and hub brake assembly Right steering knuckle and hub brake assembly
ABS controller assembly
Vacuum booster with brake

cylinder assembly
Front wheel speed Front wheel speed sensor assembly RH

sensor assembly LH
Brake pedal assembly
Brake line assembly
Parking brake control mechanism assembly
Right parking brake

cable assembly
Left parking brake cable assembly
Rear wheel speed Rear wheel speed

sensor assembly LH sensor assembly RH
Rear brake
assembly RH
Rear brake Rear brake assembly LH
drum

Brake System Maintenance

Brake fluid inspection and replacement
Brake fluid directly influences the brake performance and the operating conditions and use life of the brake
system components. Brake fluid has very strong hygroscopic properties, and thus absorbs water easily,
which will then deteriorate the metal and rubber pieces. Polluted and deteriorated brake fluid or its mixture
would cause the brake fluid to boil and gasify, hence reduces braking efficiency. Therefore, pay attention to
the items below when filling or changing the brake fluid:
1. Containers used to hold brake fluid must be tightly closed and sealed
2. Brake fluid is poisonous and damaging to the paint. Hence if it gets on the vehicle surface, rub it
off at once
3. If water or other contaminates found in the brake fluid, and the brake master cylinder's piston seal
has been broken, then the brake fluid and all the rubber pieces inside the brake system including
the brake hose must be replaced
4. The correct brake fluid level in the reservoir must be between MAX and MIN. After the vehicle has
been driven for over 1000 km, check the brake fluid level in the reservoir. If the brake fluid level is
not up to regulation, more brake fluid should be added to the reservoir until it reaches MAX.
Hydraulic component inspection and system flushing
1. If the oil-based solvent gets into the hydraulic system, flush the whole system and change all of
the rubber pieces
2. Clean your hands before installing new rubber pieces or other components
3. Do not use regular solvents (kerosene, gas, etc.) when inspecting or cleaning hydraulic
components, instead use absorbing alcohol or brake fluid
4. After inspecting the components, drain the brake fluid from the system. Use new brake fluid to
flush the system. Afterwards, add new brake fluid to perform hydraulic system exhaust
5. Flushing completion sign: When the brake fluid flowing out of the dump valve is clear from any
contaminate.
Hydraulic pressure system drainage
If the brake fluid inside the whole hydraulic pressure system needs to be emptied, open all the bleed screws
with each connected to a hose, as to allow the brake fluid to flow into a container. Step on the pedal slowly
until only air flows out. During the whole procedure, make sure all the valves are open.
Hydraulic pressure system air bleeding
The hydraulic brake system must work under a vacuum environment. The air will cause spongy brake or
overall brake failure when it flows into the hydraulic system. It is extremely necessary to bleed system air
when performing any operation on the brake system or if any air inside the brake system is suspected.
1. Air bleeding sequence
If air inside the brake master cylinder is suspected, first perform air bleeding.
(a) If numerous valves are equipped, air bleed each valve
(b) Another sequence principle is: Air bleed from the wheel brake furthest away from the master cylinder.
The air bleeding sequence for the LHD modules is: rear right wheel - left rear wheel - front right wheel
- front left wheel, Right rudder vehicles: rear right wheel - left rear wheel - front left wheel - front right
wheel.
2. Air bleeding method
(1) Manual air bleeding
Use the brake pedal or pump as the air bleeding power source. When the air bleed screws are open, vent the
brake fluid containing the bubbles from the system. Usually this is simultaneously done by two people. One
steps on the brake pedal and the other operates the air bleed screws. Important points to take note of when
performing the operation:
(a) Place the ignition switch to the off position and step on the pedal repeatedly to remove the
vacuum pressure or hydraulic pressure.
(b) Before and after air bleeding, add clean brake fluid into the master cylinder until it reaches
the correct (stated) level.
(c) Check the fluid level frequently to make sure that more than half of the reservoir's capacity is
available.
(d) Bleed screws should only be opened when the pedal is pressed down, and closed before the
pedal is loosened. Meanwhile, check if the vented brake fluid has bubbles inside.

Brake System 97
(e) Make sure not to let the system valves block the air bleeding.
(f) When the brake fluid that flows out of the hose or connector has no bubbles, it means that the air
in the system has been exhausted. There is still air inside the system if the hose inserted into the
brake fluid is still bubbling when pressing down the pedal.
(g) Keep the free end of the hose immerged in the brake fluid to avoid air from flowing into the
system while opening the screw.
(h) While air bleeding, hammer the casting part of the vibrating brake device with a rubber hammer.
This is helpful for removing bubbles deep in the brake fluid.
(i) If air in the master cylinder is suspected, then perform air bleeding on the master cylinder first,
then the wheel cylinder or brake caliper.
(j) When releasing air from the tires, generally make sure to release air out of all the tires.
(k) To avoid the possibility of air reversely entering into the system, a bleeder hose that has a check
valve could be used.
(2) Pressure blow-off
Under the proper conditions, a pressure blow-off device can be used to release the air inside the brake system.
3. Air releasing sequence
(1) Master cylinder air bleeding
If the master cylinder does not have air bleed screws, perform the following steps:
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary.
(b) Slowly take off the front brake pipe connector until the brake fluid flows out from the end.
(c) Reconnect the brake pipe, but do not tighten it.
(d) Slowly step down and press on the brake pedal, check if the brake fluid flowing out of the connector
contains bubbles.
(e) Tighten the pipe fitting.
(f) Have the assistant loosen the pedal, wait for 15 s.
(g) Repeat the above steps until all the air is released.
(h) Take off the rear brake pipe connector, repeat the above steps.
(2) Wheel brake air releasing
(a) Check the brake fluid level inside the master cylinder’s reservoir and add to it if necessary. During the
entire air releasing period, check repeatedly and add promptly.
(b) Connect one end of the bleeder hose with the bleed screw and the other end immerged in the brake fluid.
(c) Have the assistant step on the pedal several times, raise the pedal gradually until it cannot be stepped on
any more, then forcibly press on the pedal once more.
(d) Loosen the bleed screw, check if there are any bubbles in the brake fluid flowing out. Meanwhile, slowly
lower the pedal.
(e) When the brake pedal is close to the stroke end or the out flowing brake fluid does not have any bubbles,
tighten the bleed screw.
(f) Have the assistant release the pedal and wait for 15 s.
(g) Repeat the above steps until there are no bubbles in the flowing brake fluid when the screw is loosened.
(h) Release the air for all the wheels in turn using the same method.
(i) After releasing the air from the entire system, switch the ignition to the on position.
(j) Inspect the stroke of the brake pedal and its reaction.
(k) Inspect the lighting condition of the brake warning lamp, and repeatedly perform maintenance or air
bleeding if necessary.
(l ) Add brake fluid to the reservoir until the specified fluid level, air bleeding is complete.

Brake Pedal
Components
Bushing
Brake pedal lever
Nut welding assembly
Brake pedal bracket
welding assembly
Limiting stopper
Center pin
Pedal pad
Pedal shaft
Cotter pin
Return spring
Areas of Importance
1. During removal, all components should be gently handled to avoid knocking, especially the junction
surface. All components should be placed in order to avoid losing or taking the wrong parts.
2. Keep all parts clean and free of dust, scuffs, rust, corrosion, oil build-up, or any other contaminants.
3. All rubbing surfaces in a relative motion must be coated with lubricant.
4. During installation, strictly adhere to the standard torque for installing nuts.
5. While installing the return spring, be careful to avoid operator injury from it bouncing back.
Troubleshooting
Symptoms Possible causes Eliminating methods
Brake pedal cannot return Return spring is broken Replace the spring
to the original position Return spring's fixed end comes off Check, secure in place
Feels slippery when Pedal pad is worn out Replace
stepping on the pedal Pedal pad comes off Reinstall
The plastic bushing is seriously worn out Replace
Stepping on the pedal
Spring broken Replace
produces abnormal noise
Spring's fixed end comes off Check, re-fix

Brake System 99
Disassembly of the brake pedal assembly

Lock nut 1. Remove the lock nut with an outer hexagonal wrench.
2. Remove the pedal shaft.

Caution: Please do not place the pedal shaft directly
on the ground, as to guarantee its cleanness.
Pedal shaft
3. Remove the brake pedal assembly.

Caution: Set it down gently to avoid damaging its
surface finish.
Pedal lever assembly
4. Remove the pedal pad, bushing, and limiting stopper

from the pedal lever assembly.
Caution: Ensure cleanliness of the entire set's surface.
Pedal pad
Installation of the brake pedal assembly

Axle tube 1. Apply lubricant on the inside of the axle tube-brake
pedal and the outside of the bushing, then install the
bushing into the axle tube-brake pedal.
Bushing

2. Install the pedal pad and limiting stopper to the pedal

lever.
Pedal pad Limiting stopper
3. Apply lubricant on the inner bushing and the outer

pedal shaft. Install the pedal lever assembly, pedal
shaft, and brake pedal bracket welding assembly.
4. Put on a nut, and tighten the nut and spring washer

using a 30 N·m torque.
Brake pedal examination and adjustment

1. Check if the pedal height is correct.
Height between pedal and the lower cowl panel: 109 mm
Pedal push rod's working empty stroke: 2 mm
2. Adjust pedal height if necessary.
(a) Disconnect the brake lamp's switch wire connector,
loosen the lock nuts, rotate the brake switch and
Pedal height unscrew it until no contact with the brake pedal's
limiting stopper.
(b) Loosen the control rod lock nut and use combination
pliers to rotate the control rod and adjust the brake
pedal height to its standard value. After arriving at the
standard value, tighten the lock nut, and make sure the
working empty stroke of the pedal push rod is 2 mm.
(c) Rotate the brake lamp's switch and push it in until it
barely contacts with the brake pedal limiting stopper,
continue rotating 1/2-1 circle, then tighten the lock nut.
(d) Connect the brake lamp's switch wire connector.
(e) When the brake pedal is loose, the brake lamp should
be off.

Brake System 101
3. Inspect the pedal free play.

When the engine is off, step on the brake pedal two to three
times, after the brake booster's influence is removed, push
the brake pedal by hand until resistance is felt, then measure
its movement (free play). Should satisfy standard value
regulation.
Pedal free play Pedal free play: 6-9 mm
4. Adjust pedal free play if necessary.
(a) If the stroke value is incorrect, rotate the pedal push
rod to adjust the free play.
(b) Start the engine to confirm the pedal free play.
(c) After adjusting the pedal free play, check the pedal
height.
(d) The relative height gap between the brake pedal and
the clutch pedal is 0-8 mm.
Pedal’s remaining distance
(e) The relative height gap between the brake pedal and
the accelerator pedal is 45±5 mm.
5. When the clearance between the brake pedal shaft
and the bushing is too big, one should remove and re-
place the pedal.
6. As shown, check if the pedal's remaining distance is
correct.

Parking Brake Control Mechanism Assembly

Components
Parking brake control mechanism assembly
Q1460825
Right parking brake cable assembly
Q1420612
B
Q32006 Q1420616
A
C D
B
D Q1420612
Parking brake lever removal and installation

Button
Control jacket
1. Removal
control lever (a) Remove the auxiliary facia console, and pull the park-
Dust cover ing brake lever to the lowest position.
(b) Remove the two hexagon head bolts used to stablize
the parking brake lever onto the vehicle floor.
(c) Loosen the parking brake cable's adjusting nuts with a
wrench, and take the cable out from the equalizing frame.
2. Installation
Complete the parking brake control mechanism's installation
Lock nut by reversing its removal sequence. Please pay attention to
Lock nut
the items below:
(a) The open end of the parking brake lever assembly's
Switch assembly Pull rod cable clamp should face down.
Adjusting nut
(b) While installing the parking brake lever, the assembly
Equalizing frame structure must be properly adjusted, which is usually 5
to 8 gears.
(c) The tightening torque of the coupling bolt for the
parking brake control mechanism assembly and vehicle
body is 20 N·m.

Brake System 103
Vacuum Booster with Brake Cylinder Assembly

Components
Oil cup cover
Oil cup body
Vacuum booster
Check valve
Check valve
seat
Pad
Fluid supply
sealing ring Lock nut
Cylinder body Coupling nut Rod clevis

Rectangular sealing ring
Areas of Importance
1. The vacuum booster with brake cylinder assembly is tightly connected with the brake pedal assembly on
the cowl panel using four nuts. It is also connected with the brake pedal push rod via an center pin and
lock pin. Thus before removal of the assembly, first loosen the rigid pipe fitting with an open-end wrench,
disconnect the lock pin and center pin using pliers, loosen the four nuts, and then proceed with the booster.
2. Tighten the lock nuts on brake master cylinder and vacuum booster according to the specified torque,
and coat with signal paint.
3. Dimensions between the rear housing head face and the adjusting fork hole center is adjusted to
standard before it leaves factory. Please do not adjust it again.
4. The vacuum booster valve rod on the vehicle must be in a free state.
5. The brake master cylinder's working agent is DOT4 brake fluid. It must not be mixed with any other
brake fluid.
Troubleshooting
Problems and symptoms Causes Eliminating methods
Master cylinder's oil reservoir is The master cylinder, slave cylinder, or hydraulic line Eliminate the areas with leaks (in general, it may be that
severely leaking is leaking. the pipe fitting's tightening torque is not enough, check
one by one and tighten as necessary)
1. Vacuum booster not sufficient 1. Under non-operating conditions, the vacuum booster 1. Replace the front and back gas seal and control valve
2. No boost when the engine is off leaks air. assembly.
3. May lead to unsteady engine idling 2. Front and rear housing connection are not sealed. 2. Replace the vacuum booster.
when severe 3. Booster's front and rear gas seal sealing failure. 3. Replace the vacuum check valve assembly.
4. Vacuum check valve leaks.
Brake pedal is heavy with no boost 1.Under non-operating conditions, the vacuum booster 1. Replace the front, back gas seal and booster diaphragm.
effect leaks air. 2. Replace the vacuum booster.
2. Booster diaphragm worn and damaged. 3. Replace the control valve assembly.
3. Control valve ring cup worn and damaged.
Spongy pedal when braking 1. There is air in the brake fluid. 1. Eliminate the air in the system.
2. Cylinder or slave cylinder leaks oil. 2. Inspect the cylinder and sub-pump cup and replace
3. There is brake line seepage. with new parts.
3. Inspect the pipeline and eliminate the seepage.
When continuously step on the brake Pump valve opening blockage. Brake fluid cleanliness is insufficient, please replace the
pedal, the pedal will gradually change brake fluid.
and expand till the highest extend.

Push rod: Stepping onto the pedal Removal of the vacuum booster
in order to pass the force
with brake cylinder assembly
1. Discharge the vacuum.
If there is vacuum inside of the booster, before removal, step
on the brake pedal 3-5 times, so as to discharge the vacuum.
Oil cup cover 2. Oil discharge.

To avoid a large amount of brake fluid flowing out when
removing the brake pump, it's suggested to siphon the brake
fluid from the reservoir into another container using a hose,
or loosen the drain connector and collect the fluid in the
container, then drain the brake fluid inside of the pump by
stepping on the brake pedal.
Hose
Clean container
3. Remove the drain connection.

Use a M10 open-end wrench to remove the drain pipe
connection, promptly plug the outlet port to prevent pollution.
Unscrew the drain connection
4. Use needle nose pliers to remove the lock pin from

the vacuum booster and the brake pedal's connecting
center pin.
Lock pin
5. Remove the vacuum booster's push rod and the pedal's

connecting center pin, and remove the return spring.
Center pin
Return spring

Brake System 105
6. Screw off the coupling bolt between the vacuum booster

and the pedal bracket with a M13 sleeve.
Bolt
7. Extract the vacuum booster with brake cylinder assem-

bly.
Removal of the vacuum booster with brake cylinder assembly
is now complete.
Disassembling the vacuum booster with

brake cylinder assembly
1. Brake master pump removal.
Take down the lock nuts between the fixed brake master
pump and front case with a M13 sleeve, and then forcibly
pull out the brake master pump.
Lock nut Caution: Do not lose the rectangular sealing ring.
Rectangular
sealing ring
2. Remove the brake reservoir assembly.

Push out the elastic cylindrical pin from the hole of the oil
cup’s foot with a suitably sized screwdriver, and then pull
out the oil cup from the pump in the direction as shown on
the left. If necessary to take off the brake reservoir cover,
twist it off manually.
Elastic cylindrical
pin
Check valve Check valve seat 3. Remove the check valve assembly.
Pull out the check valve and valve seat from the vacuum
booster's front case as shown on the left.

4. Remove the dust cover.

If necessary to replace the dust cover, replace it using the
Dust cover Nut following steps.
(a) Twist off the rod clevis.
(b) Screw off the nut.
(c) Pull out the split ring.
(d) Pull out the dust cover.
Rod clevis Removal of the vacuum booster with brake cylinder
assembly is now complete.
Split ring
Vacuum booster with brake cylinder assem-

bly installation
1. Install the brake cylinder assembly.
Tighten the cover of the brake reservoir, place the outlet
port of the brake reservoir against the master cylinder inlet,
push the brake reservoir assembly into the master cylinder
assembly, and then insert the cylindrical pin to complete the
installation.
Caution: Check and ensure the cleanliness of the
Elastic cylindrical pin reservoir outlet port and master cylinder inlet. Do not
lose the sealing ring inside the master cylinder inlet.
Check valve Check valve seat 2. Installation of the vacuum booster assembly.
Install each part of booster using the following steps.
(a) Install the check valve seat.
Dust cover (b) Install the check valve.
Lock nut (c) Install the dust cover.
(d) Install the split ring.
(e) Install the lock nut.
(f) Install the rod clevis.
Rod clevis
Split ring
3. Installaion of the vacuum booster assembly and brake

Rectangular sealing ring cylinder assembly.
(a) Install the rectangular sealing ring, and then place the
brake pump assembly into the front case’s housing. Pay
attention when pushing the booster's push rod head into
the first piston hole.
(b) Put the two holes of the cylinder body’s flange surface
into the front case bolts of the vacuum booster, and
First piston then tighten the nuts with a torque wrench.
4. The installation of the vacuum booster with brake

cylinder assembly is the reversed procedure of its
removal. Hence no more elaboration will be provided
here.
Tightening torque of the four lock bolts on the brake
pedal: 23±3 N·m
Tightening torque of master cylinder outlet port rigid
pipe: 15 N·m

Brake System 107
Anti-lock Brake System

ABS/EBD introduction
1. Operation
The vehicle's Anti-lock Brake System (ABS) is a type of increasingly popular brake safety device. It detects the
wheel's speed using wheel speed sensor detection. After signal processing, the wheel speed will be transferred
to the computer, which controls the solenoid valve’s operating condition and the pressure inside the brake wheel
cylinder to avoid wheel locking by using certain calculations and control methods based on the wheel speed.
ABS helps the vehicle to avoid sliding, deviation, fishtailing, and losing steering control capacity. ABS improves
the vehicle’s handling capability, stability and shortens braking distance. It also helps the vehicle to avoid the
partial wear and tear of wheels, hence improves the tire's useful life.
Electronic Brake Distribution (EBD) is used to adjust the vehicle's rear wheel brake pressure by using the ABS
components when the ABS does not respond to vehicle braking. It is also used to balance the vehicle’s front and
rear wheel brake pressure, maximizing the vehicle's braking efficiency. EBD uses the ABS components, yet its
controlling logic is independent from the ABS. After the ABS responds, the EBD will disengage.
2. Basic structure
ABS control unit
Vacuum booster & master cylinder
Wheel speed signal Valve work instruction
Wheel speed sensor
Hydraulic modulator
Wheel cylinder
3. ABS working process

(a) Pressure rising phase: While service braking, oil pressure output from the pump passes the inlet solenoid
valve and enters the brake wheel cylinder. The brake generates braking force and the wheel speed sharply
declines until the ABS control unit detects that the wheel is starting to lock via the wheel speed sensor
detection.
(b) Pressure maintaining phase: When the ABS control unit detects that the wheel is starting to lock via wheel
speed sensor signal, the inlet solenoid valve closes, with the outlet solenoid valve shut as usual. The
pressure maintaining phase thus begins.
(c) Pressure drop phrase: During the pressure maintaining phase, the wheels tend to lock further. This brings
the ABS into the pressure drop phrase. With the inlet valve closed and the outlet valve open, the hydraulic
pump starts working, and brake fluid returns to the brake pump from the wheel cylinder by passing through
the low pressure accumulator. The brake pressure reduces and the brake pedal bounces back.
(d) Pressure maintaining phase: With the degree of wheel locking decreases and wheel speed begins to
increase, the pressure maintaining phrase begins.
(e) Next cycle’s pressure rising phase: When the wheels reach a certain speed, the ABS enters the pressure rise
phase and starts the next cycle.
Note: The ABS's pressure adjusting frequency is generally 2 to 4 cycles per second.

Vehicle speed
Wheel slippage
Wheel speed
Master cylinder
pressure
Wheel cylinder
brake pressure
4. EBD working process

The EBD comes into effect when the wheel brakes are lightly applied. The wheel speed sensor detects the speed
of the wheels, and the ECU calculates the speed. If the rear wheel's slip ratio increases, adjust the brake pressure
to maintain or reduce the rear wheel's braking force. The EBD guarantees the rear wheel's lateral force and even
brake force distribution. If the ABS fails to respond, the electronic brake distribution system can still adjust the
rear wheel's braking force to guarantee the rear wheels do not lock before the front wheels, in order to ensure
vehicle safety.
The EBD's working process for lifting and holding pressure is completely the same as it of the ABS working
process. However, the process for lowering pressure is quite different. When the rear wheel has a tendency to
lock up, the normally open valve of the rear wheel closes, the normally closed valve opens, and the rear wheel
pressure reduces. The difference with ABS is that the hydraulic pump does not operate at this time, and the brake
fluid released during depressurization is temporarily stored in the low pressure accumulator. After braking,the brake
pedal is loosened, and the brake pressure inside the pump drops to zero. Open the normally closed valve one more
time at this point. The brake fluid inside the low pressure accumulator returns to the pump by passing through the
normally closed valve and normally open valve. Empty the low pressure accumulator to prepare for the next brake.
ABS installation
ABS controller 1. Install the ABS controller assembly.
assembly (a) Use three hexagon bolts for flange face (Q1840825) to
ABS hydraulic pressure
fix the ABS bracket assembly onto the vehicle body.
pump shock pad (b) Fix the shock pad of the ABS hydraulic pump onto the
mounting holes of the ABS bracket assembly.
ABS mounting (c) Insert the mount pin of the ABS controller assembly
bracket assembly into the shock pad holes by simply inserting the two
anchor pins into the bracket.
2. Install the ABS front wheel speed sensor with bracket

Wheel speed sensor assembly.
with bracket assembly (a) Use a hexagon head bolt, spring washer, and flat
washer subassembly to connect the sensor and the
steering knuckle.
(b) Use a hexagon head bolt and a flat washer subassembly
Steering knuckle
(M8) to connect the sensor bracket and the damper.
Propeller shaft (c) Use a hexagon head bolt and a flat washer subassembly
(M6) to connect the sensor bracket and vehicle body.

Brake System 109
3. Installing the ABS rear wheel speed sensor with brack-

Rear wheel speed sensor et assembly.
with bracket assembly Use three hexagon head bolts, spring washers, and flat
washer subassembly connecting pieces to connect the sensor
Hexagon head bolt,
Rear hub unit spring washer, to the rear hub unit, rear twist beam, and vehicle body.
assembly and flat washer
subassembly
Hexagon head bolt,

spring washer, and flat
washer subassembly
ABS General Problem Maintenance and Areas of Importance

Common problems and solutions
1. When braking, the ABS hydraulic pressure unit noise is overly loud.
When the ABS is working, the motor inside the hydraulic pressure unit is ceaselessly rotating. At this time the
driver can feel the brake pedal bouncing back. However, this bounce back feeling will be entirely different
depending on the speed and road condition. Also, when performing an actuator movement test, the sound of the
running motor may also be sensed. When the vehicle is being driven and the brake is off, the sound of the motor
running can still occasionally be heard. This is the ABS undergoing component inspection, not a malfunction.
If the ABS hydraulic pressure unit noise is irregular, a movement test can be initiated. Compare the noise to that
of normal vehicles to determine if ABS hydraulic pressure unit noise is abnormal.
2. Inlet and outlet solenoid valve failure.
Once the ignition switch is ON, the ABS control unit automatically initiates a self-check. If an inlet and outlet solenoid
valve short circuit or open circuit is found, it will record the failure, light up the fault light, and abort the operation. If using a
scanner to adjust the problem code, make sure to use the movement test to confirm that the solenoid valve has a problem and
then replace the hydraulic pressure unit directly.
X431 data flow: While the ABS is functioning, the inlet and outlet solenoid valves rapidly change operating
conditions.
EVFL - Front inlet valve LH Off / On
AVFL - Front outlet valve LH Off / On
EVFR - Front outlet valve RH Off / On
AVFR - Rront outlet valve RH Off / On
EVRR - Rear inlet valve LH Off / On
AVRR - Rear outlet valve LH Off / On
EVRR - Rear inlet valve RH Off / On
AVRR - Rear outlet valve RH Off / On
3. Wheel speed sensor malfunction.
With the engine running, use a oscilloscope to measure the voltage between the sensor's signal line and the
ground.
Output signal when wheel is stationary:
v or v
0 0
t t
Output signal when the wheels are rotating: signal type is 0.44 V and 1.26 V square wave signal, duty cycle: 50: 50.
0
t

The X431 scanner possesses a waveform function. Wheel speed signal error (wheel speed sensor failure)
only appears when intermittent problems occure, such as high speed. When in use, some signal errors may
occasionally appear. Continue observing the waveform to make sure there is nothing abnormal.When driving
the vehicle on a flat and straight road, all four wheels' speed sensor waveform are extremely similar. One can
compare the two front wheels' with the two rear wheels' signal wave at the same time.
Mechanical causes:
Signal gear distortion, loosened hub bearings, smudges on the sensor surface, etc, all may lead to wheel speed
signal intermittency and inaccuracy. Failure examples:
V( Km/h)
60
30
Signal interrupt
As shown above, once the intermittent failures with the wheel's speed sensor signal are detected, the ABS
control unit records the sensor problems and lights up the warning lamp.
4. Wheel speed sensor velocity failure (ECU detects an excessive difference between the two wheels'
speed sensor signals).
Possible causes are the gear's wheel speed sensor gap is overly large, or the wheel speed sensor signal is
experiencing interference. For this, first determine which sensor is emitting the signal, and then use failure
three's maintenance methods.
Areas of Importance
1. Sometimes, in order to determine whether there is a common brake system problem or an ABS
problem, the ABS must be terminated by pulling out its ABSECU connector or fuse. At this time the
ABS/EBD loses function as well. On muddy, icy, or snowy roads, the vehicle may fishtail or slide, in
which cases one must be extremely careful to avoid hard braking.
2. The ABS malfunction rate is extremely low, when the brake system shows any problem (before the
warning lamp goes on), first eliminate the normal brake system problems, then consider the ABS mal-
functions.
3. When raining or on gravel, this adjusting process is longer than the standard process, because this
kind of road's unstable adhesion coefficient will lead to a difference between the sliding measurement
and calculation procedures, thus it is necessary to remind drivers to be especially careful when driving
under the circumstances mentioned above.
4. ABSECU Areas of Importance:
(a) The ABSECU is easily damaged from impacts or collisions, thus pay attention to ensure the ECU avoids
such incidents.
(b) High temperature environments can also easily damage the ECU, so when the vehicle undergoes hot paint
work, make sure to first take the ECU out of the vehicle.
(c) When the power switch is ON, do not disassemble the system's electrical elements and wire harness plugs,
in order to avoid damage to the ECU. If removal or installation must be carried out, be sure to disconnect
the ignition switch firstly. When welding components or circuits to the system, the wire harness plug

Brake System 111
should also be removed from the ECU.

(d) Do not let oil contaminate the ECU. Be especially careful of the ECU terminals, otherwise it might obstruct
the connection among terminals of the wire harness plug.
Note: The BOSCH ABS8.0 hydraulic pressure unit (integrated into the ECU) is not serviceable. If
damaged, the whole unit must be replaced.
ABS trouble code list

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

Steering Knuckle and Hub Brake Assembly

Components
Front brake caliper assembly LH
Copper washer
Front brake disc Hollow bolt
Wheel bolt
♦Heavy duty spring washer

100 ± 10
Front hub flange 9±2
♦Hexagon head bolt and

spring washer subassembly
Left brake disc cover

♦Front hub
Left steering knuckle bearing assembly
Snap ring for hole 72
Disposable parts
Steering knuckle and hub brake assembly

examination and disassembly
1. Hoist the vehicle and remove the wheels.
2. Loosen the riveted areas of the front drive shaft nut
and remove the nut.
3. Inspect the front brake disc plate surface runout.
When measuring, tighten the two wheel nuts' symmetrical
locations. The front brake disc's brake linings runout on the
two sides should be no more than 0.11 mm. If oversized,
they should be repaired or replaced.
4. Inspect front brake disc thickness.
Standard thickness: 22.0 mm
The brake disc must be changed when it reaches the minimum
level of thickness.

Brake System 113
5. Remove the front brake caliper.

Unscrew the fastened front brake caliper's bolt to remove the
brake caliper.
Caution: Remove the front brake caliper and use wire
or similar objects to firmly secure the brake caliper.
(Avoid excessive twisting, bending, or pulling off the
brake pipeline).
6. Remove the front brake disc.

After driving the vehicle for some time, it may be hard to
remove the brake discs. In this case, screw two M8 bolts
into the removed brake disc's threaded holes (refer to the left
picture for locations), and use a wrench to alternately turns
the two bolts, thereby ejecting the brake disc.
7. Inspect the front brake disc.
Inspect the wear and tear of the front brake disc. If the
brake disc has obvious scuffing, the plate surface runout
is oversized, or its thickness is smaller than the minimum
thickness, the brake disc should be replaced.
8. Remove the front brake disc cover.

Remove the fastened brake disc cover bolts with a wrench, and
remove the front brake disc cover.
9. Remove the steering knuckle's front hub bearing and

front hub flange assembly.
Suggestion: The steering knuckle's front hub bearing and
front hub flange assembly, under normal circumstances,
should not undergo disassembly. If determined to have a
problem, it should be replaced in its entirety.
10. Inspect the steering knuckle's front hub bearing and

(a) Use dye penetrant to inspect the steering knuckle for
cracks, deformities, and damage. If found, replace the
part.
(b) Rotate the front hub flange and examine the bearing for
flexible rotation. Also make sure there is no appearance
of clamping.
(c) Measure the front hub flange plate surface runout.
Caution: Runout should not exceed 0.03 mm.

(d) Measure the front hub bearing's starting torque.

SST Put the SST on the wheel bolts which are at the symmetric
locations. Put a dial torque wrench on the SST to slowly
rotate the flange assembly (45°/4s), requiring a starting
torque range of 0.1-0.3 N·m.
If the bearing rotation is not flexible, the front hub flange
plate surface movement inaccurate, or front hub bearing
starting torque is too much. The assembly must be replaced.
Steering knuckle's front hub bearing and

Bearing inner ring
front hub flange assembly
1. Removal and inspection of front hub flange assembly.
(a) Use SST like a hand held travel hammer to repeatedly
SST hammer off the front hub flange assembly from the
steering knuckle and front hub bearing. Remove the
front hub with bearing's inner ring.
(b) Remove the bearing's inner ring on the front hub.

