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Edition: January 2011 VOLUME 1
Printing: February 2011 INTRODUCTION 01

PREPARATION 02
Pulication NO: FWSM-201101 SERVICE SPECIFICATIONS 03
Printed in China DIAGNOSTICS 04
VOLUME 2
ENGINE CONTROL SYSTEM 11A
FUEL 12A
EMISSION CONTROL 13A
INTAKE AIR 14A
ENGINE MECHANICAL 15A
EXHAUST 16A
COOLING 17A
LUBRICATION 18A
IGNITION 19
STARTING AND CHARGING 20A
ENGINE CONTROL SYSTEM 11B
FUEL 12B
EMISSION CONTROL 13B
INTAKE AIR 14B
ENGINE MECHANICAL 15B
EXHAUST 16B
COOLING 17B
LUBRICATION 18B
STARTING AND CHARGING 20B
ENGINE CONTROL SYSTEM 11C
FUEL 12C
EMISSION CONTROL 13C
INTAKE AIR 14C
ENGINE MECHANICAL 15C
EXHAUST 16C
COOLING 17C
LUBRICATION 18C
STARTING AND CHARGING 20C
ENGINE CONTROL SYSTEM 11D
FUEL 12D
EMISSION CONTROL 13D
INTAKE AIR 14D
ENGINE MECHANICAL 15D
EXHAUST 16D
COOLING 17D
LUBRICATION 18D
STARTING AND CHARGING 20D
VOLUME 3
FRONT SUSPENSION 31
REAR SUSPENSION 32
TIRE AND WHEEL 33
AXLE AND PROPELLER SHAFT 34
BRAKE 35
PARKING BRAKE 36
TRANSMISSION 41
CLUTCH 42
STEERING COLUMN 51
POWER STEERING 52
HEATER AND AIR CONDITIONING 61
SEAT BELT 63
LIGHTING 64
WIPER AND WASHER 65
AUDIO SYSTEM 66
© 2011 Beiqi Foton Motor Co., Ltd. WIRING 71
COMMUNICATION SYSTEM 81
All right reserved. No part of this service WINDSHIELD 82
INSTRUMENT PANEL 83
manual may be reproduced or stored in a
SEAT 84
retrieval system, or transmitted in any
DOOR LOCKS 85
form, or by any means, electronic, DOORS 87
mechanical, photo-copying, recording or EXTERIOR AND INTERIOR TRIM 88
otherwise, without the proir written VEHICLE CONTROL SYSTEM 91
permission of Foton. INDEX
INTRODUCTION
01
HOW TO USE THIS MANUAL ........................................................... 01-1
GENERAL INFORMATION.......................................................... 01-1 01
IDENTIFICATION INFORMATION..................................................... 01-7
VEHICLE IDENTIFICATION NUMBER (VIN) .............................. 01-7 01
SERIAL NUMBER (SN) ............................................................... 01-9
REPAIR INSTRUCTION................................................................... 01-10 01
PRECAUTION............................................................................ 01-10
VEHICLE LIFT AND SUPPORT LOCATIONS........................... 01-18 01
HOW TO TROUBLESHOOT ............................................................ 01-20
GENERAL INFORMATION........................................................ 01-20 01
HOW TO PROCEED WITH TROUBLESHOOTING .................. 01-22
ELECTRONIC CIRCUIT INSPECTION PROCEDURE ............. 01-31 01
TERMS ............................................................................................. 01-35
ABBREVIATIONS USED IN THIS MANUAL ............................. 01-35
01
01
01
01
01
01
01
01
01
01
01
01
01
INTRODUCTION - HOW TO USE THIS MANUAL 01-1
HOW TO USE THIS MANUAL

INTRODUCTION
GENERAL INFORMATION
1. GENERAL DESCRIPTION. 01
(a) Carrying out operations described in this manual in the correct sequence may help you improve the
quality and efficiency during servicing. 01
(b) Generally, service operations can be separated in the following 3 main processes:
• Diagnosis 01
• Removal / Installation, Replacement, Disassembly / Assembly, (On-vehicle) Inspection and Adjustment
01
• Final Inspection
(c) This manual includes the 1st process of “Diagnosis” (Refer to “Chapter 04 diagnostics”) and the 2nd 01
process of “Removal / Installation, Replacement, Disassembly / Reassembly, (On-vehicle) Inspection
and Adjustment”, but the 3rd process of “Final Inspection” is not included. 01
(d) The following essential operations are not written in this manual. However, these operations must be
performed in actual situations. 01
• Clean a removed part when necessary
• Visual check 01
2. INDEX.
(a) An alphabetical INDEX section is provided at the end of this chapter as a reference to help you to 01
understand these abbreviation meaning.
01
3. PREPARATION.
(a) Special service tools (SST) and special service materials (SSM) may be required depending on the ser- 01
vicing situation. Be sure to use SST and SSM when they are required and follow the correct operation
sequence. A list of SST and SSM is in the “Chapter 02 preparation”. 01
4. SERVICING PROCEDURES.
(a) According to chapter content, the components’ illustration is added into chapters. 01
01
01
01
01
01
01
01
01-2 INTRODUCTION - HOW TO USE THIS MANUAL
(b) The components’ illustration shows the all parts relationship in the same assy. A table following the
illustration lists the name of each part.
Example:
(c) If installation is performed in the reverse order of removal, only important points will be described.
(d) In this manual, only items with important points are described in the procedure and the illustration
shows what and where we can do. In the explanations, details of the operational method, standard
value and notices are listed. 01
(e) Some illustrations in this manual for similar vehicle models may be the same. In this case, some details
in illustration may be different from the actual vehicle. 01
(f) The procedures are presented in a step-by-step format:
• The illustration shows what to do and where to do it. 01
• The task title tells us what to do.
• The explanation text tells us how to perform the task and includes other information such as 01
specifications, service notice and warnings.
Example:
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
5. SERVICE SPECIFICATIONS.
(a) Specifications are presented in bold type throughout the manual. You never have to leave the servicing
to look for the specifications. The specifications can also be found in the “Chapter 03 service
specifications” for quick reference.
6. TERM DEFINITIONS.
WARNING Indicates the possibility of injury to you or other persons.
CAUTION Indicates the possibility of damage to the components being

repaired and the equipments being operated.
Provides additional information to help you perform the servic-
NOTE ing efficiently.
7. INTERNATIONAL SYSTEM OF UNITS.

(a) The units used in this manual comply with the International System of Units (SI UNIT) standard.
Example:
Torque: 30 N•m
8. APPLICABLE VEHICLES.
LHD/RHD Series Engine Transmission Models

6516B1DDA-03ZA01 6516B1DDA-03ZA02 01
6516B1DDA-03ZA03 6516B1DDA-03ZA04
01
6516B1DDA-03ZA05 6516B1DDA-03ZA06
01
BJ493ZQ-13ke 5RYL 6516B1DDA-03ZA07 6516B1DDA-03ZA08
6516B1DDA-03ZA09 6516B1DDA-03ZA10 01
6516B1DDA-03ZA11 6516B1DDA-03ZA12
01
BJ6516 6516B1DDA-03ZA13
series 01
6516B1DWA-00ZA03 6516B1DWA-00ZA04
6516B1DWA-00ZA05 6516B1DWA-00ZA06 01
6516B1DWA-01ZA06 6516B1DWA-01ZA08
01
BJ491EQ1-40 TC5RYA4 6516B1DWA-01ZA10 6516B1DWA-01ZA17
01
6516B1DWA-01ZA18
6516B1DWA-05ZA03 6516B1DWA-05ZA04 01
6516B1DWA-05ZA08
01
6536B1DDA-03ZA01 6536B1DDA-03ZA02
01
6536B1DDA-03ZA03 6536B1DDA-03ZA04
LHD
6536B1DDA-03ZA05 6536B1DDA-03ZA06 01
6536B1DDA-03ZA07 6536B1DDA-03ZA08
01
BJ493ZQ-13ke 5RYL 6536B1DDA-03ZA09 6536B1DDA-03ZA10
01
6536B1DDA-03ZA11 6536B1DDA-03ZA12
6536B1DDA-03ZA13 6536B1DDA-03ZA14 01
6536B1DDA-03ZA15 6536B1DDA-03ZA16
01
BJ6536 6536B1DDA-03ZA17
series 01
6536B1DWA-S1ZA02 6536B1DWA-S1ZA25
6536B1DWA-S2ZA01 6536B1DWA-S2ZA02 01
6536B1DWA-S3ZA01
01
6536B1DWA-00ZA01 6536B1DWA-00ZA02
BJ491EQ3-30 TC5RYA4 6536B1DWA-00ZA03 6536B1DWA-00ZA04
6536B1DWA-00ZA05 6536B1DWA-00ZA06
6536B1DWA-00ZA07 6536B1DWA-00ZA09
6536B1DWA-00ZA10 6536B1DWA-00ZA11
6536B1DWA-00ZA23 6536B1DWA-00ZA26
LHD/RHD Series Engine Transmission Models

6536B1DWA-00ZA59 6536B1DWA-00ZA61
BJ491EQ1-40 TC5RYA4
6536B1DWA-00ZA65
BJ6536
6536B1DCA-00Z001 6536B1DCA-00Z002
series
4GC1 5RYA 6536B1DCA-00ZA01 6536B1DCA-00ZA02
6536B1DCA-00ZA05
LHD BJ493ZQ-13ke 5RYL 5026A12DA-00ZA01 5026EC2DA-00ZA01
5026EC5WA-03ZA02 5026EC5WA-03ZA03
BJ5026 5026EC5WA-03ZA04 5026EC5WA-03ZA08

series BJ491EQ1-40 TC5RYA4 5026EC5WA-03ZA09 5026EC5WA-03ZA10
5026EC5WA-03ZA15 5026EC5WA-03ZA23
5026EC2WA-S1ZA01
6516B1EWA-0RZA01 6516B1EWA-0RZA03
BJ6516
BJ491EQ1-40 TC5RYA4 6516B1EWA-0RZA04 6516B1EWA-0RZ001
series
6516B1DWA-0RZA03 6516B1EWA-1RZ001
6536B1DDA-2RZA01 6536B1DDA-2RZA02
RHD BJ493ZQ-13ke 5RYL
BJ6536
series
6536B1DDA-0RZA01
BJ491EQ1-40 TC5RYA4 6536B1DWA-0RZA06 6536B1DWA-0RZA07
BJ5026
BJ491EQ1-40 TC5RYA4 5026EC5WA-3RZA01
series
INTRODUCTION - IDENTIFICATION INFORMATION 01-7
IDENTIFICATION INFORMATION
VEHICLE IDENTIFICATION NUMBER (VIN)
1. VEHICLE IDENTIFICATION NUMBER (VIN). 01
(a) The Vehicle Identification Number (VIN) is stamped on the vehicle identification number label and
vehicle certification plate as shown in the illustration. 01
• Vehicle identification number label: Can be found through the windshield at front left corner of the
instrument panel. 01
• Vehicle certification plate: Can be found after turning over the driver seat.
01
• Vehicle identification number label: Can be found at assistant driver side after opening the door.
01
01
01
01
01
01
01
01
01
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01
01
01
01
01
01-8 INTRODUCTION - IDENTIFICATION INFORMATION
INTRODUCTION - IDENTIFICATION INFORMATION 01-9
SERIAL NUMBER (SN)

1. FINAL DRIVE SERIAL NUMBER.
(a) The final drive serial number is stamped on the rear axle 01
welding housing.
01
01
01
01
2. PROPELLER SHAFT SERIAL NUMBER.
(a) The propeller shaft serial number is stamped on the pro- 01
peller shaft tube.
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01-10 INTRODUCTION - REPAIR INSTRUCTION
REPAIR INSTRUCTION
PRECAUTION
1. BASIC REPAIR NOTE.
(a) Notes on operation.
• Be sure to wear a clean uniform.

1 Protection
• Be sure to wear hat and safety shoes.
• Perform safty inspection each other, when 2 or more persons servic-

ing togehter.
• When working with the engine running, pay attention to the ventilation
of the workshop.
2 Safe operation • In case of operating on high temperature parts, rotating, moving and
vibrating parts, protective clothing is necessary and pay attention not
to burn or injury yourself.
• When jacking up the vehicle, be sure to support the vehicle at correct
position and use safe jack.
• When lifting up the vehicle, use a safe and standard equipment.
Preparation of tools and • Before starting the servicing, prepare a tool stand, SST, gauge, oil,
3
measuring gauge shop rag and new parts for replacement.
INTRODUCTION - REPAIR INSTRUCTION 01-11
• Diagnose problems with a thorough understanding of the trouble

phenomenon and perform effective operations.
• Before removing the parts, check the assembly for general condition:
Removal and installstion,
deformation and damage. 01
4 disassembly and assembly
operations • When the part structure is complicated, take a note or make match
marks so as not to make mistakes that affect the function of the parts.
01
• Clean and wash the removed parts if necessary, and assemble them
after a thorough inspection.
01
• Place the removed parts in the correct order to avoid mixing up or
making them dirty. 01
5 Removed parts • As for non-reusable parts such as gasket, O-rings, and self lock nut,
replace them with new one following the instruction of manual.
01
• Put the old parts into a box and show them to the customer.
01
(b) Jacking up and supporting vehicle.
• Be carefully when jacking up and supporting the vehicle. Be sure to lift and support the vehicle at the
01
proper locations. (Refer to “Chapter 01 introduction - repair instruction, vehicle lift and support
locations”)
01
(c) Precoated part.
• Precoat removed parts like bolts, nuts, etc. that are coated with sealant at the factory. 01
• If a precoated part is retightened, loosened or caused to move in any way, it must be recoated with the
sealant. 01
• When reusing precoated parts, clean the old sealant and dry the part with compressed air. Then apply
the specified sealant to the bolts, nut or threads. 01
• Sometimes, it is necessary to leave the installed precoated parts for a specified time until the sealant
hardens. 01
(d) Gasket.
• If necessary, use a sealer or new gasket to prevent leakage. 01
(e) Bolts, nuts and screws.
01
• Always tighten the bolts, nuts and screws at the specified torque with a torque wrench.
WARNING 01
Perform the torque check with the lower limit value of the torque tolerance.
01
01
01
01
01
(f) Fuse.
• When replacing a fuse, make sure the amperage rating of new fuse is correct. The amperage rating of
new fuse should be the same as old fuse, neither more nor less.
Illustration Symbol Part Name
Fuse
Circuit Breaker
(g) Clips.
• The removal and installation methods of typical clips used in body parts are shown in the below table.
NOTE
If the clip is damaged during the servicing, replace with a new one. 01
Shape (Example) Removal / Installation 01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
Shape (Example) Removal / Installation
(h) Removal and installation of vacuum hoses.

• To disconnect the vacuum hoses, pull the hoses by
holding at the end, not at the middle of hose.
• When disconnecting vacuum hoses, use tags to identify

where they should be reconnected.
• After performing the servicing, check carefully whether
the hoses are connected properly.
• When using a vacuum gauge, never force the hose onto
a connector . Always use a adapter to connect hose. The
stretched hose may cause leakage.
(i) Torque when using a torque wrench with extension tool.

• In case of tightening with a torque wrench which has an
extended length by combining the torque wrench with
SST or extension tool, if you tighten until the reading of 01
the torque wrench reaches the specified torque value,
the actual value becomes excessive. 01
• In this manual, only the specified torque is described. In
case of using SST or an extension tool, calculate the 01
reading of the torque wrench by the following formula.
01
• Formula: T’ = T × L2 / (L1 + L2)
01
T’ Reading of torque wrench (N·m)
T Torque (N•m) 01
L1 Length of SST or extension tool (mm) 01

L2 Length of torque wrench (mm)
01
01
2. ELECTRONIC CONTROL. 01
(a) Disconnection and connection of battery terminal.
01
• Before performing electrical operations, disconnect the
battery negative terminal cable firstly so as to prevent
01
burnt-out damage by short.
01
01
01
• Disconnect the battery terminal completely without twist
after turning off all switches.
01
• When the negative (-) terminal cable is disconnected from
the battery, the memory of the clock and audio system will 01
be cleared. So before servicing, record the necessary data
of the clock and audio system. After servicing, reset the
01
clock and audio system.
(b) Handling of electronic parts. 01
• Do not open the cover or case of the module. If the IC
terminals are touched, the IC may be destroyed by static 01
electricity.
• To disconntect electronic connectors, pull the connector,
not the wire harness.
• Do not drop electronic components, such as sensors or

relays. If they are dropped on a hard floor, they should be
replaced.
• When cleaning the engine with steam, protect the

electronic components, air filter and emission-related
components from water.
• Never use an impact wrench to remove or install
temperature switches or temperature sensors.
• When checking the wire harness connector, insert the
tester probe carefully to prevent terminals from bending.
• After replacing electronic components, always perform
function check.
3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS.

(a) Place for removing and installing of fuel system parts.
• Work in a place with good air ventilation and without anything flammable such as welder, grinder, drill,
electric motor or stove in the surroundings.
• Never work in a place such as a pit or nearby a pit, as there is a place that vaporized fuel is filled in.
(b) Removing and installing of fuel system parts.
• Prepare a fire extinguisher before starting the servicing.
• For prevention of static electricity, connect the fuel changer, vehicle and fuel tank to ground and keep
floor dry to prevent slipping.
• Never use any electric equipment like an electric motor or a working light, as they may cause sparks or
high temperature.
• Never use an iron hammer, as it may cause sparks.
• Dispose the shop rag without any fuel deposit.
4. REMOVAL AND INSTALLATION OF ENGINE INTAKE PARTS.
CAUTION
If any metal chips are into the inlet pass, this may get a bad effect to the engine and turbocharger.
(a) When removing and installing the inlet system parts,

wrap the opening of engine intake system with clean rag
or tape.
(b) When installing the inlet system parts, check that there is
no mixing of metal chips.
5. HANDLING OF HOSE CLAMPS.

(a) Before removing the hose, record the depth of the inserting
portion and the old clamp position in order to reinstall it
correctly. 01
(b) If deformation or dent is found, replace it with a new one.
(c) In case of reusing the hose, install the clamp on the hose 01
where it has a clamp track.
(d) For a spring type clamp, adjust it by applying force to the 01
arrow mark direction after the installation.
01
6. FOR VEHICLES EQUIPPED WITH CATALYTIC CONVERTER.
01
CAUTION
If large amount of unburned fuel flows into the converter, it may cause overheating and a fire hazard. 01
To prevent this, observe the following precautions.
(a) Use only unleaded gasoline (gasoline vehicles). 01
(b) Avoid running the engine at idle speed for more than 20 minutes.
(c) Avoid a spark jump test. 01
• Perform a spark jump test only when absolutely necessary. Perform this test as quickly as possible.
• While testing, never race the engine. 01
(d) Avoid a prolonged engine compression measurement. This operation must be performed as quickly as
01
possible.
(e) Do not run the engine when the fuel tank is nearly empty. This may cause the engine to misfire and
01
damage the catalytic converter.
01
01
01
01
01
01
01
01
01
VEHICLE LIFT AND SUPPORT LOCATIONS

1. NOTICE ABOUT VEHICLE CONDITION WHEN JACKING UP.
(a) According to rules, the vehicle must be unloaded when jacking up. Never jack up or lift up the vehicle
with things of heavy weight loading.
(b) When removing any parts of heavy weight like the engine and transmission, the center of gravity of the
vehicle will be changed. Place a balance weight in vehicle so as to keep it from rolling, or support the
vehicle with jack at the position of specification.
2. NOTICE FOR USING JACK AND 4 POSE LIFT.
(a) Follow the instruction in this manual for a safety operation.
(b) Do not damage tires or wheels with a pry bar.
(c) Park the vehicle on a flat road with applying parking brake.
(d) Shift in the reverse position.
(e) Using a wheel stopper, fix the vehicle.
(f) Jack up the vehicle using a jack with rubber attachment.
WARNING
Be sure to jack up the vehicle at the correct support location.
(g) Lift the vehicle up by using a 4 pose lift with rubber attachment.
WARNING
Be sure to lift up the vehicle at the correct support location.
01
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01-20 INTRODUCTION - HOW TO TROUBLESHOOT
HOW TO TROUBLESHOOT
GENERAL INFORMATION
There are many electronic controlled systems in the View. In general, electronic controlled system is consid-
ered to be very complex and require a high level of technical knowledge and expert skill to troubleshoot.
However, the fact is that if you check the circuits one by one, troubleshooting of these systems is not complex.
If you have adequate understanding of the system and basic knowledge of electricity, the problem can be
accurately found out and comfirmed.
This manual is designed based on the above principle to help service technicians perform accurate and
effective troubleshooting.
The troubleshooting procedures are described on the following chapter.
System Reference
Anti-lock Brake System Chapter 04 diagnostics - anti-lock brake system
Audio System Chapter 04 diagnostics - audio system
Combined Display Chapter 04 diagnostics - combined display
Chapter 04 diagnostics - engine control system-BJ491EQ

Chapter 04 diagnostics - engine control system-BJ493ZQ
Engine Control System
Chapter 04 diagnostics - engine control system-4D20
Chapter 04 diagnostics - engine control system-4GC1
Heater And Air Conditioning System Chapter 04 diagnostics - heater and air condition system
Horn System Chapter 04 diagnostics - horn system
Instrument Cluster Chapter 04 diagnostics - instrument cluster
Lighting System Chapter 04 diagnostics - light system
Outside Mirror Chapter 04 diagnostics - outside mirrors
Power Door Locks Chapter 04 diagnostics - power door locks
Power Windows Chapter 04 diagnostics - power windows
Rear Window Defrost System Chapter 04 diagnostics - rear window defrost system
Reverse Radar System Chapter 04 diagnostics - reverse radar system
Wiper And Washer Chapter 04 diagnostics - wiper and washer

INTRODUCTION - HOW TO TROUBLESHOOT 01-21
FOR USING HAND-HELD TESTER

NOTE
• Before using the tester, be sure to read thoroughly the tester operating manual.
01
• Connect the tester to the diagnosis wire harness connector and turn the ignition switch to “ON”
position. If the tester can not communicate with the module, there is a problem on the vehicle 01
side or tester side.
• If the communication is normal when the tester is connected to another vehicle, inspect the 01
diagnosis data link or module power circuit of the vehicle.
• If the communication is still impossible when the tester is connected to another vehicle, the 01
problem is probably in the tester itself, so perform the self test procedures described in the
“Tester Operating Manual”. 01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
HOW TO PROCEED WITH TROUBLESHOOTING

NOTE
• Here, only the basic procedures are shown.
• Carry out troubleshooting in accordance with the procedures on the following pages.
• Details are provided in Chapter 04 diagnostics, showing the most effective methods for each
circuit.
• Confirm the troubleshooting procedures firstly for the relevant circuit before servicing.
1. VEHICLE VISITED TO WORKSHOP
2. CUSTOMER PROBLEM ANALYSIS
(a) Ask the customer about the conditions and environment that the problem occurred.
3. SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK
(a) Check the battery positive voltage.

Voltage: 11 ～ 14 V (Engine stopped)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the operating temperature.
(d) Confirm the problem symptoms and conditions and check for DTCs according to the related chart.
Does the DTC display?
YES > Go to next step.
NO > Go to step 5.
4. DTC CHART
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked with the DTC chart.
Go to step 6 directly.
5. PROBLEM SYMPTOMS TABLE
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system or the part
which should be checked with the problem symptoms table.
6. CIRCUIT INSPECTION OR PARTS INSPECTION
(a) Inspect the circuit or parts according to results obtained in step 4 and 5.
(b) Confirm the circuil or parts which should be repaired.
7. REPAIR
(a) Perform adjustment, repair or replacement according to the results obtained in step 6.
8. CONFIRMATION TEST
(a) After servicing, confirm that the problem has been solved.
(b) If the problem does not recur, perform a confirmation test under the same conditions and enviroment
that vehicle fault occurred at the first time.
9. END
CUSTOMER PROBLEM ANALYSIS

NOTE
• In troubleshooting, the problem symptoms must be confirmed accurately, meaning that all
01
preconceptions must be set aside in order to make an accurate judgement.
• Before comfirmation the problem symptoms, it is very important to ask the the customer about 01
some detail information of problems.
• The following 5 items are important points in the problem analysis. 01
What? Vehicle model, system name
01
When? Date, time, occurrence frequency
01
Where? Road conditions
Under what conditions? Running conditions, driving conditions, weather conditions 01

How did it happen? Problem symptoms
01
• Past problems and the repair history which are thought to be unrelated may be useful in some 01
cases. Therefore, as much information as possible should be gathered and its relationship with
the problem symptoms should be correctly ascertained for use as reference in troubleshooting. 01
01
01
01
01
01
01
01
01
01
01
01
SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

NOTE
The diagnosis system in View has various functions.
• The first function is the Diagnostic Trouble Code (DTC) checking. We could check out stored
fault in the module memory.
• Another function is the Input Signal Check, which checks whether the signals from various
switches are sent to the module correctly.
By using these check functions, it is possible to quickly find potential problem areas and
troubleshooting can be performed effectively.
System System Description DTC Signal Check Data Stream Symptom

Anti-lock Brake System - - ○ ○ ○
Audio System - - - - ○
Combined Display - - ○ - ○
Engine Control System ○ ○ ○ ○ ○
Heater And Air Conditioning - - - - ○
Horn System - - - - ○
Instrument Cluster - - ○ - ○
Lighting System - - - - ○
Outside Mirror - - - - ○
Power Door Locks - - - - ○
Power Windows - - - - ○
Rear Window Defrost System ○ - - - ○
Reverse Radar System ○ - - - ○
Wiper And Washer ○ - - - ○
(a) In the DTC checking, it is very important to determine whether the problem indicated by the DTC is cur-
rent fault or stored fault. In addition, during the problem symptom confirmation, a step must be taken
whether the malfunction indicated by the DTC is directly related to the problem symptom or not. For this
reason, the DTC should be checked before problem confirmation. If missing this step, it may result in 01
unnecessary troubleshooting for systems which are operating normally. It will cause more difficult to
detect the problem area or repair irrelevant areas. Therefore, always follow the procedures in the 01
correct order and perform the DTC check.
(b) A flow chart showing how to proceed with troubleshooting with the DTC checking is shown below. This 01
flow chart shows how to use the DTC checking effectively. Throughout this chart flow, we can know
how to process the DTC troubleshooting and the troubleshooting of problem symptoms table. 01
1. DTC CHECK
01
2. RECORD AND CLEAR THE DTC
01
NOTE 01
If a fault code is displayed in the initial DTC checking, it indicates that a trouble may have occurred in
a wire harness or connectors in the past. Therefore, check the wire harness and connectors. (Refer to 01
“Chapter 01 introduction - how to troubleshoot, electronic circuit inspection procedure”)
3. SYMPTOM CONFIRMATION 01
01
Do the problem symptoms still exist?
YES > Go to next step. 01
NO > Go to step 5.
4. SIMULATION TEST WITH THE METHODS OF SYMPTOM SIMULATION (Refer to “Chapter 01 01
introduction - how to troubleshoot, how to proceed with troubleshooting”)
01
5. DTC CHECK AGAIN
01
Does DTC display? 01

YES > Proceed with DTC chart.
NO > Go to next step. 01
6. SYMPTOM CONFIRMATION 01
Does any symptom exist? 01

NO > The system is normal. 01
7. PROCEED WITH PROBLEM SYMPTOMS TABLE 01
(a) The problem beyond the DTC system ability. The fault code displayed in the DTC is either a past
problem or a secondary problem.
8. END
SYMPTOM SIMULATION
NOTE
• The most difficult case in troubleshooting is when no symptoms occurs. In such cases, be sure
to carry out a thorough customer problem analysis. Then simulate the same or similar
conditions and enviroment in which the customer’s vehicle was and when the problem
occurred. No matter how much experience and skill a technician has. If he troubleshoot the
problem without the direction, he will tend to miss some important things during servicing and
make some mistakes, which will lead to a standstill.
• For example, for a problem which only occurs when the engine is cold, or for a problem which
occurs due to vibration caused by the road during driving, etc., the problem can never be found
out when the engine is hot or when the vehicle is stopped. Since enviroment problem like
vibration, heat or moisture which is difficult to reproduce, the symptom simulation tests
introduced here are effective measures that the external causes are applied to the vehicle in a
stationary condition.
1. IMPORTANT POINTS IN THE SYMPTOM SIMULATION TEST:
(a) In the symptom simulation test, the problem symptoms should be confirmed and the problem area or
parts must also be found. So, before starting simulation test, connect hand-held tester into the vehivle
firstly in order to reduce the range of testing.
(b) After the step aboved, carry out the symptom simulation test, judging whether the circuit being tested is
defective or normal and also confirming the problem symptoms at the same time. Refer to the problem
symptoms table of each system, find out the possible causes of the problem.
2. VIBRATION METHOD: When vibration seems to be

the major cause.
(a) Part and sensor.
• Apply slight vibration with your finger to the part or the
sensor and check whether the malfunction occurs.
CAUTION
Apply strong vibration to relays may result in open.
(b) Connectors.
• Lightly shake the connector vertically and horizontally.
(c) Wire harness.
• Lightly shake the wire harness vertically and horizontally.
The connector joint is the major area that should be checked
thoroughly.
3. HEAT METHOD: If the problem seems to occur when

the temperature is higher.
(a) Heat the component that is possible cause of the malfunction
with a hair dryer or similar object. Check it if the malfunction 01
occurs.
CAUTION 01
• Never heat the components to more than 60 ℃ to
prevent from being damaged.
01
• Never apply heat directly to the module.
01
4. WATER SPRINKLING METHOD: When the malfunction
seems to occur on a rainy day or in high-humidity. 01
(a) Sprinkle water on the vehicle and check whether the
malfunction occurs. 01
CAUTION 01
• Never spray water directly on the engine hood. Spray a
mist of water on the radiator front surface to change the 01
temperature and humidity.
• Never spray water directly on the electronic components. 01
• If a vehicle is subject to water leakage, the leaking water
may damage the module. When testing a vehicle for 01
water leakage problem, this factor must be considered.
01
5. HIGH ELECTRICAL LOAD METHODS: If the malfunction seems to occur when electrical load is
excessive. 01
(a) Turn on all the electrical equipment including the heater blower, headlights, rear windows defrost, etc.
and check whether the malfunction occurs. 01
01
01
01
01
01
01
01
DTC CHART
Take the engine control system as an example, inspection procedures are shown in the illustration below.
The chart indicates the DTCs of the engine control system and lists the corresponding troubleshooting
procedures. It will be more effective and accurate to proceed with troubleshooting in accordance with the
inspection procedures listed in the chart.
PROBLEM SYMPTOMS TABLE

The problem symptoms table indicates the suspect circuits or parts for each problem symptom, as shown in
the illustration below. Using this table to troubleshoot the problem when the problem is occuring but no DTC
displayed. The number in the table indicates the procedures of troubleshooting. 01
NOTE
When the problem is not detected by the diagnostic system even though the problem symptoms is 01
present, it may be that the problem is occuring beyond the detection range of the dignostic system.
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
01
CIRCUIT INSPECTION
How to read and use each page is shown below.
ELECTRONIC CIRCUIT INSPECTION PROCEDURE

1. BASIC INSPECTION.
(a) Resistance measuring condition.
01
• Unless special instruction, all resistance is measured at an ambient temperature of 20 ℃ .
• The resistance may be out of the specifications when measured at high temperature (such as the 01
engine is hot). So measurements should be performed when the engine is cooled down.
(b) Handling of connectors. 01

• When disconnecting the connector, press the connector
01
in the direction of engagement and remove the lock by
lightly pressing the lock claw.
01
• When removing the connector, do not pull the wire har-
ness but pull the connector. 01
• Make sure there is no deformation, damage or missing
terninals before connecting the connector. 01
• The connector with a lock should be inspected until hear-
ing a “click”. 01
• When checking the connector with a mutimeter, be sure
to check it from the backside (wire harness side) of the 01
connector by using a mini test lead.
NOTE 01
• As a water proof connector can not be checked from
01
the backside, check it by a connecting the adapter.
• Do not damage the terminals when moving the inserted 01
tester needle.
01
(c) Connector checking points.
Check when the connector is connected:
01
• Hold the connector and check the inserting condition and
01
locking efficiency (engaged condition).
Check when the connector is disconnected: 01
• Pull the wire harness lightly and check the connector for
missing terminal, terminal crimping condition and core 01
wire break.
• Check visually for any rust, metal chips, water and bent 01
terminals.
01
01
Check the contact pressure of the terminal:

• Prepare a spare male terminal and insert it into a female
terminal. Check the engaged condition and sliding.
CAUTION
Always use a gold-plated male terminal to test a gold-plated
female terminal.
(d) Repair method of connector terminal.

• If there is dirty on the contact point, clean the contact
point by using an air gun or shop rag. However, never
polish the contact point using sand paper as the plating
may come off.
• In case of abnormal contact pressure, replace the female
terminal. However, if a male terminal is gold-plated (gold
colour), use a gold-plated female termina. If it is silver-
plated (silver colour), use a silver-plated female terminal.
(e) Handling of wire harness.

• When removing the wire harness, check the position of
the wire harness and clamps before servicing, reinstall it
correctly.
• Never twist, pull or loosen the wire harness.
• Never allow the wire harness to cross a area of high-tem-
perature, rotating, moving, vibrating or sharp (edge of the
panel, tip of the screw, etc.) part.
• When installing parts, never let the wire harness be inter-
fered.
• Never cut or break the cover of the wire harness. If it is
cut or broken, replace it or repair it with electrical tape.
2. CHECK OPEN CIRCUIT.

(a) For the open circuit shown in the illustration, perform a
resistance check in step (b) or voltage check in step (c)
to comfirm fault.
(b) Check the resistance.

• Disconnect connector A & C and measure the resistance
between them.
Resistance: ＜ 2 Ω 01
NOTE
01
Measure the resistance while lightly shaking the wire har-
ness vertically and horizontally.
01
For this circuit:
The resistance between terminal 1 of connector A and terminal
01
1 of connector C: ≥ 1 MΩ
The resistance between terminal 2 of connecor A and terminal 2 01
of connector B: ＜ 2 Ω
Therefore, the cause is an open circuit between terminal 1 of 01
connector A and terminal 1 of connector C.
01
• Disconnect connector B and measure the resistance
between the connectors.
01
For this circuit:
The resistance between terminal 1 of connector A and terminal
01
1 of connector B1: ＜ 2 Ω
The resistance between terminal 1 of connector B2 and terminal 01
1 of connector C: ≥ 1 MΩ
Therefore, the cause is an open circuit between terminal 1 of 01
connector B2 and terminal 1 of connector C.
01
(c) Check the voltage.
• An open circuit which voltage is applied can be checked by 01
conducting a voltage check.
• For the open circuit which each connector is still connected 01
shown in the illustration, measure the voltage orderly
between ground and terminal 1 of connector A at the ECU 5 01
V output terminal, terminal 1 of connector B and terminal 1 of
connector C. 01
For this circuit:
The voltage between terminal 1 of connector A and ground: 5 V 01
The voltage between terminal 1 of connector B and ground: 5 V
The voltage between terminal 1 of connector C and ground: 0 V 01
Therefore, the cause is an open circuit in the wire harness
between terminal 1 of connector B and terminal 1 of connector 01
C.
01
3. CHECK SHORT CIRCUIT.

(a) For the short circuit shown in the illustration, perform a
resistance check in step (b) to locate the section.
(b) Check the resistance.

• Disconnect connector A & C and measure the resistance
between terminal 1 and 2 of connector A and ground.
Resistance: ≥ 1 MΩ
NOTE
Measure the resistance while lightly shaking the wire
harness vertically and horizontally.
For this circuit:
The resistance between terminal 1 of connector A and ground: ＜ 2
Ω
The resistance between terminal 2 of connector A and ground: ≥ 1
MΩ
Therefore, the cause is an short circuit between terminal 1 of
connector A and terminal 1 of connector C.
• Disconnect connector B and measure the resistance between

terminal 1 of connector A and B2 and ground.
For this circuit:
The resistance between terminal 1 of connector A and ground: ≥ 1 MΩ
The resistance between terminal 1 of connector B2 and ground: ＜ 2 Ω
Therefore, the cause is a short circuit between terminal 1 of
connector B2 and terminal 1 of connector C.
INTRODUCTION - TERMS 01-35
TERMS
ABBREVIATIONS USED IN THIS MANUAL
01
Abbreviations Meaning
A/C Air Conditioning 01
A/F Air-fuel Ratio
01
ABS Anti-lock Brake System
01
ACC Accessory
ASSY Assembly 01
BAT Battery
01
B-joint Ball Joint
01
BTDC Before Top Dead Center
CKP Crankshaft Position 01

CMP Camshaft Position
01
CNG Compressed Natural Gas
01
DLC3 Data Link Connector 3
DTC Diagnostic Trouble Code 01

ECM Engine Control Module
01
ECT Engine Coolant Temperature
01
ECU Engine Control Unit
EFI Engine Fuel Injection 01

EGR Exhaust Gas Recirculation
01
EVAP Evaporative Emission
01
GEN Generator
GND Ground 01
HO2S Heated Oxygen Sensor
01
HVAC Heater And Air Conditioning
01
IAT Intake Air Temperature
ISC Idle Speed Control 01

KS Knock Sensor
LSP Load Sensing Proportioning
MAF Mass Air Flow
MIL Malfunction Indicator Lamp
MWP Max Working Pressure
No. Number
01-36 INTRODUCTION - TERMS
Abbreviations Meaning
O2S Oxygen Sensor
OBD On-Board Diagnostic
PCV Positive Crankcase Ventilation
RCM Restraint Control Module
RPM Revolutions Per Minute
SFI Sequential Multiport Fuel Injection
SRS Supplemental Restraint System
SSM Special Service Materials
SST Special Service Tools
TC Turbocharger
TPS Throttle Position Sensor
U-joint Universal Joint

PREPARATION
02
DIAGNOSTICS ................................................................................... 02-1
PREPARATION ........................................................................... 02-1 02
ENGINE CONTROL SYSTEM............................................................ 02-2
PREPARATION ........................................................................... 02-2
FUEL .................................................................................................. 02-3
PREPARATION ........................................................................... 02-3
EMISSION CONTROL........................................................................ 02-4
PREPARATION ........................................................................... 02-4
INTAKE AIR ....................................................................................... 02-5
PREPARATION ........................................................................... 02-5
ENGINE MECHANICAL ..................................................................... 02-6
PREPARATION ........................................................................... 02-6
EXHAUST........................................................................................... 02-9
PREPARATION ........................................................................... 02-9
COOLING ......................................................................................... 02-10
PREPARATION ......................................................................... 02-10
LUBRICATION ................................................................................. 02-11
PREPARATION ......................................................................... 02-11
STARTING AND CHARGING .......................................................... 02-12
PREPARATION ......................................................................... 02-12
FRONT SUSPENSION ..................................................................... 02-13
PREPARATION ......................................................................... 02-13
REAR SUSPENSION ....................................................................... 02-14
PREPARATION ......................................................................... 02-14
TIRE AND WHEEL ........................................................................... 02-15
PREPARATION ......................................................................... 02-15
AXLE AND PROPELLER SHAFT.................................................... 02-16
PREPARATION ......................................................................... 02-16
BRAKE ............................................................................................. 02-19
PREPARATION ......................................................................... 02-19
PARKING BRAKE............................................................................ 02-20
PREPARATION ......................................................................... 02-20
TRANSMISSION .............................................................................. 02-21
PREPARATION ......................................................................... 02-21
CLUTCH ........................................................................................... 02-23
PREPARATION ......................................................................... 02-23
STEERING COLUMN....................................................................... 02-24
PREPARATION ......................................................................... 02-24
POWER STEERING ......................................................................... 02-25
PREPARATION ......................................................................... 02-25
HEATER AND AIR CONDITIONING................................................ 02-26
PREPARATION ......................................................................... 02-26
SEAT BELT ...................................................................................... 02-28
PREPARATION ......................................................................... 02-28
WIPER AND WASHER .................................................................... 02-29
PREPARATION ......................................................................... 02-29
WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR....... 02-30
PREPARATION ......................................................................... 02-30
INSTRUMENT PANEL/INSTRUMENT............................................. 02-31
PREPARATION ......................................................................... 02-31
SEAT ................................................................................................ 02-32
PREPARATION ......................................................................... 02-32
DOOR LOCKS.................................................................................. 02-33
PREPARATION ......................................................................... 02-33
DOORS............................................................................................. 02-34
PREPARATION ......................................................................... 02-34
VEHICLE CONTROL SYSTEM........................................................ 02-35
PREPARATION ......................................................................... 02-35
PREPARATION - DIAGNOSTICS 02-1
DIAGNOSTICS
PREPARATION
PREPARATION
02
RECOMMENDED TOOLS
02
KT600 Collective Intellegence Scan Tool ENGINE CONTROL SYSTEM
ANTI-LOCK BRAKE SYSTEM

AUDIO SYSTEM
COMBINED DISPLAY
ENGINE CONTROL SYSTEM
HEATER AND AIR
CONDITIONING SYSTEM
HORN SYSTEM
INSTRUMENT CLUSTER
Digital Multimeter
LIGHTING SYSTEM
OUTSIDE MIRROR
POWER DOOR LOCKS
POWER WINDOWS
REAR WINDOW DEFROST
SYSTEM
REVERSE RADAR SYSTEM
WIPER AND WASHER

AUDIO SYSTEM
COMBINED DISPLAY
HEATER AND AIR
CONDITIONING SYSTEM
19A
HORN SYSTEM
INSTRUMENT CLUSTER
Test Lead Set
LIGHTING SYSTEM
OUTSIDE MIRROR
POWER DOOR LOCKS
POWER WINDOWS
REAR WINDOW DEFROST
SYSTEM
WIPER AND WASHER
Torque Wrench -
EQUIPMENT
Oscilloscope -
SSM
Item Capacity Specification
Thread sealant - 3M No.4171 or equivalent
02-2 PREPARATION - ENGINE CONTROL SYSTEM

PREPARATION
RECOMMENDED TOOLS
FUEL INJECTION SYSTEM
IGNITION SYSTEM
KT600 Collective Intellegence Scan Tool SENSOR
ACTUATOR
ECM
SENSOR
Digital Multimeter ACTUATOR
ECM
SENSOR
Test Lead Set ACTUATOR
ECM
Torque Wrench -
EQUIPMENT
Oscilloscope -
SSM
Thread sealant - 3M No.4171 or equivalent
PREPARATION - FUEL 02-3
FUEL
PREPARATION
02
RECOMMENDED TOOLS
02
Needle Nose Plier FUEL PRESSURE REGULATOR
Hydraulic Jack FUEL TANK ASSY
Fuel Filter Wrench FUEL FILTER ASSY
EQUIPMENT
Fuel injector leakage tester -
19A
02-4 PREPARATION - EMISSION CONTROL
EMISSION CONTROL
PREPARATION
RECOMMENDED TOOLS
VAPER CANISTER
CANISTER CONTROL SOLENOID
Air Blow Gun
VALVE
PCV
PREPARATION - INTAKE AIR 02-5
INTAKE AIR
PREPARATION
02
RECOMMENDED TOOLS
02
Torque Wrench -
19A
02-6 PREPARATION - ENGINE MECHANICAL
ENGINE MECHANICAL
PREPARATION
SST
Camshaft Pulley Spanner Wrench CAMSHAFT TIMING PULLEY
Cylinder Cover Bolt Spanner CYLINDER COVER BOLT
Crankshaft Front Oil Seal Guide CRANKSHAFT FRONT OIL SEAL
Crankshaft Front Oil Seal Installer CRANKSHAFT FRONT OIL SEAL
Hydraulic Tappet Adjuster Leakage

HYDRAULIC TAPPET ADJUSTER
Tester
Hydraulic Tappet Adjuster Keeper HYDRAULIC TAPPET ADJUSTER
Hydraulic Tappet Adjuster Wiring HYDRAULIC TAPPET ADJUSTER
Hydraulic Tappet Adjuster Keeper HYDRAULIC TAPPET ADJUSTER
Camshaft Oil Seal Installer CAMSHAFT OIL SEAL
Pin For Belt Gear CAMSHAFT TIMING PULLEY
Oil Pan Remover OIL PAN

PREPARATION - ENGINE MECHANICAL 02-7
VALVE AND INTERRELATED

Valve Spring Compressor
PARTS
02
02
Valve Oil Seal Installer VALVE OIL SEAL
Crankshaft Rear Oil Seal Installer CRANKSHAFT REAR OIL SEAL
Crankshaft Pulley Puller CRANKSHAFT TIMING PULLEY
Piston Disassembling and

PISTON
Assembling Tool
Flywheel Holder FLYWHEEL
RECOMMENDED TOOLS
19A
CRANKSHAFT
Dial Indicator
CAMSHAFT
PISTON RING
Micrometer Calipers CRANKSHAFT
CAMSHAFT
Snap Ring Plier PISTON PIN
Hydraulic Jack ENGINE ASSY
CAMSHAFT
Vernier Caliper
CRANKSHAFT
02-8 PREPARATION - ENGINE MECHANICAL
Feeler Gauge CRANKSHAFT
Needle Nose Plier CLAMP
Torque Wrench -
EQUIPMENT
V-block -
SSM
Sealant - Foton sealant
Coolant 10 L Foton long life coolant
Engine oil gasoline 4.3 L SAE 0W-30

SAE 5W-30
SAE 5W-40
diesel 4.5 ～ 5 L CF-4 or above, 15W-40
CF-4 or above, 10W-30
PREPARATION - EXHAUST 02-9
EXHAUST
PREPARATION
02
RECOMMENDED TOOLS
02
Feeler Gauge EXHAUST MANIFOLD
Torque Wrench -
SSM
Exhaust pipe sealant - Foton sealant
19A
02-10 PREPARATION - COOLING
COOLING
PREPARATION
RECOMMENDED TOOLS
Radiator Cap Tester COOLANT RESERVOIR
Air Blow Gun COOLANT RESERVOIR
Thermometer THERMOSTAT
EQUIPMENT
Steam cleaner -
SSM
Coolant 10 L Foton long life coolant

PREPARATION - LUBRICATION 02-11
LUBRICATION
PREPARATION
SST 02
02
Oil Filter Wrench OIL FILTER
Oil Pan Remover OIL PAN
Engine Oil Pressure Switch

ENGINE OIL PRESSURE SWITCH
Remover
Crankshaft Front Oil Seal Installer CRANKSHAFT FRONT OIL SEAL
RECOMMENDED TOOLS
Rubber Hammer OIL PAN

19A
Torque Wrench -
SSM
Engine oil gasoline 4.3 L SAE 0W-30

SAE 5W-30
SAE 5W-40
diesel 4.5 ～ 5 L CF-4 or above, 15W-40
02-12 PREPARATION - STARTING AND CHARGING
STARTING AND CHARGING

PREPARATION
RECOMMENDED TOOLS
GENERATOR
Digital Multimeter
STARTER
GENERATOR
Dial Indicator
STARTER
Vernier Caliper STARTER
Puller STARTER
Soldering Gun GENERATOR
Snap Ring Plier STARTER
Torque Wrench -
EQUIPMENT
Battery charger -
PREPARATION - FRONT SUSPENSION 02-13
FRONT SUSPENSION
PREPARATION
RECOMMENDED TOOLS 02
02
Torque Wrench -
EQUIPMENT
Wheel alignment instrument -
Tire changer -
Tire dynamic balancer -
SSM
Grease - -
19A
02-14 PREPARATION - REAR SUSPENSION
REAR SUSPENSION
PREPARATION
RECOMMENDED TOOLS
Torque Wrench -
EQUIPMENT
Tire changer -
Tire dynamic balancer -
SSM
Grease - -
PREPARATION - TIRE AND WHEEL 02-15
TIRE AND WHEEL

PREPARATION
02
Tire Pressure Gauge TIRE AND WHEEL
Torque Wrench -
EQUIPMENT
Tire changer -
Tire inflater -
SSM
Balance block - -
19A
02-16 PREPARATION - AXLE AND PROPELLER SHAFT
AXLE AND PROPELLER SHAFT

PREPARATION
RECOMMENDED TOOLS
Tire Pressure Gauge TIRE
PROPELLER SHAFT SPLINE

Feeler Gauge
DRIVE AXLE SIDE GEAR
PROPELLER SHAFT U-JOINT

CENTER SUPPORT BEARING
FRONT AXLE HUB GREASE CAP
Hammer
REAR AXLE HUB BEARING
STEERING KNUCKLE
DIFFERENTIAL PINION SHAFT

FRONT AXLE HUB GREASE CAP
Brass Bar
STEERING KNUCKLE
DIFFERENTIAL PINION SHAFT

Micrometer Calipers
CROSS SPIDER

FRONT AXLE HUB BEARING
DRIVE PINION
Dial Indicator
CROWN GEAR
DRIVE AXLE SIDE GEAR
DIFFERENTIAL PINION
PINION FLANGE

Snap Ring Plier REAR AXLE HUB BEARING
OUTPUT FLANGE
PROPELLER SHAFT END YOKE

Puller AXLE SHAFT BEARING
DRIVING GEAR BEARING
FRONT AXLE HUB BEARING

Grease Gun REAR AXLE HUB BEARING
STEERING KNUCKLE
PREPARATION - AXLE AND PROPELLER SHAFT 02-17
FRONT AXLE HUB STARTING

TORQUE
Spring Scale
REAR AXLE HUB STARTING
TORQUE 02
COTTER PIN
CENTER SUPPORT BEARING OIL 02
Needle Nose Plier SEAL
OUTPUT FLANGE OIL SEAL
DRIVE PINON OIL SEAL
Tapeline REAR AXLE BACK LASH
Allen Wrenchs (Key) -
Hydraulic Jack FINAL DRIVE ASSY
DRIVE AXLE SIDE GEAR THRUST

WASHER
Vernier Caliper DIFFERENTIAL PINION THRUST
WASHER
DRIVE PINION ADJUSTING SHIM
DRIVE PINION STARTING 19A

Torque Wrench
TORQUE
EQUIPMENT
V-block -
Propeller dynamic balancer -
Vice -
Press machine -
02-18 PREPARATION - AXLE AND PROPELLER SHAFT
SSM
Balance block - -
Red lead - -
Grease propeller shaft U-joint - Lithium base grease No.2

center support bearing Lithium base grease No.2
U-joint -
front axle hub -
-
front axle hub -
axle shaft -
output flange oil seal -
drive pinion oil seal -
Final drive oil ≤ 18 ℃ API GL-5 SAE 90W

1.6 L
＞ 18 ℃ API GL-5 SAE 80W
Sealant ouput flange LOCTITE 204

crown gear - LOCTITE 204
differential bearing LOCTITE 204
PREPARATION - BRAKE 02-19
BRAKE
PREPARATION
02
Micrometer Calipers FRONT BRAKE DISK
Dial Indicator FRONT BRAKE DISK
REAR BRAKE DRUM

Vernier Caliper
REAR BRAKE SHOE
REAR BRAKE SHOE

Nipper Plier
WHEEL BRAKE CYLINDER
Tapeline BRAKE PAD
Snap Ring Plier BRAKE MASTER CYLINDER 19A
FRONT AXLE HUB

Grease Gun
REAR AXLE HUB
FRONT AXLE HUB

REAR AXLE HUB
Puller FRONT AXLE HUB OIL SEAL
REAR AXLE HUB OIL SEAL
AXLE SHAFT
Torque Wrench -
SSM
Brake fluid - V3
02-20 PREPARATION - PARKING BRAKE
PARKING BRAKE
PREPARATION
RECOMMENDED TOOLS
REAR BRAKE DRUM

Vernier Caliper
REAR BRAKE SHOE
FRONT PARKING BRAKE PULL

CABLE ASSY
REAR PARKING BRAKE PULL
Needle Nose Plier
CABLE ASSY LH
REAR PARKING BRAKE PULL
CABLE ASSY RH
EQUIPMENT
Vice -
SSM
Brake fluid - V3
PREPARATION - TRANSMISSION 02-21
TRANSMISSION
PREPARATION
02
SYNCHRONIZER ASSY
Feeler Gauge
COUNTER SHAFT WASHER
Needle Nose Plier RETURN SPRING
Brass Bar REVERSE IDLER GEAR SHAFT
Hammer REVERSE IDLER GEAR SHAFT
Dial Indicator OUTPUT SHAFT
INPUT SHAFT WASHER 19A

Micrometer Calipers
OUTPUT SHAFT
INPUT SHAFT ASSY

Snap Ring Plier OUTPUT SHAFT ASSY
SHIFT MECHANISM
GEARSHIFT FORK
Vernier Caliper
SYNCHRONIZER ASSY
OUTPUT FRONT BEARING

Puller OUTPUT MIDDLE BEARING
OUTPUT REAR BEARING
Torque Wrench -
02-22 PREPARATION - TRANSMISSION
EQUIPMENT
V-block -
Vice -
SSM
Transmission fluid GL-5 75W/90
2L GL-5 80W/90
GL-5 85W/90
Grease - Mitsubishi No.0101011
Mitsubishi No.997740
Sealant -
3M No.4170
PREPARATION - CLUTCH 02-23
CLUTCH
PREPARATION
02
FLYWHEEL
Dial Indicator
CLUTCH DISK
CLUTCH DISK
Vernier Caliper
CLUTCH COVER
Snap Ring Plier CLUTCH MASTER CYLINER ASSY
Torque Wrench -
EQUIPMENT
Vice -
SSM 19A
Brake fluid - V3
Grease - Mitsubishi No.0101011

02-24 PREPARATION - STEERING COLUMN
STEERING COLUMN
PREPARATION
RECOMMENDED TOOLS
Tapeline OFF TRACK
Allen Wrenchs (Key) HORN SWITCH ASSY
STEERING WHEEL TURNING