Use SST to remove the bearing's inner ring.
SST
(c) Use dye penetrant to inspect the front hub flange for
cracks, which should be replaced if found.
(d) If one would like to continue using the front hub flange
assembly, first inspect the dimensions for the mounting
area of the bearing for inaccurate dimensions. If
oversized, replace.
Measurement range: Φ38+0.025 +0.009 mm
2. Remove the steering knuckle's front hub bearing.

3. Remove the snap ring for hole 72.
Use a bent nose retaining ring caliper for holes to remove the
snap ring for hole 72.

Brake System 115
4. Replace the removed bearing's inner ring back to the

bearing's original position.
5. Press out the front hub bearing from inside of the steer-
ing knuckle.
On the press, withstand the bearing inner ring that was put
SST on with SST, and press out the entire front hub bearing.
Caution: The front hub bearing assembly is a disposable
part, which needs to be replaced with a new one.
SST
6. If the steering knuckle has no cracks and one would

like to continue to use it, first inspect the bearing's
mounting location dimensions of the steering knuckle's
inner hole. If the measurements are oversized, replace
the steering knuckle.
Measurement range: Φ71-0.032
-0.062 mm
Steering knuckle and hub brake assembly

SST installation
1. On the press, press the front hub bearing assembly
into the steering knuckle hole bearing mounting posi-
tion with SST.
2. Press the front hub flange assembly.

On the press, press the front hub flange into the front hub
bearing mounting position using SST.
SST
SST

3. Examine the front hub flange plate surface runout.

Examining methods are the same as the methods used
during disassembly. Plate surface runout should not exceed
0.03 mm.
4. Examine the front hub bearing assembly's starting

SST torque.
Examining methods are the same as the methods used during
disassembly. Put the SST on the wheel bolts which are at the
symmetrical locations. Put a dial torque wrench on the SST to
slowly rotate the flange's flange assembly (45°/4s), which re-
quires a starting torque range of 0.1-0.3 N·m
5. Install the snap ring for hole 72.

Use a bent nose retaining ring caliper for holes to install the
snap ring for hole 72 at the steering knuckle's retaining ring
mounting position.
6. Install the steering knuckle's front hub bearing and

7. Install the front brake disc cover.
Install the front brake disc cover on the steering knuckle, and
tighten the bolt to the set torque.
8. Install the front brake disc.

Brake System 117
9. Examine the front brake disc plate surface runout.

When measuring, tighten the two wheel nut's symmetrical
locations. The front brake disc's brake linings runout on the
two sides should be less than 0.11 mm.
10. Install the brake caliper assembly.

Install the brake caliper on the steering knuckle, and tighten
the bolt according to the set torque.

Front Brake Caliper

Components
30 ± 5
Q1840820
Caliper
Rectangular sealing ring

Air bleed
screw
Inner brake pad assembly 10 ± 2
Outer brake pad assembly Bleed screw cap

Piston
Piston dust cover

Guide pin dust cover
Brake block yoke
spring plate Inner muffler plate subassembly
Alarm plate
Outer muffler plate subassembly
Guide pin
Caliper frame Brake block yoke spring plate
Rubber grease
Disposable parts
Inner and outer brake pad assembly re-

placement
Remark: When applying the brake while driving, if the front
tires makes a continuous screeching sound, inspect the inner
and outer brake pad and friction limit alarm plate. If there
are traces of rubbing from the brake disc on the alarm plate,
the inner and outer brake pad assembly should be replaced.
1. Remove the front wheel.
2. Inspect the inner and outer brake pad's friction material

thickness.
By looking through the caliper's observation ports, inspect
the inner and outer brake pad friction material thickness. If it
is no longer within the specified range, it should be replaced.

Brake System 119
3. Remove the caliper assembly.

(a) Remove the hexagon bolt for flange face connecting
the caliper and caliper frame's lower end.
(b) Lift the caliper assembly and use a rope to hang it up to

protect the brake pipeline.
Remark: Do not unscrew the brake pipeline and bleed screw.
4. Remove the following parts.

Outer brake disc Inner shim B (a) The group of inner and outer shims B.
Outer shim B Warning device (b) The group of inner and outer shims A.
(c) The group of inner and outer brake discs.
(d) One pair of yoke springs.
Yoke spring
Outer shim A Inner brake disc Inner shim A
5. Measure the brake disc thickness.

(See steering knuckle and hub brake assembly examination and
disassembly step 4).
6. Measure the brake disc radial runout.
(See steering knuckle and hub brake assembly examination and
disassembly step 3).
7. Install the yoke spring.

Install the brake block yoke spring plate to the caliper frame.

8. Install a new inner and outer brake pad assembly and

Outer shim B Outer brake disc Inner shim B inner and outer muffler plate subassembly.
Warning device (a) Install inner shim A and B onto the inner brake disc.
(b) Install outer shim A and B onto the outer brake disc.
Outer shim A Inner brake disc Inner shim A
(c) Install the inner and outer brake pad assembly with
inner muffler plate subassembly onto the caliper frame.
Inner brake pad assembly Make the inner brake pad assembly with inner muffler
plate subassembly and alarm plate rest close to the
Outer brake pad brake caliper's inner side.
assembly
Caution: For the inner and outer brake pad assembly,
Inner muffler
plate subassembly the working surface of the brake disc must not have
Alarm plate any grease, oil or paint pollution.
(d) Siphon a small amount of brake fluid from the

reservoir. (Make sure not to let the brake fluid overflow
from the reservoir).
SST (e) Press in the piston with SST.
9. Install the caliper assembly.

Loosen the rope, remove the caliper assembly, and tighten
the hexagon bolt for flange face.
Remark: Replace one wheel's brake pad at a time, in order to
avoid the other wheel's piston from springing out.
10. Install the front wheel.
Tightening torque for the wheel retaining nut: 100±5 N·m
Front brake caliper piston removal

1. Remove the brake line.
Remove the brake line, and use a clean container to hold the
brake fluid.

Brake System 121
2. Remove the caliper assembly.

(a) Remove the two hexagon bolts for flange face connecting
the caliper and caliper frame.
(b) Remove the caliper assembly from the caliper frame.
3. Remove the following parts.

(a) The group of inner and outer shims B.
(b) The group of inner and outer shims A.
(c) The group of inner and outer brake discs.
(d) One pair of yoke springs.
4. Remove the piston and piston dust cover from the

caliper.
(a) Place a block in the middle of the caliper.
(b) Use an airgun or air pipe to align the brake pipeline
holes. Remove the piston from the caliper, and at the
same time remove the piston dust cover.
(c) Use a clean rag or other soft cloth to extract the piston.
Warning: When using compressed air, be sure not to
place fingers in front of the piston.
5. Remove the rectangular sealing ring from the caliper.

Use a paperclip to remove the rectangular sealing ring from
the caliper.
Caution: The tools being used should not be sharp, in
order to avoid tearing the rectangular sealing ring.
Inner and outer brake pad assembly exami-

nation
Measure the inner and outer brake pad assembly's thickness.
If it is smaller than the minimum level of thickness or there
are traces of uneven wear and tear, the brake pad should be
replaced.

Front brake caliper assembly installation

1. Preparations
Make sure all parts are clean and free of foreign materials
before installation.When installing, apply an appropriate
amount of rubber grease to the guide pin and piston's
working surface, as well as the rectangular sealing ring and
the piston protective cover's working surface.
2. Install the rectangular sealing ring to the caliper.

(a) Screw the bleed screw into the caliper's vent holes.
(b) After applying an appropriate amount of rubber grease
on the rectangular sealing ring's working surface, install
them into the caliper's seal groove.
3. Install the piston with piston dust cover on the caliper.

(a) Place the piston dust cover on the piston.
(b) Stretch the piston dust cover, until its card holder
exposes the bottom of the piston. Use tools (for
example, about Ф2 mm of iron wire) to assist by
stuffing the card holder into the cylinder bore card
holder's groove.
Caution: The tools being used should not be sharp, as
to avoid tearing the dust cover.
(c) Then manually press the piston into the bottom of the
cylinder bore.
Guide pin dust cover 4. Install the guide pin and guide pin dust cover onto the
caliper frame.
Guide pin
(a) Install the guide pin dust cover onto the guide pin.
(b) Screw the guide pin into the caliper frame.
Caution: Do not damage the guide pin dust cover.
5. Install an inner and outer brake pad assembly and
inner and outer muffler plate subassembly.
Caliper frame Brake block yoke
spring plate
6. Install the brake block yoke spring plate as well as the

Caliper Air bleed inner and outer brake pad assembly and inner and
screw
outer muffler plate subassembly on the caliper frame.
Inner brake pad assembly
Outer brake pad

assembly Air bleed
screw cap
Inner muffler plate
subassembly
Alarm plate

Brake System 123
7. Install the caliper assembly.

(a) Install the caliper assembly.
(b) Install and tighten the hexagon bolt for flange face.
8. Connect the brake line.

Connect the brake pipeline to the caliper.
9. Fill the brake reservoir up with brake fluid and exhaust
the air from the brake system.
10. Check for leaking brake fluid.
Caution: Bleed the air after replacing.

Rear Brake
Components
Dust cover
Bleed screw
Piston
Wheel cylinder
Bleed screw cap Ring cup
Rubber plug of the Piston spring
adjuster's observation port Ring cup
Rubber plug of the Piston Adjusting clearance shaft head

observation port gap Dust cover Adjusting clearance wheel
7.8-11.8 Washer
Return spring
Adjusting
paddle Brake leading shoe assembly
Adjusting
clearance Pin Rear brake drum
screw rod
Pressure spring
Pressure spring bar
Pressure spring cap
Lever
rotating Locking cap
shaft
Split ring
Brake lever
Side spring
Brake back plate assembly
Brake trailing Retainer spring
High temperature resistant shoe assembly
grease Brake shoe tension spring
Rubber grease
Disposable parts
Rear brake removal

1. Inspecting the brake's friction plate thickness.
Remove the rubber plug of the observation port gap and
examine the friction plate thickness via the observation port.
If it's smaller than the minimum value, the brake's leading
and trailing shoe assemblies should be replaced.
2. Remove the rear wheel.
3. Release the brake fluid.
Caution: Be sure not to spill the brake fluid onto the
paint's surface. Otherwise it must be immediately
cleaned.
4. Remove the rear brake drum.
Remark: If it is difficult to remove the rear brake drum,
follow the steps below:
Method one:
(a) Remove the rubber plug of the adjuster's observation
port, and insert a slotted screwdriver into the brake's
back plate assembly hole, and pry off the adjusting
paddle from the adjusting clearance wheel.
(b) Use another slotted screwdriver to toggle the adjusting
clearance wheel and loosen the brake's leading and
trailing shoe assembly's tension on the rear brake drum.

Brake System 125
Method two:
(a) Find two M6×40 (the thread is longer than 25 mm)
phillip screws, and screw them into the rear brake
drum's two threaded holes.
M6×40
(b) Use a screwdriver to tighten the phillip screw, and push
out the rear brake drum.
Caution: Alternately tighten the two screws.
5. Remove the brake leading and trailing shoe assembly

and adjusting paddle.
SST (a) Use SST (Special Service Tools) to separate and remove
the pressure spring cap of the brake leading and trail-
ing shoe assembly, and remove the pressure spring and
pressure spring bar.
(b) Take out the brake leading and trailing shoe assembly
from the brake back plate assembly, take down the
retainer spring, and remove the cable connector.
Remark: When taking out the brake leading and trailing
shoe assembly from the brake back plate assembly, screw
the adjusting clearance wheel thread completely into the
adjusting clearance screw rod, decrease the return spring's
tension on the brake leading and trailing shoe assembly.
(c) Use needle nose pliers to remove the brake shoe tension
spring, and take down the adjusting paddle.
(d) Use pliers to remove the return spring from the brake
leading and trailing shoe assembly, and separate the
brake leading and trailing shoe assembly.

6. Remove the return spring and ratchet adjuster assem-

bly.
(a) Remove the adjusting clearance shaft head.
(b) Remove the adjusting clearance wheel.
(c) Remove the return spring.
7. Remove the parking brake lever.

(a) Remove the split ring with pliers.
(b) Remove the brake lever rotating shaft.
(c) Remove the brake lever.
Caution: If it is the riveted structure, there is no need to
remove the parking brake lever, instead of replace the
brake trailing shoe assembly.
8. Remove the brake wheel cylinder.

(a) Remove the brake line with a M10 open-end wrench,
and use a clean plug to clog it.
(b) Use a M8 open-end wrench to remove the two bolts, thus
removing the wheel cylinder assembly.
9. Remove the following parts from the wheel cylinder as-

sembly.
(a) Two dust covers.
(b) Two pistons.
(c) One piston spring.
(d) Bleed screw.
(e) Bleed screw cap.
Brake components inspection

and maintenance
1. Inspect the components after disassembly.
After disassembling the components, check them for wear
and tear, rust, and damage.
2. Measure the rear brake drum's internal diameter.
Standard internal diameter: Ф200 mm
Maximum internal diameter: Ф201 mm

Brake System 127
3. Measure friction plate thickness.

If the friction plate thickness is smaller than the minimum
value or produces uneven wear and tear, the brake leading
and trailing shoe assemblies should be replaced.
Remark: If one of the brake shoe assembly needs to be
replaced, be sure to replace all the rear brake leading and
trailing shoe assemblies to ensure even braking ability.
4. Check to make sure the contacts of the friction plate

and rear brake drum are fine.
If the contacts of the friction plate and rear brake drum is not
good, the brake leading and trailing shoe assemblies should
be replaced.

Rear Brake Installation
Caution: Refer to the diagram for installation directions.
Foreward Foreward
Left wheel Right wheel
1. Install the brake wheel cylinder.

(a) Apply a small amount of lithium grease onto two piston
assemblies.
(b) Install the wheel cylinder assembly.
• Install two dust covers onto the two piston assemblies.
• Install a piston spring and two piston components in the
wheel cylinder body.
Remark: Refer to the diagram for precise installation
directions.
2. Install the wheel cylinder assembly.

(a) Use two bolts to install the wheel cylinder assembly
onto the brake back plate assembly.
Tightening torque: 7.8-11.8 N·m
(b) Connect the brake line to the wheel cylinder assembly.
3. Apply an appropriate amount of grease to the following

parts.
(a) Apply a small amount of high temperature resistant
grease on the brake back plate assembly and the brake
shoe connection's six convex plate surface.

Brake System 129
(b) Apply a small amount of lithium grease on the brake

leading shoe assembly and brake trailing shoe assembly
(refer to the arrows in the diagram for indicated areas).
Remark: Do not contaminate the friction plate.
(c) Insert the return spring into the adjusting clearance

screw rod and apply an appropriate amount of lithium
grease on the adjusting clearance wheel's thread and
screw, adjusting clearance screw rod's shaft head,
and adjusting clearance shaft's shaft head (refer to the
arrows in the diagram for locations).
4. Install the brake lever on the brake trailing shoe as-

sembly.
(a) Install the parking brake lever and insert the lever rotat-
ing shaft.
(b) Use pliers to install a new split ring in the lever rotating
shaft.
5. Install the return spring and ratchet adjuster assembly

on the brake leading shoe assembly and brake trailing
shoe with brake lever assembly.
Hang one side of the return spring on the brake leading shoe
assembly, and use pliers to hang the other side of the return
spring on the brake trailing shoe with brake lever assembly.
6. Install the adjusting paddle on the brake leading shoe

assembly.
(a) Install the adjusting paddle on the brake leading shoe
assembly.
(b) Use needle nose pliers to install the brake shoe tension
spring on the adjusting paddle and brake leading shoe
assembly.

7. Install the brake cable connector on the brake trailing

(a) Install the brake cable connector on the brake trailing
(b) Insert the brake trailing shoe with brake lever assembly
and the shoe end of the brake leading shoe assembly
into the wheel cylinder assembly.
Remark: Do not let oil or grease drip on the brake shoe's
lining.
8. Install the retainer spring.
9. Install the brake leading and trailing shoe assemblies

onto the brake back plate assembly.
SST (a) Insert the pressure spring bar into the brake back plate
assembly and brake leading and trailing shoe assemblies.
(b) Put the pressure spring on the pressure spring bar,
put in the pressure spring cap, and use SST (Special
Service Tools) to lock the pressure spring cap onto the
pressure spring bar.
10. Inspect the operating procedures of the automatic ad-

juster.
(a) Refer to the diagram for directions, step on and off the
brake pedal, and make sure the self-adjusting screws
can rotate. If they are unable to rotate, inspect the rear
brake to try to determine the source of the problem.
(b) Adjust the adjusting mechanisms length and make it as
short as possible.
(c) Install the rear brake drum.
(d) Press the brake pedal towards the floor until a clicking
noise cannot be heard.
11. Inspect the space between the brake's friction plate
and rear brake drum.
(a) Remove the rear brake drum.
(b) Measure the rear brake drum's internal diameter and
the brake shoe friction plate's external diameter, and
inspect if the difference between the two diameters is
within the regulated clearance range.
Single sided clearance: 0.25 mm
If not correct, inspect the braking system.
12. Install the rear wheel.
13. Fill the brake fluid reservoir up with brake fluid and
exhaust the air out of the brake system.
14. Check for leaking brake fluid

Brake System 131
Rear Support Axle

Components
100
9±1
Right parking brake
Spring cable assembly
Rear brake drum Trailing arm spindle sleeve
with nylon bushing assembly
Rear hub unit
9±1
Rear brake assembly LH
Spring
78-98
100
Rear twist beam assembly
Rear brake assembly RH

Rear hub unit
Rear brake drum

Disposable parts
Rear hub unit inspection and removal

1. Manually rotate the wheel according to the diagram,
and check the bearing of the rear hub unit for abnormal
noises and stiff rotation. If these flaws exist, please
replace the rear hub unit.
2. Remove the wheel.
3. Manually screw the two wheel nut's opposite angles on the

wheel bolt and fixed rear brake drum.
Remark: Alternately tighten the two nuts, and manually
screw it down as much as possible.

4. Measure the rear brake drum's outer end surface

runout.
Stick a dial indicator magnet to the rear wheel hub's
mounting bracket. Point the dial indicator to the rear brake
drum's outer end surface diameter at about a Φ136 mm
circumference (refer to diagrams dotted line area). Rotate the
rear brake drum, measure its runout, and maximum runout
0.11 mm is approval.
Caution: When the runout exceeds the maximum limit
of 0.11 mm, the rear hub unit should be replaced.
5. Remove the rear brake drum (See rear brake removal

step 4).
6. Examine the rear hub unit's starting torque.
(a) Manually rotate the rear hub unit and check for
abnormal sounds or looseness. If the above problems
exist, it should be replaced with a new rear hub unit.
(b) Use a spring dynamometer to inspect the load applica-
tion.
Load application (when start the engine): 1 N·m
Caution: If the load application is greater than 1 N·m,
the rear wheel hub unit must be replaced.
7. Use calipers to measure the rear brake drum's internal

diameter.
If the measured result exceeds 201 mm, the drum brake must
be replaced.
Trailing arm spindle sleeve assembly removal

1. Examine the trailing arm spindle sleeve.
(a) Inspect the trailing arm spindle sleeve for deformities,
shifting, partial or serious cracks, and the gaskets for
loosening.
(b) If it's not easy to see clearly any existing damage of

the trailing arm spindle sleeve, take the following
steps: Use clean water to wash the trailing arm spindle
sleeve's rubber areas. At the same time rub it clean with
cotton. Check and make sure the rubber surface has
none of the previously mentioned flaws. If the above
flaws exist, replace with a the new trailing arm spindle
Cotton sleeve assembly.

Brake System 133
2. Remove the trailing arm spindle sleeve.

(a) Mark with a white paint pen, and remember the
direction of the trailing arm spindle sleeve assembly .
(b) The trailing arm spindle sleeve is a disposable part. If
it is damaged, first use a pry bar to lift up the edge of
the trailing arm spindle sleeve's outer tube in order to
install SST.
(c) Use SST (Special Service Tools) to clog the spindle

sleeve's installation tube. Tighten the two bolts, twist
SST
them with a wrench and push out the spindle sleeve.
Caution: When performing the pressing out process,
be certain to ensure the trailing arm spindle sleeve is
vertically forced out.
3. Install the new trailing arm spindle sleeve with nylon

bushing assembly.
Steering alignment (a) Before installing the new trailing arm spindle sleeve
with nylon bushing assembly, first distinguish the
installation direction for the trailing arm spindle
SST sleeve's nylon bushing assembly, whereas the direction
of the nylon lining's four holes face one end of the
trailing arm.
Caution: Do not install the trailing arm spindle sleeve
with nylon bushing assembly in the opposite direction.
(b) Use SST to position the trailing arm spindle sleeve with
nylon bushing assembly, and slowly press it in.
Caution: When performing the pressing process, be
certain to ensure the trailing arm spindle sleeve is
vertically forced in.

Steering System
Steering System Maintenance............................................ 137
Power Steering Fluid Instructions........................................ 141
Technical Requirements...................................................... 141

Steering System 135
Troubleshooting
Fault
Malfunction Causes Troubleshooting
Symptoms
1. Too much clearance between the steering 1. Have the clearance adjusted by professionals,
gear and gear rack. and if it cannot be adjusted, replace the steer-
ing gear.
2. The inner and outer ball stud of the steering 2. After inspection, replace the ball stud if nec-
tie rod ball is worn out. essary.
3. Steering joint is worn out. 3. Replace the lower section of steering column.
Steering wheel
4. Steering propeller shaft and steering gear 4. Fasten the connection bolts in accordance
free play too
connection is loose. with the specified torque.
big / abnormal
5. Steering wheel and steering column connec- 5. Fasten the lock nut of the steering wheel.
noise
tor is loose. When the spline is damaged, make sure to re-
place the steering wheel or steering column.
6. Steering gear mounting bolt is loose. 6. Fasten the mounting bolts of the steering
gear.
7. The sliding spline of the lower propeller 7. Replace the lower section of steering column.
shaft is worn and loose.
1. Tire pressure insufficient. 1. Inflate according to the specified pressure.
2. Front wheel alignment angle incorrect. 2. Check and adjust the front wheel alignment
angle.
3. Clearance between the steering gear presses 3. Replace the steering gear or have profession-
too small. als adjust the clearance between the presses.
4. Steering column's spider bearing broken. 4. Replace the lower section of steering column.
5. Steering tie rod ball stud lacks oil or is dam- 5. Replace the lower section of the steering tie
aged. rod ball.
6. Front shock absorber's support bearing bro- 6. Replace the connecting components of the
ken. front shock absorber (refer to the front sus-
pension maintenance section).
7. Damaged lower swing arm ball end. 7. Replace the lower swing arm (refer to the
Hard steering front suspension maintenance section).
8. Damaged steering pump leads to insufficient 8. Replace the power steering pump.
output volume and output pressure.
9. Power steering pump belt slides. 9. Adjust the belt's tension.
10.Power steering gear internal leakage too 10. Replace the power steering gear.
much.
11. Power steering contains air bubbles and pro- 11.In place, repeatedly turn, exhaust the air
duces irregular noise. bubble, then after leaving it stationary for one
hour, replenish the power steering according
to the specific model number.
12. Power steering insufficient. 12.Fill the power steering (with specific model
number) until it reaches the PS fluid reser-
voir's specified scale mark.

Fault
Malfunction Causes Troubleshooting
Symptoms
1. Tire pressure insufficient. 1. Inflate according to the specified pressure.
2. Wheel counterweight falls off or other fac- 2. Recalibrate the wheel's dynamic balance.
tors cause extremely poor wheel balance.
3. Lower swing arm's rubber bushing is too old, 3. Replace the lower swing arm.
big difference between the left and right's
rigidity.
4. The front shock absorber's support bearing 4. Fill with grease of the specified model num-
and lower swing arm ball lacks sufficient lu- ber.
Poor steering
brications.
return
5. The four wheels' positional parameters incor- 5. Re-measure and adjust the four wheels' posi-
Straight
rect. tional parameters.
movement
6. Steering gear's gear rack meshing condition 6. Replace the steering gear.
stability poor
worsens and causes intense reverse resis-
tance.
7. Steering column bearing and spider bearing 7. Replace the steering column assembly.
damaged.
8. Power steering pump's oil supply insuffi- 8. Replace the power steering pump.
cient.
9. Inner portion of the steering gear's control 9. Replace the power steering gear.
valve performance degradation.

Steering System 137
Steering System Maintenance

Structure Introduction
The steering wheel has an airbag module which should only be inspected and repaired by a professional. The
steering column's upper section adopts a steel deformation and energy absorbing crumple structure which
ensures collision protection for the driver. The lower section uses a high precision sliding spline structure,
which can effectively eliminate structural interference caused by body deformation. The steering column angle
is adjustable, which can more easily adapt to the driver, and at the same time possesses reasonable reverse
efficiency to ensure the driver has a good feel for the road. Steering system is as shown below:
Steering wheel
PS fluid reservoir
Steering column
Steering propeller shaft

Power steering pump
Belt
Steering dust cover
Steering propeller shaft Steering protection plate

connector jacket assembly
Steering combination pipe Power steering gear
Steering column assembly removal and

installation
1. Remove the airbag.
(a) Disconnect the battery's negative cable, and wait for
one minute before canceling the airbags function in
order to avoid unnecessary injury.
(b) To ensure steering column's proper installation, during
the entire removal process, the front tires must keep
Hexagon screw straight.
(c) Remove the two hexagon screws and the airbag module.

Q32012 (M12×1.25) 2. Remove the steering wheel.

(a) Remove the lock nut Q32012 (M12×1.25) of steering
wheel with a M18 socket wrench in the counterclock-
wise direction.
(b) Grip the entire steering wheel and shake it several
times, and then to pull out the steering wheel upwards.
Upper trim cover 3. Remove the upper and lower trim cover of the combina-
tion switch.
Lower trim cover
4. Remove the left and right combination switch and the

ignition lock.
(a) Pull out the wire harness on the left and right
Left Right combination switch and the ignition lock.
combination combination (b) Remove the left and right combination switch and the
switch switch ignition lock.
Ignition lock
5. Screw off the bolt 3404202-S08 connected the steering

column and steering propeller shaft with a M13 socket
wrench in the counterclockwise direction.
3404202-S08
Q1840820 (d2=22) 6. Screw off the two flange bolts Q1840820 (d2=22) which
are in the upper part of steering column connected
to instrument brace reinforcement with a M13 socket
wrench in the counterclockwise direction, and screw
off one flange bolt Q1840850 which is in the lower
part of steering column connected to instrument brace
reinforcement with a M10 socket wrench in the counter-
clockwise direction. Follow the column's upper axes
Q1840850 and pull out the steering column assembly.

Steering System 139
7. Manually rotate the two plastic buckles 3412012-S08 in

the counterclockwise direction, and remove the steer-
ing dust cover installed on the steering propeller shaft.
3412012-S08
8. Remove the bolt 3404202-S08 connecting the steering

propeller shaft and steering drive connection shaft with
a M13 socket wrench, and then pull out the propeller
shaft.
3404202-S08
9. Pull out the steering propeller connection shaft's jacket

assembly 3412100-S08. Remove the bolts 3404202-
3404202-S08 S08 which are on the steering propeller connection
3412100-S08 shaft and steering gear with a M13 socket wrench, and
then pull out steering propeller connection shaft.
10. Install the steering column assembly by reversing the

removal steps. Pay attention to items below:
(a) While installing the steering column and propeller
shaft, and propeller shaft and steering gear, after insert-
ing the screw into the threaded hole, the screw should
align perfectly with the circular groove, as shown on
the left:
(b) When installing the steering wheel, ensure that the
front tires are in a straight line, make the vehicle logo
on the top of the steering wheel face straight ahead, and
Circular groove ensure the inner steering spine and steering shaft spline
are aligned.
(c) Fasten the bolts and nuts according to the specified
torque.
Power steering gear removal and installation

1. Screw off the flange bolt connecting the steering col-
Q5003220
umn's lower section and the power steering small gear
Q387B12
shaft with a M13 socket wrench, and then pull out
steering column’s lower section.
2. Remove the steering tie rod ball assembly.
Loosen the hexagon slotted nuts (thread space: 1.25)
Q387B12 with a M18 socket wrench.
3. Hammer the circumference of the steering knuckle arm
with a hammer along the direction of the taper bores
until the tie rod ball and steering knuckle arm's taper
fittings loosen, then pull out the tie rod ball downwards.

4. Screw off the two bolts Q1840816 of the steering

Q1840816
gear protection plates installed on the subframe with
a M10 socket wrench, and remove the steering gear
protection plate.
5. First fasten four hexagon nuts 2904013-S08 with a

3411013-S08
3411014-S08
M18 socket wrench, then screw off the four hexagon
bolt gasket groups 3411013-S08 and 3411014-S08
installed on the subframe with a M14 socket wrench.
2904013-S08
6. Remove and replace the steering tie rod ball assembly.

Fasten the hexagon nuts in the cotter pins with a M12 socket
Hexagon nut wrench, then loosen the steering tie rod ball with a M19
socket wrench, and then finally pull out steering tie rod ball
assembly.
Ball stud
Steering pipeline removal and installation

Hollow bolt 1. Disconnect the hollow bolt which connects the high
pressure oil pipe and the power steering pump with a
M22 socket wrench. When installing, please take note
of the two seal gaskets and do not allow the oil pump
port to loosen. Each of the seal gaskets should be
positioned at either side of the high pressure oil ring.
Tightening torque for the hollow bolt is 30±4 N·m.
2. Unscrew the hexagon bolts for flange face Q32008

connecting to the vehicle and low pressure pipe with a
Q1460616 M13 socket wrench. When installing, tightening torque
for this bolt is 9±2 N·m.
3. After removing the power steering gear and the
steering pipeline together with the subframe from the
Q32008
overall vehicle, disconnect the coupling nut of steering
pipeline and steering gear's high-low pressure oil
port with a M19 wrench. The removal of the steering
pipeline is then complete. While installing this area,
please ensure the two O-rings are in good condition,
and connect the high and low pressure pipeline and
steering gear low pressure oil port according to the
locations shown in the diagram. The tightening torque
of the two nuts is 46±2 N·m.
Caution: The elastic clamp mentioned during the
removal process is disposable, please replace it with a
new one after removal.