Spring Scale
FORCE
STEERING PROPELLER SHAFT

Dial Indicator
U-JOINT
Torque Wrench -
EQUIPMENT
V-block -
PREPARATION - POWER STEERING 02-25
POWER STEERING
PREPARATION
02
RECOMMENDED TOOLS
02
Tapeline OFF TRACK
Torque Wrench -
SSM
Steering fluid 0.4 L ATF- Ⅱ / Ⅲ
Grease power steering box - QL-5 80W/90
Sealant low-pressure hose - -
19A
02-26 PREPARATION - HEATER AND AIR CONDITIONING
HEATER AND AIR CONDITIONING

PREPARATION
RECOMMENDED TOOLS
REFRIGERANT
Manifold Gauge
COMPRESSOR
REFRIGERANT
Service Hoses
COMPRESSOR
REFRIGERANT
Service Coupler
COMPRESSOR
REFRIGERANT
3-way Joint
COMPRESSOR
REFRIGERANT
Service Tank
COMPRESSOR
REFRIGERANT
Vacuum Pump Connector
COMPRESSOR
Refrigerant Leakage Tester REFRIGERANT
Digital Multimeter A/C PIPE
Thermometer ENVIRONMENT TEMPERATURE
Thermistance Type Thermometer OUTLET TEMPERATURE
Belt Tension Gauge PULLEY

PREPARATION - HEATER AND AIR CONDITIONING 02-27
Refrigerant Recovery / Recycling

Station REFRIGERANT
(With this device, vacuum pump is COMPRESSOR
not required.) 02
REFRIGERANT 02
Vacuum Pump
COMPRESSOR
SSM
Refrigerant front and rear A/C 1250 +0 / -20 g R-134a
only front A/C 850 ± 25 g R-134a
Compressor oil 180 ml -
19A
02-28 PREPARATION - SEAT BELT
SEAT BELT
PREPARATION
RECOMMENDED TOOLS
Torque Wrench -
PREPARATION - WIPER AND WASHER 02-29
WIPER AND WASHER

PREPARATION
02
RECOMMENDED TOOLS
02
Torque Wrench -
19A
02-30 PREPARATION - WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR
WINDSHIELD/SIDE WINDOW GLASS/REAR VIEW MIRROR

PREPARATION
RECOMMENDED TOOLS
WINDSHIELD
Scraper SIDE WINDOW
REAR WINDOW
WINDSHIELD
Suction Cup SIDE WINDOW
REAR WINDOW
WINDSHIELD
Knife SIDE WINDOW
REAR WINDOW
WINDSHIELD
Sealer Gun SIDE WINDOW
REAR WINDOW
WINDSHIELD
Rubber Hammer SIDE WINDOW
REAR WINDOW
SSM
Protective Tape - -
Block - -
Plastic Paper - -
Steel Wire - -
Nylon Cord - -
Adhesive Tape - -
Primer - Reactive polyester primer, black
Sealant - Polyurethane sealant, black

PREPARATION - INSTRUMENT PANEL/INSTRUMENT 02-31
INSTRUMENT PANEL/INSTRUMENT
PREPARATION
02
RECOMMENDED TOOLS
02
Torque Wrench -
Allen Wrenchs (key) -
19A
02-32 PREPARATION - SEAT
SEAT
PREPARATION
RECOMMENDED TOOLS
Allen Wrenchs (Key) -
Needle Nose Plier -
Torque Wrench -
PREPARATION - DOOR LOCKS 02-33
DOOR LOCKS
PREPARATION
02
RECOMMENDED TOOLS
02
Snap Ring Plier DOOR LOCK CORE
SSM
Grease - Lithium base grease No.2
19A
02-34 PREPARATION - DOORS
DOORS
PREPARATION
RECOMMENDED TOOLS
Grease Gun DOOR
Torque Wrench -
SSM
Grease - Lithium base grease No.2
PREPARATION - VEHICLE CONTROL SYSTEM 02-35
VEHICLE CONTROL SYSTEM

PREPARATION
02
RECOMMENDED TOOLS
02
Digital Multimeter IGNITION SWITCH ASSY
Torque Wrench -
19A
MEMO
SERVICE SPECIFICATION
03
SPECIFIED TORQUE FOR SPECIFICATION BOLTS ...................... 03-1
ENGINE CONTROL SYSTEM............................................................ 03-2
SERVICE DATA........................................................................... 03-2
TORQUE SPECIFICATION ......................................................... 03-3 03
FUEL .................................................................................................. 03-5
SERVICE DATA........................................................................... 03-5
TORQUE SPECIFICATION ......................................................... 03-6
EMISSION CONTROL........................................................................ 03-7
TORQUE SPECIFICATION ......................................................... 03-7
ENGINE MECHANICAL ..................................................................... 03-8
SERVICE DATA........................................................................... 03-8
TORQUE SPECIFICATION ....................................................... 03-15
INTAKE AIR ..................................................................................... 03-17
SERVICE DATA......................................................................... 03-17
EXHAUST......................................................................................... 03-18
SERVICE DATA......................................................................... 03-18
COOLING ......................................................................................... 03-19
SERVICE DATA......................................................................... 03-19
LUBRICATION ................................................................................. 03-20
IGNITION .......................................................................................... 03-21
SERVICE DATA......................................................................... 03-21
STARTING AND CHARGING .......................................................... 03-22
SERVICE DATA......................................................................... 03-22
FRONT SUSPENSION ..................................................................... 03-24
SERVICE DATA......................................................................... 03-24
REAR SUSPENSION ....................................................................... 03-25
TIRE AND WHEEL ........................................................................... 03-26
SERVICE DATA......................................................................... 03-26
AXLE AND PROPELLER SHAFT.................................................... 03-27
SERVICE DATA......................................................................... 03-27
BRAKE ............................................................................................. 03-30
SERVICE DATA......................................................................... 03-30
PARKING BRAKE............................................................................ 03-31
TRANSMISSION .............................................................................. 03-32
SERVICE DATA......................................................................... 03-32
CLUTCH ........................................................................................... 03-35
SERVICE DATA......................................................................... 03-35
STEERING COLUMN....................................................................... 03-36
SERVICE DATA......................................................................... 03-36
POWER STEERING ......................................................................... 03-37
SERVICE DATA......................................................................... 03-37
HEATER AND AIR CONDITIONING................................................ 03-39
SERVICE DATA......................................................................... 03-39
SEAT BELT ...................................................................................... 03-40
LIGHTING......................................................................................... 03-41
WIPER AND WASHER .................................................................... 03-42
SEAT ................................................................................................ 03-43
DOORS............................................................................................. 03-44
SERVICE DATA......................................................................... 03-44
EXTERIOR AND INTERIOR TRIM ................................................... 03-45
VEHICLE CONTROL SYSTEM........................................................ 03-46
SERVICE SPECIFICATIONS - SPECIFIED TORQUE FOR SPECIFICATION BOLTS 03-1
SPECIFIED TORQUE FOR SPECIFICATION BOLTS

SERVICE SPECIFICATIONS
NOTE
The range of the tightening torques listed in the following table have already contained the error of the
used tools. 03
Torque （N·m）
Thread Standard
Grade 8.8 Grade 10.9 03
M5 9 ～ 11 12 ～ 14
M8 21 ～ 25 29 ～ 35
M8 × 1 22 ～ 27 32 ～ 39
M10 41 ～ 51 58 ～ 71
M10 × 1.25 45 ～ 55 63 ～ 77
M10 × 1 46 ～ 56 65 ～ 79
M12 73 ～ 89 105 ～ 128

M12 × 1.5 75 ～ 92 106 ～ 130
M12 × 1.25 78 ～ 96 113 ～ 138
M14 122 ～ 149 160 ～ 195

M14 × 1.5 126 ～ 154 178 ～ 218
M16 182 ～ 222 247 ～ 290

M16 × 1.5 199 ～ 243 265 ～ 311
M18 243 ～ 285 380 ～ 437

M18 × 1.5 287 ～ 336 397 ～ 457
M20 389 ～ 456 486 ～ 548

M20 × 1.5 396 ～ 465 540 ～ 596
03-2 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM

SERVICE DATA
GASOLINE ENGINE (BJ491EQ) AND CNG ENGINE (4GC1)
ECT sensor resistance 0℃ 9098 ～ 9700 Ω
20 ℃ 5494 ～ 5822 Ω
40 ℃ 3420 ～ 3602 Ω
80 ℃ 2184 ～ 2296 Ω
Engine idle speed Standard 800 ± 50 RPM
Idle air control motor coil resis-

tance Standard 28 ～ 33 Ω （ 20 ℃）
TPS resistance Standard 3.5 ～ 6.5 Ω （ 20 ℃）
IAT resistance 0℃ 5.3 ～ 6.7 KΩ

20 ℃ 2.3 ～ 3.0 KΩ
40 ℃ 1.0 ～ 1.5 KΩ
80 ℃ 0.30 ～ 0.42 KΩ
CKP resistance Standard 560 Ω ± 10% （ 20 ℃）
Upstream HO2S resistance

Terminal 3 and 4 9.6 ～ 1.5 Ω （ 20 ℃）
Downstream HO2S resistance

Terminal 3 and 4 9.6 ～ 1.5 Ω （ 20 ℃）
Canister solenoid valve Standard 19 ～ 22 Ω （ 20 ℃）
DIESEL ENGINE (BJ493ZQ)

EGR temperature sensor resistance - 20 ℃ 20.2 ± 1.95 Ω
20 ℃ 3.27 ± 0.16 Ω
40 ℃ 1.55 ± 0.09 Ω
60 ℃ 0.78 ± 0.045 Ω
80 ℃ 0.42 ± 0.02 Ω
100 ℃ 0.244 ± 0.01 Ω
Electronic fan temperature sensor resis-

tance - 20 ℃ 15.462 Ω
0℃ 5.986 Ω
20 ℃ 2.500 Ω
80 ℃ 0.323 Ω
Preheat temperature sensor resistance - 40 ℃ 10 ± 1 KΩ
EGR valve lift sensor resistance Standard -
EGR vacuum regulator resistance Standard 14 ± 10% （ 20 ℃）
TPS resistance Standard -

SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM 03-3
DIESEL ENGINE (4D20)

EGR temperature sensor resistance 20 ℃ 3.288 KΩ
40 ℃ 1.586 KΩ 03
60 ℃ 0.8 KΩ
80 ℃ 0.426 KΩ
100 ℃ 0.24 KΩ
TPS Fully opened 4.3 ± 0.1 V 03

Fully closed 1.0 ± 0.5 V
EGR valve lift sensor resistance Standard -
Inlet solenoid valve resistance Standard -
Preheat plug resistance Standard -
EGR vacuum regulator resistance Standard -
TORQUE SPECIFICATION
GASOLINE ENGINE (BJ491EQ) AND CNG ENGINE (4GC1)
Part Tightened N•m
ECM × Body 5
ECT sensor × Engine cylinder block 29.4
Idle air control motor × Throttle body 3.4
TPS × Throttle body 3.4
MAP sensor / IAT sensor × Intake manifold -
CKP sensor × flying wheel housing 7.5 ± 10%
Upstream HO2S × Exhaust pipe 40 ～ 60
Downstream HO2S × Exhaust pipe 40 ～ 60
Ignition control module 5～8
Canister solenoid valve x engine bracket -
Odometer sensor × Transmission 7.5

EGR valve control unit × Body -
Electronic fan temperature sensor 25
Preheat temperature sensor -
EGR cooling tube 15 ～ 18

03-4 SERVICE SPECIFICATIONS - ENGINE CONTROL SYSTEM

EGR valve control unit × Body 45 ～ 55
EGR temperature sensor × Engine cylinder block -
Preheat plug -
EGR vacuum regulator 8 ～ 10
EGR cooling tube 15 ～ 18
Inlet solenoid valve -

SERVICE SPECIFICATIONS - FUEL 03-5
FUEL
SERVICE DATA
03
FUEL
Gasoline engine fuel pressure

-
Ignition switch ON
-
Engine idling 03
-
Ignition switch OFF
Diesel engine fuel pressure 24 ～ 26 MPa
Injector electric power parameter

Peak current -
Holding current -
resistance 1.5 ～ 12±0.6 Ω
Fuel pump filling quantity Standard -
CNG
Gas cylinder valve Working pressure 200 bar （15 ℃）

MWP 260 bar （85 ℃）
Working temperature -40 ℃ ～ 70 ℃
Pressure rupture disk 300 bar
CNG filling valve Working pressure 200 bar

High-pressure pipeline pressure gas

Working pressure 0 ～ 20 MPa
High-pressure pipeline and connector

Working pressure 0 ～ 20 MPa
Pressure reducer Input pressure 1MPa ～ 25 MPa

Output pressure 230±5 kPa
Low-pressure pipeline filter Working pressure ＜ 4bar

CNG injector Medium pressure differential Max 392 kPa

03-6 SERVICE SPECIFICATIONS - FUEL
Fuel tank × Body 21 ～ 25
Fuel hose board retaining bolt × Body 21 ～ 25
Gasoline engine fuel filter belt bolt 21 ～ 25
Fuel level sensor sealing cover 6～8
Fuel pump sealing cover 6～8
Gasoline fuel fliter 21 ～ 25
Diesel filter hand pump bolt 15 ～ 18
VE pump timing pulley bolt 65 ～ 75
Electronic control VE pump × Flange 25 ～ 35
High-pressure tube 18 ～ 22
High-pressure tube × Injector 25 ～ 29
Injector plate retaining bolt 1st step 7.5 ～ 9

2nd step Rotation 40° ～ 45°
CNG injector bracket bolt -
Lower-pressure filter bracket bolt -
GAS cylinder retaining bolt -

SERVICE SPECIFICATIONS - EMISSION CONTROL 03-7
EMISSION CONTROL
03
Diesel engine EGR valve × EGR cooling pipe 15 ～ 18
Diesel engine EGR valve × Exhaust pipe 15 ～ 18 03
Vacuum regulator bolt 8 ～ 10

03-8 SERVICE SPECIFICATIONS - ENGINE MECHANICAL
ENGINE MECHANICAL
SERVICE DATA
GASOLINE ENGINE
ENGINE ASSY BJ491EQ
Type Four cylinder in-line, water cooling, four stroke, EFI
Cylinder 4
Combustion chamber Deed type chamber
Displacement 2.237L
Bore 91.0mm
Stroking 86.0 mm
Maximum torque 193 N·m
Rated power 76 KW （4600 r / min）
Compression ratio 8.8:1
Lubrication system Pressure, splash compound
Fuel pump type Gear type
Water pump type Centrifugal vane wheel type
TIMING BELT
Clearance between chain tensioner plug and support (

force 98N with spring scales)
Standard ≤ 13.5 mm
Thickness of rubber damper on the head of chain ten-

sioner plug
Standard 15.0 mm
Limit 12.5 mm
Thickness of rubber damper Standard 6.6 mm

Limit 5.0 mm
Length of timing belt ( force 98N with spring scales)

Limit 291.4 mm
Crankshaft timing sprocket Limit 59.0 mm
Camshaft timing sprocket Limit 114.0 mm
ROCKER ARM/ROCKER SHAFT
Rocker arm inner diameter 18.50 ～ 18.515 mm
Rocker shaft diameter 18.474 ～ 18.487 mm
Clearance Standard 0.02 ～ 0.051 mm

Limit 0.08 mm
HYDRAULIC ADJUSTER/VALVE PUSH ROD
Run-out of push rod Limit 0.30 mm

SERVICE SPECIFICATIONS - ENGINE MECHANICAL 03-9
Hydraulic adjuster external diameter Standard 21.387 ～ 21.404 mm
Hydraulic adjuster hole diameter Standard 21.417 ～ 21.443 mm
Fit clearance Standard 03

0.017 ～ 0.056 mm
Limit 0.10 mm
CAMSHAFT
Cam height Intake Standard 38.620 ～ 38.720 mm 03

Limit 38.26 mm
Exhaust Standard 38.629 ～ 38.729 mm
Limit 38.27 mm
1st camshaft journal Standard 46.459 ～ 46.475 mm
2nd camshaft journal Standard 46.209 ～ 46.225 mm
3rd camshaft journal Standard 45.959 ～ 45.975 mm
4th canshaft journa Standard 45.709 ～ 45.725 mm
5th camshaft journal Standard 45.459 ～ 45.475 mm
1st canshaft bearing bore Standard 46.500 ～ 46.570 mm
2nd canshaft bearing bore Standard 46.250 ～ 46.320 mm
3rd canshaft bearing bore Standard 46.000 ～ 46.070 mm
4th canshaft bearing bore Standard 45.750 ～ 45.820 mm
5th canshaft bearing bore Standard 45.500 ～ 45.570 mm
axial clearance between thrust plate and 1st camshaft

journal thrust surface
Standard 0.07 ～ 0.22 mm
Limit 0.30 mm
Camshaft run-out Limit 0.06 mm
CYLINDER HEAD
Cylinder head gasket surface flatness Limit 0.15 mm
VALVE
Edge thickness Intake Standard 1.0 ～ 1.4 mm

Limit 0.5 mm
Limit 0.8 mm
Valve rod diameter Standard 6.0 mm

Limit -
Crest clearance between valve rod and guide

Intake Standard 0.025 mm ～ 0.060 mm
Limit 0.10 mm
Exhaust Standard 0.030 mm ～ 0.065 mm
Limit 0.12 mm
Inclination valve Standard 44.5°
Valve rod length Intake Standard 7.970 ～ 7.985 mm

Valve height Intake Standard 108.2 mm

Limit 107.7 mm
Exhaust Standard 108.5 mm
Limit 108.0 mm
VALVE SPRING
Free height Standard 46.5 ～ 47.5 mm
Pre-loading force/operation height km/mm

Standard 27.2 kg / 44.2 mm
Limit -
Center line Standard ≤ 2°
Valve spring elastic Standard 292 ～ 336 N
PISTON
Clearance between piston ring and groove side

Limit 0.1 mm
Clearance No.1 ring Standard 0.27 ～ 0.39mm

Limit 1.11 mm
No.2 ring Standard 0.40 ～ 0.55 mm
Limit 1.07 mm
Oil ring Standard 0.20 ～ 0.70 mm
Limit 1.10 mm
Piston pin bore diameter Standard 22.003 ～ 22.006 mm
Piston pin outer diameter Standard 22.013 ～ 22.018 mm
Piston pin bore and piston pin clearance Standard 0.007 ～ 0.015 mm
piston pin wear limit 0.03 mm
Connecting rod and piston pin clearance Standard 0.021 ～ 0.037 mm
Depressing force 735 ～ 1720 N
Depressing temperature Room temperature
Axial clearance of connecting rods Standard 0.160 ～ 0.312 mm

Limit 0.35mm
CRANKSHAFT
Axial clearance of crankshaft Standard 0.02 ～ 0.22 mm

Limit 0.35mm
Clearacne between main journal and main bearing

Limit 0.1 mm
Main journal diameter Standard 57.985 ～ 58.0 mm

CYLINDER BLOCK
Upper surface flatness Standard 0.020 ～ 0.051 mm

Limit 0.1 mm
03
Upper surface grinding limit Standard 0.5 mm
Limit 0.1 mm
Cylinder hole diameter Standard 91.00 mm ～ 92.03 mm

Limit 03
91.23 mm
Clearance between piston and cylinder Standard 0.020 ～ 0.04 mm

ENGINE ASSY BJ493ZQ
Engine type Four cylinder in-line, water cooling, four stroke,

turbocharging, electronic control EGR
Cylinder 4
Chamber type Direct injection ω type
Displacement 2.771 L
Cylinder bore 93 mm
Stroke 102 mm
Maximum torque 225 N•m ≤ 2300 r/min
Rated power 70KW (3600 r/min)
Compression ratio 17.4:1
Idle speed 800 ± 20 r/min
Minimum fuel consumption 222 g/kW•h
Crankshaft direction of rotation anticlockwise
Lubrication Pressure, splash compound
CYLINDER HEAD
Cylinder head gasket surface flatness Standard 0.05 mm

Limit 0.2 mm
Cylinder head surface grind limit 0.2 mm
Cylinder head height 91.95 ～ 92.05mm
Piston protruding length 0.700 ～ 1.00 mm
VALVE
Valve rod length Intake 7.946 ～ 7.961 mm

Exhaust 7.921 ～ 7.936 mm

Limit 0.20 mm
Limit 0.25 mm
Valve clearance (engine cool) Standard 0.35 ～ 0.45 mm
Valve seat inner diameter Standard 8.000 ～ 8.017 mm
VALVE SPRING
VALVE GUIDE
Valve guide hole rebore 0.05 oversize 11.05 ～ 11.068 mm

0.25 oversize 11025 ～ 11.268 mm
0.50 oversize 11.50 ～ 11.518 mm
CAMSHAFT
Camshaft base diameter 35.5 mm
Camshaft cam height 6.511 mm
Clearance between camshaft journal and bush

Limit 0.12 mm
PISTON

No.1 ring Standard 0.078 ～ 0.137mm
Limit 0.2 mm
Limit 0.15 mm
Limit 0.15 mm

Limit 0.8 mm
Limit 1.5 mm
Limit 1.2mm

piston pin wear limit 0.03 mm

CONNECTING ROD
Axial clearance of connecting rods Standard 0.10 ～ 0.25 mm 03

Limit 0.40mm
Crankshaft connecting rod journal Standard 52.015 ～ 52.030 mm
Radial chance between connecting rod bearing and 03

journal
Limit 0.10 mm
Clearance between connecting rod and crankshaft

journal
Limit 0.35 mm
CRANKSHAFT
Crankshaft main journals 69.932 ～ 69.917 mm
CYLINDER BLOCK
Cylinder size 95.001 ～ 95.030 mm( Cylinder cylindrically: ≤ 0.01

mm)
Block top surface Warpage ≤ 0.06 mm

Grinding limit 0.2 mm
DIESEL ENGINE(4D20)
ENGINE ASSY 4D20
Engine type Four cylinder in-line, water cooling, four stroke,

turbocharging, electronic control EGR
Cylinder 4
Chamber type Direct injection ω type
Cylinder bore 86 mm
Stroke 86 mm
Maximum torque 175 N•m ≤ 2300 r/min
Rated power 52 Kw (3300 r/min)
Compression ratio 18:1
Idle speed 780 ± 20 r/min
Minimum fuel consumption 230 g/kW•h
Crankshaft direction of rotation anticlockwise
CYLINDER HEAD
Cylinder head gasket surface flatness Standard 0.05 mm

Limit 0.2 mm
Cylinder head surface grind limit 0.2 mm
Cylinder head height 91.95 ～ 92.05mm
Piston protruding length 0.36 ～ 0.57 mm
VALVE
Valve rod length Intake 7.946 ～ 7.961 mm

Exhaust 7.921 ～ 7.936 mm

Limit 0.20 mm
Limit 0.25 mm
Valve clearance (engine cool) Standard 0.35 ～ 0.45 mm
VALVE SPRING
CAMSHAFT
Camshaft base diameter 31.0 mm
Camshaft cam height 6.30 mm
Clearance between camshaft journal and bush

1 0.06 ～ 0.13 mm
2 0.07 ～ 0.13 mm
3 0.07 ～ 0.14 mm
PISTON

No.1 ring Standard 0.078 ～ 0.137mm
Limit 0.2 mm
Limit 0.18 mm
Limit 0.16 mm

Limit 0.8 mm
Limit 1.5 mm
Limit 1.20 mm
Piston pin wear limit 0.03 mm
CONNECTING ROD 03
Radial clearance between connecting rod bearing and

journal
Limit 0.20 mm 03
Axial clearance between connecting rod and

crankshaft journal
Limit 0.25 mm
CRANKSHAFT
Crankshaft main journals 69.904 ～ 69.920 mm
CYLINDER BLOCK
Cylinder size 89.00 ～ 89.02 mm (cylinder cylindrically: ≤ 0.01 mm)
Block top surface Warpage ≤ 0.06 mm

Grinding limit 0.2 mm
GASOLINE ENGINE (BJ491EQ)
Belt pulley 20 ～ 24
Timing belt cover 10
Crankshaft pulley 155 ～ 165
Rocker shaft assy 24
Rocker arm cover 5
Camshaft thrust plate retaining bolt 24
Oil pump driving shaft 24
Camshaft sprocket retaining bolt 90 ～ 100
Cylinder head bolts M12 93 ～ 105

M8 20 ～ 25
Oil dipstick bolt 10
Connecting rod cap 49 ～ 55
Rear crankshaft oil seal seat 10
Rear engine block cover 75 ～ 90
Flywheel bolts 113 ～ 133
Main bearing cap 49 ～ 55


Timing gear cover 20 ～ 25
Timing gear outside cover 15 ～ 23
Water pump pulley 21 ～ 25
Water pump belt pulley bolt 21 ～ 25
Cylinder head assy Step 1 35

Step 2 Completely loosen
Step 3 30 ～ 35
Step 4 Rotation 160° ～ 180°
Flywheel bolt 113 ～ 133
Rocker arm and rocker shaft assy bolt 46 ～ 63
Rocker arm cover 26 ～ 30
Camshaft thrust plate 26 ～ 30
Camshaft timing gear 80 ～ 90
Crankshaft bearing cap Step 1 45 ～ 50

Step 2 90 ～ 100
Step 3 168 ～ 180
Connecting rod cap Step 1 45 ～ 50

Step 2 80 ～ 90

Timing gear cover 20 ～ 25 03
Cylinder head assy main bolt 170 ～ 190

assistant bolt
03
55 ～ 65
Flywheel bolt 113 ～ 133
Rocker arm and rocker shaft assy bolt 46 ～ 63
Rocker arm cover 13
Camshaft thrust plate 21 ～ 25
Camshaft timing gear 80 ～ 90
Crankshaft bearing cap Step 1 45 ～ 50

Step 2 90 ～ 100
Step 3 168 ～ 180
Connecting rod cap 55 ～ 65

03-18 SERVICE SPECIFICATIONS - INTAKE AIR
INTAKE AIR
SERVICE DATA
Compressor blade and compressor case clearance
Minimum ≥ 0.10 mm
Turbocharger rotor axial clearance

Standard ≤ 0.1 mm
Limit ≤ 0.25 mm
GASOLINE ENGINE
Engine cover 21 ～ 25
Intake air pipe retaining bolt 21 ～ 25
Intake air filter cover bolt 9 ～ 11
Intake air filter assy 21 ～ 25
Air straining box bolt 21 ～ 25
Air grille bolt -
Intake air manifold bolt 21 ～ 25
Throttle body bolt 10

SERVICE SPECIFICATIONS - INTAKE AIR 03-19
DIESEL ENGINE
Engine cover 21 ～ 25 03
Intake air filter cover bolt 9 ～ 11
Intake air filter assy 21 ～ 25

03
Air straining box bolt 21 ～ 25
Air grille bolt -
Intake air manifold bolt 23 ～ 27
Exhaust manifold × Turbocharge 18 ～ 22
Exhaust pipe × Turbocharge 22 ～ 26
Turbocharge oil outlet pipe 7.5 ～ 8.5
Turbocharge oil inlet pipe 8 ～ 10
Intake air connect pipe × Intake manifold 23 ～ 27
Intake pipe × EGR 15 ～ 18
VE pump vacuum pipe bolt 9 ～ 11