Steering System 141
Q1401025 (M10×1.25) Q1841020 (M10×1.25) Removal and installation of the power

steering pump on the engine:
Remove the power steering pump after removing the high
pressure port of the power steering pipeline and steering
pump, as well as the inlet hose.
1. Loosen and adjust the bracket's hexagon bolts
Q1401025 (M10×1.25) with a M13 socket wrench,
Q1841025 (M10×1.25) loosen the pump belt area, and then remove the
Q1841090 (M10×1.25)
steering pump belt.
Q1840825
2. Loosen the hexagon flange mounting bolt Q1841090
(M10×1.25). After pulling out the hexagon flange mounting
bolt, complete the disassembly of the steering pump.
3. Tightening torque for installing the tension regulator
bracket: 40±4 N·m.
Install the tightening torque of the steering pump
mounting bracket: 25±3 N·m
4. After the installation of the power steering pump and
steering pump belt is completed, adjust the tension
of the entire power steering pump belt. Belt tension
should be 450±50 N.
Use an exertion force of 98 N in the middle of the belt.
Belt deflection should be 4-6 mm.
Power Steering Fluid Instructions

Replace the power steering fluid in the following situations:
1. After driving a new vehicle for 6000 km.
2. After replacing any part of the power steering gear, power steering pump and steering pipeline.
3. Driving 6000 km after replacing power steering gear and power steering pump.
Caution:
1. The expelled power steering fluid after replacing power steering components cannot be reused.
2. Only use ATF DEXRON III power steering fluid.
3. No matter when the PS fluid reservoir level drops, check the PS fluid reservoir, steering pump, power
steering gear, and steering pipeline, as well as all the connections.
Methods:
Two people are required to add power steering fluid. With the engine off, one person pours the fluid
into the PS fluid reservoir, while the other repeatedly turns the steering wheel from lock to lock for
more than 10 laps, until the steering fluid level is between MAX and MIN. Start the engine and turn
the wheel from lock to lock again (Caution: Do not leave it at the two extreme points for more than 5s).
When the fluid level goes down, refill the steering fluid until it is between MAX and MIN.
Technical Requirements
1. Mounting bolts with thread fastening glue for the power steering gear, tightening torque is 107±7 N·m
The coupling torque for the steering gear's tie rod and tie rod ball is 74±7 N·m
The coupling torque for the steering tie rod ball stud and steering knuckle is 49±5 N·m
2. The tightening torque for the steering column assembly and steering gear assembly's secure coupling
bolt is 25±3 N·m
The coupling bolt torque for the steering column and dashboard brace reinforcement is 25±3 N·m
Torque for the fixed steering wheel nut on the upper section of the steering column is 50±4 N·m
3. Fasten the steering wheel center
Keep the front wheel pointed straight ahead, make sure not to change the direction of the steering rod, and
take down the steering wheel. Install the steering wheel in the center. The steering wheel's radial should be
in the middle, and the Great Wall logo should be in the direct sight of the driver, then tighten nuts.
4. Steering wheel free clearance inspection
Keep the vehicle centered, stop the engine, and turn the wheel left with a force of about 5 N. If
resistance is felt, stop when the resistance increases. Then turn right and stop under the same
situation. Measure the angle that the steering wheel turns along the outer edge. The angle value
measured is the steering wheel's free clearance. Its standard value should be less than 20°, and from
the middle position it should not turn at a left or right angle larger than 10°.

Vehicle Body Electrical System
Basic Information on the Electrical System......................... 143

Fuse Box............................................................................. 144
Overall Vehicle’s Grounding Point Schematics................... 150
Key Electrical Component’s Module Schematics for
the Overall Vehicle.............................................................. 151
Wire Harness Distribution Chart for the Overall Vehicle...... 152
Wire Harness Relationship and Plug-in Connections
Numbered Diagram............................................................. 155
Wire Harness Plug-in Connectors and
Pin Function Diagram.......................................................... 156
Electrical Wiring Diagram for the Overall Vehicle................ 167

Vehicle Body Electronic System 143
Basic Information on the Electrical System

Electrical system schematics reading instructions
1. Configuration introduction
The GWFLORID comes in three configurations: comfort, luxury and elite. The wire harness has two types of
configurations: One is a non jam protection comfort model, which is a combination of both comfort and luxury
type, the other type is called elite. These two configurations are universally used in most of this manual. The
parts that are only available for the non jam protection comfort type have been marked in this manual, please
pay attention to these sections while performing maintenance.
2. Fuse box and power supply introduction
The fuse box located inside the left side of the dashboard is No. 1 Fuse Box, the other one inside the left side of
the engine compartment is No. 2 Fuse Box.
• 30 represents a power cord for normal power, which is from the battery positive fuse box-60 A.
• 30a represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 30b represents a power cord for normal power, which is from the battery positive fuse box-120 A.
• 15 represents a power cord for small capacity electronics. When the ignition switch is at the "ON" position,
power is supplied by relay IG.
• 15a represents a power cord for small capacity electronics. When the ignition switch is at the "ON"
position, power is directly supplied by ignition switch IG1.
• 15b represents a power cord for small capacity electronics. When the ignition switch is at the "ON"
position, power is directly supplied by ignition switch IG2.
• X represents a power cord for small capacity electronics. When the ignition switch is at the "ACC"
position, power is supplied by relay ACC.
Example: 3. Connector
(a) Negative connector pin number
Arranged from upper left to lower right.
(b) Positive connector pin number
Arranged from upper right to lower left.
Negative connector Positive connector
Example: (c) Differences between the positive and negative

connectors.
Mainly lies in their different types of interior pins.
• Every connector is indicated by its engaging part and
locked on the top.
• Please pull out the connector, insted of its wires.
Note: Before pulling out the connector, please check its
type first.
Negative connector Positive connector
4. Wire's color and sectional area (mm2)

B-Black W-White R-Red Bl-Blue Br-Brown Y-Yellow
G-Green P-Pink Or-Orange V-Violet Lg-Light green Gr-Gray
Mark the solid-colored wires with the letters in the above table. Double-colored wires' first letter is the primary
color, second letter is the secondary color.
For example:
Solid-colored wire: Red, marked as R.

Double-colored wire: Primary color is Red, secondary color is Blue, marked as RBl.
0.5BrGr means Brown wire with a Gray fine wire, and sectional area is 0.5 mm2.
Areas of importance in circuit maintenance
1. Before operating any electronic devices, and when tools or maintenance devices may easily make
contact with an uncovered electronic terminal, please make sure to turn the ignition switch to the LOCK
position, and then disconnect the battery's negative cable to avoid injury or vehicle damage. When the
ignition switch is on the ON position, please do not disconnect the battery's connecting wire or take out
the power's fuse, regardless if the engine is running or not.Otherwise it would seriously damage the
ECU and related microelectronic devices such as sensors.
2. When changing the fuse, please make sure that the new fuse possesses the proper current rating,
and is not above or below this rating.
3. When repairing the wire harnesses of the airbag and pretensioner, only specified contact points,
plugs, and wires are allowed to be used.
4. Before repairing the wire harness, make sure to eliminate any factor that might cause damage,
for example, the edge of a vehicle body part is too sharp, or the used electronics are damaged or
corroded.
5. Shielded wire should not be repaired, it must be replaced entirely once it is damaged.
6. Unless it is specified during the test, please do not use an analog multimeter to test the ECU and
sensor, instead use a high-impedance digital multimeter (internal resistance should be ≥10 kΩ) or a
vehicle multimeter for inspection.
7. When inspecting the connector with a digital multimeter, take the waterproof rubber cover off the
connector, and tightly insert the test pen along the connecting terminal. Don't use too much force, as
to avoid cracking the connector.
Circuit inspection steps
The principle of troubleshooting is to confirm the "possible cause". Once the possible cause is confirmed, the
components that need to be inspected are limited to the components that are related to the possible cause. The
confirmed possible cause should be based on theory and be supported by facts, but not just by intuition. If
one tries to solve the problem but does not adopt the proper troubleshooting steps, it may make the problem
worse. Then the possible cause not only can't be confirmed, but also maintenance can't be performed properly.
Troubleshooting should adhere to the four steps below:
1. Observe the symptoms carefully, inspect if there is anything else abnormal, and record it.
2. While confirming the possible causes, study the circuit diagram carefully, and regard it as a whole
system in order to understand the circuit. Thorough knowledge of switches, relays, and other
electronic components is obligatory for proper analysis.
3. Inspect and eliminate the problems one by one until the cause is found.
4. After the malfunction is fixed, make sure to check if the inspected system is working properly, and also
check if the maintenance may have caused any new problems.
Fuse Box
Cab No.1 fuse box
Lamplet Blower high Door and

Reserve relay Flasher relay speed relay Reserve window relay Blower relay
(Elite) (Comfort,
Luxury)
Turn signal lamp
Warning lamp
Sunroof (Elite)
Reserve
Reserve
Lamplet
Reserve Door and window Reserve Blower

Front fog lamp
Rear fog lamp
Front fog Rear fog

Compressor
Compres- Rear wiper Defroster

Rear wiper
ACC relay IG relay

Defroster
lamp relay lamp relay sor relay relay relay
Reserve
Reverse lamp
Combination
Front wiper
brake lamp
CD player
Rearview
door lock
Cigarette
Reserve
Reserve
Reserve
Reserve
lighting
Interior
Charge
Airbag
central
lighter
mirror
meter

Fuse number and bearer circuit

Fuse number Current rating Fuse type Power Bearer circuit
F01 Reserve
F02 25 A Sunroof (Elite)
Parking lamp relay, front fog lamp
F03 10 A
30 Battery (+) switch, rear fog lamp switch
F04 15 A
F05 Reserve
F06 15 A Hazard warning lamp
F07 10 A 15a IG1 Turn signal lamp
F08 15 A Front fog lamp relay
F09 10 A Rear fog lamp relay
F10 10 A Compressor relay
F11 10 A Rear wiper relay
F12 25 A Rear defroster, rearview mirror defroster
F13 10 A Combination meter
F14 10 A 30 Battery (+) Internal lighting
AutoFuse
F15 20 A Central lock controller
F16 10 A Brake lamp switch
F17 15 A Stereo
F18 Reserve
F19 Reserve
F20 Reserve
Front cigarette lighter, rear cigarette
F21 25 A X Attached lighter, backup power supply
ACC
F22 15 A Power rearview mirror
F23 15 A Front wiper motor, front and rear washer motor
F24 10 A Combination meter indicator lamp power
F25 10 A ABS ECU
15a IG1
F26 15 A Airbag
F27 Reserve
F28 10 A Reverse lamp, air conditioner controller
S/B1 Reserve
S/B2 30 A Door and window relay (Non Jam Protection)
S/B3 Reserve Slow burn fuse 30 Battery (+)
S/B4 40 A Blower relay
S/B5 Reserve

Engine compartment No.2 fuse box
Main relay Compressor relay Horn relay
10A backup 15A backup 25A backup
Fan relay Low

Fuel pump Horn Reserve Reserve Fan relay Low Fan relay High
Reserve
Starter relay Main High Low Engine ECU
relay beam beam
Reserve
Fan relay High
Starter relay High beam relay Low beam relay Reserve
Fuse number and bearer circuit

Fuse number Current rating Fuse type Power Bearer circuit
F29 30 A Starter relay
F30 25 A AutoFuse Main relay
F31 15 A Fuel pump relay
F32 30 A Slow burn fuse Low speed fan relay
F33 Reserve AutoFuse
F34 30 A Slow burn fuse High speed fan relay
F35 15 A High & low pitched horn
F36 15 A High beam light relay
F37 15 A 30 Battery (+) Low beam light relay
F38 10 A Engine ECU, diagnostic port
F39 25 A ABS ECU
F40 Reserve AutoFuse
F41 15 A AM2
F42 Reserve
F43 Backup 10 A
F44 Backup 15 A
F45 Backup 25 A

Cab No.1 fuse box back side pin diagram
B C
A
E F
D
H
Connected dashboard's Connected dashboard's

wire harness A wire harness B
Eilte
Connected dashboard's Connected dashboard's

wire harness C wire harness D
(Elite)
Connected dashboard's
wire harness E Connected dashboard's
wire harness H

Plug-in connector pin's function
Pin number Function Pin number Function
A01 Rear fog lamp A11 Empty
A02 Internal lighting A12 Empty
A03 Empty A13 Empty

Combination switch
A04 A14 Empty
(front fog lamp)
A05 Combination meter A15 Empty
A06 Front fog lamp A16 Empty
A07 Empty A17 Empty
A08 Empty A18 Empty
A09 Central lock controller A19 Empty

Combination switch
A10 A20 Empty
(rear fog lamp)
B01 Power IG (12v) B10 Empty
B02 Ground B11 Empty

Power rearview mir-
B03 B12 Window regulator motor
ror switch, CD
Front & rear cigarette
B04 Ignition switch (ACC) B13 lighter, backup
power supply
B05 Empty B14 Empty
Reverse lamp, air
B06 Compressor control B15
conditioner controller
B07 Empty B16 Empty
Front wiper, front and
B08 B17 Empty
rear washer motor
B09 Ground B18 Empty
Air conditioner con- Rear glass and rearview

C01 C08
troller (blower) mirror defroster
Air conditioner
C02 C09 Empty
controller (defroster)
C03 Airbag ECU C10 Empty
Combination switch
C04 C11 Empty
(rear wiper)
C05 ABS ECU C12 Empty
C06 Rear wiper power reset C13 Combination meter
C07 Rear wiper motor C14 Rear wiper reset

Plug-in connector pin's function (Continued)
Pin number Function Pin number Function
D01 Combination switch D09 Ignition switch (AM1)

(right turn)
D02 Combination switch D10 Combination switch

(left turn) (parking lamp)
Parking lamp, meter
D03 Right turn signal lamp D11
brightness
D04 Ground D12 Sunroof (Elite)
D05 Hazard warning switch D13 Empty
D06 Empty D14 Empty
D07 Left turn signal lamp D15 Empty
D08 Empty D16 Empty
E01 Compressor E05 Empty
E02 Stereo E06 Empty
E03 Empty E07 Empty
E04 Brake switch E08 Empty
H01 Blower F01 Blower high speed

Overall Vehicle’s Grounding Point Schematics
G01 G03
G02
G04
G05 G06
G07
G08

G10
G09
Meaning of each number representation:

Number Grounding position Remark
Inside the engine compartment's
G01, G02 Engine compartment's wire harness
left side fender
Inside the engine compartment's
G03 Engine compartment's wire harness
right side fender
Wire harness fixture un-
G04, G05 Engine & dashboard wire harness
der the right A-pillar
Wire harness fixture un-
G06 Meter wire harness
der the left A-pillar
G06 On the dashboard brace reinforcement Meter wire harness
G07 Rear fender trim LH Vehicle body wire harness
G08 Near rear combination lamp RH Vehicle body wire harness
G09 Near rear wiper motor Trunk door wire harness assembly
G10 Airbag grounding point
Key Electrical Component’s Module Schematics for the Overall

Vehicle
Central lock controller
Theft deterrent ECU
No.1 fuse box Engine ECU
Airbag ECU assembly

Key Electrical Component’s Module Schematics for the Overall

Vehicle (Continued)
Positive fuse box

ABS ECU
No. 2 fuse box
Reverse sensor
ECU
Wire Harness Distribution Chart for the Overall Vehicle

Engine compartment wire harness
Starter, starter excitation, knock sensor
Injector Speed sensor Brake fluid level switch
Engine ECU
Brake switch Clutch switch
Throttle
position sensor
ABS ECU
Camshaft
position sensor
Front wiper
Front motor
combination
lamp RH
Wheel speed Front

sensor combination
lamp LH
Washer
motor Front fog
lamp LH
Front fog
lamp RH
Radiator fan
Tristate pressure switch

High & low pitched horn
Alternator, alternator
Compressor Condenser fan Crankshaft position sensor
regulator
clutch motor Front & rear
oxygen sensor

Dashboard wire harness

Air conditioner speed adjuster, AC
switch, rear defroster switch
Theft deterrent indicator lamp Combination meter
CD/DVD Air conditioner Front Passenger side
Central lock controller temperature sensor airbag assembly
Acceleration pedal
Diagnostic port
Glove box lighting Blower
Power rearview mirror switch, light Airbag ECU assembly 2

brightness regulator Cigarette lighter and lighting
Trunk door wire harness
High mounted brake lamp
Rear defroster positive Opener switch Rear defroster negative

Rear wiper motor
Trunk lock motor, door lamp switch

Front & rear door wire harnesses
High tone speaker

Outer power
rearview mirror
Window regulator
motor
Door lock motor
Window regulator
switch
Window regulator
Door lock Door and window motor
Middle & low Middle & low
motor main switches
tone speaker tone speaker
Front door Rear door
Vehicle body wire harness
Seat belt pretensioner
Rear wheel speed sensor LH Front door light switch LH

Rear door light switch LH
Backup power supply
Rear
combination
Rear lamp RH
combination lamp LH
Fog lamp
License plate lamp
Reverse sensor
probe
Oil pump motor
Reverse sensor ECU Parking brake switch
Rear wheel speed sensor RH

Wire Harness Relationship and Plug-in Connections Numbered Diagram
Condenser
fan motor
Connected front Connected low Connected high
combination lamp LH Rediator fan motor pitched horn pitched horn
Engine groud
Connected front
fog lamp LH
Connected front combination lamp RH
Battery
Body negative
ground Connected generator Connected front fog lamp RH
Battery Connected compressor Connected engine armature
Battery Oil pressure switch
positive Front oxygen sensor Connected rear washer motor
Connected A/C pressure switch
nozzle
nozzle
cylinder
nozzle
G Rear oxygen sensor Connected front washer motor
ba ene Connected reverse switch
Connected 2nd
Connected 1st
S tte rat
cylinder injection
injection nozzle
Connected 4th
ry or
Connected 3rd
ba tar po co
cylinder injection
Connected front wheel
cylinder injection
tte ter sit nn
speed sensor LH ry co ive ec Connected inlet Connected phase sensor
po nn t to temperature pressure Connected front wheel speed sensor RH
sit ec
iv t t sensor connected
e o electronic throttle
Connected
ignition coil Connected knock sensor
Connected engine speed sensor
Left ground Connected starter field coil
Right ground
Connected speed sensor
Connected coolant temp. sensor

Connected clutch Connected starter
switch
Canister control valve
Connected ABS ECU

Connected Connected brake fluid warning switch
brake lamp
switch
Connected ground P1#

Connected front wiper motor Connected combination meter A Connected ground P2#

Connected theft deterrent indicator
Connected central door lock controller (white) Connected CD player
Connected engine ECU
Connected antenna
Theft deterrent ECU 1

Front passenger side airbag
Connected lock Connected air conditioner temperature sensor Connected speed adjustive Ground
cylinder light Connected AC switch resistance, blower plate 3
Ground plate 1 Connected ignition
switch (white)
Connected accelerator pedal
The key is inserted into the switch Ground Diagnostic Connected air conditioner governor & front
plate 2 port passenger seat belt unfastened indicator lamp
Right combination switch (wiper) Ground

plate 4
Connected airbag ECU (yellow)
Connected main airbag, horn switch
Front tweeter LH
Connected glove box lamp
Left combination switch (light)
Front tweeter LH
Connected cigarette lighter (lighting)
Left outer electric mirror

Front window regulator LH
Connected light brightness regulator switch

Connected cigarette lighter Front window regulator RH
Connected rearview mirror switch (white)

Window regulator mainly
control switch, central door
lock mainly control switch
Front window regulator switch RH

Right outer electric mirror
Front medium woofer LH

Vehicle Body Electronic System
Front passenger side central door lock switch

Driver seat belt switch Front passenger seat belt switch
Front medium woofer RH
Front door lamp switch RH
Front door lamp

switch LH Front door lock motor RH
Driver seat belt pretensioner Front passenger seat belt pretensioner
Front door lock motor LH

Connected parking brake switch
Rear window
regulator RH
Rear medium woofer RH
Rear window regulator LH Rear window
regulator switch RH
Rear wheel speed sensor RH
Rear medium woofer LH

Fuel pump, fuel sensor
Rear wheel speed
sensor LH
Rear window regulator switch LH
Rear door lamp switch RH

Rear door lamp switch LH
Ground point A
Capacitor Rear door lock motor RH
Rear door lock motor LH
Vehicle power supply
Ground point B
Rear interior dome lamp
Rear combination lamp LH

Rear fog lamp RH
Rear combination lamp RH
Rear fog lamp LH Left license plate lamp Right license plate lamp

155
Rear windshield defroster “-”
Ground point Trunk opener switch Rear wiper motor
Rear windshield defroster “+”

Trunk motor
Wire Harness Plug-in Connectors and Pin Function Diagram

Connector 1
C01
Connected engine Connected engine

compartment wire harness wire harness
C02
Connected cab fuse box Connected engine

compartment wire harness
C03
(Luxury) (Luxury)
(Elite) (Elite)
(Comfort) (Comfort)
Connected cab fuse box A-20 Connectied dashboard

wire harness

Connector 2
C04
(Comfort) (Comfort)
(Elite) (Elite)
(Luxury) (Luxury)
Connected cab fuse box B-18 Connected dashboard

wire harness
C05
(Comfort) / (Luxury) (Comfort) / (Luxury)
(Elite) (Elite)
Connected cab fuse box C-14 Connected dashboard
wire harness
C06

Connector 3
C06
(Elite) (Elite)
Connected cab fuse box D-16 Connected dashboard wire harness
C07
(Elite) (Elite)
Connected cab fuse box E-8 Connected dashboard wire harness
C08
Connected cab fuse box H-1 Connected dashboard wire harness

Connector 4
C09
(Elite) (Elite)
(Comfort) (Comfort)
(Luxury) (Luxury)
Connected dashboard Connected engine
wire harness A compartment wire harness A
C10
(Luxury) (Luxury)
(Comfort) (Comfort)

Connector 5
C10
(Elite) (Elite)
Connected dashboard Connected engine compartment
wire harness B wire harness B
C11
Connected dashboard Connected engine wire

wire harness A harness A (white)
C12
Connected dashboard Connected engine

wire harness B wire harness B
C13
(Elite) (Elite)

Connector 6
C13

Connected meter Connected front left door
wire harness A wire harness A (white)
C14
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
Connected meter Connected front left

wire harness B door wire harness B
C15
(Elite) (Elite)

Connector 7
C15
(Comfort)/(Luxury) (Comfort)/(Luxury)
Connected dashboard Connected vehicle body
wire harness A wire harness A
C16
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
Connected dashboard Connected vehicle
wire harness B body wire harness B
C17
Connected vehicle Connected engine

body wire harness compartment wire harness

Connector 8
C18
(Elite) (Elite)

Connected meter Connected front right
wire harness A door wire harness A
C19
(Elite) (Elite)
(Luxury) (Luxury)
(Comfort) (Comfort)
Connected meter Connected front right

wire harness B door wire harness B

Connector 9
C20
(Elite) (Elite)

Connected vehicle Connected rear left
body wire harness door wire harness
C21
(Elite) (Elite)

Connector 10
C21
Connected vehicle Connected rear right

body wire harness door wire harness
C22
Connected vehicle body Connected trunk wire harness A

wire harness A
C23
Connected vehicle body Connected trunk wire harness B

wire harness B

Connector 11
C24
Connected trunk wire harness 2 Connected trunk wire harness 1
C25 C26
Connected rear defroster "+" Connected rear defroster "-"

Electrical Wiring Diagram for the Overall Vehicle

Power & start-up system
Connected ABS #1
Theft
deterrent
ECU 6
Main relay
Pin
position
Shift
position
Ignition switch
ABS motor 40A
Starter relay
Engine ECU 74 pin

Clutch switch
Battery 12V 60Ah
Generator
Starter
Generator regulator Ignition switch

Airbag & ABS

Engine ECU 72
Central control ECU #17
Theft deterrent controller A7
to engine ECU 51
Brake lamp switch

SRS indicator lamp
to engine ECU 21
Airbag electric control module ABS electric control module

Clock spring
Right brake lamp

Left brake lamp
Driver seat belt Front passenger seat
pretensioner belt pretensioner
Front wheel Front wheel Rear wheel Rear wheel speed
Driver side airbag Front passenger side airbag speed sensor LH speed sensor RH speed sensor LH sensor RH
Airbag ECU housing hole location marks are signs showed on the housing
Connected brake
Airbag ECU (yellow) (Luxury, elite) lamp switch
Airbag ECU housing hole location marks are signs showed on the housing
Connected high
Airbag ECU (yellow) (Comfort) mounted brake lamp
Front wheel Front wheel speed

speed sensor LH sensor RH Main airbag
Rear wheel Rear wheel

speed sensor LH speed sensor RH
Connected front
passenger side airbag
Driver seat belt Front passenger seat

pretensioner belt pretensioner Diagnostic port

Combination meter system
Connected engine ECU #8
Connected engine ECU #59
To light brightness
regulator switch Connected central
control ECU #18
Connected coolant
temperature sensor
Low water temperature alarm

High water temperature alarm
LCD display
Seat belt unfastened indicator

Low oil pressure indicator
Brake warning lamp
Parking brake lamp
Low fuel alarm IC module Odometer
Fuel gauge
Tachometer
Brake fluid level switch
Driver seat belt switch

Parking brake switch
Oil pressure switch
Speed sensor
Fuel sensor
Connected combination meter A Connected combination meter B Brake fluid level warning switch
Driver seat belt switch Connected parking brake switch Fuel pump, fuel sensor Speed sensor Coolant temperature sensor Engine speed sensor

Air conditioning and defrosting system
170
Manually AC control sysytem Defroster system Electric AC control system
Connected position lamp relay

Connected air conditioner
pressure switch
Blower relay
To flasher relay
Defroster relay
Front passenger seat belt switch
Blower relay
Manually air

conditioner
Air conditioner panel lighting

Blower regulate module
Blower high speed relay
AC switch Air conditioner wind speed switch
Terminal Terminal Terminal

Location Location Location
Off On
On Off
Defroster switch
Electric AC controller
Front passenger seat belt unfastened indicator lamp

Rear defroster indicator
Rear defroster indicator
Rear window defroster

Right outer rearview mirror defroster
Left outer rearview mirror defroster

GWFLORID Maintenance Manual
Speed adjustive
Blower resistance
Mode damper actuator Cycle damper actuator Temperature regulation
damper actuator
Connected blower (Elite)

Rear defroster & alarm switch AC switch (comfort, luxury) Connected electric AC controller (Elite)
(comfort, luxury) Connected AC governor & front Connected mode damper actuator (Elite)
passenger seat belt unfastened indicator
lamp (comfort, luxury)
Right outer electric rearview mirror Left outer electric rearviewmirror Front passenger seat Connected speed adjustive resistance, Connected rear Connected cycle damper Connected blower regulate Connected temperature regulation
defroster (Elite) defroster (Elite) belt switch blower (Comfort, luxury) window defroster actuator (Elite) module (Elite) damper actuator (Elite)
Electronic rearview mirror & CD system
Connected parking
lamp relay
Linear control mode
Steering wheel
switch spiral coil
Outer electric rearview mirror adjustment switch Antenna

Antenna
amplifier
Front medium woofer LH

Pin position Pin position Pin position
Location Location Location
Fold switch
Reset Upper Left
Fold Left Off
Shift switch
Off Right
Mirror adjustment switch

Right Player CD integrated
Lower Front medium woofer RH
Foldable motor
Front tweeter LH Front tweeter RH
Vehicle Body Electronic System
Right mirror adjustment motor Rear medium woofer RH
Left mirror adjustment motor Front medium Rear medium Rear medium Front medium
woofer LH woofer LH woofer RH woofer RH
Rear medium woofer LH
Front tweeter LH Front tweeter LH

Connected rearview mirror adjustment switch (white) Right outer electric rearview mirror Left outer electric rearview mirror CD player
171
Wiper, washer motor, sunroof system
172
To meter brightness switch

Rear wiper motor
Sunroof switch
Rear wiper relay

Connected front washer motor Connected rear washer motor
Front
Front wiper switch

washer
INT
regulate
time
Rear
washer
GWFLORID Maintenance Manual
Rear washer
Rear wiper switch

with wiper
Pin Sunroof control module
Front wiper motor
Rear wiper motor
Front wiper motor

Rear washer motor
Front washer motor

Right combination switch (wiper)
Engine
Inlet temperature
pressure sensor
Connected
Connected generator
combination meter
Connected theft deterrent controller A8

Connected combination meter
Connected speed sensor
Connected ABS
Connected airbag
Fuel pump relay
Engine malfunction indicator lamp
Engine service indicator lamp

Spark plug
Main relay
IG1 relay
Ignition coil
Fan relay low
Fan relay high

Compressor relay
Fuel pump
Ignition coil
Injection nozzle
Compressor clutch
Phase sensor
Canister control valve
Condenser fan
Rediator fan
Scanner
Coolant temperature sensor
Electric control module
Rediator fan motor
Connected brake lamp switch
Connected brake lamp switch

Central pressure switch
Starter relay 86
AC pressure switch
Connected AC switch
Engine speed sensor
Rear oxygen sensor Front oxygen sensor Inlet pressure & tem. sensor Coolant temperature sensor Accelerator pedal module Electronic throttle AC temperature Knock sensor Engine speed sensor
sensor
Wheel speed sensor
1st cylinder injection 2nd cylinder injection 3rd cylinder injection 4th cylinder injection Connected oil Canister control
nozzle nozzle nozzle nozzle pressure switch valve
Connected clutch switch Air conditioner Engine ECU

temperature sensor Fuel pump, fuel sensor
Phase sensor Electronic throttle AC pressure switch
Connected accelerator pedal Front oxygen sensor Rear oxygen sensor Knock sensor Condenser fan motor Connected brake lamp switch

Central door locking, window regulator system
Jam protection window regulator control system Non jam protection window regulator control system

Connected high beam relay
Connected airbag ECU
Front window regulator mainly switch LH Front window regulator mainly control switch LH
Open door indicator lamp
Driver side electric switch

Central ocntrol switch
Window lock switch
Window lock switch

mainly control switch
Lighting detect
Front door electric
Rear door electric
Rear door electric

Front door electric
Rear door electric
Rear door electric

Right turn signal
Terminal
Door electric door

Left turn signal
Rise Rise Rise

Location
Window relay
Off Off Off
Airbag signal
switch RH
switch RH
switch LH
Door lock is Rise Rise Rise Rise
switch RH
switch RH
switch LH
locked
Stationary Off Off Off Off Descend Descend Descend
state
Door lock is
on Descend Descend Descend Descend
Central control module

Front door switch RH
Front door switch RH

Rear door switch RH
Rear door switch RH

Rear door switch LH
Rear door switch LH

Rise Rise Rise
Rise Rise Rise
Off Off Off
Passenger side central ocntrol switch
Off Off Off

Descend Descend Descend
Descend Descend Descend
Connected interior dome lamp
Connected reading lamp

Trunk opener switch
Lock signal
Unlock
signal
Terminal
Location
Trunk motor
Front door lock LH Lock Front door jam Front door jam Rear door jam Rear door jam
Unlock protection motor LH protection motor RH protection motor LH protection motor RH
Front door lock
motor RH
Front door lamp switch RH
Front door lamp switch LH
Rear door lamp switch RH
Rear door lamp switch LH
Front door motor LH