03-20 SERVICE SPECIFICATIONS - EXHAUST
EXHAUST
SERVICE DATA
Exhaust manifold and cylinder block cover flatnes
Standard ≤ 0.15 mm
Limit 0.20 mm
GASOLINE ENGINE
Front exhaust pipe × Exhaust manifold 41 ～ 51
Front exhaust pipe × Catalytic converter 22 ～ 25
Middle exhaust pipe bolt 41 ～ 51
Muffer × Rear exhaust pipe 41 ～ 51
Exhaust manifold bolt 41 ～ 51
Heat shield 22 ～ 25
DIESEL ENGINE
Exhaust pipe retaining belt bolt 22 ～ 25
Catalytic converter × Exhaust manifold 41 ～ 51
Front exhaust pipe × Exhaust manifold 41 ～ 51
Middle exhaust pipe bolt 73 ～ 89
Muffer × Rear exhaust pipe 73 ～ 89
Exhaust manifold bolt 22 ～ 25
Exhaust pipe × EGR 22 ～ 25
Heat shield 22 ～ 25
SERVICE SPECIFICATIONS - COOLING 03-21
COOLING
SERVICE DATA
03
Cooling system outlet temperature 75 ～ 85 ℃
Thermostat valve opening temperature 80 ～ 84 ℃
Thermostat valve lift 8 mm ( At 95 ℃ ) 03
Coolant drain plug 8 ～ 10
Coolant reservior bolt 9 ～ 11
Coolant filling pipe bolt 21 ～ 25
Radiator upper support bolt 21 ～ 25
Radiator lower support bolt 21 ～ 25
Thermostat housing bolt 21 ～ 25
Silicone oil fan bolt 10
Cooling fan(electrical) bolt 9 ～ 11
Water pump pulley bolt Gasoline 25

Diesel 19 ～ 21
Water pump bolt 21 ～ 25

03-22 SERVICE SPECIFICATIONS - LUBRICATION
LUBRICATION
GASOLINE ENGINE
Drain plug 34 ～ 45
Oil pan 6～7
Oil strainer bolt 10 ～ 15
Oil filter 13 ～ 15
Oil pump driving shaft -
DIESEL ENGINE
Oil pan 25 ～ 29
Oil filter bracket bolt 20 ～ 25
Oil pump 20 ～ 25
Oil filter 25 ～ 30
Cooler pipe x Oil filter bracket 25 ～ 30

SERVICE SPECIFICATIONS - IGNITION 03-23
IGNITION
SERVICE DATA
03
Spark plug gap 1.0 ～ 1.2mm
TORQUE SPECIFICATION 03

Spark plug -
Ignition coil 5～8

03-24 SERVICE SPECIFICATIONS - STARTING AND CHARGING

SERVICE DATA
GENERATOR
Nominal voltage 12 V
Rated current -
Rotation revolution -
Power -
Rotation mode clockwise
Polarity Negative ground
Work mode continuous rated type
Generator rotor coil resistance 3～5Ω
Generator rotor diameter Standard 14.2 mm ～ 14.4 mm

Limit 12.8 mm
Pinion-to-stopper clearance Standard 0.5 mm ～ 2.0 mm
Starter commutator run-out Standard ≤ 0.05 mm

Limit 0.10 mm
Starter commutator diameter Standard 29.4 mm

Limit 28.4 mm
Brush attrition value Limit 7.0 mm
REGULATOR
Type IC
Regulation voltage 14.40 ～ 14.70 V
STARTER
Voltage 12 V
Output power -
Direction of rotation Clockwise
Battery rated voltage 12 V

SERVICE SPECIFICATIONS - STARTING AND CHARGING 03-25
03
Regulator 6～8
Generator bracket bolt 20 ～ 24
Generator retaining bolt 20 ～ 24 03

Generator cable nut 8 ～ 12
Generator lock bolt 20 ～ 24
Starter pulley bolt -
Starter shell bolt 8 ～ 10
Magnetic switch bolt 8 ～ 10
Magnetic coil nut 14 ～ 16
Starter × Battery cable 21 ～ 25
Starter retaining bolt 68 ～ 72
Battery plate × Body 16 ～ 18
Battery hold down 8 ～ 10
Battery cable 8 ～ 10
03-26 SERVICE SPECIFICATIONS - FRONT SUSPENSION
FRONT SUSPENSION
SERVICE DATA
FRONT WHEEL ALIGNMENT
Front toe-in -
Front wheel camber -0°20′±30′ (Difference between left and right ≤ 30′)
Kingpin inclination 10°50′±30′ (Difference between left and right ≤ 30′)
Kingpin caster 1°50′±30′ (Difference between left and right ≤ 30′)
Front shock absorber × Body -
Front shock absorber × Lower control arm assy 88 ～ 97
Torsion bar × Frame 74 ～ 82
Upper control arm assy × Frame 142 ～ 152
Upper control arm ball joint × Upper control arm assy 75 ～ 90
Upper control arm assy × Torsion bar 137 ～ 147
Lower control arm assy × Frame 192 ～ 208
Lower control arm ball joint × Lower control arm assy 69 ～ 77
Stabilizer bar link × Stabilizer bar -
Stabilizer bar bracket × Frame -
Strut rod × Lower control arm assy 113 ～ 123
Strut rod × Frame 114.5 ～ 125.5

SERVICE SPECIFICATIONS - REAR SUSPENSION 03-27
REAR SUSPENSION
03
Rear shock absorber × Anchor plate 38.7 ～ 47.3
Rear shock absorber × Frame 21.6 ～ 26.7 03

Shackle pin upper bolt 87 ～ 95
Shackle pin lower bolt 142 ～ 152
Leaf spring pin nut 142 ～ 152
U-bolt nut 118 ～ 128

03-28 SERVICE SPECIFICATIONS - TIRE AND WHEEL
TIRE AND WHEEL

SERVICE DATA
TIRE PRESSURE
195/70R15C-104S Front tire 3.25 bar

Rear tire 4.5 bar
Spare tire 4.5 bar
Wheel nut 120 ～ 150
SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT 03-29

SERVICE DATA
03
PROPELLER ASSY
Propeller tube outer diameter × Thickness φ 68.9 × 2.3 mm
Operating torque Maximum 1600 N·m 03

Angle without interference Maximum 22°
Dynamic unbalance Maximum 27 g.cm （3200 r/min）
Propeller radial run-out Standard -

Limit 0.6 mm
Clearance between tube yoke and transmission output

shaft spline Standard 0.15 mm
Limit 0.35 mm
U-JOINT
Cross spider journal Standard 30 mm

Limit 29.85 mm
Clearance between needle bearing and yoke 0 mm (Interferencefit)
Clearance between cross spider and needle bearing 0.05 ～ 0.15 mm
Axial clearance of cross spider 0.10 ～ 0.03 mm
AXLE HUB
Back lash Front ≤ 0.05 mm

Rear ≤ 0.07 mm
Deviation Front ≤ 0.05 mm

Rear ≤ 0.07 mm
Primal rotating force Front ≤ 5 N·m

Rear ≤ 5 N·m
REAR AXLE
Rear wheel track 1440 mm
FINAL DRIVE ASSY
Back lash -
Number of drive pinion teeth 9
Number of crown gear teeth 41
Final ratio 4.556
DIFFERENTIAL ASSY
Crown gear deviation ≤ 0.07 mm
Crown gear back lash 0.13 ～ 0.18 mm

03-30 SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT
Contact area between drive pinion and crown gear Center of the tooth surface. The distance away from
small end ≥ 2 mm
Length ≥ 60% tooth length

Width ≥ 60% tooth width
Drive axle side gear and pinion back lash 0.05 ～ 0.20 mm
Drive axle side gear clearance 0 ～ 0.15 mm
Radial clearance between differential pinion and pinion 0.05 ～ 0.13 mm

shaft
Radial clearance between drive axle side gear and dif- 0.05 ～ 0.11 mm
ferential case
Thickness of drive axle side gear thrust washer

Standard 0.6 mm
Limit -
Thickness of differential pinion thrust washer

Limit -
DRIVE PINION
Pinion flange back lash ≤ 0.10 mm
Pinion flange deviation ≤ 0.10 mm
Drive pinion primal rotating force 1.3 ～ 2.2 N·m
Final drive pinion flange × Propeller shaft 20
Center support bearing bracket × Frame 40
End yoke retaining bolt -
Front axle hub × Front brake disc 145
Front axle hub nut 150 ～ 180
Rear wheel brake cylinder × brake tube 19 ～ 21
Steering knuckle × Upper control arm joint 135 ～ 145
Steering knuckle × Lower control arm assy 137 ～ 147
Lower control arm joint × Lower control arm 69 ～ 77
Steering knuckle × Steering knuckle arm -
Tie rod × Steering knuckle arm 81 ～ 99
Final drive drain plug -
Final drive filler cap -
Final drive vent plug -

SERVICE SPECIFICATIONS - AXLE AND PROPELLER SHAFT 03-31

Main retard assy × Final drive assy -
Crown gear × Differential case - 03
Differential bearing cap × Differential case -
Pinion nut Minimum -

Increment 13 03
Maximum 343
03-32 SERVICE SPECIFICATIONS - BRAKE
BRAKE
SERVICE DATA
BRAKE PEDAL
Height Standard 150 ～ 155 mm
Free play Standard 1 ～ 3 mm
FRONT BRAKE
Thickness of front brake pad Standard 10.0 mm
Limit 2.0 mm
Thickness of front brake disk Standard 28 mm
Limit 25.5 mm
Front brake disk run-out Standard -
Limit 0.03 mm
REAR BRAKE
Thickness of rear brake shoe Standard 6.0 mm
Limit 1.0 mm
Brake drum inside diameter 275 mm
Clearance between rear brake drum and brake shoe
Front disk brake caliper bleeding plug 4 ～6
Rear wheel brake cylinder bleeding plug 4 ～6
Brake master cylinder bolt 29 ～ 35
Brake master cylinder tube connector 19 ～ 21
Front brake disk x front wheel hub 145
Front axle hub nut 150 ～ 180

Front disk brake caliper mounting nut 100 ～ 120
Front disk brake caliper bolt 138 ～ 168
Front disk brake caliper fluid tube connector 19 ～ 21
Rear wheel cylinder brake fluid tube connector 19 ～ 21
Rear wheel brake cylinder assy 10 ～ 13
Speed sensor -
LSP assy -
SERVICE SPECIFICATIONS - PARKING BRAKE 03-33
PARKING BRAKE
03
Parking brake front part assy -
Parking brake swinging arm bracket 17 ～ 27 03

03-34 SERVICE SPECIFICATIONS - TRANSMISSION
TRANSMISSION
SERVICE DATA
5RYL / TC5RYA4
Transmission fluid 2L
1st gear ratio 4.452
2nd gear ratio 5RYL 2.398

YC5RYA4 2.619
3rd gear ratio 5RYL 1.414

YC5RYA4 1.517
4th gear ratio 1
5th gear ratio 5RYL 0.802

YC5RYA4 0.854
Reverse gear ratio 4.4725
Odometer gear ratio (Driven gear / driving gear) 5RYL 19 / 6

YC5RYA4 20 / 6
Input shaft gear bearing axial clearance

Standard -
Limit -
Output shaft radial run-out Standard -

Limit -
Output shaft journal A -

B -
C -
D -
Axial clearance between od-r synchronizer ring and

gear Standard 1.0 ～ 2.0 mm
Limit 0.8 mm
Axial clearance between 4th synchronizer ring and

Limit 0.8 mm
Axial clearance between 3rd synchronizer ring and

Limit 0.8 mm
Axial clearance between 2nd synchronizer ring and

Limit 0.8 mm
Axial clearance between 1st synchronizer ring and

Limit 0.8 mm
Radial clearance between od-r synchronizer ring and

Limit 0.8 mm
SERVICE SPECIFICATIONS - TRANSMISSION 03-35
Radial clearance between 4th synchronizer ring and

gear Standard -
Limit -
Radial clearance between 3rd synchronizer ring and 03

Limit 0.8 mm
Radial clearance between 2nd synchronizer ring and

gear Standard 03
1.0 ～ 2.0 mm
Limit 0.8 mm
Radial clearance between 1st synchronizer ring and

Limit 0.8 mm
Clearance between od-r synchronizer sleeve and

gearshift fork Standard -
Limit -
Clearance between 3rd-4th synchronizer sleeve and

Limit -
Clearance between 1st-2nd synchronizer sleeve and

Limit -
5RYL / TC5RYA4
Transmission operation mechanism × Body 30 ～ 50
Gear shifting vertical lever × Transmission operation

mechanism 21 ～ 30
Gear selecting vertical lever × Transmission operation

mechanism 21 ～ 30
Transmission lifting lug × Transmission 21 ～ 30
Transmission assy × Engine 30 ～ 45
Odometer sensor × Transmission assy 30 ～ 50
Backup lamp switch × Transmission assy 30 ～ 50
Gear shift connecting rod × Transmission assy 21 ～ 30
Gear select connecting rod × Transmission assy 21 ～ 30
Filler cap 30 ～ 50
Front bearing retainer × Transmission assy 21 ～ 30
Output shaft rear bearing baffle × Transmission assy 15 ～ 20
Reverse idler gear shaft plate × Transmission assy 21 ～ 30

03-36 SERVICE SPECIFICATIONS - TRANSMISSION

Lever housing assy × Transmission assy 30 ～ 45
Extension housing sub-assy × Transmission assy 30 ～ 45
Clutch housing × Transmission assy 30 ～ 45

SERVICE SPECIFICATIONS - CLUTCH 03-37
CLUTCH
SERVICE DATA
03
CLUTCH PEDAL
Height Standard 170 mm
Free play Standard 5 ～ 12 mm 03

Push rod play Standard 1 ～ 5 mm
CLUTCH
Clutch disk thickness Standard -

Limit 0.3 mm
Width of diaphragm spring Standard -

Limit 5 mm
Height of diaphragm spring Standard -

Limit 0.5 mm
Clutch disk run-out Standard -

Limit 0.8 mm
Flywheel run-out Standard

Limit 0.2 mm
Bleeding plug -
Clutch pedal lock nut 25
Clutch pedal pin nut -
Clutch master cylinder nut 12
Clutch master cylinder fluid tube connector 15
Clutch slave cylinder fluid tube connector -
Clutch slave cylinder bolt -
Clutch cover bolt 24

03-38 SERVICE SPECIFICATIONS - STEERING COLUMN
STEERING COLUMN
SERVICE DATA
VEHICLE
Steering radius Minimum 5.75 m
Off track (30 m，40 Km/h) Left ＜2m

Right ＜1m
STEERING WHEEL
Diameter -
Free play ± 10°
Turning force Engine stopped ＜ 200 N

Engine idling ＜ 45 N
STEERING PROPELLER SHAFT
Clearance between cross spider and bearing ≤ 0.15 mm
Steering wheel nut 31 ～ 37
Steering column assy 16 ～ 20
Main retard assy 16 ～ 20
Steering propeller shaft assy × Steering column assy 19 ～ 23
Steering propeller shaft assy × Steering box 19 ～ 23
Engine lower guard plate retaining bolt 16 ～ 20

SERVICE SPECIFICATIONS - POWER STEERING 03-39
POWER STEERING
SERVICE DATA
03
VEHICLE
Steering radius Minimum 5.75 m
Off track (30 m，40 Km/h) Left ＜2m 03

Right ＜1m
STEERING WHEEL
Diameter -
Free play ± 10°
Turning force Engine stopped ＜ 200 N

Engine idling ＜ 45 N
STEERING PUMP BELT
Deflection Gasoline vehicle ≤ 4.0 ～ 6.0 mm (98 N)

Diesel vehicle ≤ 6.0 ～ 8.0 mm (98 N)
STEERING FLUID
Operating temperature - 40 ～ 120 ℃
Level difference Engine idling → stopped ≤ 5 mm
Pressure Engine idling, valve closed -

Engine idling, valve open, steering wheel at lock position ≤ 8 Mpa
Pressure difference
Vavle open, engine running at 1000 and 3000 r/min -
STEERING BOX
Weight 9.5 Kg
Number of rack teeth 30
Number of pinion teeth 8
Module 1.85
Gear ratio 46.67
Rotating angle of rack shaft 1220°
Gross rotating turn of pinion 3.39
Pitch circle of pinion φ 16.33 mm
Radial run-out of rack 0.15 mm

03-40 SERVICE SPECIFICATIONS - POWER STEERING
Power steering line connector -
Steering wheel nut 31 ～ 37
Engine lower guard plate retaining bolt 16 ～ 20
Steering box 86 ～ 105
Steering box × Steering propeller shaft assy 19 ～ 23
Steering tie rod × Steering knuckle arm 81 ～ 99

SERVICE SPECIFICATIONS - HEATER AND AIR CONDITIONING 03-41

SERVICE DATA
03
AMOUNT OF COMPRESSOR OIL
Replace compressor Compressor has 180 ml oil, no need added
Replace all pipes 40 ～ 60 ml 03

Replace evaporator 10 ml
Replace accumulator 5 ～ 10 ml
Replace condenser No leakage 5 ml

Leakage 10 ml
Replace pipes No leakage No need added

Leakage 5 ml
Gas leakage No leakage No need added

Leakage 80 ml
Pressure of low side ON 0.15 ～ 0.25 MPa

OFF -
Pressure of high side ON 1.37 ～ 2.37 MPa

OFF -
Φ9 aluminium tube, M16×1.5 thread 12 ～ 15
Front evaporator and heater assy bolt 21 ～ 25

03-42 SERVICE SPECIFICATIONS - SEAT BELT
SEAT BELT
Driver / assistant driver seat retractor × Body 50 ～ 55
Driver / assistant driver seat belt lower anchor × Body 50 ～ 55

SERVICE SPECIFICATIONS - LIGHTING 03-43
LIGHTING
03
Front combination lamp × Frame -
Rear combination lamp × Frame - 03

03-44 SERVICE SPECIFICATIONS - WIPER AND WASHER
WIPER AND WASHER

Front wiper assy nut 13 ～ 17
Rear wiper assy nut 8 ～ 12
Front wiper motor assy bolt -
Rear wiper motor with link assy bolt -
Front wiper link assy bolt -

SERVICE SPECIFICATIONS - SEAT 03-45
SEAT
03
Driver seat assy bolt 45 ～ 55
Assistant driver seat assy bolt 45 ～ 55 03

Passenger seat assy bolt 45 ～ 55
03-46 SERVICE SPECIFICATIONS - DOORS
DOORS
SERVICE DATA
FRONT DOOR
Clearance -
Flatness -
SLIDING DOOR
Clearance -
Flatness -
REAR HATCH
Clearance -
Flatness -
Front door hinge bolt -
Front door lock catch screw -
Sliding door hinge bolt -
Sliding door concave limiting device bolt -
Rear hatch bolt -
Rear hatch concave limiting device bolt -

SERVICE SPECIFICATIONS - EXTERIOR AND INTERIOR TRIM 03-47
EXTERIOR AND INTERIOR TRIM

03
Sunvisor hook bolt -
Floor trim strip screw - 03

Front bumper assy bolt -
Rear bumper assy bolt -

03-48 SERVICE SPECIFICATIONS - VEHICLE CONTROL SYSTEM

Ignition switch assy bolt -
DIAGNOSTICS
04
GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ).................... 04-1
PRECAUTION.............................................................................. 04-1
LOCATION................................................................................... 04-4
HOW TO PERFORM DIAGNOSTICS ANALYSIS ....................... 04-6
DIAGNOSTIC HELP - INTERMITTENT FAULT .......................... 04-9
BASIC SERVICE PROCEDURE................................................ 04-11 04
ECM TERMINAL DIAGRAM (ECM SIDE) ................................. 04-12
DIAGNOSTIC SYSTEM ............................................................. 04-18
READING AND ERASING DIAGNOSTIC TROUBLE
CODE (DTC) .............................................................................. 04-20
CAPTURING DATA ................................................................... 04-22
FAIL-SAFE CHART.................................................................... 04-23
DATA STREAM LIST/ACTIVE TEST ........................................ 04-25
DIAGNOSTIC TROUBLE CODE CHART .................................. 04-29
DIAGNOSTICS TROUBLE CODE (DTC) CHECK..................... 04-37
P0117 - ECT CIRCUIT LOW VOLTAGE.................................... 04-37
P0118 - ECT CIRCUIT HIGH VOLTAGE................................... 04-37
P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN ................. 04-42
P0108 - MAP CIRCUIT HIGH VOLTAGE .................................. 04-42
P1106 - MAP CIRCUIT HIGH INTERMITTENT......................... 04-42
P1107 - MAP CIRCUIT LOW INTERMITTENT.......................... 04-42
P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN.................... 04-48
P0113 - IAT CIRCUIT HIGH VOLTAGE .................................... 04-48
P0122 - TPS CIRCUIT LOW VOLTAGE OR OPEN .................. 04-52
P0123 - TPS CIRCUIT HIGH VOLTAGE ................................... 04-52
P1121 - TPS CIRCUIT HIGH INTERMITTENT.......................... 04-52
P1122 - TPS CIRCUIT LOW INTERMITTENT .......................... 04-52
P0131 - O2S 1 CIRCUIT LOW VOLTAGE................................. 04-58
P0132 - O2S 1 CIRCUIT HIGH VOLTAGE................................ 04-58
P0134 - O2S 1 CIRCUIT INSUFFICIENT ACTIVITY OR
OPEN ......................................................................................... 04-58
P0201 - INJECTOR 1 CIRCUIT MALFUNCTION ...................... 04-65
P0336 - CKP SENSOR CIRCUIT PERFORMANCE ................. 04-72
P0337 - CKP SENSOR CIRCUIT MALFUNCTION ................... 04-72
P0480 - FAN 1 FAULT ............................................................... 04-77
P0481 - FAN 2 FAULT ............................................................... 04-77
PROBLEM SYMPTOMS TABLE................................................ 04-84
ENGINE SYMPTOM DIAGNOSTIC........................................... 04-85
DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)...................... 04-128
PRECAUTION.......................................................................... 04-128
LOCATION............................................................................... 04-131
ENGINE ROOM ....................................................................... 04-131
HOW TO PERFORM DIAGNOSTICS ANALYSIS .................. 04-134
CAUTIONS FOR CIRCUIT TROUBLESHOOTING ................. 04-136
DIAGNOSTIC HELP - INTERMITTENT FAULT ...................... 04-138
BASIC SERVICE PROCEDURE.............................................. 04-140
DIAGNOSTIC SYSTEM ........................................................... 04-143
SYMPTOM OF FAILURE......................................................... 04-144
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS ........ 04-148
DIESEL ENGINE CONTROL SYSTEM (4D20) ............................. 04-166
PRECAUTION.......................................................................... 04-166
LOCATION............................................................................... 04-169
ENGINE ROOM ....................................................................... 04-169
HOW TO PERFORM DIAGNOSTICS ANALYSIS ................... 04-171
CAUTIONS FOR CIRCUIT TROUBLESHOOTING ................. 04-173
EGR VALVE ELECTRONIC CONTROL MODULE
TERMINAL DIAGRAM ............................................................. 04-179
CODE (DTC) ............................................................................ 04-183
DIAGNOSTIC SCAN TOOL MAIN FUNCTION ....................... 04-184
USAGE METHOD .................................................................... 04-184
COMPULSORY DIAGNOSIS FUNCTION (ACCESSIBILITY
FOR THE DIAGNOSIS OF LOW-TEMPERATURE HOT
VEHICLE)................................................................................. 04-185
CONSIDERATIONS................................................................. 04-185
DIAGNOSTIC TROUBLE CODE CHART ................................ 04-186
DIAGNOSTICS TROUBLE CODE (DTC) CHECK................... 04-189
1 - EGR VALVE LIFT SENSOR OR CIRCUIT FAULT............. 04-189
2 - EGR VALVE IS STUCK AND DOES NOT CLOSE........... 04-189
3 - EGR VALVE SEAT CARBON AND CLOSE LAX ............... 04-189
4 - THROTTLE POSITION SENSOR OR CIRCUIT FAULT .... 04-193
5 - SPEED SENSOR OR CIRCUIT FAULT ............................. 04-197
6 - ENGINE COOLANT TEMPERATURE SENSOR
OR CIRCUITFAULT................................................................. 04-202
15 - GLOW PLUG RELAY ADHESION.................................... 04-206
16 - GLOW PLUG RELAY NO POWER .................................. 04-206
31 - TIMING SOLENOID VALVE OR CIRCUIT FAULT ........... 04-210
32 - TIMING STROKE SENSOR OR CIRCUIT FAULT ........... 04-214
34 - RETURN FUEL SOLENOID VALVE OPEN OR
CIRCUIT FAULT ...................................................................... 04-219
35 - RETURN FUEL SOLENOID VALVE ADHESION ............. 04-219
36 - RETURN FUEL SOLENOID VALVE NO POWER............ 04-219
LIST OF SYMPTOM OF FAILURE .......................................... 04-223
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS ........ 04-227
CNG ENGINE CONTROL SYSTEM (4GC1) ................................. 04-242
PRECAUTION.......................................................................... 04-242
LOCATION............................................................................... 04-245
ENGINE ROOM ....................................................................... 04-245
HOW TO PERFORM DIAGNOSTICS ANALYSIS ................... 04-247
ECM TERMINAL DIAGRAM (ECM SIDE) ............................... 04-253
INJECTOR CONTROL UNIT TERMINAL DIAGRAM .............. 04-257
CODE (DTC) ............................................................................ 04-260
CAPTURING DATA ................................................................. 04-262
ANALYSIS OF DATA ............................................................... 04-263
FAIL-SAFE CHART.................................................................. 04-264
DATA STREAM LIST/ACTIVE TEST ...................................... 04-266
DIAGNOSTICS TROUBLE CODE (DTC) CHECK................... 04-276
P0115-1 - ECT TOO LOW ....................................................... 04-276
P0115-2 - ECT TOO HIGH ...................................................... 04-276
P0105-1 - MAP PRESSURE TOO HIGH ................................. 04-281 04
P0105-2 - MAP PRESSURE TOO LOW.................................. 04-281
P0110-1 - INLET AIR TEMPERATURE TOO LOW ................. 04-286
P0110-2 - INLET AIR TEMPERATURE TOO HIGH ................ 04-286
P0120-1 - THROTTLE POSITION TOO HIGH ........................ 04-290
P0120-2 - THROTTLE POSITION TOO LOW ......................... 04-290
P0130-4 - OXYGEN SENSOR NO SIGNAL ............................ 04-295
P0170-1 - OXYGEN SENSOR SIGNAL RICH FOR A 04
LONG TIME ............................................................................. 04-295
P0170-2 - OXYGEN SENSOR SIGNAL LEAN FOR A
LONG TIME ............................................................................. 04-295
P0335-0 - NO 58X CKP SENSOR SIGNAL............................. 04-302
P0335-8 - 58X CKP SENSOR CIRCUIT FAULT ..................... 04-302
P0480-1 - FAN RELAY SHORT TO THE BATTERY ............... 04-307
P0480-2 - FAN RELAY SHORT TO GROUND OR OPEN ...... 04-307
P0481-1 - FAN RELAY SHORT TO THE BATTERY ............... 04-307
P0481-2 - FAN RELAY SHORT TO GROUND OR OPEN ...... 04-307
P1297 - HIGH PRESSURE SOLENOID VALVE RELAY
FAULT...................................................................................... 04-314
P1299 - FUEL SELECTION RELAY FAULT............................ 04-319
PROBLEM SYMPTOMS TABLE.............................................. 04-324
ENGINE SYMPTOM DIAGNOSTIC......................................... 04-325
ANTI-LOCK BRAKE SYSTEM....................................................... 04-368
PRECAUTION.......................................................................... 04-368
LOCATION............................................................................... 04-369
ABS MODULE CONNECTOR ................................................. 04-371
PRE - CHECK .......................................................................... 04-375
2 - SPEED SENSOR MEASURING CIRCUIT OPEN .............. 04-376
3 - SPEED SENSOR MEASURING CIRCUIT SHORT............ 04-376
4 - STOP VALVE DRIVER CIRCUIT OPEN ............................ 04-380
5 - STOP VALVE DRIVER CIRCUIT SHORT.......................... 04-380
6 - PRESSURE RELIEF VALVE DRIVER CIRCUIT OPEN..... 04-384
7 - PRESSURE RELIEF VALVE DRIVER
CIRCUIT SHORT ..................................................................... 04-384
ABS WARNING LIGHT IS ALWAYS ON ................................. 04-388
ABS WARNING LIGHT IS INOPERATIVE .............................. 04-390
ABS WARNING LIGHT IS INTERMITTENT ON
(ABS MODULE CHECK FAULT INTERMITTENTLY) ............. 04-394
ABS IS INOPERATIVE ............................................................ 04-399
HEATER AND AIR CONDITIONING SYSTEM.............................. 04-408
PRECAUTION.......................................................................... 04-408
BASIC INSPECTION ............................................................... 04-409
LOCATION............................................................................... 04-410
A/C SYSTEM IS INOPERATIVE.............................................. 04-414
AIR FLOW CONTROL: FRONT BLOWER MOTOR IS
INOPERATIVE ......................................................................... 04-420
AIR FLOW CONTROL: REAR EVAPORATOR MOTORS
ARE INOPERATIVE................................................................. 04-424
AIR FLOW CONTROL: FRONT AIR FLOW IS
INSUFFICIENT ........................................................................ 04-430
AIR FLOW CONTROL: REAR AIR FLOW IS
INSUFFICIENT ........................................................................ 04-433
TEMPERATURE CONTROL: TEMPERATURE
CONTROL IS INOPERATIVE .................................................. 04-437
LIGHTING SYSTEM ....................................................................... 04-443
PRECAUTION.......................................................................... 04-443
LOCATION............................................................................... 04-445
PROBLEM SYMPTOMS TABLE - 09 LATE PRODUCTION ... 04-447
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) .......... 04-452
LO-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ......................................................................... 04-454
HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........... 04-456
HI-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ......................................................................... 04-458
LO-BEAM AND HI-BEAM HEADLAMPS ARE
INOPERATIVE (ONE SIDE) .................................................... 04-460
ALL HEADLAMPS ARE INOPERATIVE .................................. 04-464
FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-469
FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-473
REAR FOG LAMPS ARE INOPERATIVE................................ 04-475
REAR FOG LAMPS ARE ALWAYS ON .................................. 04-478
ALL FOG LAMPS ARE INOPERATIVE ................................... 04-480
HAZARD WARNING LAMPS ARE INOPERATIVE
(TURN SIGNAL LAMPS ARE NORMAL)................................. 04-486
TURN SIGNAL LAMPS ARE INOPERATIVE
(HAZARD WARNING LAMPS ARE NORMAL)........................ 04-492
HAZARD WARNING AND TURN SIGNAL LAMPS
ARE INOPERATIVE................................................................. 04-498
TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-503
HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-506
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) ............... 04-509
STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-512
HIGH-MOUNTED STOP LAMP IS INOPERATIVE.................. 04-514
BACK-UP LAMP IS INOPERATIVE(ONE SIDE) ..................... 04-516
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) ......... 04-518
FRONT DOME LIGHT IS INOPERATIVE ................................ 04-523
REAR DOME LIGHT IS INOPERATIVE .................................. 04-526
STEP LAMPS ARE INOPERATIVE ......................................... 04-530
ILLUMINATED SYSTEM IS NOT INOPERATIVE ................... 04-533
INSTRUMENT CLUSTER ILLUMINATION IS
INOPERATIVE ......................................................................... 04-538
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE...... 04-540
CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE .... 04-542
FRONT A/C SWITCH ILLUMINATION IS INOPERATIVE ....... 04-544
BLOWER SWITCH ILLUMINATION IS INOPERATIVE........... 04-546
AUDIO ILLUMINATION IS INOPERATIVE .............................. 04-548
HAZARD SWITCH ILLUMINATION IS INOPERATIVE ........... 04-550
FRONT PARKING LAMPS ARE INOPERATIVE ..................... 04-552
TAIL LAMPS ARE INOPERATIVE........................................... 04-554
LICENSE LAMP IS INOPERATIVE ......................................... 04-556
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE
LAMP ARE INOPERATIVE...................................................... 04-558
PROBLEM SYMPTOMS TABLE - EARLY PRODUCTION ..... 04-563
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) .......... 04-568
LO-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ......................................................................... 04-570 04
HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE) ........... 04-573
HI-BEAM HEADLAMPS ARE INOPERATIVE
(BOTH SIDES) ......................................................................... 04-575
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE
(ONE SIDE) ............................................................................. 04-578
ALL HEADLAMPS ARE INOPERATIVE .................................. 04-582
FRONT FOG LAMPS ARE INOPERATIVE ............................. 04-587 04
FRONT FOG LAMPS ARE ALWAYS ON ................................ 04-591
REAR FOG LAMPS ARE INOPERATIVE................................ 04-593
REAR FOG LAMPS ARE ALWAYS ON .................................. 04-596
ALL FOG LAMPS ARE INOPERATIVE ................................... 04-598
HAZARD WARNING LAMPS ARE INOPERATIVE
(TURN SIGNAL LAMPS ARE NORMAL)................................. 04-605
TURN SIGNAL LAMPS ARE INOPERATIVE
(HAZARD WARNING LAMPS ARE NORMAL)........................ 04-609
HAZARD WARNING AND TURN SIGNAL LAMPS ARE
INOPERATIVE ......................................................................... 04-615
TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)...... 04-620
HAZARD WARNING LAMPS ARE ALWAYS ON .................... 04-623
STOP LAMPS ARE INOPERATIVE (BOTH SIDES) ............... 04-626
STOP LAMP IS INOPERATIVE (ONE SIDE) .......................... 04-629
HIGH-MOUNTED STOP LAMP IS INOPERATIVE.................. 04-631
BACK-UP LAMP IS INOPERATIVE......................................... 04-633
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES) ......... 04-635
FRONT DOME LIGHT IS INOPERATIVE................................ 04-640
REAR DOME LIGHT IS INOPERATIVE .................................. 04-642
STEP LAMPS ARE INOPERATIVE ......................................... 04-645
ILLUMINATED SYSTEM IS NOT INOPERATIVE ................... 04-647
INSTRUMENT CLUSTER ILLUMINATION IS
INOPERATIVE ......................................................................... 04-651
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE...... 04-653
FRONT A/C SWITCH ILLUMINATION IS INOPERATIVE....... 04-655
BLOWER SWITCH ILLUMINATION IS INOPERATIVE........... 04-657
RADIO ILLUMINATION IS INOPERATIVE .............................. 04-659
FRONT PARKING LAMPS ARE INOPERATIVE..................... 04-661
TAIL LAMPS ARE INOPERATIVE........................................... 04-663
LICENSE LAMP IS INOPERATIVE ......................................... 04-665
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP
ARE INOPERATIVE................................................................. 04-667
WIPER AND WASHER .................................................................. 04-670
PRECAUTION.......................................................................... 04-670
LOCATION............................................................................... 04-671
SYSTEM DESCRIPTION......................................................... 04-673
WIPERS ARE INOPERATIVE - WINDSHIELD........................ 04-677
WIPERS ARE INOPERATIVE AT LOW
SPEED - WINDSHIELD ........................................................... 04-682
WIPERS ARE INOPERATIVE AT HIGH
SPEED - WINDSHIELD ........................................................... 04-686
WIPERS ARE INOPERATIVE IN INTERMITTENT
MODE - WINDSHIELD............................................................. 04-690
WASHER PUMP IS INOPERATIVE - WINDSHIELD............... 04-694
WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE
DOES NOT RETRACT ............................................................ 04-697
WIPER IS INOPERATIVE - REAR WINDOW .......................... 04-700
WIPER IS INOPERATIVE IN INTERMITTENT
MODE - REAR WINDOW ....................................................... 04-704
WASHER PUMP IS INOPERATIVE - REAR WINDOW .......... 04-708
AUDIO SYSTEM............................................................................. 04-711
PRECAUTION.......................................................................... 04-711
LOCATION............................................................................... 04-712
TERMINALS OF RADIO .......................................................... 04-713
RADIO DOES NOT WORK...................................................... 04-716
RADIO RECEPTION IS POOR................................................ 04-721
POOR SOUND QUALITY....................................................... 04-722
SPEAKER DOES NOT WORK ................................................ 04-723
HORN SYSTEM.............................................................................. 04-726
LOCATION............................................................................... 04-726
HORN IS INOPERATIVE ......................................................... 04-728
HORN IS ALWAYS ON............................................................ 04-732
COMBINED DISPLAY.................................................................... 04-734
PRECAUTION.......................................................................... 04-734
LOCATION............................................................................... 04-735
TERMINALS OF COMBINED DISPLAY .................................. 04-736
COMBINED DISPLAY IS INOPERATIVE ................................ 04-739
IN-VEHICLE TEMPERATURE DOES NOT DISPLAY
OR DISPLAY INCORRECTLY................................................. 04-742
AMBIENT TEMPERATURE DOES NOT DISPLAY OR
DISPLAY INCORRECTLY ....................................................... 04-744
REVERSE DATA DOES NOT DISPLAY OR DISPLAY
INCORRECTLY ....................................................................... 04-746
REVERSE RADAR SYSTEM ......................................................... 04-748
PRECAUTION.......................................................................... 04-748
LOCATION............................................................................... 04-749
SYSTEM DESCRIPTION ......................................................... 04-750
REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL ........ 04-755
SELF-CHECK FUNCTION IS INOPERATIVE ......................... 04-759
REVERSE RADAR SYSTEM IS OPERATIVE WHEN
THE SHIFT LEVER IS OUT OF REVERSE POSITION .......... 04-762
REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN
SPECIFIED DISTANCE ........................................................... 04-764
REVERSE RADAR SYSTEM IS OPERATIVE BUT
THERE IS NO OBSTACLE BEHIND VEHICLE ....................... 04-767
BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY
WITHIN SPECIFIED DISTANCE ............................................. 04-770
COMBINED DISPLAY IS INOPERATIVE WITHIN
SPECIFIED DISTANCE ........................................................... 04-773
POWER WINDOWS ....................................................................... 04-775
PRECAUTION.......................................................................... 04-775
LOCATION............................................................................... 04-776
TERMINALS OF MAIN POWER WINDOW LOCK/UNLOCK
SWITCH ................................................................................... 04-777
TERMINALS OF POWER WINDOW SWITCH RH.................. 04-778 04
TERMINALS OF POWER WINDOW CONTROLLER.............. 04-779
ALL POWER WINDOWS ARE INOPERATIVE ....................... 04-783
FRONT POWER WINDOW IS INOPERATIVE........................ 04-788
FRONT POWER WINDOW LH DOES NOT CLOSE............... 04-794
FRONT POWER WINDOW LH DOES NOT OPEN................. 04-800 04
FRONT POWER WINDOW RH IS INOPERATIVE.................. 04-806
FRONT WINDOW RH IS INOPERATIVE
(USING THE FRONT POWER WINDOW SWITCH RH) ......... 04-813
OUTSIDE MIRROR ........................................................................ 04-819
LOCATION............................................................................... 04-819
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH..... 04-820
MIRRORS ARE INOPERATIVE (BOTH SIDES) ..................... 04-823
A SINGLE MIRROR IS INOPERATIVE ................................... 04-826
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE ......... 04-829
MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE...... 04-831
REAR WINDOW DEFROSTER SYSTEM ...................................... 04-833
LOCATION............................................................................... 04-833
SYSTEM DESCRIPTION......................................................... 04-834
DEFROSTER SYSTEM IS INOPERATIVE.............................. 04-837
INSTRUMENT CLUSTER .............................................................. 04-843
PRECAUTION.......................................................................... 04-843
LOCATION (4 CONNECTORS)............................................... 04-844
INSTRUMENT CLUSTER INFORMATION.............................. 04-845
TERMINALS OF INSTRUMENT CLUSTER ............................ 04-847
MALFUNCTION IN SPEEDOMETER ...................................... 04-854
MALFUNCTION IN TACHOMETER ........................................ 04-856
MALFUCTION IN FUEL GAUGE / LOW FUEL
WARNING LIGHT NEVER OR ALWAYS ON .......................... 04-858
MALFUCTION IN ENGINE COOLANT TEMPERATURE
GAUGE .................................................................................... 04-861
BRAKE WARNING LIGHT NEVER / ALWAYS ON ................. 04-864
ENGINE OIL PRESSURE WARNING
LIGHT NEVER / ALWAYS ON................................................. 04-870
COOLANT FLUID LEVEL WARNING LIGHT
NEVER / ALWAYS ON ............................................................ 04-873
DOOR AJAR WAINING LIGHT NEVER / ALWAYS ON .......... 04-876
LOCATION (3 CONNECTORS)............................................... 04-885
INSTRUMENT CLUSTER INFORMATION.............................. 04-886
TERMINALS OF INSTRUMENT CLUSTER ............................ 04-888
MALFUCTION IN SPEEDOMETER......................................... 04-894
MAIFUCTION IN FUEL GAUGE / LOW FUEL WARNING
LIGHT NEVER OR ALWAYS ON ............................................ 04-896
MALFUCTION IN ENGINE COOLANT TEMPERATURE
GAUGE .................................................................................... 04-900
BRAKE WARNING LIGHT NEVER / ALWAYS ON ................. 04-903
ENGINE OIL PRESSURE WARNING
LIGHT NEVER / ALWAYS ON................................................. 04-909
COOLANT FLUID LEVEL WARNING LIGHT NEVER / ALWAYS ON
04-912
POWER DOOR LOCKS ................................................................. 04-916
PRECAUTION.......................................................................... 04-916
LOCATION............................................................................... 04-917
TERMINALS OF POWER DOOR LOCK CONTROL UNIT ..... 04-918
TERMINALS OF REMOTE KEYLESS ENTRY RECEIVER .... 04-919
THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE
(USING THE KEY) ................................................................... 04-923
ONE DOOR IS INOPERATIVE (USING THE KEY) ................. 04-929
DOOR DOES NOT OPEN (USING THE REMOTE KEY) ........ 04-931
DOORS DO NOT CLOSE (USING THE REMOTE KEY) ........ 04-939
DIAGNOSTICS - GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ) 04-1
GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)

DIAGNOSTICS
PRECAUTION
1. POWER OFF. 04
(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to
prevent damage to the device or persoanl injury.
(b) The ignition switch must be turned off without any special descriptions.
WARNING
The ignition and illumination switches must be turned off before removing or installing the battery 04
negative cable (the semiconductor maybe damage without doing that).
CAUTION
Do not leave the ignition switch in the vehicle in case the doors are locked before disconnecting the
negative battery cable for the vehicle equipped with remote control central lock.
2. RESET THE ODOMETER AND CLOCK IF DISCONNECTING THE COMBINATION INSTRUMENT
NEGATIVE BATTERY CABLE.
CAUTION
The total course will not be reset.
3. THE SAVING DATA SETTING WILL BE LOST IF DISCONNECTING THE NEGATIVE BATTERY
CABLE.
CAUTION
After connecting the negative battery cable, the audio system shoud be reset.
4. EXPRESSIONS OF IGNITION SWITCH.
Switch Type Ignition Switch (position) Ignition Switch (condition)

Ignition switch off LOCK Off
Ignition switch on (IG) ON On (IG)

Expression
Ignition switch on (ACC) ACC On (ACC)
Engine start START Start
5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE.

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous over-
voltage damage the ECM and sensors.
(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that perform-
ing the repair work beside the ECM or sensors.
(c) The system will resume its normal state temporarily or competely by removing and reinstalling the sus-
picious faulty components when the connector terminals or the installing state of the components go
out of order.
(d) The high impedance type digital multimeter should be used to the test except the special description of
the procedure in place of the traditional analogue types multimeter.
(e) Don’t check any electric appliance connecting the ECM with a test light.
(f) Never connect the negative and positive battery cables. The negative battery cable must be grounded.
(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and
sensors and washing them more.
(h) Prevent human body static electricity from damaging ECM. The operator body must be grounded when
operator checks ECM or replace chips.
04-2 DIAGNOSTICS - GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)
(i) In order to identify the faulty position, we must check the vehicle condition while vehicle goes out of
order. For example, we check the faults through the DTC. And we record these faults states before
disconnecting every connector or removing and installing components.
(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF
unless there is additional specification in the checking procedure.
(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be
checked after completing installation. Using the special diagnosis tool, check DTC.
(l) Check the ECM connector terminals with a digital multimeter.
• Connect the small probing pin to the probe of a digital multimeter.
• Check voltage value of terminals referring to the inspection sheet by backprobing ECM connectors
terminals.
(m) When diagnosis, turn the ignition switch ON and the connectors are dissociated. DTCs of other system
will be set. After diagnosis, confirm DTCs in all systems.Turn the ignition switch OFF when the
connectors are connected and disconnected.
(n) The test probe must not be probed in wire harness.This will reduce the waterproofness. And it also
cause corossion. Use the test wire, wire connector to measure wire and so on.
(o) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, do not insert by force.
(p) If check the common connectors when they are not in connection status (check male connectors):
• Do not short terminals circuit by using a probe. This will damage the interior circuits in ECM.
• The system is to be checked and other system will store DTC when they aren’t in connecting status.
(q) If check the common connectors when they are not in connection status (check female connectors):
• Use the special tools to check wire harness.
(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam-
age wire harness, sensor, ECM and other components. So we must carefully handle when checking.
(s) Do not check with the list order.
• If the check results are different from the standard value, then check related sensors, actuators and
wire harness. Repair or replace as necessary.
• Check with the voltage meter again after repairing or replacing. Confirm whether the faults have been
eliminated.
(t) Check resistance and continuity between terminals of ECM with multimeter.
• Ignition switch: OFF
• Disconnect ECM harness connector
(u) Ground inspection.
• Ground connections are very important to the proper operation of electrical and electronic circuits.
Ground connections are often exposed to moisture, dirt and other corrosive elements. The corrosion
(rust) can become an unwanted resistance. This unwanted resistance can change the way a circuit
works.
• Electronically controlled circuits are very sensitive to proper grounding. A loose or corroded ground can
drastically affect an electronically controlled circuit. A poor or corroded ground can easily affect the
circuit. Even when the ground connection looks clean, there can be a thin film of rust on the surface.
(v) When inspecting a ground connection, follow these rules:
04
04
1 Remove Bolt (Screw) 3 Reinstall Bolt (Screw) Securely
Inspect Mating Surface For Tarnish, Dirt,

2 Rust, Etc. Clear As Required To Assure
Good Contact.
• Remove the ground bolt or screw.

• Inspect all mating surfaces for tarnish, dirt and rust, etc.
• Clean as required to assure good contact.
• Reinstall bolt or screw securely.
• Inspect for “add-on” accessories which may be interfering with the ground circuit.
• If several wires are crimped into one ground eyelet terminal, check for improper crimps. Make sure all
of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased
in one eyelet make sure no ground wires have excess wire insulation.
LOCATION
ENGINE ROOM
1 Engine Control Module 2 Data Link Connector

ENGINE
04
04
1 Engine Coolant Temperature Sensor 6 Fuel Pressure Regulator
Manifold Absolute Pressure/Intake Air 7 Upstream Oxygen Sensor

2
Temperature Sensor
8 Crankshaft Position Sensor
3 Throttle Body
9 Exhaust Manifold
4 Idle Air Control Motor
5 Canister Solenoid Valve

HOW TO PERFORM DIAGNOSTICS ANALYSIS

NOTE
USE DIAGNOSTIC SCANNER TO DIAGNOSE VEHICLE.
1. VEHICLE GOES INTO REPAIR SHOP

2. COLLECT AND ANALYSE THE SYMPTOM DESCRIPTION OF CUSTOMER

3. CONNECT THE DIAGNOSTIC SCAN TOOL TO DLC

4. CHECK DTC AND DATA/FREEZE-FRAME DATA

5. ERASE DTC

6. VISUAL CHECK

7. CONFIRM FAULT SYMPTOM
If the engine does not start, first perform the "CHECK FOR DTC" procedures and "CONDUCT BASIC
INSPECTION"procedures below.
Result Proceed To
Fault present The next step
Normal Step 9
8. SIMULATE FAULT SYMPTOM

9. CHECK IF DTC IS PRESENT
Result Proceed To
DTC present The next step
Normal Step 11
10. REFER TO DTC
YES > Go to step 13.

11. BASIC CHECK
Result Proceed To
04
Fault can not be confirmed The next step
Fault can be confirmed Step 16
12. REFER TO SYMPTOM TABLE
04
Result Proceed To
Fault can be confirmed on wiring circuit The next step
Fault can be confirmed on part Step 15
13. CHECK ECM POWER SUPPLY CIRCUIT

14. CHECK ELECTRIC CIRCUIT
Result Proceed To
15. CHECK INTERMITTENT FAULT

16. CHECK PARTS

17. CONFIRM FAULT

18. ADJUST OR REPAIR

19. PERFORM CONFIRMATION TEST
YES > END.

THE MAIN POINTS OF REPAIRING BURNED FUSE OUT

CAUTION
DTC may be stored as the fuse burned down.
1. CHECK DESCRIPTION.
(a) Turn the ignition switch OFF. Remove the burned fuse.
Check the resistance between the load side and ground
where the fuse burned. Turn off all the switch that
connecting to the fuse. If the resistance is almost zero,
the switch and the load components circuit must be
shorted somewhere. If the resistance is not zero, there is
no circuit for short. But the temporally shorted circuit also
will cause the fuse burning.
(b) The shortage caused by following:
• Clipped harness
• Damaged harness
• Connectors or circuits with water
• Wrong operation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Circuit shorted
DIAGNOSTIC HELP - INTERMITTENT FAULT

If an intermittent fault exists, perform diagnosis as follow:
CAUTION
04
Intermittent incidents may occur. In many cases, the malfunction resolves itself (the part or circuit
function returns to normal without intervention). It is important to realize that the symptoms described
in the customer's complaint. Do not recur on (1st trip) DTC visits. Realize also that the most frequent
cause of intermittent incidents occurrences is poor electrical connections. Because of this, the
conditions under which the incident occurred may not be clear. Therefore, circuit checks made as part
of the standard diagnostic procedure may not indicate the specific malfunctioning area. In this case,
04
the maintenance staff must find out the situation in detail from the customer, asking the car owner for
the details of driving conditions, weather conditions, frequency of occurrence and symptom of failure,
take analysis and simulate the same or similar conditions and environment, then, determine if the
symptom of failure is caused by vibration, temperature or other factors. No matter how experienced
the maintenance staff are, how skilled their technique is, if analyzing the failure without checking, they
would certainly neglect some important factors during repairing which causes wrong speculation and
the repair work will take an indirect route or can’t go forward. The following checking will help to find
out this kind of failure.
1. VIBRATION METHOD.
• Connector: Shake the connector lightly in vertical or
horizontal directions, check if the wiring harness
connector connecting the connector and corresponding
parts is loose, the terminal is dirty, rusty, worn or bended
and if the connection is loose because of the terminal
extension.
• Harness: Shake the harness lightly in vertical or
horizontal directions, thoroughly check the harness
breakaway condition in the connector connecting
vibration section and engine/cab instruments.
• Relay, part and sensor: Pat the sensor, relay and part
considered as the failure cause lightly with hands, check
them for failure, don't hit the relay with force, otherwise
the relay may be open.
2. HEATING METHOD.
• If one doubtful region is considered to cause a failure, heat the part which is the most possible cause of
failure with an electric blower or the like to check if the failure occurs.
CAUTION
Don’t heat over 60 ℃ (the heating temperature should be in the limit of touching the part with hands),
don’t heat the control module.
3. SPRAYING METHOD.
• If the failure is considered to occur in rainy day or wet weather, spray water to the vehicle to check if the
failure occurs.
CAUTION
• Don’t spray water to the diesel engine directly to cool the engine, sprinkle water on the front
face of radiator to change the temperature and humidity indirectly.
• Don’t spray water on electronic parts directly.
• Please take extra care to sprinkle water on vehicle leaking water,as the water leaked into vehicle
may damage ECM.
4. ELECTRIC APPLIANCE CONNECTED FULLY METHOD.
• If the failure is possible to be caused by electric overload, connect all electrical loads, including the
heater blower, the headlamps and the rear-window defroster, to check if the failure occurs. The trouble
location or failure part must be found out while the symptom is confirmed during the failure symptom
simulation test. To do this, narrow the range of circuit which is possible to failure based on the symptom
of failure before starting the test and the pre-connection of connectors, then carry out the symptom
simulation test and judge if the circuit tested is normal. When a puzzling failure occurs, make full use of
troubleshooting and diagnostic code list for fault analysis and diagnosis to narrow the failure range and
find out the trouble location quickly; This method is very practical and effective.
5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER.
• Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the
diagnostic scanner, make the rated data status to simulate the fault conditions based on the freeze-
frame on the diagnostic scanner.
6. OSCILLOSCOPE METHOD.
• Using the oscilloscope, capture waveform can be more helpful to find intermittent malfunction.
7. OTHER METHODS.
• Replace parts: Before replacing ECM of other electronic control modules in part replacing method, take
full diagnosis for other external causes. ECM or other electronic control modules are expensive
products with high reliability.
CAUTION
When replacing and testing possible damaged ECM or control modules, install the possible damaged
ECM or control modules on a failure-free vehicle for testing. Don’t install new control modules on a
failed vehicle for testing to avoid damaging the control modules.
BASIC SERVICE PROCEDURE

1. CHECK BATTERY VOLTAGE
04
CAUTION
When engine stops or the ignition switch is in OFF position, perform the test.
Result Proceed To
More than 11V The next step
Less than11V Charge or change battery 04
2. CHECK WHETHER THE ENGINE STARTS
Is the check result normal?