Back door lamp switch
Rear door lock

motor LH
Front door motor RH Rear door motor LH Rear door motor RH
Rear door lock
motor RH
Connected central door Window regulator mainly switch, central door lock mainly Window regulator mainly switch, central door lock Connected front passenger side Front window regulator switch RH (Elite) Connected front window regulator switch Connected front window regulator switch Connected rear window regulator switch
lock controller (white) control switch (comfort, luxury) mainly control switch (Elite) central door lock switch RH (comfort, luxury) RH (comfort, luxury) LH (Elite)
Connected front Connected front Connected rear Connected rear Connected rear Rear window regulator RH Front door lamp Front door lamp Rear door lamp Rear door lamp Front door lock motor LH Front door lock motor RH The key is inserted into the
window regulator LH window regulator RH window regulator LH window regulator RH window regulator LH switch LH switch RH switch LH switch RH detected switch
Connected rear window regulator LH Connected rear window regulator RH (Elite) Connected rear window Front window regulator LH Front window regulator RH Rear door lock motor LH Rear door lock motor RH Back door lamp ON Back door open switch Back door lock motor
(comfort, luxury) regulator RH (comfort, luxury)

Light, signal alarm system

Electric horn Lighting system Steering & alarm lamp control system Interior lighting system
Connected combination
meter A18
Connected central
control ECU #8
Connected central
control ECU #1
Connected central
control ECU #2
Connected central
control ECU #14
Turn signal lamp switch

Pin
position
Left turn
Parking lamp relay

Front fog lamp relay
Rear fog lamp relay
High beam relay
Low beam relay

Off
Right turn
Horn relay
Flasher relay
Rear interior dome lamp

Front turn signal
Ignition key cylinder light

lamp LH
Reading lamp (Elite)

Glove box lamp
Connected central control ECU #9

Reading lamp
Rear turn signal
lamp LH
Low
beam
Lamp Front parking Left turn
High
Horn switch
ON signal lamp
Light brightness regulator switch

beam lamp LH
Over-
Fog lamp switch
Pin
taking
Headlight vertical switch
position
Off High Front parking Left turn
signal lamp
Lamp beam lamp RH
Front fog
lamp Off Low
beam
Rear fog
lamp Over- Rear parking Front turn
taking lamp LH signal lamp RH
Right headlight adjustment motor
High pitched Electric horn
Low pitched Electric horn
Left headlight adjustment motor
Rear parking Rear turn signal

lamp RH lamp RH
Rear fog indicator lamp
red and red and

white white
Left license Right turn Terminal
Alarm switch
High beam indicator
plate lamp signal lamp

Right headlight
Location
Left headlight
Front fog lamp LH
Front fog lamp RH
On
Rear fog lamp LH
Rear fog lamp RH
Right license Right turn Off

plate lamp signal lamp
Light main switch indicator
Front fog lamp RH Front fog lamp LH Front combination lamp RH Front combination lamp LH Rear combination lamp LH Rear combination lamp RH Rear defroster & alarm switch Connected rear fog lamp RH Connected rear fog lamp LH Connected left headlight Connected right headlight Connected right license
vertical adjustment motor vertical adjustment motor plate lamp
Left outer electric rearview mirror Right outer electric rearview mirror Left combination switch (light) Horn switch High pitched horn Low pitched horn Connected left Connected light brightness Connected headlight vertical
(left turn signal lamp) (right turn signal lamp) license plate lamp regulator switch adjustment switch

Auxiliary system
To diagnostic port
To ECU 29#
To ECU 71#
Reverse lamp switch

Theft deterrent indicator
Ignition switch IG1
Buzzer
Theft deterrent controller Reverse sensor controller

Detector No. 1
Detector No. 2
Detector No. 3
Detector No. 4
Right reverse lamp
Left reverse lamp
Theft deterrent coil
Connected theft deterrent ECU

Connected theft deterrent indicator Connected reverse sensor controller Connected reverse sensor buzzer
Detector No. 1 Detector No. 2 Detector No. 3 Detector No. 4
Connected diagnostic port

Electrical Accessories 177
Electrical Accessories
Reverse Sensor................................................................. 178

Combination Meter............................................................ 180
Central Door Lock............................................................. 181
Power Windows................................................................. 184
Immobilizer System........................................................... 186
CD Player.......................................................................... 193
DVD Player........................................................................ 195

Reverse Sensor
Reverse sensor operation (ultrasonic wave distance-measurement)
Sound is a kind of wave. Sound frequency that can be heard by human beings range from 20 Hz to 20 KHz.
Those that exceed 20 KHz are called ultrasonic waves. Since an ultrasonic wave is also a kind of sound, its
velocity in the air also equals the sound velocity of 340 m/s. Part of the ultrasonic wave will rebound when it
encounters an obstacle. So the distance between the sound source and the obstacle can be calculated according
to the sonic speed and the time difference between the emission of sound and the receipt of sound.
Reverse sensor system composition
This system is composed of a reverse sensor head unit (ECU), four sensors (SENSOR) and an external buzzer.
Reverse power supply:

Red (+)
Black (-)
Inductor L
Inductor CL Controller
Inductor CR
Inductor R
Plug
Definition Remark
number
1 GND Ground wire of the head unit's power supply
2 BUZZER - Buzzer ground wire
3 DATA Reserve display data wire
4 GND Reserve buzzer ground wire
5 L (SENSOR) Inductor signal wire (four inductors)
6 CL (SENSOR)
7 CR (SENSOR)
8 R (SENSOR)
9 GND Inductor ground wire (four inductors)
10 GND
11 GND
12 GND
13 GND
14 VCC Reserve display power wire
15 BUZZER + Buzzer power wire
16 + 12 V Head unit power wire

Functional description and display program

1. This system will be activated within the first second after engaging the reverse gear. There will be two
beeps indicating the system is working properly.
2. After the self-check, it will start its normal detection mode. The relationship between the obstacle
distance and the alarm frequency is as follows:
A Zone B Zone C Zone
(long alarm) (8 Hz continuous sound) (4 Hz intermittent sound)
40±4 cm 90±4 cm 150±4 cm
A Zone: When it is a long sounding alarm, the obstacle is within the distance of (0-40±4) cm.
B Zone: When the alarm frequency is an 8 Hz continuous sound, the obstacle is within the distance of
(40±4-90±4) cm.
C Zone: When the alarm frequency is a 4 Hz intermittent sound, the obstacle is within the distance of (90±4-
150±4) cm.
Areas of importance
1. When placed near a car equipped with the same system or a similar system (having been activated)
offered by other suppliers, though this system may receive interference, it can still operate normally.
2. When the relative rate of travel between the obstacle and the car is lower than 1 m/s, this system will
operate as normal. When reverse speed is accelerated, the sensing accuracy of the reverse system
may decrease. A low speed of 6 km/h is suggested.
3. When it is a long sounding alarm, please stop the car at once, because there may be an obstacle
within 40cm.
4. The inductor precision level is high. It will be very difficult to return it to normal after opening the inner
portion.
5. The reflected signal may not be received due to the location, angle, size, or material of the object.
Furthermore, the reflected signal in a complex environment may not be accurate.
System malfunction causes and solutions
1. A lack of power or a low supply voltage may lead to the abnormal operation of the reverse sensor
system. Under such circumstances, check whether the supply battery voltage is normal, or whether
the ignition switch connector and other connections are accurately placed.
2. If the power supply is on, irregular system operation may be caused by the incorrect position of the
socket. Under such circumstances, correctly re-place all the sockets.
3. A long sounding alarm from the buzzer may be caused by the inductor coming off, incorrect installa-
tion, damage to the inductor, or detecting the car or ground. Under such circumstances, please repair
or replace the sensor.
4. Incorrect indication of an obstacle's distance may be caused by abnormal battery voltage, inaccurate
socket positioning, or inductor connection damage. At this time, check whether the battery voltage
is normal, and whether the inductor connection is connected to the exhaust pipe and muffler. It is
suggested that the system be turned off and all the sockets be correctly placed.
Reverse sensor system parameters

Rated operation voltage DC 12 V
Operation voltage range DC (9.6-16) V
Operation temperature range -30-80 oC
Storage temperature range -40-85 oC
Power consumption <2W
Detect segment 3 segments: 150-90-40 cm
Maximum sensing distance 150±4 cm
Effective distance (15±4) cm- (150±4) cm
Detect mode Ultrasonic wave

Combination Meter
If something is wrong with the meter, check the relevant component and circuit according to the connector defi-
nition. If the failure still cannot be eliminated, check whether the instrument itself has malfunctioned in the fur-
ther steps. The following diagram shows the view of the meter connector and its number.
12-core connector 32-core connector
Pin definition of each combination meter

32-core connector
Pin No. Function Pin No. Function
1 Meter ground 17 Signal ground
2 Speed signal input 18 Internal lighting (+)
3 Vehicle speed signal input 19 Airbag indicator lamp
4 Fuel gauge input 20 Door open warning lamp
5 Water temperature gauge input 21 Seat belt unfastened indicator lamp
6 Vehicle speed signal output 22 Battery
7 Central door lock signal 23 Ignition
8 Clock test 24 High beam ( - )
9 Meter interior communication 25 High beam (+)
10 Empty 26 Right turn signal lamp
11 ABS failure indicator 27 Left turn signal lamp
12 Engine failure indicator 28 Charging indicator
13 Brake system failure indicator 29 Engine maintenance indicator
14 Oil pressure indicator 30 EBD indicator
15 Rear fog lamp indicator 31 O/D switch indicator
16 Parking brake indicator 32 Front fog lamp indicator
12-core connector
Pin No. Function Pin No. Function
1 P position 7 Master lighting switch indicator
2 R position 8 Rear deforster indicator
3 N position 9 CAN H
4 D position 10 CAN L
5 2nd gear 11 Oil/water separator indicator
6 1st gear 12 Diesel engine preheating indicator

Central Door Lock

1. Lock
After closing the door (when unlocked), press the LOCK button once on the remote controller, the car lamp
flashs once, and all five doors will be locked.
2. Unlock
When locked, press the UNLOCK button once on the remote controller, the car lamp will flash twice, and all
four front doors will be unlocked.
3. Vehicle pager function
Press the LOCK button once on the remote controller while all the doors are closed and locked. The car lamp
will then flash ten times. Press the UNLOCK button to exit the vehicle pager function. If the doors are not well
closed and locked, then press the LOCK button once on the remote controller, in which case the lamps will not
flash.
4. Auto-defense function
While locked, press the UNLOCK button on the remote controller. If the doors are not open, it will automatically
lock after 30s.
5. Auto-close window function (jam protection window regulator)
(a) Pull the key out and make sure all the doors are closed, then press the LOCK button on remote controller,
the side windows will close after 1 second of negative output.
(b) After pulling out the key, the sunroof will close after 60 seconds of negative output (reserve).
6. Remote controller function suspension
When the key is inserted into the ignition lock, the remote controller will not work, but the head unit will work
as normal.
7. Manual lock and unlock
Locking or unlocking can be manually controlled.
8. Deleting or registering remote learning functions of the remote controller
Step one: Under normal circumstances, open the front left door (do not close). Insert the key into the ignition
lock, within five seconds, switch it ON and LOCK five times and stop it at the ON position the fifth time. The
buzzer will sound once and the light will flash once. It is now in the learning state.
Step two: Press any key on the remote controller within 10 seconds, the buzzer will sound twice, and the light
will flash twice. This is the first learning state. Press any key on another remote controller, it will sound twice,
and the light will flash twice. Second learning successful (A total of four remote controllers can learn).
Step three: After successful learning, pull the key out (ON-LOCK) to exit the learning state. If no key is pressed
within 10 seconds, the system will exit from the learning state automatically.
9. Dome lamp delay function
(a) Open the door and then close it, the lamp will light for 10 seconds. If the key is inserted into the ignition
lock head or door lock within these 10 seconds, the lamp will gradually extinguish.
(b) When the key is pulled out of the ignition lock head, the dome lamp will turn on. If the key is inserted into
it again or the door is locked, the dome lamp will turn off gradually after one minute.
10. Alert function
(a) If the key is inserted (low) and is not at the ON gear (high), when the front left door is opened (low), the
buzzer will emit an intermittent chirp.
(b) If the key is not inserted (low) and the lamplet is on (high), when the front left door is open (low), the
buzzer will emit a long chirp.
11. Trunk door independent open function
(a) After pressing the trunk lock striker of the remote controller and turning the trunk door switch on, the trunk
door actuator will open (14th pin will output positive voltage), and then the trunk door can be opened. If
the trunk door does not open after pressing the trunk lock striker for 60 seconds and then switching the
trunk door on, then the trunk door actuator is unable to open (14th pin is not outputting positive voltage).
(b) When the trunk lock striker of the remote controller is not pressed or the trunk door is not opened after
pressing the button for 60 seconds, the trunk door actuator cannot be opened after switching the trunk door
on (14th pin is not outputting positive voltage).

VA-882 remote controller central door lock's connection wire definition
10 1
1 10
11 22
22 11
Controller plug front view
Controller socket front view
The door lamp signal and side window

signal uses a triode transistor emitter
open-drain output.
The door lamp signal and side window signal uses a triode transistor emitter open-drain output.
Power supply positive pole

Headlight (+) test Headlight switch
Right turn signal lamp output (12 V)
Negative Power supply 12 V
Sunroof positive output (12 V) (reserve) Driver side door and
Positive window switch
Power door and window negative output (100 mA) Power sunroof relay
Connected side window remote
Central door lock unlocking positive output (12 V) controller negative trigger
Central door lock locking positive output (12 V) Actuator
Key insert diagnostic (-)
Left turn signal lamp output (12 V) When the actuator is at the unlock
position, the inner switch is connected
Front reading lamp
Reading lamp negative output (3.3 A) Power supply positive pole
Fastener switch lock diagnostic
No connection
Power supply ON diagnostic (12 V)
Connected car key ON wire
Power supply negative pole
Trunk door motor
Ground
Trunk door switch
Power supply positive pole (12 V)
Door lamp indicator + 12 V
No connection
Door lamp signal 10 kΩ
Manual lock signal
Manual switch lock rocker switch
Manual unlock signal
Front left door diagnostic Driver side door switch
Front right door diagnostic
Front right door switch
1. Headlight
Connected to the positive wire of the vehicle's headlight, this wire will hold 12 V when the headlight is turned on.
2. Right turn signal lamp
Connected to the positive wire of the vehicle's right turn signal lamp, this wire will hold 12 V when the wire is in use.
3. Sunroof positive output (reserve)
Connected to one end of the wire package of the window lift relay, this wire will output 12 V when the key is
turned to the ON position. After the key is pulled out, the wire will maintain 12 V for 60 seconds.
4. Side window negative output
Connected to the negative trigger wire of the side window remote controller, this wire will output a negative
signal for 10 seconds after the door is remotely locked by the system.
5. Central door lock unlocking output
Connected to the unlock wire of the central remote controller actuator, this wire will output 12 V when
unlocking.

6. Central door lock locking output

Connected to the locking wire of the central door lock actuator, this wire will output 12 V when locking.
7. Key insert diagnostic
Connected to the detecting wire of the lock head, the electric potential of this wire will lower when a key being
inserted into the lock is detected.
8. Left turn signal lamp
Connected to the positive wire of the left turn signal lamp, this wire outputs 12 V during its use.
9. Reading lamp output
Connected to the negative trigger wire of the front reading lamp, this wire uses a low electric potential output to
control the reading lamp's lighting.
10. Fastener switch lock diagnostic
Connected to the inner switch wire of the driver side door fastener, the inside switches will be connected and the
wire's electric potential will lower when the fastener is unlocked.
11. No connection
12. Power supply ON diagnostic

Connected to the ON wire of the key switch, this wire holds 12 V when the key is turned to the ON position.
13. Power supply negative pole
Wire is grounded (too long a wire can create interference sources).
14. Trunk door motor
This wire is connected to the trunk door motor and will output 12 V when the UNLOCK button of the remote
controller or the manually unlock switch is pressed.
15. Trunk door switch
This wire is connected to the trunk door switch and will connect with the power supply's negative pole when in
use.
16. Power supply positive pole
This wire is connected to the battery positive (red fire wire).
17. No connection
18. Door lamp signal
This wire is connected to the door lamp indicator of the combination meter and holds 100 mA negative output
when in use (the indicator light is on when any door is detected open).
19. Manual lock signal
This wire is connected to the locking control wire of the front left door's manual switch and will pass through
the power supply's negative pole (ground) when in use.
20. Manual unlock signal
This wire is connected to the unlocking control wire of the front left door's manual switch and will pass through
the power supply's negative pole (ground) when in use.
21. Front left door switch
This wire is connected to the front left door's switch control wire and will pass through the power supply's
negative pole (ground) when in use.
22. Front right door switch
This wire is connected to the front right door's switch control wire and will pass through the power supply's
negative pole (ground) when in use.

Power Windows
The GWFLORID electric power window actuator consist of a motor and module. Its functions include: jam
protection, centralized control rise, soft-stop, characterized by easy control, long life, etc.
The functions of electric power window actuator
1. Jam protection
Power windows have an jam protection function when manually or automatically rising after it has been
initialized. There is no limit on the amount of jam protections. When room temperature is 25±5 oC, wire
resistance 150 mΩ and 14.5 V working voltage, the jam protection force risen glass is less than 100 N. When the
window is manually or electrically rising, once it encounters a force greater than the jam protection force, the glass
will immediately stop rising and make the motor rotate in reverse. Reverse rotation distance is about 125 mm.
2. Centralized control rise
The central door lock controller provides four lifters with a low level signal. The power windows will close until
they are completely closed. This enables the two power window actuators to start separately, which can avoid
hitting peak currents if they start up at the same time. As long as the centralized controller's rising pin receives
the low level signal, the motor will close the window until it is completely closed.
3. Soft-stop
If the motor suffers from an impacting block when the window is rolled all the way up or all the way down, it
would shorten the power window actuator's use life. In order to avoid this, the soft-stop function must be used,
in which both manual and automatic rolling up and down should have this function.
(a) Soft close function:
When the window is about to get to the top, that is to say, when it's rising to the soft-stop point, the engine's
power will cut off to make the motor stop working, meanwhile the rising inertia will continue to roll the
window up to the top. The soft-stop point is about 2 mm under the top limiting position.
(b) When the window is about to lower to the bottom, that is to say, when it's lowering to the soft-stop point,
the engine's power will cut off to make it stop working, meanwhile the lowering inertia will continue to roll
the window down to the bottom. The soft-stop point is about 12 mm above the bottom limiting position.
(c) Zero position calibration: This position takes the top limiting position as the zero position. In order to
guarantee reliable and safer system operation while in use, the zero position will need constant calibration.
Manual calibration: When the window stops at the rising soft-stop position after rising for a period,
press the rise button so it will rise to the limiting position. Zero calibration is then complete.
Automatic calibration: After the motor runs forward and reverse more than 20 times, it will undergo
zero position calibration one time. That is to say, when it completely starts or stops operating, the motor will
be blocked one time. Currently, there is no soft close or start-up function. Zero position calibration is com-
pleted when the window is completely closed to the limiting position.
4. Motor locked protection
The control module will cut off the power supply to stop the motor from working within 250 ms of the locking.
5. Motor temperature protection
When the control module is powered on, the initial temperature of the motor is set at 40oC. There are two
temperature limits for the motor's thermal protection function. If the temperature of the coil exceeds the first
temperature limit (170oC), the motor will not respond to any new operation input, but it will still complete the present
operation. If the motor's temperature exceeds the first temperature limit during its operation, it will keep working until
the temperature of the motor coil reaches the second temperature limit (190oC), then the motor will not be limited by
the second temperature's threshold while reversing, so as to guarantee the safety of the users. Once the temperature of
the motor has lowered below the temperature limit, the motor will work normally.
6. Self-diagnostic protection function
So as to guarantee the system's reliability while improving the system's average non-failure time, self-diagnostic
protection measures are used: If the power supply voltage exceeds 16 V, the control module will close the auto-
rising function.
(a) Switch contact point adhesion:
If it is detected that the switch contact point adhesion has reached up to 10 m input instructions will no
longer be received. If later the switch contact is detected to be disconnected again, it's function will return
to normal.
(b) Relay contact point adhesion:
The power window actuator is controlled by two contact point relays.
After a shutoff command is sent to one of the relays, if the system detects that this relay is still on, then
the system will choose this relay contact point for adhesion. Thereupon, the system will send out another
command to make the other electric relay switch on as well, so as to guarantee the motor's power supply is

cut off. Before sending out any new input instructions, the software will first detect whether the adhesive
contact point of the relay has been released. If it has been released, then all the operations, including the
sleep pattern, will once again be executable. If the contact point is still adhered, then only operations
going in one direction have the possibility of execution (depending on which direction the relay contact is
adhered). Then soon afterwards, activate the contact point adhesion handling function again.
(c) Motor protection when the Hall element failed or magnetic ring damaged.
If the Hall element or magnetic ring has malfunctioned, the control module can not receive the Hall
element's signal. In this case, the control module will return to the state before basic initialization, which
means it can only rise about 45 mm at most, and it will not have the jam protection function. During
the process of a centralized control rise, re-initialization is prohibited. Once any switch is activated, the
window will stop moving.
Maintenance areas of importance

1. Initialization
Considering the system's stable and reliable operation is directly related to the state of the vehicle's door sheet
and weatherstrip, the initialization process is required at the assembly line for the overall vehicle. Continuously press
the rise button of the power window actuator to roll up the window. The window will stop rising after only rolling up
45 mm. Then, after releasing the glass switch, continuously press the rise button again. It will still only roll up 45 mm.
Basic initialization will be completed when the rise has been blocked. At this point, the system will possess all the
functions except the lowering soft-stop function. During the basic initialization rise process, there is no jam protection
function. The basic initialization is completed, and it will still have the automatic lowering function.
2. Re-initialization & operating instructions are as follows
(a) This function is executable only when the following items are carried out.
• Manually correct the zero position function.
• The window rests at the mechanism dead center zero position.
(b) Within two seconds of the zero position (after the motor is blocked), release the button, then press the
button again for at least 20 s.
(c) After 20 s, the window will automatically lower about 46 mm, indicating that the characteristic curve and
zero position have been deleted.
(d) After it is deleted, the power window will only have manual function.
(e) Start initialization again.
Regulator components
Front door window regulator LH Front door window regulator RH
Rear door window regulator LH Rear door window regulator RH

Immobilizer System
Immobilizer system composition
This vehicle's engine immobilizer system consists of a theft deterrent ECU assembly, a theft deterrent coil as-
sembly, and two theft deterrent converter assemblies. The theft deterrent coil assembly is put on the head of
ignition lock cylinder, with the other end connected to the theft deterrent ECU assembly. The two theft deterrent
converter assemblies are separately installed inside the plastic handles of the two keys.
1. Position diagram
All the components of immobilizer system are assembled on the overall vehicle except for the theft deterrent
converter assemblies inside the keys. They achieve communication functions via the wire harness connections.
The following figure shows the position of each component in the overall vehicle.
Theft deterrent controller
Ignition lock key

Steering column
Theft deterrent coil
2. Theft deterrent controller

The theft deterrent controller assembly mainly consists of a microprocessor and peripheral components. It com-
municates with the password transmitter assembly and engine ECU. The theft deterrent controller assembly
communicates with the engine ECU via the W wire, while communicating with the theft deterrent transponder
assembly via radio frequency. The theft deterrent controller connects with the scanner via the K wire. Through
the scanner, it can initiate matching, state controlling, and malfunction diagnostic on the immobilizer system.
3. Theft deterrent coil
The theft deterrent coil assembly is installed on the ignition lock cylinder, the other end of wire harness
plug is connected to the theft deterrent controller assembly. The theft deterrent coil assembly can generate
an electromagnetic field to achieve communication between the theft deterrent controller assembly and the
password transmitter assembly.
4. Transponder
The theft deterrent transponder is installed inside the key handle. It has no power supply, maintains a small size,
and long use life. It acquires electric energy and transmission signals using the stimulation of the electromagnetic
field generated by the theft deterrent coil, so as to communicate with the theft deterrent controller assembly.

5. Immobilizer system wire connection diagram
LED
ON Battery - +
A4 A1
Ignition switch Ground Battery
A2
620 Ω
W wire
A8
LED Engine ECU
A3 R wire
A5
ANTA
B1
ANTB K wire Diagnostic
Coil B2 A7
GND
B3 scanner
6. Theft deterrent controller's connecting plug

The theft deterrent controller has two connecting plugs: an 8-core A plug and a 3-core B plug.
Theft deterrent controller Coil 3-core B plug pin definition

8-core A plug
Rated working Working Pin Pin definition

Pin Pin definition
voltage current
B1 Coil terminal A
A1 Connected battery 12 V <200 mA
positive pole B2 Coil terminal B
A2 Ground 0V <200 mA
B3 GND
A3 Connected LED 12 V <50 mA
A4 Connected ON end 12 V <50 mA
A5 Connected R wire 12 V <200 mA
A6 No connection
A7 Connected K wire 12 V <200 mA
A8 Connected W wire 12 V <200 mA
Note: Do not connect the A3 pin if the vehicle does not
have a theft deterrent indicator lamp
7. Immobilizer system matching

System matching is defined as a composition of independent immobilizer system components: The theft deter-
rent controller assembly, theft deterrent transponder, theft deterrent coil assembly, and engine ECU are com-
bined into a immobilizer control system through relevant downline matching equipment or scanners.The engine
can only start up when the well matched immobilizer system works normally.
Engine immobilizer system fault diagnostic and troubleshooting
Immobilizer system failure will lead to the engine ECU being blocked and the engine unable to start up. It does

not necessarily mean that engine start failure is due to a immobilizer system malfunction. The reasons for start-
ing engine failures are numerous, including factors like fuel, gas, fire, electricity, wires, etc. If the engine cannot
start, first check if the immobilizer system is working normally. This can be judged by looking at the flashing
theft deterrent indicator lamp which is located on the dashboard in front of the driver seat: Insert the key into the
lock cylinder and turn it to the "ON" position. If a legal key is used to start the engine, once the warning lamp is
connected to the ON end and the transponder is confirmed, the LED will remain unlit. Then when the ON end is
disconnected and the key is pulled out, the LED will shine for 0.25 s and darken for 4 s, as to act as a warning.
If an illegal key is used to start up the engine or there is something wrong with the system, the alarm indicator
lamp will shine for 0.25 s and darken for 4 s. If all is normal, then check the other parts of the engine. If abnor-
mal, first perform immobilizer system troubleshooting. A scanner can be used to judge if the immobilizer system
is working normally, but the precondition is that the scanner must be able to establish communication with the
theft deterrent controller.
1. If communication cannot be established, consider the following:
(a) Check whether the battery voltage is higher than 9 V
(b) Check whether the scanner plug is well contacted to the vehicle socket
(c) Use a multimeter to check whether the 7 pin of the OBD-II plug (diagnostic plug) is connected to the theft
deterrent controller's A7 pin
(d) Check whether the power supply of the theft deterrent controller is normal. (Use a multimeter to measure
whether the voltage of the theft deterrent controller's socket A1 pin and A2 pin is higher than 9 V)
(e) Then adopt the substitution method, which is to replace the theft deterrent controller to check if there is
anything wrong with the theft deterrent controller.
• If the failure is related to the theft deterrent controller, change it and initiate re-matching.
• If the failure has nothing to do with the theft deterrent controller, remove the electronic controller which
is connected to the alarm's K wire, such as the ABS controller, engine electrojet controller, airbag ECU
assembly, etc., as to ascertain if the present fault is caused by the wire harness connected with the theft
deterrent controller's K wire.
2. If communication can be established
Connect the scanner to the vehicle diagnostic port. Insert the key into the steering lock, and turn it to the "ON"
position, then select the scanner to check the immobilizer system's trouble code.
3. Security system troubleshooting
Investigate the problem and perform troubleshooting according to the trouble code on the scanner:
Trouble Code
Failure cause Troubleshooting methods
code significance
B1000 Theft deterrent Theft deterrent coil open 111 Check whether the theft deterrent coil's connecting plug and
controller circuit or short circuit. Theft the theft deterrent controller is well connected.
internal deterrent controller internal 222 Check whether the theft deterrent coil's wire harness plug is sliding
malfunction malfunction. or touching each other.
333 Remove the theft deterrent coil plug, and then use a
multimeter to check the resistance between the B1 and B2
pins. The normal resistance is about 5-30 Ω. If the resistance
is close to zero, that means the coil has been short circuited.
If the resistance is infinite, then it means the coil's circuit is
open. Measure the resistance between pins B1 and B3, and
B2 and B3, normally they are infinite. If the resistance gains
a certain value, then it means the coil is short circuited or
leaking electricity.
444 If there is nothing wrong with the coil, the next step is to
check the theft deterrent controller. Adopt the substitution
approach, replace it with a non-matched new theft deterrent
controller or an theft deterrent controller which has been
reset (please refer to the immobilizer system component
replacement). Insert the key into the ignition lock and turn it
to the "ON" position and read the trouble code. If there is no
9000 failure, it means the replaced controller has an internal
malfunction, and the new replaced controller must be re-
matched.

Trouble Code
code significance
B3040 W wire failure, There is no response from 111 First check whether the two failures B043 and B0422
communication the electrojet controller after coexist. If so, first solve these two problems.
the theft deterrent controller 222 Check whether the 8-core plug of the theft deterrent
sends out communication controller is well connected. Check whether the wire harness
requests. connecting the A8 pin (N wire) of the 8-core plug and
electrojet is well connected, not short circuited, and has no
poor contact. Check whether the electrojet wire harness and
the connector is well connected.
333 Replace the alarm (please refer to the immobilizer system
component replacement). Check whether the above failures
exist. If they do not, the fault most likely exists in the alarm.
444 Replace the electrojet (please refer to immobilizer system
exist. If they do not, the fault most likely exists in the
electrojet.
B3042 W wire Short circuiting happens 111 Check whether the theft deterrent controller's 8-core plug
grounding between the W wire and the wire harness is touching each other.
ground 222 Check whether the wire harness which connects the 8-core
plug's A8 pin (W wire) and the electrojet is short circuited to
the ground.
333 Replace the alarm (please refer to immobilizer system
exist. If they do not, the fault most likely exists in the alarm
electrojet.
B3043 W wire and Short circuiting happens 111 Check whether the theft deterrent controller's 8-core plug
power is short between the W wire (A8 wire harness is touching each other.
circuited pin) and the battery positive. 222 Check whether the wire harness which connects the 8-core
plug's A8 pin (W wire) and the electrojet battery positive has
short circuited
exist. If they do not, the fault most likely exists in the alarm
electrojet.
B3045 LED has a The wire harness (A3 111 Check whether the theft deterrent controller's 8-core plug
(vehicles short circuit or pin) connected to the theft wire harness is touching each other.
without open circuit, deterrent indicator (LED) 222 Check whether the wire harness which connects the 8-core
the theft LED operates has short circuited to the plug's A3 pin and the immobilizer indicator has short
deterrent abnormally ground. The wire harness circuited to the ground.
indicator (A3 pin) connected to 333 Check whether the wire harness which connects the 8-core
lamp will the immobilizer indicator plug's A3 pin and the immobilizer indicator has an open
show this (LED) has an open circuit. circuit.
trouble
code, but
it will
not affect
immobilizer
system
validation.)