NO > Go to symptom chart.
3. CHECK FILTER

NO > Replace or clean filter.
4. CHECK IDLE SPEED

NO > Go to fault symptom chart - “Unstable idle - The engine cannot keep stability”.
5. CHECK FUEL PRESSURE

NO > Eliminate fuel pressure fault, and go to next step.
6. CHECK IGNITION

YES > Go to fault symptom chart - “When driving - Poor Acceleration”.
NO > Eliminate ignition system fault.
13.
ECM TERMINAL DIAGRAM (ECM SIDE)

CHECK ECM TERMINAL WITH MULTIMETER

CAUTION
The normal standard voltage of per terminal as follow “normal condition”. The table also point out the
check condition. 04
Terminal No. Terminal Description Detection Condition Specified Condition

55 No.1 Injector
70 No.2 Injector
Idle: depress accelerator suddenly Voltage: 11 ～ 14 V 04
56 No.3 Injector
71 No.4 Injector
54 Idle air control motor loop A
53 Idle air control motor loop B Engine: warm condition, start

engine Voltage: 0 ～ 3 V
33 Idle air control motor loop C
34 Idle air control motor loop D
Ignition switch: ON Battery voltage

47 Pump relay
Engine: idle 0～3V

63 EVAP solenoid
Engine: warm condition, 3000 RPM 0～3V
32 Ignition control: (1 - 4) Engine: 3000 RPM 0.3 ～ 3.0 V
17
Continuity power supply Ignition switch: OFF Battery voltage
18
31 MIL Ignition switch: OFF → ON 0～3V
Ignition switch: OFF Battery voltage

58 Main relay
Ignition switch: ON 0～3V
Engine: warm condition, idle 0～3V

61 Heated front oxygen sensor
Engine: 5000 RPM Battery voltage
IAT: 0 ℃ 3.2 ～ 3.8 V
IAT: 20 ℃ 2.3 ～ 2.9 V

27 IAT sensor Ignition switch: ON
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
62 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ～ 0.9 V
20 5V standard sensor power Ignition switch: ON 4.5 ～ 5.5 V
1 Ignition signal Ignition switch: ON Battery voltage

ECT: 0 ℃ 3.2 ～ 3.8 V
ECT: 20 ℃ 2.3 ～ 2.9 V

43 ECT sensor Ignition switch: ON
ECT: 40 ℃ 1.3 ～ 1.9 V
ECT: 80 ℃ 0.3 ～ 0.9 V
TPS: idle 0.3 ～ 1.0 V

24 TPS Ignition switch: ON
Open widely 4.5 ～ 5.5 V
Ignition switch: ON
3 VSS 0～5V
Move forward slowly
start motor 0.4 ～ 4.0 V

12 CKP sensor
Idle 1.5 ～ 2.5 V
73 Ground - 0V
4 - 0V
Sensor ground
5 - 0V
11 Diagnostic signal Ignition switch: ON Pulse signal
30 Diagnostic request Ignition switch: ON Pulse signal

ECM TERMINAL DEFINITION

Terminal No. Color Terminal Description Terminal No. Color Terminal Description
1 BR Ignition signal 38 - - 04
2 - - 39 B-W A/C request signal
3 R-B VSS 40 - -
4 GR-B Sensor ground 41 - -
5 GR Sensor ground 42 G MAP signal 04
Oxygen sensor
6 L-G 43 R-L ECT signal
(low voltage)
7 - - 44 - -
8 - - 45 - -
9 - - 46 B-R A/C control
10 - - 47 L-W Pump control
11 BR-Y Diagnostic communication 48 - -
Revolution signal
12 L 49 - -
(high voltage)
13 - - 50 BR High fan control
14 - - 51 - -
15 - - 52 BR-G Ignition control (2 - 3)
16 - - 53 W-Y Idle air control motor loop B
17 R Continuity power supply 54 Y-L Idle air control motor loop A
18 R Continuity power supply 55 G-Y Injector 1
19 - - 56 BR-R Injector 3
20 R-W 5 V standard power supply 57 - -
21 L-BR 5 V standard power supply 58 B Main relay
22 - - 59 - -
23 - - 60 - -
Heated upstream oxygen

24 L-Y TPS signal 61 R-Y
sensor control
Upstream oxygen signal

25 - - 62 Y-R
(high voltage)
26 - - 63 B-L EVAP control
GR-
27 IAT signal 64 - -
BR
Revolution signal
28 GR 65 - -
(low voltage)
29 - - 66 - -
30 L-B Diagnostic request 67 V-W Low fan control
31 V MIL 68 - -
32 Y Ignition control (1 - 4) 69 - -
33 V-G Idle air control motor loop C 70 G-R Injector 2
34 Y-B Idle air control motor loop D 71 GR-R Injector4
35 L-R - 72 - -
36 - - 73 B Ground
37 - - 74 - -
CHECK ECM HARNESS-SIDE TERMINAL WITH A DIGITAL MULTIMETER

Standard normal resistance and continuity as follow.
No. Item Normal Condition 04

1 Injector (BJ491EQ1-40) 12 ± 0.6 Ω (20 ℃ )
2 Injector (BJ491EQ1-41) 12 ± 0.6 Ω (20 ℃ )
3 Injector (BJ491EQ3-3) 12 ± 0.6 Ω (20 ℃ )
4 Injector (BJ491EQ3-30) 1.5 Ω (20 ℃ ) 04
5 Idle air control motor loop A, B terminal

53 Ω ± 10% (27 ℃ )
6 Idle air control motor loop C, D terminal
7 CKP sensor 560 Ω (20 ℃ )
8 EVAP solenoid valve 19 ～ 22 Ω (20 ℃ )
9 ECM ground Continuity
10 Heated oxygen sensor 9.6 ± 1.5 Ω (20 ℃ )
9098 ～ 9700 Ω (0 ℃ )
5494 ～ 5822 Ω (10 ℃ )

11 ECT sensor
3420 ～ 3602 Ω (20 ℃ )
2184 ～ 2296 Ω (30 ℃ )
12 Primary resistance of ignition coil 0.52 ± 0.05 Ω (23 ± 5 ℃ )
13 Secondary resistance of ignition coil 9840 ± 980 Ω (23 ± 5 ℃ )

DIAGNOSTIC SYSTEM
1. THE FAILURE OF ENGINE ELECTRIC CONTROL
SYSTEM.
(a) Malfunction Indicator Lamp (MIL) (1) (OBD MIL)
illuminated. When the MIL lights, based on relevant
requirements of national rules, it needs to be treated
immediately, otherwise the system will limit the speed of
the engine so as to affect the normal operating of
vehicle.
(b) The failures should be checked with diagnostic scan tool
with corresponding functions.
2. READ DTC.
(a) The Diagnostic Trouble Code (DTC) record and data
related with sensors and actuators in ECM can be read
by KT600 diagnostic scan tool. Additional, the actuator
can be positive driven by the diagnostic scan tool under
specified conditions.
3. DLC - DATA LINK CONNECTOR.

(a) ECM communicates with DLC.
(b) DLC signal name on connector terminal and check the
results of the terminal.
Terminal No. Name Check Result

Diagnostic request Pulse signal (when
1
signal commnicate)
Diagnostic Pulse signal (when

7
communication commnicate)
16 Battery positive 9 ～ 14 V
NOTE
• Connect the diagnostic scanner cable to DLC. Turn
ignition switch ON. Try to open it. If error communication
displayedon screen, then the diagnostic scanner faults.
• If the diagnostic scanner communicates with other
vehicle normally, then check the DLC on the original
vehicle.
ENGINE CONTROL SYSTEM SELF-DIAGNOSTIC ITEM

No. Check Item
1 Injector 04
2 Main Relay
3 Fuel Pump
4 Ignition Coil
5 Oxygen Sensor 04
6 EVAP Solenoid
7 Vehicle Speed Sensor
8 CKP Sensor
9 Throttle Position Sensor
10 ECT Sensor
11 MAP/IAT Sensor
READING AND ERASING DIAGNOSTIC TROUBLE CODE (DTC)

NOTE
The troubles are tested and determined by the engine control system and stored in the engine
electronic control module; the system troubles can be current or history.
1. DTC DESCRIPTION:
(a) Current troubles: Exist in ECM currently, for example: The circuit of Engine Coolant Temperature (ECT)
sensor is open. The current troubles must be repaired, otherwise, they can’t be erased from memory.
(b) History troubles: Two storage types:
• The trouble has been repaired and actual trouble has disappeared, but the memory hasn’t been erased
from ECM.
• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact
of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before
being erased from the memory, or it can be processed referring to the troubleshoot methods for
intermittent malfunction.
CAUTION
• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the
battery voltage must be tested before checking and the voltage should not be less than 11V.
• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be
erased.
• Before connecting or disconnecting KT600 smart diagnostic scan tool, be sure to confirm the
ignition switch is in OFF position.
• Using the KT600 collective smart scan tool, read DTC.
2. USING THE SCAN TOOL, PERFORM THE READING DTC PROCEDURE:
(a) Check and confirm the following conditions:

• The throttle: Closed
• A/C switch: OFF
• Transmission: N
(b) Turn the ignition switch OFF.
(c) Connect the KT600 scan tool to the Data Link Connector
(DLC) - use the most current software available.
(d) Turn the ignition switch ON.
(e) Select the item “AUTO DIAGNOSIS\FOTON\ LIGHT BUS\
VIEW\ENGINE\491 GASOLINE ENGINE\ MT20U2\ACTIVE
TEST”.
(f) Check DTC and data stream. After recording, delete it (If
DTC cannot be deleted, then perform the diagnosis
procedure refering to “Diagnostics trouble code check”.
Repair faults ).
(g) Start engine and warm it to normal operating temperature.
(h) Under one of the condition, run engine to MIL ON:
• Simulate DTC setting condition.
• Simulate the customer’s description.
• Simulate the scan tool freeze data.
(i) Using the scan tool, read the DTC in ECM.
(j) If there are DTCs but the data stream is normal or the
function is good, then refer to the diagnostics help. If there
are DTCs but the stream is not normal or the function is
not good, then perform diagnosis procedure refering to 04
“Diagnostics trouble code chart”.
NOTE
Use the scan tool to delete DTCs. As soon as DTC is
detected, ECM will record the vehicle and driving
conditions as the type of freeze stream. When eliminating
faults, the catching function will help to confirm the 04
condition of the fault, such as warm condition, stop
condition and lean or rich A/F ration and other data.
3. DTC SETTING CONDITION INCLUDE THE FOLLOWING ITEMS:
(a) Engine speed
(b) VSS
(c) ECT sensor
(d) MAP sensor
(e) Barometric sensor
(f) IAT sensor
(g) TPS
(h) EVAP
(i) Fuel pressure adjustment
(j) A/C switch
4. THE WAY OF CLEAR DTC:
(a) Turn the ignition switch OFF.
(b) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(c) Turn the ignition switch ON.
(d) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ ACTIVE TEST”.
CAPTURING DATA
CAUTION
• Once DTC is captured and stored, ECM records the vehicle and driving conditions information
as a form of rated data. During troubleshooting, the rated data can help determine if the vehicle
was running or parked, and data of other sensors and actuators has been recorded when the
trouble occurred.
• If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM
records the engine condition in form of freeze-frame data at regular intervals. The diagnostic
scan tool can be used to read several sets of freeze-frame data respectively; KT600 diagnostic
scan tool provides powerful random data flow help function. Select “Read Data Flow” function
menu in engine system, enter the data flow testing result display interface, click “?Help” button
to eject the following windows:
(a) Driving Record Playback
(b) Calculator
(c) Data Range Reference
(d) Data Capture
(e) Data Comparisons
(f) Data Flow Settings
(g) Data/Waveform Display
(h) Driving Recorder Menu
(i) The data can be used to simulate the vehicle conditions as the failure occurs. It also can help determine
the cause of trouble and judge if it’s temporary fault. When the engine is running with trouble, select the
item “Auto Diagnosis\Foton\Light Bus\View\Engine\491 Gasoline Engine\MT20U2\Read Data Flow
(Click “?Help”)\Data Capture\Click “Record”\Click “?Help”\Data Comparisons.
FAIL-SAFE CHART
NOTE
When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up.
04
No. Item Control Contents Period Of Fault
• The MIL light will turn on.

• Unstable idle.
1 Injector • Lack of engine power.
• Engine will not start. 04
• Poor acceleration.

2 Relay • System is out of work.
• Can not start engine.

• Noisy fuel pump operation.
3 Fuel pump
• Engine will not start.

• Unstable idle.
• Lack of engine power.
4 Ignition coil
• Poor fuel economy.
• Excessive exhaust emissions.
• Weak spark.

5 Oxygen sensor • Excessive exhaust emissions.
• Sluggish acceleration.
• Poor driving capability.

• The engine base fuel closed-loop control self-learning will be shut off.
6 EVAP solenoid valve
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle.

• The engine RPM will be limited.
7 VSS
• No VSS diaplay.

8 IAT sensor
• The IAT is equal to ECT.

• Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 4000 RPM.
9 CKP sensor
• No ignition signal to the ECM.
• The tachometer does not work.
• Rough engine operation.
10 TPS

• Hard to start when cold.
• Hard to start when hot.
11 ECT sensor • Poor driving capability.
• If the sensor circuit is shorted to power, the engine will run under the
default values.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP.

12 MAP/IAT sensor
• Unstable idle.
DATA STREAM LIST/ACTIVE TEST

NOTE
• Through reading the data stream displayed on scan tool sreen, we can check the sensor, 04
actuator and switch data value but not removing any components. As first step, this way is the
best way to short diagnosis period .
• The following arranged the data stream under the normal condition. It only offer to reference.
Don’t judge a component normal or not only depend on these value.
1. READ DATA STREAM PROCEDURE.
(a) Start the engine and warm it to normal operating temperature. 04
(c) Connect the KT600 scan tool to the Data Link Connector (DLC).
(d) Turn the ignition switch ON. Use the most current software available.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ READ DATA STREAM”.
2. THE TABLE BELOW LISTS THE DATA FOUND IN INSPECTION ITEMS AT DIFFERENT STATES
BY KT600 WITHIN “DATA LIST” ITEMS.
(a) If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and
accessories switch are in the OFF position.
(b) Injector driving time means time is taken by crankshaft at speed of less than 2500 RPM and power
supply voltage of 11 V.
(c) For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more
than standard time.
(d) For new vehicle (within operation distance of 500 km), sometimes step length of stepper motor is more
than 30 steps than standard step length.
Displayed Item Check Item Specified Condition
• Engine: Warm Engine suddenly

decelerate from 4000 RPM ≤ 0.2 V
• A/F: Mixture is made leaner
when decelerating, Mixture
is made richer when Engine suddenly
accelerate 0.6 ～ 1 V
Oxygen sensor accelerating
• Engine: Warm Engine: Idle ≤ 0.4 V

• Check A/F with oxygen
sensor 2500 RPM 0.6 ～ 1 V
IAT: -20 ℃ -20 ℃
IAT: 0 ℃ 0℃
• Ignition switch: ON
IAT sensor IAT: 20 ℃ 20 ℃
• Engine is running
IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
Engine: Idle 0.3 ～ 1 V (0%)
TPS Ignition switch: ON TP open slowly Increase proportionally
Wide open 4.5 ～ 5.5 V
Power supply Ignition switch: ON System voltage
Engine: Stop OFF

Ignition switch Ignition switch: ON
Engine: Start ON
ECT: -20 ℃ -20 ℃
ECT: 0 ℃ 0℃
ECT sensor ECT: 20 ℃ 20 ℃
• Engine is running
ECT: 40 ℃ 40 ℃
ECT: 80 ℃ 80 ℃
Altitude: 0 m 101 kPa

Barometric sensor Ignition switch: ON
Engine: Idle A/C switch: OFF OFF

A/C switch (Turn A/C switch ON, A/C
compressor works) A/C switch: ON ON
ECT: 0 ℃ 60 ～ 90 ms
Injector Engine: Running ECT: 20 ℃ 30 ～ 50 ms
ECT: 80 ℃ 6.7 ～ 10.1 ms


Engine: Idle 2.2 ～ 3.4 ms
• ECT: 80 ～ 95 ℃ 04
Injector 2500 RPM 1.9 ～ 3.1 ms
• Accessorie: OFF
• Transmission: Neutral Engine runs at high speed
Increase
suddenly
Engine: Idle 2 ～ 18 BTDC

Ignition coil Engine: Warm
2500 RPM 27 ～ 47 BTDC 04
• ECT: 80 ～ 95 ℃ A/C switch: OFF 2 ～ 25 steps
• Accessorie: OFF
Idle air control
motor • Transmission: Neutral
• Engine: Idle A/C switch: OFF → ON A/C switch: OFF → ON
• A/C works
Not activate (Compressor

A/C switch: OFF
clutch does not work)
A/C relay Engine: Warm and idle
Activate (Compressor
A/C switch: ON
clutch works)
Compare the values read

• Engine: Running
from tachometer and The same
• Tachometer: Connection KT600 respectively
ECT: -20 ℃ 1275 ～ 1475 RPM
CKP sensor ECT: 0 ℃ 1225 ～ 1425 RPM
Engine: Idle ECT: 20 ℃ 1100 ～ 1300 RPM
ECT: 40 ℃ 950 ～ 1150 RPM
ECT: 80 ℃ 650 ～ 850 RPM

3. ACTIVE TEST.
CAUTION
The active test function for us to check the sensor, actuator and switch data value but not removing
any components. We can use the scan tool to perform the test. As the first step, this way is the best
way to short diagnosis period.
Active test procedure.
available.
MT20U2\ ACTIVE TEST”.
(e) Refer to the following chart, perform the active test. The following chart is the item which in the
“ACTIVE TEST” of the KT600 scan tool.
(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair.
(g) After repairing, using the KT600, perform again, confirm the DTC no longer appears.
(h) Disconnect KT600 scan tool.
(i) Restart engine to perform test. Confirm the faults has been eliminated.
Scanner Display Test Component Control Area Diagnosis Remark

MIL Control MIL ON / OFF -
EVAP Control EVAP solenoid valve ON / OFF -
Fuel pump relay Fuel pump relay ON / OFF -
Low fan Control low fan ON / OFF -
High fan Control high fan ON / OFF -
A/C relay Shut off A/C relay ON / OFF -
Injector (A/B/C/D) Shut off fuel injection ON / OFF -

DIAGNOSTIC TROUBLE CODE CHART

NOTE
• If a malfunction code is displayed during the DTC check in the check mode, check the harness 04
or connectors for the codes listed in the table below. for details of each code, refer to the DTC
chart.
• Fault type.
A: MIL light immediately.
B: The failure is measured within two consecutive trips, MIL light.
D: No MIL. 04
E: The failure is measured within three consecutive trips, MIL light.
Z: Diagnostic disabled.
DTC No. DTC Definition Suspect Area Type
• MAP sensor
P0106 MAP/TPS Rationality • Open or short in MAP sensor harness or E
connectors
• ECM
• MAP sensor
P0107 MAP Circuit Low Voltage or Open • Short in MAP sensor harness or A
connectors
• ECM
• MAP sensor
P0108 MAP Circuit High Voltage • Open or short in MAP sensor harness or A
connectors
• ECM
• MAP sensor
P1106 MAP Circuit High Intermittent • Intermittent open or short in MAP sensor D
harness or connectors
• ECM
• MAP sensor
P1107 MAP Circuit Low Intermittent • Intermittent short in MAP sensor harness D
or connectors
• ECM
• IAT sensor
P0112 IAT Circuit Low Voltage or Open • Short in IAT sensor harness or connectors Z
• ECM
• IAT sensor
P0113 IAT Circuit High Voltage • Open or short in IAT sensor harness or Z
connectors
• ECM
• IAT sensor
P1111 IAT Circuit High Voltage Intermittent • Intermittent open or short in IAT sensor Z
• ECM
• IAT sensor
P1112 IAT Circuit Low Voltage Intermittent • Intermittent short in IAT sensor harness or E
connectors
• ECM
• ECT sensor
P0115 ECT Sensor Output Stuck • Open or short in ECT sensor harness or B
connectors
• ECM
• ECT sensor
P0116 ECT Skewed High • Open or short in ECT sensor harness or B
connectors
• ECM
• ECT sensor
P0117 ECT Circuit Low Voltage • Short in ECT sensor harness or A
connectors
• ECM
• ECT sensor
P0118 ECT Circuit High Voltage • Open or short in ECT sensor harness or A
connectors
• ECM
• ECT sensor
P0126 ECT Low Temperature • Open or short in ECT sensor harness or B
connectors
• ECM
• Engine coolant
P0217 Thermostat Closed B
• ECM
• ECT sensor
P1114 ECT Circuit Low Intermittent • Intermittent short in ECT sensor harness D
or connectors
• ECM
• ECT sensor
P1115 ECT Circuit High Intermittent • Intermittent open or short in ECT sensor D
• ECM
• Throttle position sensor

P0122 TPS Circuit Low Voltage Or Open • Open or short in throttle position sensor A
• ECM

P0123 TPS Circuit High Voltage • Short in throttle position sensor harness or A
connectors
• ECM

P1121 TPS Circuit High Intermittent • Intermittent short in throttle position D
sensor harness or connectors
• ECM

P1122 TPS Circuit Low Intermittent • Intermittent short in throttle position D
• ECM
• 1 cylinder ignition coil

P0351 EST Output #1 • 1 cylinder ignition coil driver harness or A 04
connectors
• ECM

P0352 EST Output #2 • 2 cylinder ignition coil driver harness or A
connectors
• ECM 04
P0353 EST Output #3 • 3 cylinder ignition coil driver harness or Z
connectors
• ECM

P0354 EST Output #4 • 4 cylinder ignition coil driver harness or Z
connectors
• ECM
• Exhaust system
• Engine mechanical
P0420 Catalyst Efficiency Below Threshold • Oxygen sensor aging or contamination A
• Oxygen sensor harness or connectors
• Catalytic converters
• Upstream oxygen sensor

P0131 O2S 1 Circuit Low Voltage • Short in upstream oxygen sensor harness A
or connectors
• ECM

P0132 O2S 1 Circuit High Voltage • Short in upstream oxygen sensor harness A
or connectors
• ECM

P0133 O2S 1 Slow Response • Open or short in upstream oxygen sensor E
• ECM

P0134 O2S 1 Circuit Insufficient Activity or Open • Open in upstream oxygen sensor harness A
or connectors
• ECM
• Upstream oxygen heater

P0135 O2S 1 Heater Circuit Not Functioning • Open or short in upstream oxygen heater Z
• ECM

P1133 O2S 1 Insufficient Switching E
• ECM

P1134 O2S 1 Transition Time Ratio E
• ECM
• Downstream oxygen sensor

P0137 O2S 2 Circuit Low Voltage • Open or short in downstream oxygen E
• ECM

P0138 O2S 2 Circuit High Voltage • Open or short in downstream oxygen E
• ECM

P0140 O2S 2 Circuit Insufficient Activity or Open • Open in downstream oxygen sensor E
• ECM
• Downstream oxygen heater

P0141 O2S 2 Heater Circuit Not Functioning • Open or short in downstream oxygen E
heater harness or connectors
• ECM
• Intake air system

• Injector blockage
• MAP sensor
• Engine coolant temperature sensor
• Fuel pressure
• Gas leakage in exhaust system
P0171 Fuel Trim System Lean • Open or short in oxygen sensor circuit B
• Oxygen sensor
• Oxygen sensor heater
• Relay and harness
• PCV valve and hose
• PCV hose connection
• ECM
• Injector leak or blockage

• MAP sensor
• Ignition system
• Fuel pressure
P0172 Fuel Trim System Rich • Gas leakage in exhaust system B
• Open or short in oxygen sensor harness
or connectors
• Oxygen sensor
• Relay and harness
• ECM
• Injector 1
P0201 Injector 1 Circuit Malfunction • Injector 1 harness or connectors A
• ECM
• Injector 2
• ECM
• Injector 3
P0203 Injector 3 Circuit Malfunction • Injector 3 harness or connectors A 04
• ECM
• Injector 4
• ECM
• Open or short in engine harness or 04

connectors
• Vacuum hose connection
• Ignition system
• Injector
• Fuel pressure
• MAP sensor
P0300 Missfire B/A
• ECT sensor
• Compression pressure
• Valve clearance
• Valve timing
• PCV hose
• ECM
• CKP sensor
P0336 CKP Sensor Circuit Performance • Open or short in CKP sensor harness or E
connectors
• ECM
• CKP sensor
P0337 CKP Sensor Circuit Malfunction • Open or short in CKP sensorharness or A
connectors
• ECM
• Open or short in purge solenoid harness

or connectors
P0443 Purge Solenoid E
• Purge solenoid
• ECM
• Vent solenoid
P0449 Vent Solenoid Circuit Fault • Vent solenoid harness or connectors Z
• ECM
• Fuel tank pressure sensor

P0452 Fuel Tank Pressure Sensor - Low Volts • Fuel tank pressure sensor harness or Z
connectors
• ECM
• Fuel tank pressure sensor

P0453 Fuel tank Pressure Sensor - High Volts • Fuel tank pressure sensor harness or Z
connectors
• ECM
• Evaporative system vacuum

• Evaporative system leakage
• Evaporative hose
P0440 EVAP System - Large leak Z
• Vent solenoid
• Vent solenoid harness or connectors
• ECM

P0442 EVAP System - Small Leak (1mm) Z
• Vent solenoid
• ECM

P0446 EVAP System - Blocked Vent Z
• Vent solenoid
• ECM

P0456 EVAP System - Very Small Leak Z
• Vent solenoid
• ECM
• Fan1
P0480 Fan 1 Fault • Fan 1 harness or connectors E
• ECM
• Fan 2
P0481 Fan 2 Fault • Fan 2 charness or connectors E
• ECM

P1441 EVAP System - Purge Solenoid Leak Z
• Vent solenoid
• ECM
• Fuel level sensor

P0461 Fuel Level Sensor Rationality - Stuck • Fuel level sensor harness or connectors D
• ECM

P0462 Fuel Level Sensor Circuit Low Input • Fuel level sensor harness or connectors D
• ECM

P0463 Fuel Level Sensor Circuit High Input • Fuel level sensor harness or connectors D
• ECM

P0464 Fuel Level Sensor Intermittent - Noisy • Fuel level sensor harness or connectors Z 04
• ECM
• Vehicle speed sensor

P0502 Vehicle Speed Signal Missing • Vehicle speed sensor harness or E
connectors
• ECM
04
• Idle control system
P0506 Idle Speed Control - Low RPM E
• ECM

P0507 Idle Speed Control - High RPM E
• ECM
• A/C clutch harness or connector

P0532 A/C Pressure Circuit High Voltage D
• ECM

P0533 A/C Pressure Circuit Low Voltage or Open D
• ECM
• A/C clutch
P0645 A/C Clutch Output Circuit Fault • A/C clutch harness or connector Z
• ECM
• Charging system
P0562 System Voltage High D
• ECM
• Charging system
P0563 System Voltage Low • Battery D
• ECM
P0601 ECM Checksum Error • ECM A
P0602 S/w And Calibration Mismatch • ECM A
P0607 Low Power Counter • ECM D
P1607 Low Power Counter Reset • ECM D
• Open or short in upstream oxygen sensor

P1167 O2 Signal Rich In DFCO • Engine hood main relay A
• Upstream oxygen heater and main relay
• ECM
• Open or short in upstream oxygen sensor

P1171 O2 Signal Lean In PE • Engine hood main relay B
• Upstream oxygen heater and main relay
• ECM
P0317 No Rough Road Sensor Detected • ECM D


P1380 PWM Rough Road Output - System • ECM D
• Communication harness
P1381 PWM Rough Road Output - Serial Data D
• ECM
P1396 WSSD Rough Road Output - System • ECM Z
• CKP sesnor not installed

P1397 TEC Not Learned Z
• ECM
• Accelarator sensor
P1391 G Sensor Rationality D
• ECM
• Accelerator sensor
P1392 G Sensor Short Low • Short in accelerator sensor harness or D
connectors
• ECM
• Accelerator
P1393 G Sensor Short High • Short or open in accelerator sensor D
• ECM
P1625 Controller Reset • ECM Z

DIAGNOSTICS TROUBLE CODE (DTC) CHECK

P0117 - ECT CIRCUIT LOW VOLTAGE
04
P0118 - ECT CIRCUIT HIGH VOLTAGE
1 Electric Appliance Connector
2 Cabinet
3 NTC Resistance 04
DESCRIPTION
1. This sensor is one Negative Temperature Coefficient (NTC) thermistance, of which the
resistance will reduce following the increasing of the temperature in non-linear relation. When
the coolant temperature is low, the resistance in the thermistor increases. When the
temperature is high, the resistance drops. The variations in resistance are reflected in the
voltage output from the sensor.
2. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant
temperature.
WIRING DIAGRAM
DTC No. DTC Definition DTC Detection Condition Suspect Area
• 60 seconds since the ignition switch is • ECT sensor
turned “ON” or after engine starts
P0117 ECT circuit low voltage • Short at ECT
• Sensor output voltage continues to be 0.2 sensor harness
V or lower (corresponding to an intake
• ECM
airtemperature of 145 ℃ or higher) for 4
seconds
turned “ON” or after engine starts • Open or short at
P0118 ECT circuit high voltage • Sensor output voltage continues to be 4.6 ECT sensor har-
V or higher (corresponding to an intakeair ness
temperature of -45 ℃ or lower) for 4 • ECM
seconds
NOTE
• While performing electrical diagnosis & testing, assure the ECM ground is in good contact.
• While performing electrical diagnosis & testing, always refer to the electrical schematics for
specific circuit and component information.
• While performing electrical diagnosis & testing, look for broken, bent, pushed out or corroded
terminals.
• If the ECM detects the DTC P0117 or P0118, it operates the fail–safe function in which the engine
coolant temperature is assumed to be a default value. At the same time, with the ignition switch
on, the cooling fans will operate at high speed. The fail–safe function will not untill the ECM
detects the acceptance condition.
• If any DTC is detected, using the scan tool, select the item“AUTO DIAGNOSIS\FOTON\LIGHT BUS\
VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\READ DATA STREAM\COOLANT TEMPERATURE”.
Temperature Displayed Malfunction

04
-40 °C Open or short circuit
140 °C Short circuit
INSPECTION PROCEDURE
1. READ VALUE AND DTC 04
(a) Start the engine and warm it to normal operating temperature.