Trouble Code
code significance
B3048 The LED has The wire harness (A3 111 Check whether the theft deterrent controller's 8-core plug
a short circuit pin) connecting to the wire harness is touching each other.
or open circuit immobilizer indicator 222 Check whether the wire harness which connects the 8-core
to the power (LED) has short circuited to plug's A3 pin and the immobilizer indicator has short
supply the battery positive. circuited to the battery positive.
B3055 Transponder No transponder inside the 111 Check whether there is transponder in the key.
cannot key, transponder damage, 222 Check whether the theft deterrent coil is correct as specified
modulate and the theft deterrent coil in Article 1.
or without damage will lead to theft 333 Replace the transponder (please refer to immobilizer system
transponder deterrent controller receiver component replacement).
failure of the response
signal from the transponder.
B3056 No key The theft deterrent controller Re-learn the keys.
message is hasn't been matched or
stored in the has no key duplicate, thus
theft deterrent there is no transponder
controller identification code stored
inside the theft deterrent
controller
B3057 PIN is not The theft deterrent controller Set up the safety code and match the theft deterrent controller
recognized is new or has been reset. again.
by the theft
deterrent
controller
B3059 No request The theft deterrent 111 Check whether the theft deterrent controller's 8-core plug is
signal from controller doesn't receive well connected.
the electrojet the communication request 222 Check whether the wire harness connecting the A5 pin (R
controller is signal from the electrojet wire) of the 8-core plug and electrojet is well connected, is
received controller. not short circuited, and is not poorly connected.
exists. If they do not, the fault most likely exists in the alarm.
exists. If not, the fault most likely exists in the electrojet.
B3060 Illegal key No transponder Use the scanner to carry out the "learning keys" function.
message is identification code stored in
received the theft deterrent controller.
B3061 The The transponder 111 Check whether the theft deterrent coil is correct as specified
communication can not establish in Article 1.
with the key is communication with the 222 Check whether the transponder is new or not matching.
interrupted theft deterrent controller, Rematch it if it is not matched;
the communication 333 If the transponder has been matched, make sure to check
is interrupted, or the whether the transponder has been changed, or the electrojet
communicating data is changed or reset
incorrect. The electrojet • If the transponder has been changed, then it cannot be used
key is not identical to the again, and must be replaced with a new one and then re-
transponder's. matched
• If the transponder hasn't been changed and only the
electrojet has been reset, then it only needs to matched again.
• If the transponder has not been changed but the electrojet
has been changed, make sure the replacing electrojet
is new or has been reset. If the substituted electrojet is
matched but not yet reset, then it must be replaced with a
new or reset one and then re-matched.

4. Security system component replacement

When a failure appears in one of the immobilizer system components, this component must be replaced. After
the replacement, perform matching on the immobilizer system again.
Only changing the coil
There is no need to match the immobilizer system again.
Only changing the key (theft deterrent transponder assembly)
(a) Get the vehicle's PIN code from the code located inside the burglar-proof classified envelope
(b) Connect the scanner with the vehicle's diagnostic connection
(c) Insert the key into the ignition lock and turn it to the "ON" position
(d) Check whether the key is legal and matched. If it is illegal or already been matched, then it cannot be
matched again, but will have to be replaced
(e) Input the PIN code with the scanner
(f) Erase the damaged lost key's information
(g) Match the new key according to the scanner's prompt
(h) If it is necessary to match another key, insert the key, and after resetting the scanner, operate according to
steps c, d, e, and g.
Caution: Make sure the key is legal and hasn't been matched before learning the key. Otherwise, the
immobilizer system won’t successfully match or the scanner will display that it has been matched but
the electrojet's validation is not available.
Only replacing the theft deterrent controller assembly
(a) Get the vehicle's PIN code from the code inside the burglar-proof classified envelope
(b) Turn off the ignition switch, and replace with an unmatched new theft deterrent controller or reset the theft
deterrent controller
(c) Insert the key into the ignition lock and turn it to the ON position
(d) Input the PIN code with the scanner
(e) Match the theft deterrent controller assembly according to the scanner prompts
(f) Because the theft deterrent controller is new, there is no VIN and original key information stored in it. It
will need the VIN inputted and must be matched with the original key, otherwise the original key will not
work.
Caution:
(a) Replace the new alarm remote controller or reset the alarm remote controller, or the alarm re-
mote controller system matching can not be completed.
(b) Select "Read EMS to alarm remote controller", not "Read alarm remote controller to EMS", or it
will make the transponder inoperable.
Only replacing the engine ECU
(a) Get the vehicle's PIN code from the code inside the burglar-proof classified envelope
(b) Turn off the ignition switch, and replace with a new non-matched or reset ECU
(c) Insert the key into the ignition lock and turn it to the ON position
(d) Input the PIN code with the scanner
(e) Match the ECU according to the prompts on the scanner, and complete the ECU and theft deterrent
controller matching.
Caution:
(a) Make sure to replace it with a new or reset ECU, otherwise the immobilizer system matching can-
not be completed.
(b) Select the menu of "Read EMS to theft deterrent controller", but not "Read theft deterrent control-
ler to EMS", or it will make the transponder inoperable.
Replacing the theft deterrent controller and EMS controller at the same time
If both the theft deterrent controller and EMS controller need to be changed at the same time, then the transpon-
der that has been matched must also be replaced, otherwise the immobilizer system matching cannot be com-
pleted. The immobilizer system needs to be re-matched after being replace.
Matching after sales stage
Problems caused by lost keys or immobilizer system failures requires a duplicate key, replaced parts, etc. These
problems cannot be solved without re-matching the immobilizer system's parts. During the matching, input the
correct PIN code with scanner. Specific possible problems and matching methods the maintenance station may
encounter are as follows:
1. Match an empty key:
(a) Properly connect the engine ECU and the theft deterrent controller, and then insert the key to be matched,
and switch the ignition switch to the ON position

(b) Input the PIN code and the key matching instructions with the scanner
(c) If the PIN code is correct, after receiving the key matching instructions, transponder learning will be
complete
(d) Switch off the ignition switch
2. Check the key quantity:
Check the alarm's currently matched key quantity and matchable key quantity with the scanner.
3. Match the theft deterrent controller:
(a) Properly connect the engine ECU and the theft deterrent controller
(b) Input the PIN code and theft deterrent controller matching instructions with the scanner
(c) If the PIN code is correct, after receiving the theft deterrent controller matching instructions, matching will
be complete.
After theft deterrent controller matching is done, it needs to re-learn each key if the original key is still to be
used. If the original key will not be in use any more, then it needs to rematch the new key.
4. Match the engine ECU
(a) Properly connect the engine ECU and the theft deterrent controller.
(b) Input the PIN code and engine ECU matching instruction with the scanner.
(c) If the PIN code and instructions are correct, the matching process will be completed automatically.
5. PIN code scan-resisting strategy
From the matching process above, it's apparently that the PIN code is a security code for the matching process.
This code is passed to the vehicle owner in document format during the sales service. If it is lost accidentally,
the customer service staff can check the vehicle identification code stored in the theft deterrent controller with a
scanner, and then send it to the authorized staff in the factory to check the PIN code. In order to prevent someone
from illegally scanning the PIN code, it uses a forced time-delay method to prevent divulgence of information.

CD Player
CD player outside view
ISO pin definition Function

Pin
A B
Linear control ground
1 Rear horn RH (+) (Violet)
cable
Rear horn RH ( - ) (Violet/Black
2 Mute (Pink)
striped)
3 Linear control Front horn RH (+) (Grey)
Connected ignition
4 Front horn RH (-) (Grey/Black striped)
switch (Red)
Automatic antenna
5 Front horn LH (+) (White)
(Blue/White)
Lighting wire Front horn LH (- ) (White/Black
6
(Brown) striped)
To engine battery
7 Rear horn LH (+) (Green)
positive (+) (Yellow)
8 Ground cable (Black) Rear horn LH (-) (Green/Black striped)
Common faults and solutions
General problems
Symptoms Causes Solutions
Burnt fuse Replace with a new fuse of the same
specification
Cannot start Vehicle supply battery fuse is burnt Replace the vehicle supply battery fuse
Illegal operation and other factors Press the reset button to reset the system
The volume of the head unit or the Raise the volume of the head unit or the
connected component is too low connected component
Speaker possibly damaged Check the speaker
The sound balance settings lean to one Adjust the sound balance
side
No sound or sound is too low Speaker's connection wire touches the Use insulated conductor to connect the
vehicle body speaker and use insulating cement to cover
the exposed connections
Disc is not genuine Use a genuine disc
Speaker is incorrectly connected Please refer to the "Electrical connection
diagram" to correct the connection


Speaker's connection wire touches the Check the speaker's connection wire
vehicle body
"MUTE" wire touches the metal parts Ensure the telephone silence control wire is
The sound quality is poor or
of the vehicle body insulated from the vehicle body
distorted
A connection error between the Please refer to the "Eelectrical connection
ignition coil ACC and positive power diagram" to correct the connection
line "BATT"
Trouble code
Display character Malfunction Solutions
ERR3 Disc is placed upside down Eject the disc and reload
ERR4 Incompatible disc file or format Check the disc format
ERR1
Disc structure error Eject the disc and replay
ERR1
Electrical connection diagram
6 7 8
5 4 3
2 1
Radio antenna Pin Definition

1 Karaoke control wire
2 Microphone audio output
3 Power supply (+)
4 Microphone audio ground cable
ISO pin definition
5 Auxiliary left audio output
Function
Pin 6 Auxiliary right audio output
A B
7 Auxiliary audio ground cable
Linear control ground
1 Rear horn RH (+) (Violet) 8 Power supply ground cable
cable
2 Mute (Pink) Rear horn RH ( -) (Violet/Black striped)
3 Linear control Front horn RH (+) (Grey)
Connected ignition
4 Front horn RH ( - ) (Grey/Black striped)
swith (Red)
Automatic antenna
5 Front horn LH (+) (White)
(Blue/White)
Lighting wire
6 Front horn LH ( - ) (White/Black striped)
(Brown)
to engine battery
7 Rear horn LH (+) (Green)
positive (+) (Yellow)
8 Ground cable (Black) Rear horn LH ( - ) (Green/Black striped)

DVD Player
Head unit outside view
Head unit ISO interface definition

Pin Pin definition
1 Power supply ground cable
2 Headlight diagnostic
3 Ignition diagnostic
4 Mute diagnostic
5 Power supply +
6 Radio antenna power supply control
7 Key-drive
8 Key-drive ground cable
9 15 A fuse
10 15 A fuse
Pin Pin definition Pin Pin definition

11 Rear left audio output - 21 Disc changer communication wire (reserve)
12 Front left audio output - 22 Power supply ground cable (reserve)
13 Front right audio output - 23 Communication wire (reserve)
14 Rear right audio output - 24 Disc changer right-channel output (reserve)
15 Rear left audio output + 25 Power supply + (reserve)
16 Front left audio output + 26 Audio ground cable (reserve)
17 Front right audio output + 27 Key-drive ground cable
18 Rear right audio output + 28 Amplifier control
19 Disc changer left-channel output (reserve) 29 Key-drive B
20 Ignition diagnostic (reserve) 30 Key-drive A

Pin Pin definition Pin Pin definition

31 Brake diagnostic 35 Rearview mirror power supply
Rearview mirror power supply ground
32 Reverse diagnostic 36
cable
33 Disc changer video input (reserve) 37 Rearview mirror video input
34 Video ground cable 38 Video ground cable
Head unit 36 PIN socket definition
Pin Pin definition Pin Pin definition Pin Pin definition

Navigator communication line
1 Auxiliary audio ground cable 13 25 Rear right audio output (reserve)
(head unit receive)
Navigator communication line
2 Auxiliary left audio input 14 26 Mid-audio output (reserve)
(reserve)
3 Auxiliary right audio input 15 Digital ground cable 27 Super bass audio output (reserve)
4 Digital ground cable 16 Navigator composite video signal 28 Audio ground cable (reserve)
Background left audio output
5 Auxiliary video input 17 Navigator red video signal 29
(reserve)
SV-6269:Karaoke control wire Background right audio output
6 18 Digital ground cable 30
SV-6268: NC (reserve)
Background video output 1
7 Power supply + 19 Navigator green video signal 31
(reserve)
8 Ignition diagnostic 20 Navigator blue video signal 32 Auxiliary audio input 2 (reserve)
9 Navigator audio input 21 Front left audio output (reserve) 33 Digital ground cable (reserve)
SV-6269:Microphone audio input
10 22 Front right audio output (reserve) 34 Audio ground cable (reserve)
SV-6268: NC
Auxiliary left audio output 2
11 Navigator audio ground cable 23 Audio ground cable (reserve) 35
(reserve)
Navigator communication line Auxiliary right audio input 2
12 24 Rear left audio output (reserve) 36
(head unit send) (reserve)
Karaoke box MINI8PIN socket

Pin Pin definition
1 Karaoke control wire
2 Microphone audio output
8 7 6
3 Power supply +
5 4 3
4 Microphone audio ground cable
5 Auxiliary left audio output
6 Auxiliary right audio output
2 1
7 Auxiliary audio ground cable
8 Power supply ground cable

Common faults and solutions

If the following faults occur while using this machine, please refer to the troubleshooting guide.
General problems
Replace with a new fuse of the same
Burnt fuse
specification
Cannot start Vehicle supply battery fuse is burnt Replace the vehicle supply battery fuse
Illegal operation and other factors Press the reset button to reset the system
Remote controller battery is low Replace the remote controller battery
Remote controller doesn't
work Remote controller battery is reversely
Proper battery installation
installed
The volume of the head unit or the Raise the volume of the head unit or the
connected component is too low connected component
Speaker possibly damaged Check the speaker
The sound balance settings lean to one
Adjust the sound balance
side
No sound or sound is too low Use insulated conductor to connect the
Speaker's connection wire touches the
speaker and use insulating cement to cover
vehicle body
the exposed connections
Disc is not genuine Use a genuine disc
Please refer to the "Equipment connection
Speaker is incorrectly connected
drawing" to correct the connection
Speaker's connection wire touches the
Check the speaker's connection wire
vehicle body
The sound quality is poor or "MUTE" wire touches the metal parts of Ensure the telephone silence control wire
distorted the vehicle body is insulated from the vehicle body
A connection error between ignition coil Please refer to the "equipment connection
ACC and positive power wire "BATT" drawing" to correct the connection
Common display characters and fault meaning

Display character Malfunction Solutions
Disc is dirty Clean or replace the disc
The read side of the disc is inserted Insert the disc into the player with the
No Disc
upside-down label side up
No disc in the player Insert the disc
Disc is dirty Clean or replace the disc
Bad disc The read side of the disc is reversely Insert the disc into the player with the
inserted label side up
Unknown disc Player cannot read disc Please use discs supported by this player
The region code of this disc does not Use discs that have a region code identical
Region error
match the region code for this player to this player's

TFT display screen common faults and solutions

No image is shown on the
Parking control wire "PRK SW" is not Please refer to the "Equipment connection
display screen, only a warning
properly connected drawing" to correct the connection
image
The DVD output image format does not
Change the screen format to automatic
match the display screen format
Abnormal display status, like Some non-genuine discs’ actual display Use a genuine disc
pulsing lines, appear in the format do not match the labeled format
image Video wire is damaged Replace the video wire
Please refer to the "Equipment connection
Video wire connection error
drawing" to correct the connection
Displayed characters are
Shutoff and restart, or switch to another
messed up or displayed Incorrect operation
source and then try again
incorrectly
Radio reception failure and solution

Check if the radio reception automatic
antenna's control wire ANT.CONT is
Automatic antenna fails to extend
properly connected. Please refer to the
"Equipment connection drawing"
Poor lock channel effect Properly connect the radio reception
Failure to connect the radio reception
antenna. Please refer to the "Equipment
antenna
connection drawing"
Switch off the local search function, please
Local search function is in the on-state
refer to the "Local search"
DVD playing faults and solutions

Eject the disc from the inside of the player
Cannot insert disc There is a disc in the player
and insert a new one
Disc is scratched and unable to be read Replace the disc
Disc is too dirty or wet Clean the disc with a soft cloth
Clean the laser head with a laser head
Laser head is dirty
cleaning disc
Disc is unable to play The disc is not supported by this player Check the disc type
Child lock grade too high Chang the child lock settings
The read side of the disc is inserted Insert the disc into the player with its label
upside-down side up
The region code of the disc does not Use discs that have a region code identical
match the region code of the player to this player's
Subtitle does not display The disc does not contain a subtitle file Use discs containing a subtitle file
Language or subtitle switch The disc only has one type of language Use discs containing multi-channel voice
does not work or subtitle or subtitle files
The disc only has one visual angle Use discs that support multi-angle play
Multi-angle switch does not
work The section in play does not support Select a section that supports multi-angle
multi-angle play


The player is compatible with the copy
system, so if the disc is copy protected, it
Image is blurred and distorted The disc is copy protected
may not be able to play, and is not a problem
with the player
PBC function has no effect
The disc contains no PBC function Use discs that support the PBC function
when playing a VCD disc
Repeat function and album/
PBC is set to on Turn off the PBC function
time search are unavailable
MP3 playing faults and solution

Disc is scratched or dirty Clean the disc with soft cloth
Clean the laser head with a laser head
Laser head is dirty
cleaning disc
Cannot play MP3
The disc is not supported by this player Please use discs supported by this player
The read side of the disc is inserted Insert the disc into the player with its label
upside-down side up
The disc is too dirty or scratched Clean or replace the disc
The sound is not smooth when
Partial content is damaged Replace the disc
playing MP3
Bad record condition Re-record the disc
Name of MP3 file is not
Irregular file name Do not use Chinese names
displayed normally

Equipment connection drawing
Antenna
Navigator
Rear view mirror

power supply
Yellow ground wire
AUX IN VIDEO
AUX IN J/B
AUX IN/Karaoke J/B
Rear view mirror

power supply
ground wire
CAMERA—B+ Red
Rear view mirror
power supply
ground wire
CAMERA—GND Black
Rear view mirror

Yellow audio input
CAMERA—VIDEO
Blue & white

Yellow
Power amplifier
control
P.CONT
Green
Reverse shift switch
Green & white

Brake diagnosis
Blue
P.CONT
Pink
Reverse detect
REVERSE

Control wire connection areas of importance

1. This player is used on vehicles with a 12 V battery and negative ground. If this player is to be installed
on a vehicle with a 24 V battery, please install voltage reduction equipment.
2. To avoid short circuiting the electrical system, cut off the battery negative end's connection wire before
installation.
3. Please arrange the connection wires at fixed locations, as to make sure they will not make contact
with any portable parts, such as the parking brake control mechanism assembly, gear lever, the seat's
fixed track, and so on. Please do not arrange the wires in a heat source area, like near the discharge
outlet of the heater, etc. Otherwise the heat source will cause the insulating layer to melt or wear out,
and then lead to a short circuit between the connection wire and the vehicle body.
4. Do not put the power cord through the mounting hole into the engine box and then connect it to the
battery. Otherwise it might damage the power cord and then lead to a short circuit between the power
cord and the vehicle body.
5. When changing the fuse, please use the specified 15 A fuse. Fuses with an unmatched size will lead
to abnormal operation, and even damage the player or cause a fire hazard.
6. Please do not share the player's power supply with other equipment, otherwise it might lead to a
malfunction due to overloading.
7. Please wrap up the exposed places of the wire with insulating cement to avoid short circuiting.
8. Bind up all the connection wires well to avoid any connecting term inal touching the player or other
mental parts of the vehicle body and leading to a short circuit.
9. When switching the player's power on, the external connection amplifier's controlling signal will output
through the lead wire P.CONT. If the player is connected with an external connection amplifier, please
do not connect the lead wire P.CONT to the amplifier's supply terminal, otherwise it will cause a
malfunction.
10. The player's outputting terminal must not be grounded, otherwise the amplifier may burn out. Please
do not use a 3-wire type speaker system which shares the ground cable. Please do not connect the
speaker wire to the vehicle body.
11. The maximum rated power of the speaker connected to this player is 50 W, resistance value is 4 Ω.

Air Conditioning System

Technical Parameters.......................................................... 203
Air Conditioning System's Structure Diagram and
Fundamentals...................................................................... 207
Air Conditioning System Overview...................................... 207
Air Conditioning System Terminal Definition........................ 208
Compressor......................................................................... 208
Electromagnetic Clutch....................................................... 210
Vacuuming and Charging Refrigerant................................. 211
Filling Quantity and Method for Refrigerant Oil................... 212
Daily Maintenance of the Air Conditioning System . ........... 212

Air Conditioning System 203
Areas of Importance
1. When putting in a new compressor, adjust the new compressor's inner lubricant to make it the same
level as of the old compressor's.
2. When the air conditioner malfunctions, if the pipeline, condenser or evaporator is the source of the
damage leading to its replacement, just add model number RS20 professional lubricant 5-10 ml.
3. The compressor is a high speed operating component, the smallest impurity in the air conditioning
system can lead to the compressor's damage, therefore the entire air conditioning system must be
cleaned.
4. In order to avoid liquid damage to the compressor, pay careful attention when filling the refrigerant.
When the vehicle stopped, fill the liquid refrigerant from the high pressure side. When in operation, fill
the liquid refrigerant from the low pressure side.
5. When undergoing maintenance, pay attention that the amount of refrigerant being added is 510±10 g.
Observe through the check glass to determine if there is sufficient new refrigerant charge.
Technical Parameters
Item Parameter
Model Rotary vane compressor (JSS-96TV4-4)
Discharge capacity 96 ml/r
Number of vanes 5
Normal rotational speed range 800-7800 r/min
Max. speed 8400 r/min
Weight 4.744 kg (without clutch)
Compressor Low pressure side 50 kg/cm2, High pressure
Pressure resistance
side 75 kg/cm2
Leakage ≤14 g/year
Direction of rotation Clockwise (looking from the clutch)
Refrigerant R134a
Lubricant number RS20
Lubricant capacity 200±10 ml
Min. pull-in voltage 7.5 V (12 V)
Pulley style 4PK810
Weight 2.1 kg
Clutch Rated voltage 12 V (DC)
Power consumption ≤45W (20oC DC 12 V)
Static friction torque ≥40 N·m
Pulley diameter φ110 mm
Coil resistance (3.5±5%) Ω
Operating temperature On / Off (130±5)oC/(150±5)oC
Thermal protector
Rated voltage, current 16 V, 5 A

Troubleshooting
Failure Symptoms Cause analysis
Air con- Compressor Blown fuse, compressor relay damaged
ditioning does not work Pressure switch contact broken, short circuited, or open circuit
system fails Compressor electromagnetic clutch open circuit
to produce Switch burnt out
cold air Main relay burnt out
Clutch slips
Compressor belt broken or loose
Compressor failure
Insufficient coolant, system pressure below 0.196 MPa
System pressure exceeds 3.14 MPa
Engine water temperature is too high
Clutch voltage is below 7 V
Compressor Compressor relay often open contact bond, system coolant leaks severely,
pulling in system has no coolant
Blower does not work
Blower has no wind Blown fuse
Blower motor brush damaged
Blower switch damaged
Wiring connector detached or open circuit
Speed regulation module damaged
Blower has no wind at high speeds, high speed relay damaged
Note: Blower's non operational process has a resistance value of 0, with a
open circuit resistance value of
The cool- Compressor operates Cooling system has ice blockage
ing system normally Thermistor or thermometer bulb malfunction
sometimes Abnormal A/C switch contact
works, some- Condenser blower damaged
times not
Compressor operates Clutch slides, clutch coil loose, clutch coil bad connection
abnormally
Insufficient Low wind volume Blower fan normal: air pipe damaged
cooling Cooling fan operates abnormally:
(1) Blower switch abnormal
(2) Supply voltage low
(3) Speed regulation module damaged
Wind vol- Compressor operates normally

ume normal (1) High and low pressure side's pressure is low
(a) Expansion valve is blocked
(b) Expansion valve opening is too small
(2) High and low pressure pipe's pressure is high
(a) High pressure pipeline malfunction, uneven flow
(b) Thermistor failure
(c) Expansion valve opening is too big
(d) Too much refrigerant oil
(e) Too much refrigerant
(f) Poor condenser heat dissipation
Note: When the speed is at 2000 r/min, cooling fan at max gear, and air tem-
perature at 30-35oC, the system's low pressure side pressure should be 147-
192 KPa, and high pressure side pressure 1373-1668 KPa

Troubleshooting (Continued)
Insufficient Wind vol- Compressor operates normally
cooling ume normal (3) High pressure side pressure is too low
(a) Low pressure pipeline damaged
(b) Low pressure pipeline blocked
(4) Low pressure side pressure is too low
(a) Evaporator frost
(b) Expansion valve is blocked
(c) Low pressure pipeline not clear
(d) Thermal speed adjustive resistance failure
(5) Low pressure side's pressure sometimes normal, sometimes negative,
moisture in the cooling system, and ice blockage
(6) Low pressure side's negative pressure, high pressure side's pressure too
low, blockage in the cooling system
(7) Low pressure side pressure too low, high pressure side pressure too high
(a) Inner portion of the condenser is blocked
(b) High pressure pipeline blocked
(8) Low pressure side pressure too high, high pressure side pressure too low
(a) Compressor leaks
(b) Compressor valve damaged
(9) Low wind volume of the condenser blower can lead to poor heat dissipation
Compressor operates abnormally
(1) Compressor internal malfunction
(2) Compressor belt loose, slides
(3) Electromagnetic clutch malfunction
(a) Supply voltage low
(b) Interference between the stator and the rotor
(c) Idling stabilizing amplifier malfunction
(d) Circuit broken, connector detached
(e) Bad switch and relay operation
(f) Short, open circuit
(g) Bad ground
Other causes
Dysfunctional Carriage seal
Cooling Noise too loud Belt loose or overly worn
system is Compressor's mounting bracket set screw loose
too noisy Compressor's mounting bracket damaged
Compressor's internal components are damaged
Refrigerant too little or empty
Clutch slip noise
Clutch bearing lacks oil or is damaged
Blower motor bearing damaged
Blower bracket broken or loose
Blower vane broken or loose
Blower vane rubs against other components

Troubleshooting (Continued)
Heating sys- No or insuffi- Air conditioner blower malfunction
tem cient heating Blower relay damaged
Hot air duct blockage
Cooling water pipe blockage
Temperature change throttle actuator damaged
Coolant insufficient
Blower does Fuse blown or ill switch contact
not work Blower motor burnt out
Blower's high speed relay broken
Speed adjustive resistance damaged
Open circuit
Water leakage Heater water pipe degradation, poor connection
Over heated Fan's speed adjustive resistance damaged
Temperature change throttle actuator damaged
Defroster’s hot Mode cable damaged
air insufficient Vent is not in place
Air outlet blockage
Insufficient heating
Air duct mounting
Open circuit

Air Conditioning System's Structure Diagram and Fundamentals
Expansion valve
Condenser
Pipeline
Accumulating
dehydrator
Air conditioner
Compressor
Condenser fan
Air Conditioning System Overview

Basic composition
Composed of air conditioner, compressor assembly, condenser
assembly, pipeline, defroster system, heating & ventilation
system, etc. The air conditioner also includes evaporator and
blower components.
Function
This system is a manually controlled air conditioning
system, with steam compression as its cooling method.
Residual heat water warming is the heating method the
engine adopts. Inner & outer circulation, blowing mode,
and cold & warm temperature adjustment are all controlled
by individual cables from the air conditioning controller. It
achieves ventilation, warming, and cooling integration.
Caution: While starting the compressor, you must open
the air regulation knob first, otherwise it cannot start.
Operation
The compressor is driven directly by the engine. High
temperature and high pressure refrigerant vapor exhausted
from the compressor will pass through the high pressure
pipe into the condenser, dissipate the heat via temperature
difference, and then form a high pressure liquid. High
pressure liquid passes through the accumulating dehydrator
into the expansion valve, and after passing through the
throttle valve, it becomes a low pressure liquid. Heat
exchange via the evaporator will cool down the room’s air,
and then the refrigerant inside the system will become a low
temperature and low pressure vapor, which is then sucked
into the compressor and compressed into high temperature
and high pressure air again. Thus a cooling cycle is formed.
The circulation continues, which maintains a comfortable
temperature inside the vehicle.

Air Conditioning System Terminal Definition
Air conditioner switch Hazard warning switch + rear defroster switch Blower + night lighting + safety instruction
Pin Interface signal Pin Interface signal

A Emergency lamp relay 2 Parking lamp drive +
Safety indicator
B Power supply (+) 3
lamp drive +
C Ground 4 Blower LO gear drive +
Blower common
D Power supply 5
terminal GND
Air conditioner
E 6 Blower HI gear drive +
request signal
F Blower relay 9 Blower M1 gear drive +
10 Blower M2 gear drive +
Compressor
Entire outline structure (shown on the left)
Rotary vane compressor’s operation

Blade
As the diagram shows, when the rotor is rotating under an
external force, due to the synergism of centrifugal force and the
oil pressure difference on the five vanes of the rotor, their edge
Exhaust
valve clings to the cylinder wall. Because the fixed cylinder is oval
shaped, while rotating on the rotor, the rotor vanes spread and
Exhaust valve retract according to the cylinder's geometrical shape, which in
turn makes the crescent shape consisting of the cylinder, vanes,
Rotor etc. to change continuously, so as to achieve the functions of
Cylinder suction, compression, and exhaustion.

Compressor Removal
1. Hoist the vehicle with a jack.
2. Remove the bottom mudguard.
3. Remove the compressor.
Compressor Installation
Before installing, manually rotate the compressor several
circles, allowing each component in the relative motion to be
covered with lubricant.
Clearance between the compressor's auricular branch and
bracket should be less than 0.1 mm. If the clearance is too
big, fill the clearance with a washer.
1. Loosen the engine's adjusting bolt firstly, take down the
engine belt, and then change the compressor belt.
2. Fix the compressor bracket onto the engine body with
the bolts. The bracket must be fastened tightly with suf-
ficient intensity. Fix the compressor bracket onto the
engine with four M10 ×1.25 (Q1461030 FD) bolts and
a tightening torque of 45±5 N·m, and then install the
compressor onto the bracket with a tightening torque of
22±3 N·m.
3. Take off the suction and exhaust cap. Select the
Suction port (S-end) size Exhaust port (D-end) size suction duct and exhaust duct that matches the size
C-C B-B of the suction and exhaust port to connect with each
2:1 2:1 other (size of suction and exhaust port shown in the
diagram). Then tighten the coupling bolt.
Engine pulley
4. Put the 4PK850 type compressor belt onto the pulley,
and then adjust the bracket to make the belt reach the
specified tension. That is, if a force of 100-120 N is
Water pump pulley
Tensioner pulley used on the belt, deformation of the belt is 8-10 mm.
Steering
pump pulley
Crank pulley Compressor pulley

5. Insert the thermal protector plug into the relevant plug
of the air conditioning system's wire harness.

Electromagnetic Clutch
Clutch composition
Electromagnetic clutch consists of an armature, a solenoid,
and a pulley.
Areas of importance during clutch usage
Because the joint of the electromagnetic clutch
operates under high speeds, separation-joint marks on
the pulley and armature are completely normal, and do
not harm clutch usage.
The clutch's operating voltage must be consistent with
the specified voltage rating. Too high or too low will
affect its normal usage.
The clearance between the coil and the pulley is
very important. If too big, the effect of the magnetic
field reduces. If too small, the high speed pulley rubs
against the fixed coil, causing the clutch to burn.
The clearance between the armature and the pulley
is also very important. If too big, it leads to insufficient
clutch pull-in force. If too small, it may cause armature
damage.
Clutch removal
1. Seize the clutch's triangular piece and secure the
clutch's armature with a clamp. Then take down the
inner hexagon lock screws of the main shaft with an
inner hexagon spanner.
2. After removing the lock screws, manually grasp the
triangular piece and take out the armature, at the same
time remove the clamp spring with the circlip pliers.
3. Remove the clutch's pulley with pullers as shown, and

remove the compressor pulley and its bearing.
4. The gasket on the main shaft is used to adjust the
clearance between the pulley and the armature. Use it
to adjust the clearance value to be as specified during
installation, and do not lose it during removal.
5. Remove the mounting screw from the solenoid coil

connector with a screwdriver, and use circlip pliers to
take down the retaining ring inside the coil and remove
the solenoid coil.