(b) Using the KT600 scan tool, perform the DTC confirming procedure.
(c) Read sensor value displayed on the KT600 scan tool.
Temperature Displayed And DTC Proceed To Malfunction
• P0118
The next step Open or short to power
• -40 °C
• P0117
Step 5 Short to ground
• 140 °C or more
• P0117 or P0118
Diagnostic help Check for intermittent problems
• 80 °C - 100°C

YES > Go to diagnostic help for checking intermittent problems.
NO > If there is an open circuit, go to next step.
If there is a short circuit, go to step 5.
2. READ VALUE ON KT600

(b) Disconnect the E021 ECT sensor connector.
(c) Connect terminals A and B at the E021 engine coolant

temperature sensor connector on the wire harness side.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT
BUS\VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\
READ DATA STREAM\COOLANT TEMP”.
(f) Read ECT value displayed on the KT600 scan tool.
Temperature value: 140 ℃ or more

YES > Confirm good connection at sensor. If OK, replace engine coolant temperature sensor.
NO > Go to next step.
3. CHECK HARNESS AND CONNECTOR (ECT SENSOR - GROUND )
(a) Disconnect the connection terminals A and B of the E021

engine coolant temperature sensor connector on the wire
harness side.
(b) Measure the voltage according to the value in the table
below.
Standard voltage
Tester Connection Specified Condition

E021 (B) - Ground 5.0 ± 0.25 V

NO > Repair or replace harness or connector. If OK, replace ECM.
4. CHECK HARNESS AND CONNECTOR (ECT SENSOR - ECM)

(b) Disconnect the E001 ECM connector.
(c) Measure the resistance according to the value in the
table below.
Standard resistance (check for open)

E021 (A) - E001 (5) ＜2Ω

YES > Go to step 6.
NO > Repair or replace harness or connector.

(b) Disconnect ECT sensor connector.
MT20U2\READ DATA STREAM\COOLANT TEMP”.
(e) Read ECT value displayed on the KT600 scan tool.
Temperature value: -40 °C
YES > Replace ECT sensor.
6. CHECK HARNESS AND CONNECTOR (ECT SENSOR - GROUND)

(b) Disconnect the E001 ECM connector. 04
table below.
Standard resistance (check for short)

04
E021 (A) - E021 (B)
≥ 1 MΩ
E021 (B) - Ground

YES > Replace ECM.
P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN

P0108 - MAP CIRCUIT HIGH VOLTAGE
P1106 - MAP CIRCUIT HIGH INTERMITTENT
P1107 - MAP CIRCUIT LOW INTERMITTENT
DESCRIPTION
MT20U2 adopts speed-density air measurement method to check the air intake volume into the engine
so as to control the fuel injection pulse width for the precise control of engine power output.
Meanwhile, this system adopts intake pressure cylinder determination technology and the intake air
sensor is installed near the inlet opening of cylinder 4 intake manifold. At the moment when the throttle
is opened, there will be one instantaneous pressure drop at the sensor, of which the value is about 1
kPa. When the ECM detected and received this instantaneous pressure drop, the ECM will determine
the compression upper dead center signal after software diagnosis treatment (its functions is similar
with the camshaft position sensor of traditional electric injection system, also referred as phase
sensor).
WIRING DIAGRAM
• MAP sensor
• MAP sensor loose 04
connector
• Open or short at MAP
sensor signal circuit
• No TPS faults
• Short at MAP sensor
P0107 MAP circuit low voltage or open • ECM detects that the MAP signal circuit
input signal is less than
• Open at MAP sensor
acceptable value 04
5V circuit
• Open at MAP sensor
ground circuit
• ECM
• MAP sensor
• Engine: running
• Short at MAP sensor
• No TPS faults signal circuit
P0108 MAP circuit high voltage • ECM detects that the MAP • Short at MAP sensor
input signal is higher than 5V power circuit
acceptable value
• ECM
• MAP sensor
• Engine: running • Intermittent short at
MAP sensor signal
• No TPS faults circuit
P1106 MAP circuit high intermittent • ECM detects that the MAP • Intermittent short at
input signal is intermittent MAP sensor 5V power
higher than acceptable value circuit
• ECM
• MAP sensor
• MAP sensor loose
connector
• Intermittent open or
short at MAP sensor
• Ignition switch: ON signal circuit
• No TPS faults • Intermittent short at
P1107 MAP circuit low intermittent • ECM detects that the MAP MAP sensor signal
input signal is intermittent circuit
less than acceptable value • Intermittent open at
MAP sensor 5V circuit
• Intermittent open at
MAP sensor ground
circuit
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item“AUTO DIAGNOSIS\FOTON\LIGHT
BUS\VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
1. READ VALUE AND DTC

(c) Read MAP value displayed on the KT600 scan tool.
Pressure Displayed And DTC Proceed To Malfunction
• P0108
• P1106 The next step Short to voltage
• About 45 kPa (or 4 V)
• P0107
• P1107 The next step Open or short to ground
• P0107 or P0108
• P1106 or P1107 Diagnostic help Check for intermittent problems
• Pressure normal

NO > If there is an open or short circuit, go to next step.
2. CHECK HARNESS AND CONNECTOR (MAP SENSOR - GROUND)

(b) Disconnect the E010 MAP sensor connector.
(d) Measure the voltage according to the value in the table

below.
Standard voltage

E010 (D) - Ground 5.0 ± 0.25 V

YES > Go to the next step.
3. CHECK HARNESS AND CONNECTOR
(a) Connect terminals A and D of the E010 MAP sensor

connector on the wire harness side. 04
(b) Read MAP value displayed on the KT600 scan tool.
Standard voltage: 5.0 ± 0.25 V
04

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (MAP SENSOR - ECM)

(b) Disconnect the connection terminals A and D of the E010
MAP sensor connector on the wire harness side.
(c) Disconnect the E001 ECM connector.
(d) Measure the resistance according to the value in the
table below.

E010 (B) - E001 (4) ＜2Ω

(a) Connect the E010 MAP sensor connector.

(b) Connect the E001 ECM connector.
(c) Start engine. Measure the voltage according to the value

in the table below.
Standard voltage

E010 (D) - Ground 5.0 ± 0.25 V
• Idle: 1.3 V
• No load condition, opening
E010 (A) - Ground throttle slowly: 1.3 V
• Open quickly: 4 V, then
return back to 1.5 V


(e) Measure the voltage according to the value in the table
below.
Standard voltage

E010 (A) - Ground 0V

7. READ MAP SIGNAL VOLTAGE

(c) Connect terminals A and D of the E010 MAP sensor
connector.
(e) Using scan tool, select the item “DIAGNOSIS\

FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
ENGINE\MT20U2\READ DATA STREAM\MAP SENSOR
VOLTAGE VALUE”.
Standard voltage: 4 V

8. REPLACE ECM
(a) Replace ECM.

(b) With the KT600 scan tool, perform the DTC confirming procedure. 04
(c) Perform reading sensor data stream procedure.
(d) Confirm no DTC and data normal.
04
P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN

P0113 - IAT CIRCUIT HIGH VOLTAGE
DESCRIPTION
The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake
air. When the air temperature is low, the resistance in the thermistor increases. When the temperature
is high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM
terminal.
WIRING DIAGRAM
• IAT sensor 04
• 60 seconds since the ignition switch
is turned “ON” or after engine starts • Short at IAT
sensor 5 V
P0112 IAT circuit low voltage or open • Sensor output voltage continues to reference circuit
be 0.2 V or lower (corresponding to to ground
an intake air temperature of 125 ℃ • ECM
or lower) for 4 seconds
• Ignition switch: ON 04
• IAT sensor
• 60 seconds since the ignition switch
is turned “ON” or after engine starts • Open at IAT
P0113 IAT circuit high voltage sensor 5 V
• Sensor output voltage continues to reference circuit
be 4.6 V or higher (corresponding to battery
to an intake air temperature of -45
• ECM
℃ or lower) for 4 seconds
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\
VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.

(c) Read IAT value displayed on the KT600 scan tool.
Temperature: Same value as the actual intake air temperature.
• P0113
Step 4 Short to voltage
• About 45 ℃
• P0112
The next step Open or short to ground
• About 45 ℃
• P0112 or P0113
• Temperature is normal

2. READ VALUE ON KT600 SCAN TOOL (IAT)

(b) Disconnect the E010 IAT sensor connector.
(c) Connect terminal B and C at the E010 IAT sensor

connector.
(e) Using scan tool, select the item “DIAGNOSIS\FOTON
\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ READ DATA STREAM\IAT SENSOR VALUE”.
(f) Read IAT value.
Temperature value: About 140 ℃

YES > Confirm good connection at sensor. If OK, replace IAT sensor.
3. CHECK HARNESS AND CONNECTOR (IAT SENSOR - GROUND)
(a) Disconnect the connection terminals B and C of the E010

IAT sensor wire harness side connector.
below.
Standard voltage
E010 (C) - Ground 4.5 ～ 5.0 V

4. CHECK HARNESS AND CONNECTOR (IAT SENSOR - ECM)

table below.

E010 (B) - E001 (4) ＜2Ω

YES > Go to step 7.
5. READ VALUE ON KT600 SCAN TOOL

(b) Disconnect the E010 IAT sensor connector. 04
(d) Using scan tool, select the item “DIAGNOSIS \FOTON \LIGHT BUS\ VIEW\ENGINE\491 GASOLINE
ENGINE\ MT20U2\READ DATA STREAM\IAT SENSOR VALUE”.
(e) Read IAT value.
Temperature value: About -40 ℃
Is the check result normal? 04
YES > Repalce IAT sensor.


table below.

E010 (A) - E010 (C)
≥ 1 MΩ
E010 (C) - Ground

7. REPLACE ECM
(a) Replace ECM.

P0122 - TPS CIRCUIT LOW VOLTAGE OR OPEN

P0123 - TPS CIRCUIT HIGH VOLTAGE
P1121 - TPS CIRCUIT HIGH INTERMITTENT
P1122 - TPS CIRCUIT LOW INTERMITTENT
DESCRIPTION
MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle
position information to the ECM, based on the ECM can obtain the engine load information, operating
mode (such as start, idle, reverse towing, partial load, full load) and acceleration & deceleration
information. This sensor is of 3-line type and the ECM will check the throttle open extent by monitoring
the voltage variation.
WIRING DIAGRAM
• 60 seconds since the ignition • TPS failed or 04
switch is turned “ON” or after maladjusted
P0122 TPS circuit low voltage or open engine starts • Open or short at
• Sensor output voltage continues TPS circuit
to be 0.2V or lower for 4 • ECM
seconds
• 60 seconds since the ignition • TPS failed or
P0123 TPS circuit high voltage engine starts
• Short at TPS circuit
• The sensor output voltage
• ECM
continues to be 2V or higher for
4 seconds
P1121 TPS circuit high intermittent engine starts
• Short at TPS circuit
• The sensor output voltage to be
• ECM
2V or higher for 4 seconds
intermittently
P1122 TPS circuit low intermittent engine starts • Open or short at
• Sensor output voltage to be TPS circuit
0.2V or lower for 4 seconds • ECM
intermittently
NOTE
terminals.
1. READ VALUE AND DTC (TPS)

(c) Read TPS value displayed on the KT600 scan tool.
Voltage Displayed And DTC Proceed To Malfunction
• P0122 ( ＜ 0.2 V) Step 4 Short to voltage
• P0123 ( ＞ 2 V) The next step Open or short to ground
• P0122 or P0123
• Signal is normal

2. CHECK HARNESS AND CONNECTOR (TPS - GROUND)

(b) Disconnect the E007 TPS connector.

below.
Standard voltage
E007 (A) - Ground 4.5 ～ 5.0 V

3. CHECK TPS DATA STREAM
(a) Connect terminals A and B at the E007 TPS connector

on the wire harness side. 04
(b) Perform reading sensor data stream procedure with scan
tool.
Voltage value: 4 V
04

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (TPS - ECM)

(b) Disconnect the connection terminals A and B at the E007
TPS connector on the wire harness side.
table below.

E007 (B) - E001 (5) ＜2Ω

(a) Connect the E007 TPS connector.


below.
Standard voltage

E007 (A) - Ground • Ignition switch ON: 5.0 V
• Ignition switch ON (TP close

completely): 0.5 V (scan tool: 0%)
E007 (C) - Ground
• Ignition switch ON (TP is full
opening): 4.5 V (scan tool: 100%)


below.
Standard voltage

E007 (C) - Ground 0V

7. CHECK TPS DATA STREAM

(b) Connect terminals A and C at the E007 TPS connector
on the wire harness side.
(d) Using scan tool, select the item”DIAGNOSIS\FOTON\

LIGHT BUS\ VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ READ DATA STREAM\ TPS VALUE”.
Voltage: 4 V

8. REPLACE ECM
(a) Replace ECM.

(b) Using the KT600 scan tool, perform the DTC confirming procedure. 04
04
P0131 - O2S 1 CIRCUIT LOW VOLTAGE

P0132 - O2S 1 CIRCUIT HIGH VOLTAGE
P0134 - O2S 1 CIRCUIT INSUFFICIENT ACTIVITY OR OPEN
1 Air
2 Case
3 Solid electrolyte
4 Platinum electrode
5 Heater
6 Lining
7 Exhaust gas
8 Rich
9 Air-fuel ratio
10 Lean
DESCRIPTION
The Engine Control Module (ECM) supplies a voltage of about 0.45 V between the ECM terminals 62
and 6. The oxygen sensor varies the voltage within a range of about 1 V if the exhaust is rich, down to
about 0.1 V if the exhaust is lean. The oxygen sensor is like an open circuit and produces no voltage
when it is below 350°C. An open oxygen sensor circuit or a cold oxygen sensor causes “open loop”
operation.
WIRING DIAGRAM
04
04
• The engine controls system is in

closed loop
• Upstream oxygen
• The engine speed is below 6000 sensor (O2
RPM sensor1)
P0131 O2S 1 circuit low voltage • Upstream oxygen sensor feedback • Short at upstream
voltage continues to be 0.07 V or oxygen sensor
lower at least 40 seconds circuit
• DTC P0107, P0108, P0117, • ECM
P0118, P0122, P0123, P0335 are
not set
• Upstream oxygen
• Upstream oxygen sensor feedback sensor (O2
voltage continues to be 4.8 V or sensor1)
higher for at least 0.2 seconds
P0132 O2S 1 circuit high voltage • Short at upstream
• DTC P0107, P0108, P0117, oxygen sensor
P0118, P0122, P0123, P0335 are circuit
not set
• ECM
• Upstream oxygen
• Upstream oxygen sensor feedback
sensor (O2
voltage continues to be between
sensor1)
O2S 1 circuit insufficient 0.42 ～ 0.48 V
P0134 • Open at upstream
activity or open • DTC P0107, P0108, P0117, oxygen sensor
P0118, P0122, P0123, P0335 are circuit
not set
• ECM
NOTE
terminals.
DIAGNOSIC HELP
• Normally scan tool voltage varies between 0.1 to 1.0 V while in closed loop.
• Check upstream oxygen sensor harness, make sure the upstream oxygen sensor is not well installed
and it touches the exhaust pipe.
• Check if there is intermittent ground existent between ECM and upstream oxygen sensor.
• Perform an injector balance test. Check if the lean mixture was caused by injector blocked.
• The vacuum leaking of crankcase causes lean mixture.
• The air outside enters into exhaust pipe and through upstream oxygen sensor by the leaking of
exhaust manifold wsaher.

(c) Read upstream oxygen sensor value displayed on the KT600 scan tool.
(d) Engine runs at idle.

04
• P0131 ( ＜ 0.21 V) Step 6 Short to ground
• P0132 ( ＞ 4.8 V) Step 7 Short to power
• P0134 (0.42 V ～ 0.48 V) The next step Open

YES > Go to DIAGNOSTIC HELP for checking intermittent problems.
If there is a short to groung circuit, go to step 6.
If there is a short to power circuit, go to step 7.
2. CHECK HARNESS AND CONNECTOR (UPSTREAM OXYGEN SENSOR)

(b) Disconnect the E017 upstream oxygen sensor
connector.
below.
Standard voltage

E017 (1) - E017 (2) 0.45 V

YES > Replace upstream oxygen sensor.
3. CHECK HARNESS AND CONNECTOR (UPSTREAM OXYGEN SENSOR - GROUND)

(b) Disconnect the E017 sensor connector.
(c) Connect the E017 upstream oxygen sensor connector
terminal 1 and ground.
below.
Standard voltage

E017 (2) - Ground 0.45 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (UPSTREAM OXYGEN SENSOR - ECM)

table below.

E017 (2) - E001 (62) ＜2Ω

(a) Disconnect the E017 upstream oxygen sensor connec-

tor.
table below.

E017 (1) - E001 (6) ＜2Ω

(a) Measure the resistance according to the value in the

table below. 04

E017 (2) - Ground
≥ 1 MΩ
E017 (1) - E017 (2) 04


below.
Standard voltage

E017 (2) - Ground 0V

(a) Turn the ignition switch ON.

below.
Standard voltage


9. REPLACE ECM
(a) Replace ECM.

P0201 - INJECTOR 1 CIRCUIT MALFUNCTION
04
04
DESCRIPTION
The Engine Control Module (ECM) has 4 individual injector driver circuits, each of which controls an
injector. The ECM monitors the current in each driver circuit. The ECM measures a voltage drop
through a fixed resistor and controls it. The voltage on each driver is monitored to detect a fault. If the
voltage is not what the ECM expects to monitor on the circuit, a Diagnostic Trouble Code (DTC) is set.
WIRING DIAGRAM
• Injector 1
• Engine: running • Open or short at 04
injector 1 control
• The pump operate normally.
circuit
P0201 Injector 1 circuit malfunction • Ignition voltage: ＞ 10 V
• Open or short at
• ECM detectes that open or short at injector 1 power
injector1 harness or connector. circuit
• ECM
04
NOTE
specific circuit and circuit and component information.
terminals.
• If any DTC is detected, using the scan tool, select the item “DIAGNOSIS\FOTON\LIGHT
BUS\VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\READ DATA STREAM”.
1. READ DTC ON KT600 SCAN TOOL (INJECTOR)

(c) Using scan tool, select the item”DIAGNOSIS \FOTON \LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\READ DATA STREAM\THE AMOUNT OF CURRENT INJECTION.
Is DTC present?
NO > System is normal.
2. PERFORM ACTIVE TEST ON SCAN TOOL
(a) Using scan tool, select the item”DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ ACTIVE TEST\DISABLE FUEL INJECTION.
(b) Perform active test.
3. CHECK DTC
(a) Using the KT600 scan tool, perform the DTC confirming procedure.
DTC Proceed To Malfunction

P0201 Next step Circuit or injector
4. INSPECT FUSE

(b) Open the engine fusible link box A017.
(c) Remove EFI main relay fuse (15A).
(d) Inspect EFI main relay fuse (15A).
Is the inspection result normal?

NO > Go to step 9.
5. CHECK INJECTOR

(b) Disconnect the E002 injector connector.
table below.
Standard resistance

(1) - (2) 12 ± 0.6 Ω (20 ℃ )

NO > Replace injector.
6. CHECK HARNESS AND CONNECTOR (INJECTOR - GROUND)

below.
Standard voltage

E002 (1) - Ground 12 V

7. INSPECT EFI MAIN RELAY
(a) Remove EFI main relay A016 from relay box.

(b) Measure the resistance according to the value in the
table below. 04
Standard resistance
≥ 1 MΩ
(Not apply battery voltage
between terminal 1 and 2)
A016 (3) - A016 (5)
＜1Ω
(Apply battery voltage between
terminal 1 and 2)

NO > Replace EFI main relay.
8. CHECK HARNESS AND CONNECTOR (INJECTOR - EFI MAIN RELAY)
(a) Remove EFI main relay.

table below.

E002 (1) - A016 (3) ＜2Ω

(a) Disconnect the E001 ECM connector.

table below.

E002 (1) - Ground ≥ 1 MΩ

table below.

A016 (5) - Ground ≥ 1 MΩ

NO > Repair or replace harness or connector. Replace fuse A017 (15A).
10. CHECK HARNESS AND CONNECTOR (INJECTOR - ECM)

table below.

E002 (2) - E001 (55) ＜2Ω


table below. 04

E002 (2) - Ground ≥ 1 MΩ
04


below.
Standard voltage


13. REPLACE ECM
(a) Replace ECM.

P0336 - CKP SENSOR CIRCUIT PERFORMANCE

P0337 - CKP SENSOR CIRCUIT MALFUNCTION
1 Shielded cable
2 Permanent magnet
3 Sensor case
4 Mounting bracket
5 Soft magnet iron core
6 Coil
7 Air clearance
DESCRIPTION
The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control
Module (ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly
monitors the number of pulses on the 58X reference circuit and compares them to the number of MAP
signal being received. If the ECM receives incorrect number of pulses on the 58X reference circuit,
Diagnostic Trouble Code (DTC) P0336, P0337 will be set.
WIRING DIAGRAM
DTC Detection
DTC No. DTC Definition Suspect Area
Condition
• CKP sensor 04
• Ignition switch: ON • CKP loose connector
P0336 CKP sensor circuit performance • ECM received no or • Open or short at CKP sensor
error signal circuit
• ECM
• CKP sensor
04
• Ignition switch: ON • CKP loose connector
P0337 CKP sensor circuit malfunction • ECM received no or • Open or short at CKP sensor
error signal circuit
• ECM
NOTE
terminals.
1. READ VALUE AND DTC ON KT600 SCAN TOOL

(c) Read CKP sensor value displayed on the KT600 scan tool.
(e) Using scan tool, perform the CKP sensor waveform confirming procedure.
2. CHECK CKP SIGNAL WITH THE OSCILLOSCOPE
(a) Raise vehicle.
(b) Using the oscilloscope, check the CKP sensor waveform.


YES > Go to step 5.
3. CHECK CKP SENSOR

(b) Disconnect the E013 CKP sensor connecrtor.
(c) Check the resistance according to the value in the table
below.
Standard resistance

E013 (A) - E013 (B) 560 Ω ± 10% (25 ± 5 ℃ )

NO > Replace CKP sensor.
4. CHECK CKP SENSOR WAVEFORM
(a) Replace the on-vehicle CKP sensor with a known good

one.
(b) Using the oscilloscope, check the CKP sensor waveform.

NO > Go to step 7.
5. CHECK CKP SENSOR HARNESS AND CONNECTOR (CKP SENSOR - ECM)

table below.

E013 (B) - E001 (28)
＜2Ω
E013 (A) - E001 (12)

table below.
04
E013 (A) - Ground
≥ 1 MΩ
E013 (B) - Ground
04

6. CHECK CKP SENSOR HARNES AND CONNECTOR (CKP SENSOR - GROUND)

below.
Standard voltage

E013 (A) - Ground
0V
E013 (B) - Ground

7. CHECK CKP SENSOR SIGNAL PLATE

(b) Check for a problem such as scrap, dirt, foreign body
and loose with the 58X CKP signal plate and signal
tooth.
(c) Check the mounting clearance of the CKP sensor.
Clearance: 0.3 ～ 1.5 mm

NO > Remove any foreign obstacles and clean 58X signal tooth. If there is fault present, replace 58X signal
plate.
8. REPLACE ECM
(a) Replace ECM.(Refer to “ Chapter 11A engine control system - ECM, replacement”)
P0480 - FAN 1 FAULT

P0481 - FAN 2 FAULT
04
04
DESCRIPTION
The coolant fans are used to reduce heat in the engine system. And the condensator after the A/C is
turned on.
WIRING DIAGRAM
• Main low fan relay

• Electronic fan: running
• Short or open at main low fan relay
• ECM detects that faults con- control harness
P0480 Fan 1 fault tinues to be present at main
• Short or open at main low fan relay
low fan relay harness for 3
drive harness
seconds
• ECM
• Main high fan relay

• Electronic fan: running
• Short or open at main high fan relay
• ECM detects that faults con- control harness
P0481 Fan 2 fault tinues to be present at main
• Short or open at main high fan relay
high fan relay harness for 3
drive harness
seconds
• ECM
NOTE
terminals.
1. PERFORM ACTIVE TEST BY SCAN TOOL (OPERATE FAN)
(a) Connect the KT600 scan tool to the DLC.