Clutch Installation
1. Install the solenoid coil at the place pressing up against the head cover's end surface and pay atten-
tion to insert the dowel pin of the solenoid coil into the bottom hole of the head cover. Put the retaining
ring into the groove with circlip pliers, and press the solenoid coil's connecting wire onto the pressing
line plate on the head cover with a SST.
2. Put the compressor on a specially designed fixture or platform, with its head cover facing upwards.
Press the pulley into the head cover shaft, and put the pulley bearing's retaining ring into the groove
with circlip pliers.
3. Install the armature onto the main shaft's spline and seize the clutch's triangular piece with a clamp.
Then tighten the inner hexagon lock screws and washers with a torque wrench. Screw torque should
be between 150-180 N·m. After installation is done, make sure to check if the clutch's pulley and
armature are able to operate freely, and also check the clearance between the pulley and armature,
which should be 0.3-0.6 mm.
Low pressure
High pressure Vacuuming and Charging Refrigerant
Manifold gauge
Blue Initiate vacuum pumping by using the manifold pressure
Low pressure Red gauge connected to the air conditioner (compressor) pipeline
pipe
and vacuum pump. When the vacuum pumping starts, open
Quick coupler the manifold pressure gauge's high and low pressure valve,
High pressure pipe
and open the vacuum pump's end surface valve (if equipped),
Vacuum pump Quick coupler then press the "ON" button to start the vacuum pump, and let it
run for at least 20 minutes. When the manifold pressure gauge
shows -760 mmHg or lower, close the high and low pressure
valve, and press the switch to turn off the vacuum pump.
Manifold gauge Inspect air tightness

Low pressure High pressure
gauge gauge After shutting off the vacuum pump, continue to inspect
the pressure reading of the manifold pressure gauge. If the
pressure reading remains unchanged for 20 minutes after
the vacuum pump stops operating, the refrigeration system
is proven to have no leak. One may continue to the next
Yellow step. If the reading changes, the system has a leak. Carry out
an inspection, and after repairing the leaking section, start
vacuum pumping once more.
Blue Yellow Red
Charge refrigerant
After verifying the system's air tightness, connect the
refrigerant tank (or gas cylinder) and yellow air supply hose
Close head. Connect the yellow air supply hose's other head with
Air purge the injection port in the middle of the manifold pressure
Red gauge. Ensure the refrigerant tank and air supply hose's nut
Yellow is tightly connected, then open the refrigerant tank's valve.
At this time, the high and low pressure valve is closed. Use
a tip shaped screwdriver or similar instrument and press
Blue the valve core at the side port for 1-2 s, then expel the air
Refrigerant tank
between the air supply hose and manifold gauge.
Perform switch operations according to the

Low pressure
High pressure
Blue Open following methods
Open
1. Switch the front and rear blower speed control switch
Red to the highest settings, and rotate the temperature
control switch to the coldest position.
2. Press down the A/C switch, and set inner/outer circula-
Yellow tion to inner circulation mode. Open the doors and win-
dows during this procedure.
3. Adjust the engine's speed to the regulated idle speed.
Refrigerant tank 4. Hold up the refrigerant tank or gas cylinder (emptying

the refrigerant into the refrigeration system in the gas

form), and open the manifold pressure gauge's low
pressure valve.
5. When charging the refrigerant, carefully observe the
High pressure high pressure side of the manifold pressure gauge as
side pressure well as the refrigerant's rate of flow (limpid, foamy, hazy)
(MPa) which can all be seen from the inspection window. Use
Appropriate this window to determine the appropriate time to stop
pressure charging the refrigerant (by closing the low pressure
Appropriate Excessive
valve).
charge charge When the compressor is operating, please do not close the
high pressure valve.
Before inspecting the cooling level, confirm the regulated
Refrigerant charge (g)
refrigerant charge quantity for the air conditioning system.
Determine the charge amount for the refrigerant charge.
Please carry out the setup according to the following
working conditions.
Engine's water tank temperature: steady
Engine speed: normal idle
A/C switch: ON
Blower speed control switch: highest gear
Temperature controller: inner circulation
Door: completely open
Window: completely open
Filling Quantity and Method for Refrigerant Oil

First vacuum the refrigerant system to 0.2 × 10-5 Pa, then fill it with model number RS20 refrigerant. The steps
are as follows:
1. Close the high pressure, manually operated valve and the auxiliary valve.
2. Remove the high pressure side's hose from the manifold pressure gauge and insert it into the oil cup.
3. Open the auxiliary valve and draw the refrigerant from the oil cup to the refrigeration system.
4. When refrigerant in the oil cup is about to be fully vacuumed, immediately close the auxiliary valve, in
order to avoid sucking air into the system.
5. Screw the high pressure side hose connector onto the manifold pressure gauge, start the vacuum
pump and open the high pressure, manually operated valve, then open the auxiliary valve to vacuum
the system until it reaches 0.2 × 10-5 Pa, and continue to vacuum for 15 minutes to exhaust the air
which is entering the system following the oil.
Caution: When replacing an old compressor with a new one, be sure to bleed out some oil in order to
level off the new and the old compressor's oil level, and to avoid an excessive oil amount influencing
the cooling effect. When using an old or repaired compressor, be sure to keep the refrigerant inside
the compressor the same level as the one that is being replaced.
Daily Maintenance of the Air Conditioning System

In order to guarantee the air conditioning system's normal operation, regular maintenance should be performed.
Daily maintenance for the air conditioning system is as follows:
1. Inspect and clean the air conditioning system's condenser. The cooling fin's insides need to be
cleaned, with no blockage in between. After driving in the rain or on a muddy road, check the
condenser fan for silt or rocks. If any are found, immediately clean them up.
2. Inspect the refrigeration system's refrigerant amount: When the air conditioning unit is operating
normally, observe the oil check glass. Under normal conditions, the oil check glass should have no air
bubbles.
3. Inspect the drive belt. The belt between the compressor and the decoration cover should be tight.
4. Check the air conditioning system to make sure there is no irregular noise or unusual odors.
5. Check the compressor's inlet and exhaust port areas to make sure the temperature is normal.
6. Check to make sure the appearance of the refrigeration system's hose is correct and that all the
connections are firm.
7. Inspect if the refrigeration system's pipelines run into other components, and any traces of leaking oil
at each connection.
8. Check and make sure the refrigeration system's circuit connector is firm, and any sign of circuit
disconnection.
9. Inspect if the compressor's fastening bolts are sturdy, reliable or flawed.

Airbags 213
Airbags
Airbag Electronic Control Unit........................................... 214

Diagnostic Scanner........................................................... 215
Troubleshooting................................................................. 216
Vehicle Collision Diagnostics............................................. 226
Removal Method for Individual Components.................... 227
Driver Side Airbag Module (DAB), Front Passenger Side
Airbag Module (PAB), Clock Spring, and Steering Wheel..... 228
Airbag Module Disposal.................................................... 230
Airbag’s Diagnostic Methods Without a
Diagnostic Scanner........................................................... 232

Airbag Electronic Control Unit

Driver side airbag assembly
Front passenger side

airbag assembly
Diagnostic interface position

Airbag ECU assembly 2
Driver side electronic pretensioner
Front passenger side electronic pretensioner
Areas of Importance
1. While performing maintenance on the SRS airbag, make sure to work in accordance with this
chapter's steps and notes.
2. Be sure to use the specified test apparatus and SST (Special Service Tools) which are mentioned in this
chapter.
3. While performing maintenance on the following mentioned components, if there is any problem with a
component, be sure to replace it with a new one.
• Airbag ECU assembly.
• Clock spring assembly.
• Driver side airbag assembly.
• Front passenger side airbag module.
• Driver side preload seat belt.
• Front passenger side preload seat belt.
• Airbag wire harness.
4. While performing maintenance, please disconnect the battery's negative terminal connector, and then
after waiting for 60 s, commence operation. Furthermore, wrap up the removed negative terminal with
insulating tape.
After the battery power is cut off, the capacitor in the airbag ECU will still maintain a set amount of electrical
energy. If used without waiting a sufficient amount of time, it may lead to serious injury and accidents due to
the airbag's faulty deployment.
5. When painting the vehicle, excessive heat may influence the components, in which case the SRS-ECU,
airbag module, clock spring, etc., should first be removed and set aside.
Use a diagnostic scanner to clear the trouble code after the SRS airbag is repaired, as to ensure the warning
lamp will continue to work normaly.
Airbag warning lamp

The position of the airbag warning
lamp inside the combination meter

Airbags 215
Airbag electronic control interface and interface-pin definition
No. Name Description

1 DRV A/B + Driver side airbag assembly, high end
2 DRV A/B - Driver side airbag assembly, low end
3 PSG A/B + Front passenger side airbag assembly, high end
4 PSG A/B - Front passenger side airbag assembly, low end
7 PSG PRETENSIONER - Front passenger seat belt pretensioner, low end
8 DRV PRETENSIONER + Driver seat belt pretensioner, high end
9 DRV PRETENSIONER - Driver seat belt pretensioner, low end
10 WARNING LAMP Warning lamp
11 GND Ground cable
25 BPT Hi ON power supply
30 PSG PRETENSIONER - Front passenger seat belt pretensioner, high end
46 K-LINE Serial data I/O (K wire) diagnosis
Diagnostic Scanner
Instrument Name Application
X-431 diagnostic scanner Check the system malfunction
of the SRS airbag system and
clear the ECU trouble code.

Troubleshooting
Basic processes of the malfunction diagnostic
There are two SRS-ECU malfunctions types classified by time: current malfunction and history malfunction.
The malfunction types categorized by property are: external malfunction and internal malfunction.
Current malfunction trouble codes and history malfunction trouble codes may exist at the same time. External
malfunction trouble codes can be eliminated with a diagnostic instrument, but the internal malfunction trouble
codes cannot be cleared unless the SRS-ECU is changed.
Caution: After installing a new SRS airbag system electronic control unit, the airbag system warning
lamp will remain on for 6-7 s when the ignition switch is set to the ON position. This indicates that
the SRS airbag is operating properly. At this point, the system does not need to be inspected and
repaired. Aside from this case however, the system should be diagnosed and repaired.
Connect the scanner

Warning lamp Detected fault Troubleshooting Clear the
and K wire to
abnormal trouble codes
scan the ECU
SRS airbag warning lamp inspection

1. When the ignition switch is set to the ON position, check if the SRS warning lamp remains on for 6-7 s.
2. If the SRS warning lamp shuts off after 6-7 s, this is normal.
3. Except for the items listed above, diagnostic inspection is still needed.
System diagnosis
Airbag ECU will initiate a series of diagnostic test cycles to check if the airbag system functions are ready for
use. This diagnostic test can guard against the restraint system's faulty execution and at the same time guarantee
prompt execution in a collision. If a malfunction appears, airbag ECU will store the appropriate trouble code and
light up the warning lamp to point out the malfunction, as to make maintenance more convenient.
Diagnostic interface

Airbags 217
Malfunction judgment
1. Malfunction record (trouble code storage)
After the ECU performs the diagnostic test cycle in order to verify a malfunction, the SRS-ECU will store the
relevant code, the initial detection time, the final detection time, and the number of times it occurred in the
EEPROM.
The SRS-ECU can store 16 codes at most.
2. SRS-ECU approved trouble codes
Trouble Possible
No. Malfunction introduction Type code
code removal
(Front passenger side preload seat belt), connected to the
1 03H 01H Removable
power supply
(Driver side front row preload seat belt), connected to the
2 03H 02H Removable
power supply
(Driver side airbag assembly), connected to the power
3 03H 03H Removable
supply
(Front passenger side airbag assembly), connected to the
4 03H 04H Removable
power supply
5 (Front passenger side seat preload seat belt), grounded 02H 01H Removable
6 (Driver side front row preload seat belt), grounded 02H 02H Removable
7 (Driver side airbag assembly), grounded 02H 03H Removable
8 (Front passenger side airbag assembly), grounded 02H 04H Removable
(Front passenger side preload seat belt), resistance too
9 01H 01H Removable
high or open circuit
(Driver side front row preload seat belt), resistance too
10 01H 02H Removable
(Driver side airbag assembly), resistance too high or open
circuit
(Front passenger side airbag assembly), resistance too
(Front passenger side preload seat belt), resistance too
13 0CH 01H Removable
low or short circuit
(Driver side preload seat belt), resistance too low or short
circuit
(Driver side airbag assembly), resistance too low or short
circuit
(Front passenger side airbag assembly), resistance too
low or short circuit
Power supply voltage is out of range (high voltage or low
voltage)
18 Power cord contact dysfunctional 11H 42H Removable
Warning lamp fault - connected to the power supply or
bulb is short circuited
20 Warning lamp fault - grounded or open circuit in filament 02H 41H Removable
21 Configuration error 06H 44H Removable
Internal malfunction 0DH >80H Irremovable
22 Replace
airbag ECU
Trouble code transmission is completed the SRS-ECU outputs through the maintenance program's
serial data interface to the specified diagnostic instrument (X-431 diagnostic scanner).
3. Internal malfunction
The microcontroller can detect the following items not only when starting up detection, but also during the
diagnostic detection cycle.
(a) The ignition circuit triggers the transistor: The high-end transistor will be detected not only when starting up

detection but also during the diagnostic detection cycle. However, if a short circuit on the power supply causes
a malfunction, and the low-end transistor is opened while malfunctioned, the low-end transistor can only be
detected when starting up detection, as to avoid faulty execution.
(b) Ignition voltage is provided by a pressure increase converter.
(c) Acceleration sensor performs self-detection when starting up detection.
(d) Allowed offset range of the acceleration sensor during a diagnostic cycle.
(e) Microcontroller includes AD converter, ROM, RAM, etc.
(f) Security sensor status.
Caution: There is a short-circuiting bar inside the squib circuit connector. When the connector is not
connected, the short circuit happens between the squib circuit's terminal (+) and terminal (-), as to
avoid faulty deployment caused by static electricity. When the connector is bad and the short-circuiting
bar is connected, the fault symptom may not be eliminated.
4. Clear the trouble code
When the X-431 diagnostic instrument receives the "Clear the trouble code" order sent through the serial inter-
face, the trouble code inside the ECU will be cleared. However, if an internal trouble code is recorded or has a
collision record, it will not carry out this order.
(a) Malfunction status display.
When the working voltage is supplied to the SRS-ECU through a battery, the SRS-ECU will light the warning
lamp to inspect the light bulbs. During the initialization stage, the warning lamp will remain on for 6-7 s, and
in order to inform the driver that the system has a malfunction, the warning lamp will continue to remain on
after the working voltage is supplied. If the history trouble code’s quantity is less than 16, the warning lamp
will remain lit for 6-7 s after turning the ignition on and then turn off automatically. If the history trouble code’s
quantity is 16 and the current malfunction appears, it will be recorded and the first history malfunction record
will be automatically removed.
(b) Malfunction indicator.
When the system has malfunctioned, the warning lamp will be always on.
A displayed or history malfunction can only be reset by service personnel. A SRS-ECU internal malfunction or
malfunction’s "collision record" cannot be reset. In this situation, the SRS-ECU must be replaced.
(c) Microcontroller - independent warning lamp is lit.
The controller has a self-diagnosis function. If the inner controller malfunctions, the warning lamp will always
be on.
(d) If the airbag warning lamp is always on, please inspect it according to the following steps.
The first step of inspecting any of the malfunctions is to detect the malfunction’s position with a scanner. Then
carry out the inspection using the corresponding part’s inspection method. If the scanning result is an internal
malfunction or having to do with airbag execution, the SRS-ECU can be directly replaced.

Airbags 219
Malfunction diagnosis and troubleshooting

1. Warning lamp is not on or always on
NO. Troubleshooting list Explanation
1 Airbag system warning lamp not lit Airbag system warns of circuit malfunction
Airbag system warns of circuit
2 Airbag system warning lamp is always on
malfunction or external malfunction
2. Airbag system warning lamp does not lit

Inspection
Airbag system warning lamp does not lit.
status
• Voltage disappears (fuse open circuit)
Possible
• Combination meter malfunction
causes
• Wire harness malfunction between the instrument cluster and ECU unit
Diagnostic procedures
While performing the first malfunction detection, it is suggested to wiggle the wire harness and plugs to check for
intermittent or poor contact. If there is, please check whether the plugs, terminals, and the wire harness are connected
properly and undamaged. If the above mentioned problems do not exist, please take the following steps.
Steps Inspection Operation
Detect other wire harness and instrument cluster indicator Set the ignition switch to the LOCK
lamps Yes position, and then proceed to the
• Set the ignition switch to the ON position next step
1
• Are other warning and indicator lamps on? Detect the instrument cluster's
No power supply system and the
grounded system (fuse)
Inspect the light bulbs Go to the next step
Warning:
Incorrect airbag system component operation will cause the
Yes
airbag and preload seat belt to opened accidentally, which
may cause serious injuries. Please read the airbag system
services warning before working on the airbag components
2
• Set the ignition switch to the LOCK position Replace the combination meter
• Disconnect the battery's negative cable and maintain for at
least 60 s
No
• Remove the combination meter
• Check whether the two corresponding pins of the airbag
warning lamp are conducting
Detect the wire harness connection between the ECU unit and Yes Go to the next step
the instrument cluster
Replace the wire harness
• Set the ignition switch to the LOCK position
3 • Disconnect the battery's negative cable
• Disconnect the instrument cluster plugs No
• Check whether the warning lamp's corresponding circuits
are conducting

3. Airbag system warning lamp is always on

2 Airbag system warning lamp is always on
Inspection Airbag system warning lamp is always on
status
Possible • Battery power supply is insufficient
causes • ECU internal malfunction
• Combination meter airbag warning lamp malfunction
• ECU plug is improperly connected
• Combination meter plug poorly contacted
• ECU power supply fuse circuit broken or poorly contacted
• Poor ECU plug terminal connection
• Poor wire harness contact between the ECU plug terminal and the ground
• Driver side or front passenger side airbag circuit malfunction
• Driver side and front passenger side preload seat belt malfunction
When starting inspection, please first use the specially designed diagnostic instrument (X - 431 diagnostic scanner)
and the ECU to diagnose the communication and determine the causes of malfunction. If communication fails,
please perform the following inspections
Examine the battery
• Check the battery voltage Yes Go to the next step
1
• Is the voltage higher than 9 V?
Battery power supply
Examine the charging/discharging system, and then go to step No is insufficient
5
Examine the conducting state of the wire harness between the
ECU unit and combination meter
• Set the ignition switch to the LOCK position Yes Go to the next step
• Disconnect the battery's negative terminal
• Open the dashboard base
2
• Disconnect the instrument cluster connectors
• Connect the battery's negative
• Set the ignition switch to the ON position Check the circuit, and then
No
• Check whether the corresponding connector terminal's go to step 5 after it is fixed
voltage is 12 V (power supply and meter connection)
• Set the ignition switch to the LOCK position Yes Go to the next step
• Check if the meter connector's corresponding terminal and
3 Repair or replace the wire
diagnostic interface's corresponding terminal are conducting
No harness.Then go to step 5
(diagnose the K wire's two ends)
Be sure to disconnect the battery's negative cable and
maintain for at least 1 min Yes Go to the next step
• Disconnect the ECU connector
4 • Disconnect the instrument cluster plugs
• Are the ECU connector terminal 25, 10, 46, and instrument Replace the wire harness,
No
cluster's connectors conducting? and then go to step 5
Remove the ECU to check whether the terminal is in good Yes Replace the ECU
5 condition. Is the short-circuiting bar broken? Reconnect the ECU connector,
No
and then go to the next step

Airbags 221

Check and make sure the malfunction symptom does not After the malfunction
appear again after they are repaired is removed, explain the
• Set the ignition switch to the LOCK position maintenance procedure
Yes
• Disconnect the battery's negative cable and maintain for at to the client
least 1 min
• Connect all of the ECU plugs
6 • Connect the airbag subassembly plugs at the driver side Recheck the malfunction
• Connect the airbag subassembly plugs at the passenger side symptom, if the malfunction
• Connect the driver and passenger side preload seat belt plugs happens again, repeat
• Connect the clock spring plugs No the repairing procedures
• Connect the battery's negative cable starting from the first step
• Set the ignition switch to the ON position
• Does the airbag warning lamp work properly?
4. Internal malfunction
Type SRS airbag system unit internal malfunction
code 0D
Trouble
code >80
Detecting Warning
conditions • This malfunction's diagnosis requires a trouble code not to be shown prior to inspection. Use a DTC
to perform inspection. Performing this malfunction detection might cause operator injury or system
damage due to incorrect operation. Therefore, before inspection, please properly prepare.
• SRS airbag system electronic control unit circuit internal malfunction
Possible
SRS airbag system unit internal malfunction
causes
Operation Replace the SRS airbag system unit. Refer to airbag system and SRS airbag system unit removal and installation
5. Power supply
Trouble The SRS airbag system electronic control unit's power supply voltage is out of the standard range
code 12
and 42
Detecting Warning
conditions • This malfunction's diagnosis requires that a trouble code not be shown prior to inspection. Use a
DTC to perform inspection. Performing this malfunction detection might cause operator injury or
system damage due to incorrect operation. Therefore, before inspection, please properly prepare.
• Voltage of the SRS airbag system unit's 5 and 6 connector pins is lower than 9 V
Possible • Battery voltage too low

causes The wire harness between the battery and SRS airbag system electronic control unit has a
malfunction
Inspect the battery Yes Go to the next step
1 Measure the battery voltage Battery's voltage too low. Inspect
Is the voltage higher than 9 V? No
the charging/discharging system
Inspect the wire harness between the battery and the fuse box
Yes Go to the next step
Take out the fuse box making sure not to loosen the connector,
2 and set the ignition switch to the ON position
Inspect and repair
Is the fuse box's two corresponding terminal stub voltage higher No
the wire harness
than 9 V?


Inspect the wire harness between the fuse box and SRS airbag
system unit connectors
Warning
If not handled properly, the airbag module and stretch tension
type seat belt may open or tense up, causing serious operator
injury. Therefore, before performing maintenance, please read
the maintenance warnings carefully.
See also airbag system maintenance warning
Set the ignition switch to the "LOCK" position
Loosen the battery's negative cable and wait for at least 1 min
3
Take out the steering column housing
Loosen the clock spring connector
Take out the glove box (with the front passenger side airbag
module)
Loosen the front passenger side airbag module connectors
No Replace the wire harness
Take out the dashboard base
Loosen all the SRS airbag system unit connectors
Install the battery's negative cable, and set the ignition switch to
the ON position. Is the airbag system unit's 25 and 11 connector
pin voltage higher than 9 V?
Set the ignition switch to the "LOCK" position [Current trouble code]
Loosen the battery's negative cable and wait for at least 1 min Replace the SRS airbag system
Take out the left side inner decoration board unit
Disconnect the SRS airbag system unit switching connectors See also SRS airbag system
Yes
4 Install the battery's negative cable, and set the ignition switch SRS airbag system unit
to the ON position. Is the voltage of the switching connector's removal/installation
corresponding pin and ground higher than 9 V? [History trouble code]
Fault diagnosis complete
No Replace the wire harness
6. Driver side malfunction

Type Driver side airbag malfunction (resistance too low or too high, short circuit grounded, etc)
code 02
Trouble
code
01, 02, 03
Detecting Warning
conditions • If it's not handled properly, the airbag module and stretch tension type seat belt may open or tense
up, causing serious operator injury. Therefore, before performing maintenance, please read the
maintenance warnings carefully.
If there is a driver side front airbag
• The resistance between the terminal stubs of the SRS airbag system unit connector is out of the
specified range
Wire harness related SRS driver side airbag is short or open circuited
Pos- • Driver side airbag module malfunction
sible causes • Clock spring internal malfunction
• Connector malfunction between the clock spring and SRS electronic control unit
• The wire harness between the clock spring and the SRS electronic control unit circuit is broken or
short circuited
• SRS driver side airbag generator connectors are improperly connected

Airbags 223
Inspect the clock spring
Warning
If not handled properly, the airbag module may deploy Normal Go to the next step
and cause serious operator injury. Therefore, before
maintenance, please read the maintenance warnings
1 carefully. Replace the clock spring
See also airbag system maintenance warning See also airbag system and clock
Are the components relating to the clock spring work- Abnormal spring removal/installation
ing normally? (The relationship between each pin is
normal, no unnecessary short or open circuit, etc.).
Check whether the malfunction is on the driver side Replace the driver side
airbag module or other components airbag module
Replace with a good DAB module Yes See also airbag system and
Install the battery's negative cable driver side airbag module
2
Set the ignition switch to the "ON" position removal/installation
Is the trouble code still displayed? Or can it be cleared?
No Go to the next step
Inspect the clock spring's wire harness connectors

Set the ignition switch to the "LOCK" position Normal Go to the next step
Loosen the battery's negative cable and wait for at least
3 1 min
Take out the steering column housing
Loosen the clock spring connector Abnormal Replace the wire harness
Is the clock spring working normally?
Check whether the malfunction is on the clock spring
or other components Yes Go to the next step
Set the dedicated detector at 2 Ω position
4 Replace the clock spring
Install the battery's negative cable
No See also airbag system and clock
Set the ignition switch to the "ON" position
spring removal/installation
Is a trouble code displayed?
Check the wire harness between the clock spring and Replace the SRS airbag system
SRS electronic control unit unit
Set the ignition switch to the "LOCK" position Normal See also SRS airbag system
Loosen the battery's negative cable and then wait for at SRS airbag system unit removal/
least 1 min installation
Take out the glove box (with the front passenger side
airbag module)
Loosen the front passenger side airbag module
connectors
5 Take out the dashboard base
Check the wire harness of the connectors and terminal
Abnormal Replace the wire harness
studs between the SRS airbag system electronic control
unit and the clock spring to determine whether they
have the following problems
• Ground
• Short connected with the power supply
• Open circuit
Is the above wire harness normal?
Check the clock spring connector Normal Go to the next step
6 Loosen the clock spring connector Replace the wire harness
Is the clock spring connector normal? Abnormal
or connectors


Inspect the clock spring Normal Go to the next step
Take the clock spring off
See also airbag system and clock spring removal/ Replace the clock spring
7 installation See also airbag system and clock
Abnormal
Inspect the clock spring spring removal/installation
See also airbag system and clock spring inspection
Check the clock spring. Is it normal?
Check the wire harness between the clock spring and Replace the driver side
SRS electronic control unit airbag module
Set the ignition switch to the "LOCK" position Normal See also SRS airbag system
Loosen the battery's negative cable and then wait for at Driver side airbag module
least 1 min removal/installation
Take the glove box off (with the front passenger side
airbag)
Loosen the front passenger side airbag module
connectors
8 Take out the dashboard base
Check the wire harness of the connectors' terminal
studs between the SRS electronic control unit and the
clock spring to see whether they have the following
problems.
• Ground
• Open circuit
Is the above wire harness normal?
7. Front passenger side malfunction

Type code 02
Trouble code Front passenger side airbag module (resistance too low or too high, short circuit, or grounded)
01, 02, 03
Detecting Warning
conditions • If not handled properly, the airbag module and stretch tension type seat belt may open or tense up,
causing serious operator injury. Therefore, before performing maintenance, please read the mainte-
nance warnings carefully.
If there is a front passenger side airbag
• The resistance between the SRS airbag system unit connector's 3 and 4 pin is out of the specified
range
• The wire harness between the SRS airbag system unit connector’s 3 and 4 pins is short-circuited
• The SRS airbag system unit connector's 1 and 2, and 3 and 4 pins are open-circuited, if there is no
front passenger side airbag
Possible • Front passenger side airbag module malfunction
causes • Connector between the front passenger side airbag module and the SRS airbag system electronic
control unit malfunction
• Connectors between the SRS airbag system unit and the grounded point malfunction
• Circuit between the front passenger side airbag module and the SRS airbag system electronic control
unit is broken or short circuited
• Circuit between the SRS airbag system unit and the grounded point is broken or short circuited
• SRS airbag system unit malfunction

Airbags 225
Is the vehicle equipped with a front passenger side Yes Go to the next step
1
airbag module? No Line fault, inspect the wire harness
Check the front passenger side airbag module connec- [Current trouble code]
tor warning Go to the next step
• If not handled properly, the airbag module may deploy Normal [History trouble code]
and cause serious operator injury. Therefore, before Go to the next step
maintenance, please read the maintenance warnings
carefully.
2 Set the ignition switch to the "LOCK" position
Loosen the battery's negative cable and wait for at least
1 min
Take the glove box off
Loosen the front passenger side airbag module connec-
tors
Is the front passenger side airbag module connector
normal?
Check whether the malfunction is on the front passen-
ger side airbag module or the other components
Replace the front passenger side
Connect a good module with the front passenger side
airbag module
3 airbag module connector's A and B terminal studs
No See also airbag system and front
Connect the battery's negative cable
passenger side airbag module re-
Set the ignition switch to the "ON" position
moval/installation
Is a trouble code displayed?
Inspect the wire harness between front passenger side [Current trouble code]
airbag module and SRS airbag system electronic con- Replace the SRS airbag system
trol unit unit
Set the ignition switch to the "LOCK" position See also SRS airbag system
Loosen the battery's negative cable and then wait for at Normal SRS airbag system unit removal/
least 1 min installation
Take the steering column housing off [History trouble code]
Loosen the clock spring connector Fault diagnosis complete
Loosen the driver side and front passenger side airbag
module connectors
4
Take out the dashboard base
Inspect the circuit between the connector terminal stubs
of SRS airbag system electronic control unit and front
passenger side airbag module, and check if it has the Abnormal Replace related wire harness
following problems
• Ground
• Open circuit
Is the related wire harness normal?

Vehicle Collision Diagnostics

Whether the airbag is deployed or not, vehicle collision diagnostic and maintenance must be conducted
according to the following procedures.
1. Check the SRS-ECU diagnostic signal
(a) Connect the diagnostic connector (X-431 diagnostic scanner).
(b) Read the diagnostic result with the X-431 diagnostic.
Caution: Due to impact, and when the battery's power supply is insufficient, the scanner will be unable
to communicate with the SRS-ECU. At this time, use an external power supply, or make sure to
perform inspection and maintenance on the dashboard's wire harness.
2. Maintenance sequence
When the airbag is deployed, the following components should be replaced.
(a) Driver side airbag module.
(b) Front passenger side airbag module.
(c) SRS-ECU.
(d) Driver side and front passenger side preload seat belts.
Inspect the following components, if anything is abnormal, replace with a new one.
(a) Clock spring.
(b) Steering wheel, steering column, and steering lower shaft components.
Installation status of the driver side airbag module regarding the steering wheel.
(a) Inspect whether the steering wheel's noise is abnormal, for improper movement, or abnormal clearance.
(b) Inspect whether the wire harness connectors are broken and whether the terminals are deformed.
3. SRS-ECU
(a) Inspect whether the SRS-ECU housing and bracket are
sunken or depressed, cracked, deformed, etc.
(b) Inspect for broken connectors as well as deformed
terminals.
(c) Inspect the SRS-ECU bracket's installation status.
• Inspect whether the cover is sunken or depressed,
cracked, deformed, etc.
• Inspect for broken connectors as well as deformed
terminals and biting wire harnesses.
• Check whether the gas generator's housing is sunken or
depressed, cracked, deformed, etc.
• Inspect whether the arrow's direction is pointed towards
the front of the vehicle.
(d) Inspect the airbag module's installation status.
4. Inspect the driver side airbag module
5. Clock spring
(a) Inspect for broken connectors and protective tube and deformed terminals.
(b) Inspect for deformed housing.
6. Steering wheel, steering column, and lower shaft components
(a) Inspect the driver side airbag module's installation status.
(b) Inspect the steering wheel for abnormal noise, and whether the clearance is normal.
7. Inspect the wire harness connectors (dashboard wire harness).
8. Inspect whether the wire harnesses are firm. Check for damaged connectors, and deformed terminals.
Warning label
The driver side, clock spring, SRS-ECU, and front passenger side airbag, all have warning labels, with the
caution areas shown by an image. While maintenaning and using the SRS airbag, please work in accordance
with the label.Furthermore, when a label becomes damaged or dirty, please replace it with a new one.

Airbags 227
Removal Method for Individual Components

SRS airbag system electronic control component (SRS-ECU)
1. Areas of Importance
(a) After taking off the battery's negative (-) terminal, wait for 60 s before operating. Wrap the removed
negative (-) terminal in tape to insulate it.
(b) The SRS-ECU can not be dismantled or repaired. If there is any malfunction, please replace it with a new
one.
(c) Do not let the SRS-ECU vibrate or collide with anything. If sunken or depressed, cracked, deformed, etc.,
please replace with a new SRS-ECU.
(d) Every time the airbag is deployed, please replace with a new SRS-ECU.
(e) Do not knock the SRS-ECU while removing or performing maintenance on the SRS-ECU's surrounding
components.
2. Operation before removal
(a) Set the ignition switch to the LOCK position.
(b) After taking off the battery's negative (-) terminal, put them in a proper place or wrap them in tape.
3. Removal sequence
(a) Remove the auxiliary facia console.
(b) Reomve the connectors connected with the airbag ECU.
(c) Remove the SRS-ECU.
4. Installation sequence
(a) SRS-ECU.
(b) Install the connectors connected with the airbag ECU.
(c) Dashboard base.
(d) Connect the battery's negative (-) terminal.
5. Installation points
(a) Install the SRS-ECU
Caution: If SRS-ECU isn't installed correctly, the SRS airbag will not operate properly.
(b) Inspection after installation
• Set the ignition switch to the ON position.
• SRS warning lamp stays on for 6-7 s.
• If the lamp does not turn off, malfunction inspection and troubleshooting should be performed.
6. Inspection
(a) Whether the SRS-ECU cover has sunken or depressed, cracked, deformed, etc.
(b) Whether the connectors are damaged or deformed.
Caution: Please replace with a new SRS-ECU, if there is any sunkeness or depression, cracking, de-
formity, etc.
Except for the areas described above, to perform SRS-ECU inspections, please refer to the related troubleshooting
contents.

Driver Side Airbag Module (DAB), Front Passenger Side Air-

bag Module (PAB), Clock Spring, and Steering Wheel
Areas of Importance
1. Take off the battery's negative (-) terminal, and wait for 60 s before operating. Wrap the removed
negative (-) terminal in tape to insulate it.
2. The airbag module and clock spring must not be dismantled or repaired. If there is any malfunction,
replace the part.
3. Pay attention to the usage of the airbag module and clock spring. Do not drop it or immerge it in water
or oil. Furthermore, if there is any sinking or depression, cracking, deformity, etc., please replace it
with a new part.
4. Make sure the extended surface is faced upwards when the airbag module is to be deployed. Put it on
a flat surface and do not place anything on top of it.
5. Do not put the airbag module in a place where the temperature is over 93oC.
6. After the airbag module is deployed, replace it with a new one. At the same time, inspect the clock
spring (contact resistance between corresponding terminals should not be more than 0.8 Ω). If there
is anything abnormal, replace it with a new one.
7. Use gloves and protective glasses while operating on a deployed airbag.
8. While scraping an undeployed airbag, make sure to discard it after it has been deployed first.
9. During removal, to avoid experiencing static electricity interference leading to faulty execution, make
sure to remove the other wire harness connectors after the DAB and PAB module wire harness
connectors have been removed. Installation is done in reverse order.
Driver side front airbag, steering wheel, and clock spring removal
1. Operation before removal
(a) When the steering wheel and front tires are pointing straight ahead, take out the ignition switch.
(b) Disconnect the battery's negative (-) terminal.
2. Driver side airbag module removal sequence
(a) Loosen the screws on both sides.
(b) Lightly pick up the airbag module.
(c) Disconnect the wire harness plug-in which is plugged into the airbag module.
(d) Remove the driver side airbag module.
(e) Remove steering wheel mounting bolt on the steering column.
(f) Remove the steering wheel.
3. Clock spring removal sequence (after steering wheel removal is completed)
(a) Lightly remove the steering wheel (please refer to the areas of importance).
(b) Open the combination switch's upper and lower protective cover, find and disconnect the wire harness connector
at lower end.
(c) Remove the clock spring.
Driver side front airbag, steering wheel, and clock spring installation
1. Clock spring installation sequence
(a) Inspection before installation.
This operation requires the inspection of the front tires to make sure they are first pointed straight ahead. If they
are not, be sure to place them in the right position first.
• Install the clock spring onto the steering column.
• Firmly wedge the clock spring to the steering column.
• Install the dashboard wire harness under the clock spring.
• Install the combination switch hood.
(b) Inspection after installation.
2. Steering wheel installation sequence (after clock spring installation is completed)
(a) Pull out the clock spring's position pin.
(b) Install the steering wheel, making sure to insert the wire above the clock spring through the hole on the
steering wheel body.
(c) Tighten the steering wheel mounting nuts.

Airbags 229
3. Driver side airbag module installation sequence (after steering wheel installation is completed)
(a) Install the horn's wire harness.
(b) Install the airbag module executing equipment's (gas generator) wire harness.
(c) Place the airbag module onto the steering wheel's proper installation position (avoid heavy knocking while
placing).
(d) Tighten the airbag module mounting bolt.
(e) Connect the battery's negative (-) terminal.
(f) Inspection after installation.
Auxiliary airbag removal and installation
1. Auxiliary airbag removal
(a) Remove the glove box.
(b) Pull out the dashboard wire harness and the auxiliary airbag wire harness connectors.
(c) Remove the airbag mounting bolt.
(d) Remove the upper dashboard.
(e) Remove the auxiliary airbag's two mounting nuts.
(f) Press the buckle and remove the auxiliary airbag.
2. Installation sequence for the auxiliary airbag is reverse to the removal sequence.
Caution: Please do not place anything on the auxiliary airbag, as to avoid accidents while deploying
the airbag.
Operation essentials
1. Driver side airbag and steering wheel removal
Caution: The following operations should only be performed after the battery's negative (-) terminal
has been disconnected, and after the ignition switch key has been pulled out for 60 s.
(a) Remove the mounting screws from the two holes under the steering wheel bottom cap, and lightly pick up
the driver side airbag module.
(b) Pull out the deployed airbag module's wire harness and the horn line, and remove the airbag module.
Attention: Diagnose the airbag module's circuit with an electrical measuring instruments but do not
dismantle it. Face the bottom of the removed passenger side airbag upwards and store it in a clean
and dry place.
(c) Remove the steering wheel mounting bolt on the steering column.
Caution: Due to the over-tight occlusion of the spline and column, the steering wheel and steering
column may be hard to separate, in which case make sure not to use force to remove the steering
wheel. The correct method is to tighten the screw into the column just a bit, and then pull up the
steering wheel (because the steering wheel bottom is connected to the clock spring, if force is used to
remove it, it may damage it).
2. Clock spring removal
(a) After steering wheel removal is completed, remove the combination switch hood.
(b) Pull out the dashboard wire harness connectors under the clock spring.
(c) Take off the clock spring.
Caution: Store the removed clock spring in a clean and dry place.
3. Installation notes
(a) Inspection before installation, inspection of driver side airbag module.
(b) Inspect the new airbag or clock spring before installing them.
4. Driver side airbag module inspection
Inspect each of the following items. If any faults are found, replace with a new corresponding airbag module
part. Discard the old components after they have been deployed in the proper order.
(a) Whether the cover sunken or depressed, cracked, or deformed.
(b) Whether the wire harness has broken connectors and deformed terminals.
(c) Whether the gas generator's housing is sunken or depressed, cracked, or deformed.
(d) Airbag module installation status.
Caution: The specified measuring instrument cannot measure the airbag module (tube rupture) circuit
resistance. Test the resistance with a testing instrument. There is an electric current in the tube rup-
ture which may lead to accidental deployment due to static electricity and cause serious accidents.
5. Clock spring inspection
Inspect each of the following items. If any fault is found, replace with a new clock spring.

(a) Whether there are broken connectors or protective

pipes and deformed terminals.
(b) Whether the housing is damaged.
(c) Inspect whether the clock spring's upper connector
terminal and lower corresponding connector terminal is
conducting.
Clock spring central involution
Screw in the clock spring clockwise all the way, and then
turn it 3.5 circles in the reverse direction, until the position
pin's block boss matches the block hole (as shown on the
left).
Caution: If the clock spring is not in the involution
central, the steering wheel will be unable to rotate
midway or cause clock spring circuit failure, which will
obstruct the normal operation of the SRS airbag.
Alignment area
6. Steering wheel and airbag module subassembly installation

(a) After pulling out the clock spring's position pin, install the steering wheel and airbag module subassembly.
Caution: While installing the steering wheel and airbag module subassembly, please do not block the
clock spring wire harness.
(b) After installation, try to turn the steering wheel left and right to its proper position, and check for anything
abnormal.
7. Inspection after installation
(a) Lightly turn the steering wheel left and right to check whether there is anything abnormal or for any
strange noise. (Driver side airbag module, clock spring).
(b) Set the ignition switch to the ON position.
(c) The SRS warning lamp will remain on for 6-7 s and will then die out.
(d) If the warning lamp is always on or shows other symptoms after 6-7 s, troubleshooting must be performed.
(e) Inspect whether the clock spring circuit is open circuited. If yes, please replace it with a new one.
(f) If no, check the other circuits.
Airbag Module Disposal
While discarding the airbag module or a vehicle carrying a SRS airbag, please discard according to the following
steps.
Discarding essentials of the airbag module before deployment
1. Deploy the airbag before discarding SRS airbag.
2. Deploy the airbag outside the vehicle when replacing the airbag module.
3. There may be some smoke when deploying the airbag, so make sure to operate near a smoke
detector.
4. When deploying the airbag, the sound will be very loud. Please ask nearby people to plug their ears,
and try not to operate near residential areas.
Airbag deployment
1 Warning: The following steps can prevent static
electricity trigged accidental deployment, so please
carefully follow them.
3
1. Park the vehicle on a flat surface.
2. Disconnect the battery's negative and positive
terminals, and remove the battery from the car.
2
Caution: Avoid wearing apparel which may generate
friction due to electricity. Disconnect the battery's
positive and negative terminals, and commence
operation after waiting 60 s.
3. Remove the airbag module according to the driver side
airbag's normal removal procedures.

Airbags 231
4. Deploy the wire harness after removing the No. 2

Wire harness used
for deployment
connector of the clock spring.
Short circuit area Prepare two wire harnesses longer than 6 m for deployment,
and connect one of their ends together (to short circuit).
Caution: When deploying the airbag, make sure to
maintain a distance of at least 6 m away from objects
or people, and perform the deployment on a flat sur-
face. While deploying the airbag module outdoors,
avoid strong winds, and ignite it against the wind.
Longer than 6 m
5. Insert the airbag deployment wire harness into the

airbag execution device.
Driver side airbag module 6. Install the unused bolts on the driver side airbag
Wire harness used module's inner side bolts, and bound the wheel rim with
for deployment
a thick metal wire, so as to set the wheel rim in place.
7. Connect the wire harness used for deployment which is
connected with the driver side airbag module with the
lower part of the old tire which is used for installing the
wheel rim. Upwardly fix the driver side airbag module
with the metal wire which is connected to the bolt
(shown on the left).
8. Place three old tires with no hub on the tires which are
used to fix in place the driver side airbag module (shown
on the left).
Old tire with no hub
Wire harness used for
deployment
9. Cut off the connection of the driver side airbag module's

wire harness which is used for deployment at a place as
far away from the vehicle as possible and connect it to
the two terminals removed from the vehicle battery, caus-
ing it to deploy (shown on the left).
Caution: Deploy it only after ensuring that there are no
people around the airbag module. After the deployment
of driver side airbag module, the gas generator will be ex-
tremely hot. Continue to use it only after 30 min cooling.
Wire harness used
for deployment 10. Discard the deployed driver side airbag module accord-
ing to the discarding essentials.

Airbag’s Diagnostic Methods Without a Diagnostic Scanner
Airbag indicator lamp warning
Check the airbag ECU connectors for looseness,

check for warnings after correct installation.
No
Disconnect the driver side airbag line and Yes Inspect whether the clock spring is
replace it with a 2 Ω resistor to see whether
airbag warning lamp is still on. conducting
No No
Disconnect the front passenger side airbag line Yes

and replace it with a 2 Ω resistor to see whether Check whether the alarm continues
airbag warning lamp is still on. after replacing the clock spring
No
Disconnect the driver side seat belt pretensioner
wires and replace it with a 2 Ω resistor to see
whether airbag warning lamp is still on.
No
Disconnect the front passenger side seat belt
pretensioner wires and replace it with a 2 Ω
resistor to see whether airbag warning lamp is
still on.
No
Go to a professional maintenance station to
perform inspection

Vehicle Body 233
Vehicle Body
Front Door Lock Assembly................................................ 234

Rear Door Lock Assembly................................................. 237
Trunk Door Lock Assembly................................................ 239
Wiper Arm and Vent Panel Assembly................................ 240
Front & Rear Window Glasses.......................................... 241
Dashboard......................................................................... 242
Cooling Unit....................................................................... 246
Front Door Assembly......................................................... 248
Rear Door Assembly......................................................... 251
Trunk Door Assembly........................................................ 254
Front Bumper.................................................................... 256
Rear Bumper..................................................................... 259
Seat Belt............................................................................ 262
Seats................................................................................. 266
Sunroof Assembly............................................................. 268

Front Door Lock Assembly

Components
Inside handle assembly
Front door locking cable installing buckle
Front door unlock cable

Front door lock cable
Front door outside handle framework

Gasket
Front door lock assembly LH
Front door outside handle
Lock mounting screw
Front door tie rod assembly

Lock cylinder decorative cap
Q2580820 + Q141F32
Front door lock cylinder assembly LH Front door lock latch
Front door lock installation and removal

1. Install the outside handle framework.
Install the door lock tie rod on the outside handle's framework,
install the outside handle framework, and tighten
the mounting screw.
Door lock tie rod

Framework mounting screw
2. Install the gasket.

3. Install the outside handle of the front door on the out-
side handle framework.
Gasket
mounting hole Front
door
Gasket
outside
handle

Vehicle Body 235
4. Separate installation for the front door lock assembly.

Separately install the front door lock, lock cable, unlock
cable, cable installing buckle, and side door inside handle
assembly. On the left is the schematic diagram after installa-
tion.
Door lock socket 5. Install the front door lock assembly.

Install the assembled assembly, tighten the lock mounting
screws (pay attention to put the outwardly opened tie rod in
and block the lock's outwardly opened swing arm lever clip
sheath), and insert the wire harness plug-in into door lock
socket.
6. Install the cable buckle.
Install the buckle in the door inner decoration board, and put
the cable in the buckle.
7. Install the inside handle.

Clamp the inside handle clip to the door inner decoration
board, and then firmly press the inside handle clip dowel pin
into the mounting hole.
Inside handle clip Inside handle dowel pin
8. Install the front door lock cylinder.

Clip the decorative cap of the driver side door onto the lock
Lock cylinder cylinder, install the lock cylinder into the lock hole, and then
decorative cap tighten the lock cylinder’s mounting screw.
Mounting screw
Lock cylinder
9. Install the door lock inside handle screws.

When the door cylinder panel assembly is installed, tighten
the inside handle's mounting screw.
Mounting screw
Door lock inside handle

10. Install the door lock latch.

Door lock latch
Q2580820 + Q141F32
11. Front door lock removal.

For the removal, please simply reverse the installation steps.
Caution: The front door tie rod can be removed following
the outside handle framework. The front door tie rod
can be removed after the removal of the outside handle
framework.

Vehicle Body 237
Rear Door Lock Assembly

Components
Rear door inside handle assembly LH
Rear door outside handle

Rear door outside handle gasket
Rear door outside handle framework LH

Rear door handle
decorative cap
Rear door lock cable

installing buckle
Rear door outside

handle gasket 2
Lock mounting screw
Q2580816 Rear door lock assembly LH
Rear door lock latch
Rear door lock installation and removal

1. Install the outside handle framework, and tighten the
framework mounting screw.
Framework mounting screw
2. Install the gasket.

Put the gasket onto the mounting hole (similar to the
Gasket
installation for the front door).
3. Install the rear door outside handle on the outside han-
dle framework.
4. Separate installation for the rear door lock assembly.
Separately install the rear door lock, lock cable, unlock
Rear door cable, cable installing buckle, and rear door inside handle as-
outside handle sembly (similar to the installation for the front door).

5. Install the rear door lock assembly.

Install the assembled assembly, tighten the lock mounting
screws (pay attention to put the outwardly open swing arm
lever clip of the lock onto the outer opened fork of the out-
side handle framework), and then insert the wire harness
plug-in into the door lock socket.
6. Install the cable buckle.
Door lock fork
7. Install the inside handle.

Clamp the inside handle clip to the door inner decoration
board, and then firmly press the inside handle clip dowel pin
into the mounting hole.
8. Install the rear door outside handle decorative cap, and
tighten the decorative cap mounting bolt.
Inside handle clip

Inside handle dowel pin
9. Install the inside handle screw.

When the door cylinder panel assembly is installed, tighten
the inside handle's mounting screw.
Mounting screw
Door lock inside handle
10. Install the rear door lock latch.
Rear door lock latch
Q2580822
11. For rear door lock removal, please simply reverse the
installation steps.

Vehicle Body 239
Trunk Door Lock Assembly

Components
Trunk door lock assembly
Q2580820 + Q141F32
Trunk door lock latch
Q1460620 (Q402) F3
Connect the door lamp indicator
Q1840616F3
Connect the central door lock controller Trunk door outside handle assembly
Trunk door lock installation and removal

1. Install the trunk door outside handle.
Connect the central door Install the trunk door outside handle assembly, tighten the
lock controller mounting screw, and install the wire harness plug-in.
Q1840616F3
2. Install the trunk door main lock assembly.

Install the trunk door main lock assembly, and tighten the
mounting screw.
Q1460620 (Q402) F3 3. Install the trunk lock latch.
4. For trunk lock removal, please simply reverse the

Connect the door installation steps.
lamp indicator

Wiper Arm and Vent Panel Assembly

Components
Right vent panel
Left wiper arm

Right wiper arm
Screw Wiper arm bolt cover
Wiper arm bolt
Left vent panel
Engine hood rear weatherstrip
Screw
Wiper arm and vent panel removal and in-

stallation
Wiper arm bolt cover
1. Remove the bolt cover of the wiper arm.
Wiper arm bolt
2. Remove the retaining bolt of the wiper arm.
Wiper arm 3. Wobble the wiper arm to remove it.
4. Take off the rear weatherstrip of the engine hood from

the vent panel.
Vent panel expansion button 5. Remove the screws from the two ends of vent panel.
6. Remove the expansion button in the middle of the right
and left vent panels.
7. For wiper arm and vent panel Installation, please simply
reverse the removal steps.
Engine hood rear

weatherstrip Screw

Vehicle Body 241
Windshield trim strip

Front & Rear Window Glasses
Windshield removal
Inner rearview
mirror 1. Use steel wire to strip the glass sealant from the four
sides of the windshield.
2. Remove the windshield and trim strip from the vehicle.
3. Remove the trim strip and inner rearview mirror from
the windshield.
Windshield
4. Use a blade to remove the glass sealant on the end of
the glass.
5. Use a polisher to remove the glass sealant on the glass
window frame, and polish clean the glass sealant.
Windshield installation
1. Install the trim strip and inner rearview mirror on the
windshield.
2. Coat the windshield frame and its edge with primer.
3. Use a glue gun to coat the windshield with glass
sealant, glass sealant height is 10±2 mm.
4. Use adhesive tape fix the windshield and the
windshield's outside sheet metal.
5. Remove the tape after the glass sealant has solidified
for 24 hours.
Rear window glass Rear window glass removal

1. Disconnect the battery's negative cable.
2. Disconnect the defogger electrical connector of the
rear window.
3. Use steel wire to strip the glass sealant off the rear
window glass.
4. Remove the rear window glass.
Defogger electrical connector 5. Use a blade to remove the glass sealant.
6. Use a polisher to remove the glass sealant on the
glass frame.
Rear window glass installation

1. Coat glass sealant primer on the rear door's sheet
metal seam and rear window glass.
2. Coat the rear window glass with glass sealant, glass
sealant height is 10±2 mm.
3. Install the rear window glass.
4. Use adhesive tape fix the rear window glass and back
door, and fix the rear window glass.
5. Connect the defogger electrical connector of the rear
window.
6. Connect battery's negative cable.
7. Remove the tape after the glass sealant has been on
24 hours.

Dashboard
Components
Air-conditioner air outlet tray assembly
Air-conditioner air outlet wind-ball assembly
Side air outlet decorative cap
Combination meter hood assembly

Dashboard top assembly Dashboard lower framework
assembly Glove box
assembly
Air-conditioner
center right air outlet
Air-conditioner left air tray assembly
outlet tray assembly
Small glove
box assembly
Combination switch
cover assembly
Dashboard right
trim strip
Dashboard left trim strip Dashboard center console right

Ash tray trim strip assembly
assembly Dashboard center console assembly
Dashboard center console
left trim strip
Fuse box Coin box cover
Front ash tray assembly
Coin box bottom Auxiliary facia console
Shift handle cover assembly
Dashboard removal
Front ash tray assembly
1. Remove the auxiliary facia console.
Parking brake lever panel (a) Take down the front ash tray assembly
Auxiliary facia console (b) Take down the auxiliary facia console decorative carpet.
decorative carpet
(c) Remove one screw.
Screw
(d) Remove the parking brake lever panel.
(e) Remove the shift lever cap.
Buckle (f) Remove the auxiliary facia console assembly.
Auxiliary facia console
2. Remove the left & right trim strip assembly of the dash-
Dashboard right trim
strip assembly
board.

Vehicle Body 243
3. Remove the dashboard center console left & right side

trim strip assembly.
Right trim
strip
Left trim strip
4. Remove the glove box assembly.
Glove box
assembly
5. Remove the combination switch cover assembly.

(a) Remove the three screws.
(b) Pry the upper and lower cover off, and remove the up-
per and lower cover of the combination switch.
Combination switch cover assembly Screw
6. Remove the combination meter hood assembly.

(a) Remove the two buckles.
(b) Remove the combination meter hood assembly.
Buckle
Combination
meter hood
7. Remove the dashboard center console assembly.

(a) Remove the air-conditioner's control buttons.
(b) Remove the four screws.
(c) Remove the dashboard center console assembly.
8. Remove the CD player (refer to CD player removal for
details).
Screw 9. Remove the left and right A-pillar protective panel (refer
to inner decorative panel removal for details).
10. Remove the combination meter (refer to combination
meter removal for details).
Dashboard center console assembly

11. Remove the dashboard top assembly.

Dashboard top assembly
(a) Remove the four screws.
Screw (b) Remove the dashboard top assembly.
12. Remove the air conditioner controller (refer to air con-
ditioner controller removal for details).
Screw
13. Remove the small glove box assembly.

(a) Remove the four screws.
Screw (b) Remove the small glove box assembly.
Small glove box assembly
14. Remove the ash tray assembly.

(a) Remove the two screws.
(b) Remove the ash tray assembly.
Ash tray assembly
Screw
15. Remove the coin box cover.
Coin box cover
16. Remove the coin box bottom.

(b) Remove the coin box bottom.
17. Remove the combination switch (refer to combination
switch removal for details).
Buckle
Coin box
Buckle bottom

Vehicle Body 245
18. Remove the dashboard bottom and brace reinforce-

ment assembly.
(a) Remove the engine hood handle assembly (refer to
engine hood handle removal for details).
(b) Remove the ten bolts.
(c) Pull the electrical connector out, and remove the dash-
board bottom and brace reinforcement assembly.
Bolt
Brace reinforcement assembly 19. Remove the dashboard bottom and brace reinforce-
ment assembly.
Nut
(b) Remove the two screws.
Buckle (c) Remove the two nuts.
Buckle
Nut (d) Remove the dashboard lower framework assembly.
Screw
Dashboard lower framework assembly
20. For dashboard installation, please simply reverse the
removal steps.

Cooling Unit
Components
Radiator inlet connecting pipe

Radiator upper mount
Radiator assembly Radiator filler assembly
Attachment Overflow pipe

clip
Radiator inlet pipe
Electronic fan
with overflow
tank assembly
Radiator lower mount
Attachment clip Mounting bolt
Radiator outlet pipe
Radiator upper Radiator removal

cross member
Radiator 1. Remove the battery negative (-) terminal.
Fan inlet pipe 2. Remove the electronic fan connector.
connection 3. Screw off the radiator drain valve, and drain the cool-
port Radiator ant.
outlet
pipe
4. Disconnect the engine's water inlet and outlet pipes.
Caution: Avoid impurities entering the pipes.
5. Use a No. 10 wrench to separate the radiator upper
cross member from the vehicle body.
Radiator drain valve
6. Take the radiator out of its mounting hole.

Radiator upper mount 7. Remove the radiator inlet and outlet pipe.
Radiator inlet pipe
Radiator
outlet
pipe
Radiator
lower
mount

Vehicle Body 247
8. Remove the radiator and electronic fan with overflow

Mounting bolt
tank assembly.
Mounting bolt Use a No. 10 wrench to remove the three mounting bolts of
the electronic fan with overflow tank assembly.
Radiator examination
1. Check for impurities between the radiator pipes.
Mounting bolt 2. Check whether the radiator is broken, and repair it if
necessary.
3. Check whether the radiator core is corroded, broken,
or corroded, and change it if necessary.
4. Check whether the pipe is cracked or broken.
5. According to the device circuit, check the operation
conditions of the electronic fan and change it if neces-
sary.
Electronic fan operation conditions:
Direction of rotation Low rotational speed High rotational speed
(looking from the radiator) (r/min) (r/min)
Counterclockwise 1850±250 2250±250
6. Check the sealing conditions of the radiator filler cap:
Connect the diagnostic scanner of the radiator filler
cap, and pressurize until the scanner indicator stops. If
the indicator does not stop at the specified point within
10 s, replace the filler cap.
Caution: Opening pressure of pressure valve is
108±14.7 KPa.
Radiator installation
1. Install the electronic fan onto the radiator assembly
with three mounting bolts.
2. Install four radiator mounts onto the four radiator instal-
lation points.
3. Install the radiator and electronic fan assembly be-
tween the upper and lower radiator cross member.
4. Install the inlet and outlet pipes connecting the radiator
and engine.
5. Fill up the radiator with coolant.
6. Check whether leakage exists in the radiator assembly,
the hose, and the connection.

Front Door Assembly

Components
Front door
window LH
Front door glass run LH

Front door window rear guide rail assembly LH
Front door window front

guide rail assembly LH
Front door Left external rearview

weatherstrip LH mirror assembly
Front door triangular

protector LH
Front door upper

Front door external weatherstrip LH hinge assembly LH
Front door lock assembly LH Front door retainer LH
Front door lower

Window regulator assembly hinge assembly LH
Front door assembly LH
Front door internal

weatherstrip LH
Front door armrest LH
Front door protector assembly LH
Front door removal

Front door armrest LH 1. Remove the front door inner decoration board.
(a) Remove the interior armrest screw and armrest.
(b) Remove the door inside handle screw and inside
handle.
Front door window
switch assembly LH (c) Remove the electrical switch and pull out the wire
harness.
(d) Insert buckle screwdriver between the fixed buckle and
Front door protector LH
the door inner decoration board to pry them loose.
Caution: Before using a buckle screwdriver, make sure
to wrap its head in tape.
(e) Take down the door inner decoration board.

Vehicle Body 249
Front door Front door glass run LH 2. Remove the front door external weatherstrip.
window LH Lower the window and manually grasp the weatherstrip
Front door
Front door external window front firmly, then pull it up to remove.
weatherstrip LH guide rail LH 3. Remove the front door window assembly.
(a) Adjust the window to make the window bracket
mounting bolts level with door inner decoration board
mounting hole, and remove the two window bracket
mounting bolts.
(b) Pull the window upwards and then tilt it to remove.
Front door window rear 4. Remove the front door glass run.
guide rail LH Front door assembly LH
5. Remove the front door window guide rail assembly.
6. Remove the window regulator.

Front door upper (a) Remove the six mounting bolts from the regulator
hinge LH bracket.
(b) Remove the regulator via the auxiliary hole.
7. Remove the vehicle inner lock button.
Window regulator
assembly
Front door lower hinge LH
8. Front door window assembly replacement.

(a) Adjust the front door window to make the window
bracket mounting bolts level with door inner decora-
tion board mounting hole.
Front door
(b) Remove the window bracket's mounting bolts to take
window LH the glass out for replacement.
Front door
assembly LH
Front door installation

1. Coat grease.
Front door outside Coat MP grease on the components before installing them.
handle LH
(a) Coat MP grease to sliding surfaces and the gears of the
window regulator.
Caution: Do not coat MP grease to the spring of the
window regulator.
Window regulator
assembly (b) Coat MP grease to the sliding surface of the door lock.
Front door lock assembly LH
Front door outside handle LH 2. Install the door outside handle with lock cylinder and
door lock.
(a) Install the lock cylinder on the door outside handle with
spring clasp.
(b) Install the door outside handle and lock cylinder with
two bolts with spring clasp.
Front door
inside (c) Install the door lock with three bolts.
handle LH (d) Connect the control lever to the door outside handle.
3. Install the door inner lock button.
Install the door inner lock button and connect the control
Front door lock assembly LH Front door assembly LH lever.

4. Install the window regulator.

Window regulator
assembly (a) Install the regulator via the auxiliary hole.
(b) Install the six mounting bolts of the regulator.
5. Install the guide rail and bolts on the front door window
guide rail assembly.
Front door
assembly LH
6. Install the front door glass run.

7. Install the front door window assembly.
Install the window on door chamber and fix the window and
window regulator with two bolts.
Front door
window LH
Front door
assembly LH
8. Install the front door external weatherstrip.

Front door assembly LH Lower the window and make the external weatherstrip
wedge into the seam of the door's external panel.
Front door external

weatherstrip LH
9. Install the door inner decoration board.

Front door inside 10. Install the front door inside handle.
handle LH (a) Push the door handle into the door panel and slide it
backward.
(b) Screw in the screws.
11. Insert the wire harness of the front door power window
Front door armrest LH
switch and install the door handle.
Front door protector LH

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Rear Door Assembly

Components
Rear door glass run LH
Rear door weatherstrip LH
Rear door window LH
Rear door outside triangu-

lar protector assembly LH
Rear door inner triangular

protector assembly LH
Rear door external
weatherstrip LH
Rear door window

rear guide rail LH
Rear door outside

handle assembly LH
Rear door internal weatherstrip LH

Rear door window front
guide rail LH
Rear door
window
regulator LH Rear door retainer LH
Rear door assembly LH
Rear door power window switch LH
Rear door inner decoration board assembly LH
Rear door protector trim strip LH
Rear door internal Rear door removal

weatherstrip LH
1. Remove the rear door inner decoration board.
Rear door inner (a) Remove the rear door armrest screw and armrest.
decoration board
assembly LH (b) Remove the inside handle screw and inside handle.
Rear door power (c) Remove the electrical switch, pull out the wire harness,
window switch LH and then remove the rear door power window switch.
(d) Remove the rear door internal weatherstrip.
Rear door armrest LH (e) Remove the rear door protector trim strip.
Rear door protector (f) Insert a buckle screwdriver between the fixed buckle
trim strip LH and inner decoration board to pry them loose.
Caution: Before using a buckle screwdriver, make sure
(g) Take the door inner decoration board off.

Rear door window LH Rear door glass run LH 2. Remove the rear door external weatherstrip.
Lower the window and manually grasp the weatherstrip
Rear door window rear firmly, then pull it up to remove.
guide rail LH
3. Remove the rear door window assembly.
(a) Pull the rear door regulator down in a position that en-
ables the rocker to turn freely, and then lower the win-
dow. Finally make the rocker slide out of the guide rail
Rear door below the window.
Rear door external window front
weatherstrip LH (b) Pull the window upwards and then tilt it to remove.
guide rail LH
Rear door window regulator LH
4. Remove the rear door glass run.
5. Remove the rear door window guide rail assembly.
6. Remove the window regulator.

(a) Remove the four mounting bolts of the regulator
bracket.
(b) Remove the regulator via the auxiliary hole.
8. Rear door window assembly replacement.
Rear door outside (a) Adjust the rear door window to make the window
handle assembly LH Rear door
assembly LH bracket mounting bolts level with the door inner
decoration board mounting hole.
(b) Remove the window bracket mounting bolts to take the
Rear door window regulator LH window out for replacement.
Rear door outside handle assembly LH Rear door installation

1. Coat grease.
Rear door Coat MP grease on the components before installing them.
assembly (a) Coat MP grease to sliding surfaces and the gears of
LH window regulator.
Caution: Do not coat MP grease to the spring of the
window regulator.
Rear door lock
assembly LH
(b) Coat MP grease to the sliding surface of the door lock.
Rear door window
regulator LH
2. Install the door outside handle with lock cylinder and

Rear door
assembly LH Rear door outside handle door lock.
assembly LH (a) Install the lock cylinder on the door outside handle with
spring clasp.
(b) Install the door outside handle and lock cylinder with
two bolts.
(c) Install the door lock with three bolts.
(d) Connect the control lever to the door outside handle.
3. Install the door inner lock button and connect the con-
Rear door lock trol lever.
assembly LH
Rear door 4. Install the window regulator.

assembly LH (a) Install the regulator via the auxiliary hole.
(b) Install the four regulator's mounting bolts.
Rear door window regulator LH

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Rear door window LH Rear door glass run LH 5. Install the guide rail and bolts on the rear door window
guide rail assembly.
Rear door window
rear guide rail LH 6. Install the rear door glass run.
7. Install the rear door window assembly.
Pull the regulator down in a position that enables the rocker
to turn freely, install the window into the door chamber, then
make the rocker of the regulator smoothly slide out of the
guide rail below the window.
Rear door window
front guide rail LH
Rear door assembly LH
8. Install the rear door external weatherstrip.

Rear door external weatherstrip LH
Lower the window and make the external weatherstrip
wedge into the seam of the door's external panel.
Rear door
assembly LH
9. Install the door inner decoration board.

Rear door inner decoration board assembly LH
10. Install the door inner handle.
(a) Push the door handle into the door panel and make it
slide backward.
Rear door power (b) Screw in the screws.
window switch LH
11. Insert the wire harness of the rear door power window
switch and install the door handle.

Trunk Door Assembly

Components
Spoiler panel assembly
Trunk door glass

weatherstrip Trunk door glass weatherstrip
Trunk door assembly
High mount brake lampshade

High mount brake lamp cap
High mount brake
lamp assembly 2
Rear wiper assembly High mount brake lamp assembly
Trunk door main lock assembly
Trunk door right side air spring
Trunk door left

side air spring Trunk door resonance block
Trunk door lock button
Trunk door hinge assembly
Right side
Left side deco- decorative block
rative block
Trunk door weatherstrip
Trunk door
assembly
Trunk door outside

Trunk door protector assembly handle assembly
Trunk door handle
Trunk door plate

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Trunk door removal

Trunk door 1. Remove the door inner decoration board.
assembly (a) Remove the inside handle.
(b) Insert the buckle screwdriver between the fixed buckle
Trunk door and the door inner decoration board to pry them loose.
protector assembly Caution: Before using a buckle screwdriver, make sure
(c) Take the door inner decoration board off.
3. Remove the rear wiper arm assembly.

Rear wiper blade
(a) Remove a rear wiper arm mounting bolt, and pull out
the rear wiper arm.
(b) Remove the three mounting bolts of the rear wiper mo-
Rear wiper motor
tor, and pull the rear wiper motor out.
(c) Remove the rear wiper waterproof rubber plug.
4. Install it by reversing the removal steps.
Rear wiper arm
Rear wiper waterproof rubber plug
Trunk door left side air spring Trunk door air spring removal
1. Open the trunk door.
2. Remove the air spring mounting bolts from the trunk
door.
Trunk door assembly
3. Remove the air spring mounting bolts from the side

Body sheet metal sheet metal of the rear body.
Trunk door left side air spring
Trunk door air spring installation

Body sheet metal
Special Note: Different metals making direct contact
will accelerate corrosion. Make sure to use the correct
fastening piece to avoid premature corrosion.
1. Open the trunk door.
Trunk door 2. Install the air spring bracket onto side sheet metal of
assembly the rear body with bolts.
Trunk door left side 3. Install the air spring bracket onto the side sheet metal
air spring
of the trunk door with bolts.

Front Bumper
Components
11 1
5
3
11
10
11
2
11
11
6 4
3
8
5
6
9 7
8
1. Front bumper plastic support

2. Front bumper energy absorbing block
3. Cross slot & concave hexagon head self-tapping screw and large washer subassembly (Q2754819+Q422)
4. Front bumper left mounting bracket
5. Cross slot & concave hexagon head self-tapping screw and large washer subassembly (Q2756319+Q421)
6. Front bumper plastic nut seat 1
7. Front bumper body
8. Hexagon head bolt and flat washer subassembly (Q1400616)
9. Front bumper plastic nut seat 2
10. Front bumper right mounting bracket
11. Expansion button

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Front bumper removal

1. Remove nut seat 2.
Screw off the lower air guide plate mounting screws below
Front bumper body
the vehicle body from left & right front bumper plastic nut
seat 2, and remove left & right front bumper plastic nut seat 2.
Front bumper plastic nut seat 2
2. Remove nut seat 1.

Screw off the screws of the front splash pad from the left &
right front bumper plastic nut seat 1, and pull left & right
Front bumper body front bumper plastic nut seat 1 out, then screw off the self-
tapping screws which are installed on the front bumper of
the left & right lower air guide plate and splash pad.
Front bumper plastic

nut seat 1
3. Remove the vehicle body bolts.

Screw off the hexagon head bolt and flat washer subassem-
bly (Q1400616) that is on the left & right side bracket of the
bumper and connected to vehicle body.
Front bumper body
Hexagon head bolt and flat

washer subassembly
4. Remove the bumper bolts.

Screw off the mounting bolts where the front bumper and
Cross slot & concave left & right side bracket connects.
hexagon head self-tap-
ping screw and large
washer subassembly
Front bumper left side

mounting bracket
Front bumper body
Expansion button 5. Remove the expansion button connecting the upper

part of the front bumper and vehicle body.
6. Pull the front bumper body out of the mounting bracket
of the left & right side bumper.
Front bumper body

7. Disconnect the wire harness of the left & right fog lamps.
Front bumper plastic 8. Remove the bumper attachments.
support
Remove the front bumper plastic support and energy absorb-
ing block from the vehicle body respectively.
Front bumper energy

absorbing block
Front bumper body
Cross slot & concave 9. Remove the bumper bracket.

hexagon head self- Screw off the cross slot & concave hexagon head self-tapping
tapping screw and large screw and large washer subassembly (Q2756319+Q422) on the
washer subassembly
left / right side mounting bracket of the front bumper, and pull
the left / right side mounting bracket out.
Front bumper body
Front bumper left side mounting bracket

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Rear Bumper
Components
1
4 3
5 1
2 6 10
3
8
7 11
1 12
18
1
11
13
13
14
13
13
17 16
15
1. Cross slot & concave hexagon head self-tapping screw and large 10. Front mounting bracket RH of the rear bumper
washer subassembly 11. Rear bumper trim panel buckle
2. Rear mounting bracket LH of the rear bumper 12. Rear bumper right trim panel
3. Rear bumper mounting bolt 13. Expansion button
4. Hexagon nut for flange face 14. Rear bumper body
5. Rubber cushion of the rear bumper central mounting bracket 15. Rear bumper plastic buffer anchor
6. Rear bumper central mounting bracket bolt 16. Rear bumper drawbar close lid
7. Central left mounting bracket of the rear bumper 17. Rear bumper left trim panel
8. Central right mounting bracket of the rear bumper 18. Front mounting bracket LH of the rear bumper
9. Rear mounting bracket RH of the rear bumper
Rear bumper left side trim panel

Rear bumper removal
1. Remove the trim panel.
Cross slot & con- Screw off the cross slot & concave hexagon head self-tap-
cave hexagon head
self-tapping screw ping screw and large washer subassembly, which are on the
and large washer rear bumper's left & right trim panel, the rear bumper trim
subassembly panel buckle, and the expansion button whose bottom is con-
nected with the bumper body. Then pull the left & right trim
Rear bumper trim
panel buckle
panel of the rear bumper off.
Rear bumper body
Expansion button

2. Remove the nut and gasket.

Hexagon nut for flange face Screw off the hexagon nut for flange face from the rear bum-
Rubber cushion of the per left & right side central mounting bolt, and the rubber
rear bumper central cushion of the rear bumper left & right side central mounting
mounting bracket
bracket.
Rear bumper
3. Remove the expansion button connecting the left &

right side bracket below the rear bumper and vehicle
body.
Rear bumper body Expansion button
4. Remove the bumper mounting bolt.

Rear bumper mounting bolt Screw off the rear bumper mounting bolt connecting the left
& right side above the rear bumper and vehicle body.
Rear bumper body
Rear mounting bracket Central left mounting 5. Pull the bumper out.
LH of the rear bumper bracket of the rear bumper Pull the rear bumper out of the left & right side bracket of
Rear bumper central
mounting bracket bolt
the rear bumper, and make the central part of the rear bum-
per slide out along the rear bumper central mounting bracket
bolt.
Front mounting bracket

LH of the rear bumper
Rear bumper body
6. Remove the three rear bumper plastic buffer anchor

Rear bumper body from the rear impact beam.
Rear bumper plastic buffer anchor

Vehicle Body 261
Cross slot & concave hexagon head self- 7. Remove the front bracket.
tapping screw and large washer subassembly Screw off the cross slot & concave hexagon head self-tap-
ping screw and large washer subassembly on the left & right
front mounting bracket of the rear bumper, and pull the left
& right front mounting bracket of rear bumper out.
Front mount-
ing bracket LH of
the rear bumper Rear bumper body
8. Remove the rear bracket.

Rear mounting bracket LH of the rear bumper Screw off the cross slot & concave hexagon head self-tap-
ping screw and large washer subassembly on the left & right
rear mounting bracket of the rear bumper, and pull off the
Cross slot & concave left & right rear mounting bracket of the rear bumper.
hexagon head self-tap-
ping screw and large
washer subassembly
Rear bumper body
Engine hood lock cable removal and installa-

Dashboard tion
Removal
1. Open the engine hood.
2. Remove the engine hood release lever from the dash-
Release lever board.
3. Remove the cable from the engine hood release lever
4. Remove the bolts and engine hood lock latch release
mechanism.
5. Remove the cable from the engine hood lock latch re-
lease mechanism assembly.
Installation
Areas of Importance: Different metals making direct
Engine hood Bolt contact will accelerate corrosion. Make sure to use the
lock latch release correct fastening piece to avoid premature corrosion.
mechanism
1. Install the cable onto the engine hood lock latch re-
lease mechanism assembly.
Cable 2. Install the engine hood lock latch release mechanism
assembly with the bolts.
3. Install the cable onto the engine hood lock latch re-
lease lever.
4. Install the engine hood release lever onto the dash-
board.

Seat Belt
Components
Rear seat belt guide ring Front seat belt

45±5 guide ring
45±5 Rear seat belt retractor
45±5 Front seat belt retractor
45±5 45±5
Seat belt lower mounting bolt
Seat belt lower mounting bolt
Guide ring mounting bolt
45±5 45±5
Body B-pillar Guide ring
sheet metal
Vertical adjuster
mounting bolt Woven band
Vertical adjuster
Retractor
Seat belt retaining

end piece
45±5
Front seat belt removal

1. Remove the end piece hood.
Remove the end piece hood under the seat belt, and expose
the seat belt lower mounting bolt.
Seat belt lower

mounting bolt

Vehicle Body 263
2. Remove the seat belt lower mounting bolt and B-pillar

lower decoration board.
Seat belt upper 3. Remove the guide ring cover.
mounting bolt Remove the seat belt guide ring cover, and expose the seat
belt upper set mounting bolt.
4. Remove the seat belt guide ring.

Remove the seat belt upper mounting bolt and B-pillar upper
decoration board, and expose the seat belt vertical adjuster.
Adjuster upper 5. Remove the vertical adjuster.
mounting bolt
Remove the seat belt vertical adjuster mounting bolts one by
one from bottom to top.
Adjuster lower
mounting bolt
6. Remove the seat belt retractor upper mounting bolt

(hexagon bolt for flange face).
7. Remove the seat belt retractor lower mounting bolt.
Retractor upper
mounting bolt
Retractor lower
mounting bolt
Front seat belt installation

1. Install the seat belt vertical adjuster.
(a) Tighten the seat belt vertical adjuster mounting bolts.
Adjuster upper (b) Conduct torque calibration on the seat belt vertical ad-
mounting bolt
juster mounting bolts.
Seat belt vertical adjuster mounting bolt torque is
Adjuster lower 45±5 N·m.
mounting bolt
2. Install the B-pillar upper trim panel.
3. Install the retractor lower mounting bolt.

Tighten the seat belt retractor lower mounting bolt. Seat belt
retractor lower mounting bolt torque is 45±5 N·m.
4. Install the retractor upper mounting bolt.
Retractor upper Tighten the seat belt retractor upper mounting bolt (hexagon
mounting bolt
bolt for flange face). Seat belt retractor upper mounting bolt
torque is 9±3 N·m.
Retractor lower
mounting bolt

5. Install the seat belt guide ring.

Fix the seat belt upper mounting bolt onto the vertical ad-
Seat belt upper juster. Seat belt upper mounting bolt torque is 45±5 N·m.
mounting bolt
6. Install the B-pillar lower trim panel.

7. Install the seat belt retaining end piece.
Fix the seat belt lower mounting bolt on the floor of the ve-
hicle body. Seat belt lower mounting bolt torque is 45±5 N·m.
Seat belt lower

mounting bolt
Rear three-point seat belt removal

1. Remove the seat belt lower mounting bolt.
2. Remove the C-pillar protector.
Lower mounting
bolt
3. Remove the guide ring cover.

Remove the seat belt guide ring cover, and expose the seat
Guide ring belt guide ring mounting bolt (refer to front seat removal
mounting bolt methods for details).
4. Remove the seat belt guide ring mounting bolt and re-
tractor lower mounting bolt.
Retractor lower mounting bolt
Rear three-point seat belt installation

1. Install the retractor.
Guide ring
Tighten the seat belt retractor lower mounting bolt. Seat belt
mounting bolt
retractor lower mounting bolt torque is 45±5 N·m.
2. Install the guide ring.
Tighten the seat belt guide ring mounting bolt. Guide ring
mounting bolt torque is 45± 5 N·m.
Retractor lower mounting bolt

Vehicle Body 265
3. Install the C-pillar protector.
Side sheet metal
C-pillar
protector
4. Install the seat belt lower mounting bolt.
Lower
mounting bolt
General Instructions and Operations of Seat Belt

Front seat belt warning:
The front seat belts are equipped with seat belt indicator. The driver seat belt indicator is located on the dash-
board and that of the front passenger is on the air conditioner panel. If the ignition switch is on but the front pas-
senger does not fasten the seatbelts, the indicator will turn on.
Preload three-point type belt retractor:
The front seat belts utilize preload three-point type belt retractors. The preload three-point type belt retractor is
loose, enabling the passenger to move freely unless there is an emergency, such as emergency braking, hard ac-
celeration, or hard turning.
Operation notice and function examination:
Areas of Importance
If the seat belt retractor is installed incorrectly, the seat belt will lose its function in the event of an accident, and
thus fail to protect the passenger!
Prevent sharp and harmful substances from touching the seat belt.
Avoid winding or breaking the seat belt lock tongue and seat belt lock button.
Do not bleach or dye the seat belt woren band. Wash it with neutral liquid soap and water only.
Before installing the seat belt mounting bolt, manually tighten the seat belt bolts to avoid improper clipping.
Do not repair the seat belt retractor or seat belt lock button. If the seat belt is broken, the seat belt assembly must
be replaced.
Change the broken or damaged seat belt.
Function examination:
1. Check whether all the seat belt mounting bolts are tightened.
2. Check the seat belt lock button. The lock button should be unlocked and able to lock easily.
3. After locking the seat belt, the seat belt lock tongue can no longer loosen.
4. Pull all the seat belts out. Seat belts cannot have knots or tears.
5. The belt should retract smoothly but not roughly.
Warning:
Different metals making direct contact will accelerate corrosion. Make sure to use the correct fastening
piece to avoid premature corrosion!

Seats
Components
Rear seat
Front passenger seat
Driver seat
Backrest regulating lever
Areas of Importance
1. Pay attention to safety in the process of removal, transportation, and installation, as to avoid
scratching or crushing injury caused by the seat.
2. Take note to protect the inner decorative components in the process of installation and transporta-
tion, as to avoid scratching the side panels.
3. After finishing installation, make sure to calibrate the tightening torque of mounting bolts.
Front seat removal and installation

Removal
1. Disconnect the seat belt terminal harness (seat bottom).
Rear foundation 2. Remove the rear foundation hoods 1 & 2 and mounting
hood 1 bolts 3 & 4.
Rear
3. Remove the front foundation hoods 1 & 2 and mounting
Front foundation bolts 1 & 2.
foundation hood 2
hood 1 4. Remove the seat.
Front foundation hood 2

Installation
Special Note: Different metals making direct contact
will accelerate corrosion. Make sure to use the correct
1. Install the seat.
2. Connect the seat belt terminal harness.
3. Tighten the rear foundation bolt and install the rear
foundation hood.
4. Tighten the front foundation bolt and install the front
Mounting bolt 3
Mounting bolt 4
foundation hood.
Mounting bolt 1 Remarks: Front seats are symmetrical.
Mounting bolt 2

Vehicle Body 267
Rear seat removal and installation

Removal
1. Remove the mounting bolts (5) on the
40% of the rear seat backrest (3).
2. Remove the mouting bolts (6) on the
4 60% of the rear seat backrest (4).
3. Lift the rear seat cushion up and make
3 hook 11 slide out of clamping frame 9.
2 6
4. Continue to lift the seat cushion up, and tilt it upwards
1
8 6 5 to make hook 12 behind seat cushion slide out of the
8
7 5 rear seat fixed cross member hook 13. Finally, remove
8 1 2 the rear seat cushion.
Remarks: Mounting bolt (2) refers to the rear seat backrest (1)
10 12
mounting bolt.
9 Installation
11 Special Note: Different metals making direct contact
9 will accelerate corrosion. Make sure to use the correct
1. Hang hook 12 behind the seat cushion on the fixed
cross member hook 13, and then press the hook under
the cushion into clamping frame 9.
2. Install the rear fixed cross member (7) and mounting
bolt (8) of the rear seat on the vehicle body.
3. Install the mounting bolts (6) of the 60% rear seat
backrest (4).
4. Install the mounting bolts (5) of the 40% rear seat
backrest (3).

Sunroof Assembly
Components
Sunroof panel
Sunroof window weatherstrip
Movable sun visor
Slider
Spacing tube Upper trim strip
Lower trim strip
Air guide plate Bolt

4.5
Rear guide device Roof drip channel
Wind guard
Spring Guide device latch hook
End piece
Guide rail assembly

Drive device
Bolt
3.5

Vehicle Body 269
Troubleshooting
Fault classification Fault symptom Fault diagnosis Fault maintenance
Window panel Window panel (sunroof) Check if anything is blocking the guide rail Replace the sunroof guide rail assem-
motion failure cannot open, rise, or close for window panel movement. Check whether bly. Replace the motor.
from its initial position the mechanism moves smoothly or stiffly.
Check whether the mechanism is broken.
Check whether the guide rail is deformed.
Check whether the motor works normally.
The window panel can- Diagnosis: Check whether there are oddities Clean the objects and close the sun-
not close while half- impeding the window panel's movement . roof by force when the jam protection
opened or half-tilted Check whether the wind guard or rear roof function is started, then open it again
drip channel is arched or deformed. for operation. Replace the wind guard
and rear roof drip channel.
Sun visor push/pull Sun visor cannot open Check whether the guide rail for the sun visor Clean the oddities in the guide rail.
fault or close normally is blocked by oddities. Check whether the sun Change the sun visor. Change the sun
visor bracket is broken. visor bracket.
The sun visor cannot open Check whether the front part of sun visor Replace the sun visor. Replace the
and close completely arches. Check whether the sun visor lever has sun visor lever.
been broken off.
Sunroof leakage fault Sunroof leakage Check the clearance between the window Adjust and enlarge the window panel
panel and the car roof hatch. weatherstrip.
Check whether a build up of sand or dust ex- Clean the weatherstrip surface and
ists on the surface of window panel weather- car roof hatch.
strip.
Check the sealing conditions between the Replace the sunroof guide rail assem-
guide rail & front roof drip channel and rear bly.
roof drip channel.
Check whether the front roof drip channel Replace the sunroof guide rail assem-
and rear roof drip channel are broken. bly or rear roof drip channel.
Abnormal noise There is abnormal noise (1) Check the positioning of the closed win- (1) Adjust the window panel's position.
when closing the sunroof dow panel. (2) Place the wind deflector spring in
(2) Check whether the wind deflector spring is the right position .
in the right position. (3) Re-install the fixed spring.
(3) Check whether the rear roof drip channel's (4) Re-install the rubber block.
fixed spring has broken off.
(4) Check whether the wind deflector buffer
rubber block has broken off.
There is abnormal (1) Check whether the motor is working nor- (1) Replace the motor.
noise when the sun- mally. (2) Clean out any contamination.
roof is operating (2) Check whether oddities exist in the guide (3) Lubricate the components.
rail for mechanism movement . (4) Replace the components or the
(3) Check the grease's conditions on the mov- sunroof guide rail assembly.
ing components .
(4) Check whether the moving components
are broken.
Plastic gasket Sunroof assembly removal

1. Remove the ceiling.
2. Disconnect and pull the connector of the sunroof ac-
tuator out.
3. Pull the four sunroof drainage pipes out (positions indi-
cated by the arrows in the diagram).
4. Remove the sunroof.
Sunroof
Drive device assembly Remove the bolt and plastic gasket, and carry the sunroof
assembly out of car with the help of an assistant.
Mounting bolt Drainage pipe port

Upper trim strip Sunroof panel removal

1. Move sun visor to the back position.
2. Open sunroof in the slanted position.
3. Adjust the lower trim strip.
Loosen the front part of the lower trim strip in the direction
of car's interior to take the rear part off the hook.
4. Adjust the upper trim strip.
Loosen the front and middle parts of the upper trim strip to
take the rear part off the hook.
Lower trim strip
5. Remove the sunroof's left and right side mounting bolts

Mounting bolt Mounting bolt 6. Pull up the sunroof panel.
Caution: After removing the sunroof panel, do not turn
the sunroof switch to the "Open" position. Because the
window panel will no longer press the roof drip channel
at this time, the roof drip channel will tilt into the sun-
roof.
Sunroof panel installation

Air guide plate
The window panel must be installed at the initial position
(window panel is closed).
1. Window panel location
The mark (indicated by the arrow) on the top of rear guide
device, which is on the window panel's two sides, must be
level with the "a" mark on the air guide plate.
The air guide plate must be installed in the guide rail (cannot
Guide device be manually moved).
If there is no guide rail on the air guide plate, please adjust
it.
2. Place the sunroof from the top down
3. Adjust the clearance

Insert six sheets of paper, each of about 0.3 mm thickness,
around the window panel to make sure that clearances
around the panel is symmetrical.
4. Tighten the mounting bolt
Tightening torque: 4.5 N·m.
Sunroof panel adjustment

1. Adjust the front part.
a = 0-1 mm, lower than the level position of the sunroof.
The arrow refers to the driving direction (facing forward).

Vehicle Body 271
2. Adjust the rear part.

b = 0-1 mm, higher than the level position of the sunroof.
The arrow refers to the driving direction (facing forward).
3. Adjust the window panel weatherstrip.

Use a sheet of paper of 0.3 mm thickness to check whether
the prestress between the weatherstrip and vehicle body is
consistent.
(a) If the prestress is insufficient, use a plastic wedged
instrument to enlarge the weatherstrip's clearance.
(b) If the prestress is excessive, use a stick to compress the

weatherstrip's clearance.
Replace the weatherstrip

Window
Weatherstrip 1. Remove the window panel weatherstrip.
2. Install the weatherstrip.

Start from the center of the rear part and install the new
Window
Weatherstrip weatherstrip onto the window panel from the top down.
Instructions: In order to install the weatherstrip more easily,
it is suggested to coat soap liquid around window panel first.
If the weatherstrip is installed incorrectly, it will cause the
upper part's surface be to wavy. The weatherstrip must be cut
short according to the window panel's perimeter.

Wind deflector removal and installation

1. Remove the wind deflector.
(a) Completely open the sunroof.
(b) Pry the wind guard mounting bracket on the left and
right side guide rails out with a small screwdriver
(according to direction indicated by the arrow).
(c) Pull out the wind deflector.
2. Install the wind deflector.

Bracket locating seat Location slot The locating seat of the wind deflector mounting bracket
should wedge into the location slot of the sunroof assembly
guide rail.
Movable sun visor removal

Precondition: The sunroof panel has been removed and the
sunroof is in the closed position.
1. Remove the sun visor.
Move the sun visor to the front position and then push it to
one side. Pry the front slider on the two sides of sun visor
out of the guide rail with a screwdriver. Then move the sun
visor forward, push it to one side, and pry the rear slider on
the two sides of sun visor out of guide rail with a screw-
driver. Finally, pull out the sun visor.
2. Install the sun visor.

Place the sun visor into the sunroof opening. Install the rear
slider on the two sides of sun visor into the guide rail. Move
the rear movable sun visor backward. Install the front slider
on the two sides of the sun visor into the guide rail.
Caution: Once the mounting bolts of the drive device
have been removed, they must be replaced with new
ones. Adjust the sunroof drive device's position (initial
position).
If the following circumstances happen, the initial position of
the sunroof drive device must be adjusted:
(a) A new drive device has been installed.
(b) The drive device was removed when it was not on the
initial position.
(c) Open or close the sunroof with an emergency operation
wrench.

Vehicle Body 273
Adjust the initial position of drive device

Precondition:
(a) Remove the drive device, but leave the electric plug-in
connected.
(b) The sunroof is on the initial position. Sunroof panel has
been installed correctly.
Caution: The gear of drive device cannot contact
anything while adjusting.
1. Select the "Tilt Sunroof" function (position 1) with the
rotary switch.
2. Select the "Close Sunroof" function (position 2) with the
rotary switch.
Air guide plate 3. Select the "Open Sunroof" function (position 3) with the
rotary switch.
4. Select the "Close Sunroof" function (position 2) with the
rotary switch.
5. Mark "1" is shown on the observation panel.
6. The drive device is on the initial position.
Guide device Parallel operation condition examination

1. The mark (indicated by the arrow) above the rear guide
device on the window panel's two sides must be level
with the "a" mark on the air guide plate.
2. The air guide plate must be installed in the guide rail
(cannot be manually moved).
Adjust the parallel operation condition

Instructions: Only when the sunroof is on the initial position,
and the drive device and window panel are removed, can the
parallel operation conditions be adjusted.
1. The mark (indicated by the arrow) above the rear guide
device on the window panel's two sides must be level
with the "a" mark on the air guide plate.
2. The air guide plate must be installed in the guide rail
(cannot be manually moved).
3. From the front, slide the top of the guide device and
position it between the two symbols.
4. Position.
Mount the drive device at this position (initial position) and
then examine the initial position.
Sunroof assembly installation

Plastic gasket 1. Install the sunroof assembly into the ceiling opening
B with the help of an assistant.
B 2. The three dowel pins ("B" position on the diagram)
must be placed in the location holes.
Drive device
3. Check the condition of the circuit connection.
Sunroof
B assembly 4. Install the bolts.
Mounting bolt Tighten them successively from the left and right side to the
rear part of the sunroof drive device. Tightening torque for
all is 8 N·m.
5. Install the outlet pipe.
6. Insert the drive device plug.


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How to Use This Manual..................................................... 2

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How to Use This Manual

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N·m : Specified torque

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Identifying Number Location

Engine Manufacturing Number

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Comprehensive Repair Instructions

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6. Clip removal and installation.

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Push out the king pin, remove it,

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Small clip extractor

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Basic Parameters of the Overall Vehicle............................. 11

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Basic Parameters of the Overall Vehicle

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Outter acceleration noise dB (A) ≤74 ≤75

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Electrical System Structure and Parameters (Continued)