(b) Start the engine and warm it to normal operating temperature.
(c) Using the KT600 scan tool, perform the DTC confirming
procedure.
(e) Using scan tool, select the item”DIAGNOSIS\FOTON
\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE \
MT20U2\ACTIVE TEST\SECONDARY FAN”.
Scan Tool Operation Specified Condition

Low Fan: ON Low Fan: Running
High Fan: ON High Fan: Running

NO > If low fan is abnormal, go to next step.
If high fan is abnormal, go to step 7.
2. INSPECT FUSE

04
(b) Remove fuse A009 (30A).
(c) Inspect fuse.
04
Is the inspection normal?

NO > Go to step 5.
3. INSPECT MAIN LOW FAN RELAY
(a) Remove the main low fan relay from fan relay box in
engine room.
table below.
Standard resistance
≥ 1 MΩ
(Not apply battery voltage between
terminal 1 and 2)
(3) - (5)
＜1Ω
terminal 1 and 2)

NO > Replace main low fan relay.
4. CHECK HARNESS AND CONNECTOR (MAIN LOW FAN RELAY - ECM)

table below.

A014 (1) - E001 (67) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (MAIN LOW FAN RELAY - GROUND)

table below.

A014 (1) - Ground ≥ 1 MΩ

6. CHECK HARNESS AND CONNECTOR (MAIN LOW FAN RELAY - GROUND)

below.
Standard voltage

A014 (1) - Ground 0V

7. INSPECT FUSE

04
(c) Inspect fuse.
04

NO > Go to step 10.
8. INSPECT MAIN HIGH FAN RELAY
(a) Remove the fan relay from fan junction box in engine
room.
table below.
≥ 1 MΩ
(Not apply battery voltage between
terminal 1 and 2)
(3) - (5)
＜1Ω
terminal 1 and 2)

NO > Replace main high fan relay.
9. CHECK HARNESS AND CONNECTOR (MAIN HIGH FAN RELAY - ECM)
(a) Disconnect the E001 ECM connector .

(b) Measure the resistance according to the value(s) in the
table below.

A013 (1) - E001 (50) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (MAIN HIGH FAN RELAY - GROUND)
(a) Measure the resistance according to the value(s) in the

table below.

A013 (1) - Ground ≥ 1 MΩ

11. CHECK HARNESS AND CONNECTOR (MAIN HIGH FAN RELAY - GROUND)

(b) Measure the voltage according to the value(s) in the
table below.
Standard voltage


12. REPLACE ECM
04

When a malfunction is not confirmed by a DTC (DiagnosticTrouble Code) check and the causes of problems
cannot be identified through a basic inspection, troubleshoot according to the priority order indicated in the
table below.
GASOLINE ENGINE CONTROL SYSTEM SYMPTOM

Symptom Check Order
Communication fault with KT600 KT600 fails to communicate with ECM 1
Engine cranks, but will not start 2

Starting
When engine is cold, it starts difficultly and body shock 3
Unstable idle (Rough idle, hunting) 4

Idling stably (Improper idling)
Idle speed is high (Improper idle speed) 5
When the engine is cold, it stalls (At idle) 6

Idling stably (Engine stalls)
The engine stalls when accelerating 7
Reaction of acceleration is slow, acceleration disturbance 8

Driving
Poor acceleration capability 9
ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION

Item Symptom
The starter is used to crank the engine, but there is
Failed to start no combustion within the cylinders, and the engine
Starting does not start
Hard starting Engine starts after cranking a while
Hunting Engine speed does not remain constant
Incorrect idle speed The engine does not idle at the usual correct speed
Idling stably Engine stall easily when ECT is low after it start for
Engine will stall when it is cold (Idle)
a while
The engine stalls when the accelerator pedal is

Engine stalls when moving
depressed
Hesitation is the delay in response of the vehicle

speed that occurs when the accelerator is
Reaction of acceleration is slow, depressed in order to accelerate from the speed at
acceleration disturbance which the vehicle is now traveling or a temporary
drop in vehicle speed during such acceleration.
Driving Serious hesitation is called “sag”
Poor acceleration is the inability to obtain an

acceleration corresponding to the degree of throttle
Poor acceleration capability
opening(Even though acceleration is smooth) or the
inability to reach maximum speed
ENGINE SYMPTOM DIAGNOSTIC

CAUTION
Some symptom diagnostics require visual and additional inspection. Perform these inspections first.
04
These inspections can deal with the problem that needn’t to be check deeply. And it can save the
service time.
1. INQUIRY CUSTOMER ABOUT THE FAULT AFTER TAKING OVER VEHICLE.
(a) The faults appear at first time.
(b) Engine temperature when the faults appear.
(c) Vehicle roadhaul. 04
(d) The road condition the customer usually drives.
(e) The vehicle maintenance log.
(f) The vehicle maintenance record.
(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be
shorted.
2. PERFORM THE PRIMARY INSPECTION.
(a) Confirm the engine MIL is normal. If it is not good, repair it first.
(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate the fault.
(c) With the scan tool to inspect the engine control system hot data stream. And confirm them in the nor-
mal range.
(d) Confirm the fault and the reason.
(e) When repairing the vehicle, confirm the repair record.
3. VISUAL INSPECTION.
(a) Check the fuel system for any fuel leakage.
(b) Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
(c) Check the intake air pipe for being jammed, leaking, or damaged.
(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is
correct.
(e) Check the engine ground cable and verify a clean and tight connection.
(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
CAUTION
The carbon deposits in the back of the valve will cause the poor engine acceleration, unsteady idling,
starting difficulty in cold temperature, ect.
4. VALVE, CARBON DEPOSITS IN THE COMBUSTION CHAMBER.
Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out
the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine
is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake
valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol
remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the
carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many
impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon
deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel
injected into the cylinder every time will be attached, making the air-fuel mixture strength actually into
the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating,
backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and
other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed
valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t
return. Now the motion interference occurs between the valve and the piston which would damage the
engine finally.
5. CARBON DEPOSITS IN THE INTAKE MANIFOLD.

As the running of each piston in the whole engine is not synchronous, when the engine is shut off,
some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is
oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at
the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse;
the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air-fuel
mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed control
device clamped or exceeding its regulation range, leading to low idling speed and rough idling.
6. IF THE CARBON DEPOSIT IN THE CYLINDER IS TOO MUCH, USUALLY IT WILL CAUSE THE
HIGH PRESSURE. BUT THE VEHICLE HAS MORE MILEAGE, THERE IS MUCH MORE CARBON
DEPOSIT IN THE CYLINDER. BECAUSE OF THE WEAR, THE CYLINDER PRESSURE WILL
DECLINE. SO IT IS NOT THE GOOD WAY TO JUDGE IF THERE IS THE CARBON DEPOSIT IN
THE CYLINDER. THE GOOD WAY IS:
(a) With the electronic endoscopy.
(b) Inspect the feedback voltage.　　
(c) Disassembly way.
7. CARBON DEPOSIT.
It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine normal
running. When the engine cold starting is hard and the idling is rough, it shows that the carbon deposits
are quite serious, if further it will cause misfire and cylinder fuel cut, until the engine unable to start.
When the cold starting is hard, check the engine at once, clean the valve carbon deposits in time after
removing other factors to avoid damage caused by removing the cylinder cover.
8. PAY ATTENTION TO THE FOLLOWING FOR THE DANGER OF THE CARBON DEPOSIT.
(a) Fill with the high quality gasoline.
(b) Do not idle long.
(c) Run at high speed usually.
SYMPTOM (1)
Symptom Diagnostic Logic Suspect Area

04
• No power supply • ECM power supply
Communication fault with KT600 • Open in the harness of ECM and • Open in the harness of ECM and
scan tool KT600 scan tool KT600
• ECM • ECM
04
1. CHECK DATA STREAM

(b) Connect the KT600 scan tool to the diagnostic connector
(DLC) - use the most current software available, press
the POWER key to start the KT600.
(d) Using scan tool, select the item “DIAGNOSIS\FOTON
\LIGHTBUS\VIEW\ENGINE\491 GASOLINE ENGINE
\MT20U2\READ DATA STREAM”.
(e) With the KT600 scan tool, read data stream displayed on
the screen.
Does the ECM data stream can be read?

2. CHECK OTHER MODULE DATA STREAM
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ ABS\READ DATA STREAM”.
(b) Read the data stream on the scan tool.
If the ABS data stream can be read?
YES > Go to step 4.
3. CHECK HARNESS OR CONNECTOR (DLC COMMUNICATION K - ECM)
(a) Turn the ignition switch OFF .

(b) Disconnect ECM connector.
(c) Check the continuity between the connector C401 terminal 7 - ECM connector terminal 11.
Resistance: ＜ 2 Ω
(d) Using the multimeter, check the continuity between the connector C401 terminal 7 and ground.
(e) Turn the ignition switch ON, using the multimeter,check the voltage between diagnostic box C401 termi-
nal 7 and ground.
Voltage: 0 V

NO > Repair or replace ECM harness or connector.
4. CHECK ECM POWER AND GROUND
(a) Check ECM power.

(b) Check ECM ground.
NO > Repair or replace ECM harness or connector.
5. REPLACE ECM
SYMPTOM (2)
Symptom Condition Diagnostic Logic Suspect Area
• Malfunction of the igni- 04

• Engine run nor- tion system
mally
The cause is probably • Malfunction of the fuel
• Battery is nor- pump system
that a spark plugs are
mal
fouled defective, or that • Malfunction of the
Engine cranks, but will not start • MIL is normal the supply of fuel to the injector
• No phenome- combustion • Leakage or malfunc-
non of burning chamber is defective tion of intake air sys- 04
when cranking tem
the engine
• ECM
NOTE
If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and
control system don’t fully lose the functions even though work normally. The cause of this starting
failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air-
fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition
system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at
last.
1. INSPECTION MIL AND DTC
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04A engine control
system - read and clear DTC)
Is the DTC present?
YES > Refer to DTC chart. Perform the diagnostic procedure.
2. VISUAL INSPECTION
(a) Perform the visual inspection.

NO > Eliminate the exterior problems.
3. CHECK THE SECONDARY IGNITION SYSTEM
(a) Disconnect the injector fuse.

(b) Remove any of the 4 spark plugs.
(c) Connect the spark plug to spark plug wire.

(d) Ground the spark plug on the cylinder block.
(e) Crank the engine to test the secondary ignition system
with the spark plugs removed.
Normal result: A strong blue spark is visible at each
spark plug while cranking the engine

YES > Go to step 6.
(a) Check ignitioin coil resistance, and clear connector terminals.
(b) Check whether there is carbon deposit in plug, carbon

tracking, residual current in insulating ceramics cause of
crack, clearance, burned in the positive and negative.
And clear the plug.
(c) Check the spark plug gap.
Standard: 1.0 ~ 1.2 mm

NO > Clear, replace the faulty components.
5. CHECK IGNITION SPARK PLUG WIRE
(a) With multimeter, check resistance of the ignition spark wire.

Resistance: ≥ 4 kΩ
NO > Replace the ignition spark wire.
6. CHECK CKP SENSOR
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
ENGINE\MT20U2\READ DATA STREAM”.
(b) Read the displayed CKP sensor value. It should be within the specified value.
NO > Check whether the sensor installation is correct. Repair or replace harness or connector or damaged
component.
7. CHECK THE THROTTLE BODY
(a) Depress the accelerator slightly. Start egnine. Check whether the engine can start.
Can the engine start? 04
YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor con-
nector, check whether there is 12 V. And the resistance value is 28 ～ 33 Ω when the temperature is 20 ℃
. Check whether the idle air control motor is clip. If necesasary, repair or replace it.
CAUTION
The carbon and grease beside the throttle and air path change the cross section of the idle air path. It
04
makes the ECM control the idle air impossilly. And it will cause the A/F too lean or too rich. The
burning will not be normal. And the usual reasons of unnormal burning are: carbon and grease, grease
beside the throttle air path, carbon and grease with the idle air control motor.
8. CHECK ECT SENSOR AND MAP/IAT SENSOR
(a) Check whether the installation of the MAP/IAT is normal.

(b) Check whether the MAP/IAT sensor is dirty.
(c) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
(d) Turn ignition switch: ON. Read the displayed ECT and MAP/IAT sensor value. It should reach the spec-
ified value.
NO > Clear, repair or replace the harness or connector. If the MAP value is still abnormal, go to step 15.
9. CHECK THE FUEL SYSTEM CIRCUIT
(a) Turn the ignition switch: ON

(b) Check whether the pump relay and pump operate normally.
NO > Repair or replace the fuel pump harness or connector.
10. CHECK THE FUEL SYSTEM PRESSURE
(a) Release the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)
(b) Check the fuel system pressure. (Refer to “Chapter 12A fuel system - precaution”)
NO > Repair or replace the fuel system parts and harness:
• If the pressure is higher than 350 kPa, check the return pipe:
(1) If the return pipe is bent or twisted, repair or replace it.
(2) If the return pipe is normal, replace the pressure regulator.
• If the pressure is less than 350 kPa, turn ignition switch: ON, make the pump operate, check the
pressure again:
(1) If the pressure can be established, go to step 12.
(2) If the pressure cannot be established, go to step 13.
11. INSPECT INJECTOR
(a) Disconnect the injector connector.

(b) Remove the injector and fuel rail assy.
(c) Apply 12 V battery voltage to the injector directly.
(d) Check whether every injector can spray even and
standard quantity gasoline.
CAUTION
If the spraying condition is abnormal just as the “cylindrical
growth”, or the spraying quantity is not equal much more
under the same condition (more than 5 ml), then replace the
injector.
WARNING
When check the fuel system:
• Place a “Caution - No inflammable” symbol inside the
operation area.
• Release fuel system pressure before servicing fuel
system components.
• Service vehicles in well-ventilated areas and avoid
ignition sources.
• Never smoke while servicing the vehicle.
YES > Go to step14.
NO > Replace the injector. If it is not OK, go to next step.
12. CHECK FUEL SYSTEM RETURN
(a) Using the fuel return blocker, clamp the return pipe, make the system fuel can not return. Check
whether the system pressure can establish again quickly.
YES > Replace the fuel pressure regulation.
NO > Repair or replace the fuel supply pipe, pump or injector.
13. CHEKC FUEL SYSTEM SUPPLY
(a) Check whether the input pipe leakage or block.

(b) Turn the ignition switch ON (Do not crank the engine), make sure the fuel pressure can establish in the
fuel pipe. Check whether fuel leaks at fuel pipe connection.
YES > Repair or replace the inlet fuel pipe.
NO > Replace fuel pump.
14. CHECK CYLINDER PRESSURE
(a) Perform the cylinder compression pressure test. The standard values are as following:
• Per cylinder pressure: 1270 kPa 04
• Per cylinder limit: 880 kPa
• Per cylinder difference limit: less than 25%
YES > Go to step16.
15. CHECK ENGINE VALVE-TIMING
(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. If the
jumping over teeth exists.
NO > Perform the valve-timming align operation or replace the valve-timing belt.(Refer to “Chapter 15A
engine mechanism- timing belt, replacement”)
16. CHECK ENGINE MECHANISM
(a) Perform the engine mechanism inspection:

• Check the cylinder with the endoscopy.
• Inspect the feedback voltage.
• Disassemble the engine faulty parts.
NO > Repair the engine inner mechanism faults.
17. REPLACE ECM
SYMPTOM (3)
1. A/F is not correct • Ignition system

2. Carbon deposit at • Supply fuel system
valve • Injector
• Engine runs normally 3. Operation condition is • Leakage of the inlet
• MIL is normal not equal between system
Engine starts difficultly • It needs several times every cylinder
when it is cold • Cylinder compression
for engine starts suc- 4. ECT sensor is fault pressure
cessfully when it is 5. Others：
cold. • Engine management
• MAP/IAT sensor system
• Idle step motor • Battery
• Fuel quality • ECM
NOTE
Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with
clear starting symptom, but the engine only run after continuous starting or the starter driving for a
long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot
starting, or both of them. The cause of this failure is from the fuel injection system generally; check it
in the following method.
1. CHECK ENGINE MIL AND DTC
system - read and clear DTC)
Is the DTC present?
2. CHECK THE VISUAL INSPECTION

(b) Check following after opening the engine hood.
• Filter
• Leakage of the intake manifold
3. CHECK BATTERY
(a) Check the battery voltage when cranking the engine.

Battery voltage: ≥ 9.6 V
NO > Charge battery or replace it.
4. CHECK STARTER
(a) Check whether the starter or the starter circuit is fault.

5. CHECK CKP SENSOR
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491GASOLINE

04
(b) Read the displayed CKP sensor value. It should reach the specified value.
NO > Check whether the sensor installation is correct, repair or replace harness or connector.
6. CHECK ECT SENSOR
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491GASOLINE

(b) Check the ECT sensor or feedback voltage with the multimeter.
NO > Repair or replace the ECT sensor.
7. CHECK MAP SENSOR
(a) Check MAP sensor after starting engine successfully.

Pressure value: 35 ～ 55 kPa
NO > Eliminate the leakage of intake system.
8. CHECK THROTTLE BODY
Can the engine start?
NO > Go to step 10.
9. CHECK IDLE AIR CONTROL MOTOR
(a) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value
is 28 ～ 33 Ω when the temperature is 20 ℃ .
(b) Remove the idle air control motor to test:
• Check expansion of the idle air control motor when turning the ignition switch ON.
• Check whether the idle air control motor can move when turning the ignition switch OFF.
NO > Repair or replace harness or connector or the idle air control motor.

(c) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491GASOLINE
(d) Turn the ignition switch: ON. Read the displayed ECT and MAP/IAT sensor value. It should be within
the specified value.
NO > Clear or repair or replace the harness or connector. If the MAP value is still abnormal, go to step 15.
(a) Release the fuel system pressure. (Refer to “Chapter

12A fuel system - precaution”)
(b) Check the fuel system pressure. (Refer to “Chapter 12A
fuel system - precaution”)

• If the pressure is less than 350 kPa, turn the ignition switch ON, make the pump operate, check
the pressure again:

04
(d) Check whether every injector can spray even and
CAUTION
If the spraying condition is abnormal just as the “cylindrical 04
injector.
WARNING
operation area.
system components.
ignition sources.
YES > Go to step15.
NO > Clean the injector. Check the injector operation condition again. If it is not OK, replace it. Confirm the
fault isnot present. If it is not OK, go to next step.
(a) Using the fuel return blocker, clamp the return pipe and make the system fuel not return. Check
NO > Repair or replace the fuel supply pipe, pump, injector.
(a) Check whether the input pipe leaks or block.

(b) Turn the ignition switch ON (Do not crank the engine). Make sure the fuel pressure can establish in the
fuel pipe. Check whether fuel leakage at fuel pipe connection.
15. CHECK SECONDARY IGNITION SYSTEM



YES > Go to step18.

tracking，residual current in insulating ceramics cause of
And clear the plug.

NO > Clear or replace the faulty components.

(a) Perform the cylinder compression pressure test. The standard value are as following:
• Per cylinder pressure: 1270 kPa 04
(a) Check whether the engine valve-timing gear mark is aligned, damaged and the belt is loose.
NO > Perform the valve timing align operation or replace the valve-timing belt. (Refer to “Chapter 15A
engine mechanism- timing belt, replacement”)

• Disassemble the faulty parts.
21. REPLACE ECM
SYMPTOM (4)
• Malfunction of the
The cause is probably ignition system
that the ignition system,
Unstable idle (Rough idle, The engine cannot keep • Malfunction of air-fuel
air-fuelratio, IAC motor or
hunting) stability ratio control system
compression pressure is
defective. • Poor compression
• ECM
NOTE
The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc.
When performing the diagnosis and elimination, analyse according to the specific symptom.
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04A engine control
system - read and clear DTC”) .
Is the DTC present?
YES > Refer to DTC chart. Perform the diagnosis procedure.

(b) Check after opening the engine hood.
• Inspect the engine operating condition.
• Inspect the tachometer if the pointer deviates the idle target value.
• Inspect if the idle trembles is normal or load reasons, such as: A/C, lighting, push the lever into gear,
turn the steering wheel, etc.
• Check the vacuum system for any broken, kinked or incorrectly linked vacuum pipes or hoses.
• Check whether the exhaust pipe emit black smoke.
• Check whether the throttle cable is adjusted to be appropriate.
3. CHECK THROTTLE AND IDLE AIR CONTROL MOTOR
(a) Check throttle body and idle air path. Clear the carbon deposit and greasy dirt.
(b) Start engine and runs at idle. 04
ENGINE\MT20U2\ACTIVE TEST”.
(d) Perform the idle air control motor test. When the scan tool control the rotation of expansion of the idle
air control motor, the engine RPM changes from high to low in synchronism (touching the idle air control
motor, can feel vibration).
(e) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value is 28 04
～ 33 Ω when the temperature is 20 ℃ . If necesasary, repair or replace it.
(f) Remove the idle air control motor. Connect the connector:
• Check whether the idle air control motor can extend-retract when turning the switch on.
• Check whether the idle air control motor can move when turning the ignition switch off.
4. CHECK IGNITION SYSTEM
(a) Engine runs at idle speed. Brennschluss one by one. Inspect if the idle speed changes.
CAUTION
It is better that use the active test function of the scan tool to perform the brennschluss test. If without
the scan tool or the scan tool without the function, the brennschluss period not be too long, if not, the
Three Way Catalytic Converter (TWC) will be damaged.
(b) When brennschluss every cylinder, the same RPM should decline obviously or the same vibration.
YES > Go to step12.



YES > Go to step 8.

And clear the plug.

NO > Replace the faulty components.
(a) Check resistance of the ignition spark wire with multimeter.

8. CHECK THE INJECTOR
(b) Perform the injector active test.
(c) Check whether the same engine RPM decline obviously and shortly in synchronism (touching the injec-
tor, can feel vibration, or with the voice-tool, touch the injector, the action voice should be hearded).
NO > Repair or replace injector or harness.
CAUTION
If the spraying condition is abnormal just as the “cylindrical growth”, or the 4 injectors spraying quan-
tity is not equal much more under the same condition (more than 5 ml), then replace the injector.
WARNING
• Place a “Caution - No inflammable” symbol inside the operation area.
• Release fuel system pressure before servicing fuel system components.
• Service vehicles in well-ventilated areas and avoid open flame sources.

12A fuel system - precaution”) 04
04

pressure again:
(a) Using the fuel return blocker and clamp the return pipe, make the system fuel not return. Check
(a) Check whether the input pipe leaks or blocked.

(b) Turn the ignition switch ON (not crank the engine). Apply pressure on the fuel pipe. Check whether fuel
leaks at fuel pipe connection.
12. CHECK INTAKE AND EXHAUST SYSTEM
(a) Check the engine intake system for any leakage.

(d) Check the engine ground cable and verify a clean and tight connection.
(e) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
(f) Check the PCV valve for leaking.
(g) Check whether the EVAP system leakage.
(h) Check whether the fuel pressure regulator vacuum pipe broken, kinked or crack.
(i) Check whether the Three Way Catalytic Converter (TWC) is blocked.
(j) Check whether the throttle body gasket leakage.
(k) Check whether the intake manifold gasket leakage.
NO > Repair or replace the faulty components.
13. CHECK MAP/IAT SENSOR

(b) Remove the MAP/IAT sensor.
(c) Check whether the MAP/IAT sensor is dirty.
(d) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\ VIEW\ENGINE\491 GASOLINE
(e) Read the scan tool displaied MAP/IAT sensor data stream value.
(f) With the 3 kinds of the basic types: idle test, accerlerate suddenlly test and blocked test in exhaust
system. Test the vaccum rate in the intake manifold.
NO > Clear and reinstall or repair. If it is not OK, go to step 15.
14. CHECK OXYGEN SENSOR
(a) Engine idle. Inspect the displayed scan tool data stream. When the temperature is normal after the
engine enter into the closed-loop control, inspect if the oxygen sensor operate normally.
(b) Oxygen sensor normal value: 0 ～ 1 V. Change 5 ～ 8 times in 10 seconds periodically.
NO > Replace xoygen sensor or harness.
• Per cylinder pressure:1270 kPa
YES > Go to step17.
NO > Perform the valve timing align operation or replace timing belt. (Refer to “Chapter 15A engine mecha-
nism- timing belt, replace”)

• Check the cylinder with the endoscopy. 04
• Disassembly the faulty faults.
NO > Repair the engine inner mechanism faults. 04
18. REPLACE ECM
SYMPTOM (5)
• Malfunction of the Idle

Idle is too high (The The cause is probably air control motor
Engine idle speed too
engine does not idle at that the intake air volume • Malfunction of the
high
the usual correct speed) during idle is too great throttle body
• ECM
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04A engine control
system - read and clear DTC”)
Is the DTC present?

• Inspect whether the idle trembles is normal.
• Check whether the exhaust pipe emits black smoke.
3. CHECK THE ACCELERATOR PEDAL
(a) Check whether the accelerator pedal cable blocked.

NO > Adjust or replace the accelerator cable.
4. CHECK THE RELATED ACCESSORIES
(a) Check the fuel pressure vacuum regualtor.

(b) Check whether the PCV vacuum pipe installation is reliable.
(c) Check whether the braking system vacuum booster pipe installation is reliable.
NO > Adjust or replace.
5. CHECK IDLE
(a) Engine runs at idle speed. Gear in N position. Depress brake pedal. Check whether the idle speed is
too high. 04
NO > Go to step 7.
6. CHECK THE VACUUM BOOSTER
04
(a) Blocking the vacuum pipe, inspect if the idle become normal.
NO > Repair or replace the vacuum booster.
7. CHECK PCV VALVE
(a) Clipping the PCV vacuum pipe, inspect whether the idle become normal.
(b) Check whether the PCV valve clip, the opening degree is normal.
NO > Replace PCV valve.
(a) Start engine and run at idle.

(b) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
(c) Perform the idle air control motor test. When the scan tool control the rotation of expansion of the idle
(d) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value
(e) Remove the idle air control motor to test.
NO > Repair or replace harness, connector or the idle air control motor.
9. CHECK INTAKE SYSTEM
(a) Check the intake system for any broken, linked or incorrectly linked vacuum pipes or hoses.
(b) Check the intake air pipe for being jammed, leaking, or damaged.
NO > Repair or replace it.
(a) Check whether the installation of the MAP/IAT sensor is normal.

(d) Read the displayed ECT and MAP/IAT sensor value. It should be within the specified value.
NO > Repair or replace the harness or sensor.


YES > Go to step13.
NO > Repair or replace components of fuel system:
(1)If the return pipe is bent or twisted, repair or replace it.
• If the pressure is less than 350 kPa. Go to next step.
12. CHECK INJECTOR

(b) Remove the injector and fuel rail assy. 04
(c) Apply battery voltage to the injector directly.
(d) Check whether every injector can spray evenly and standard quantity gasoline.
WARNING
04
YES > Replace the injector washer.
NO > Clean the injectpor and recheck it. Every injector can spray evenly and standard quantity gasoline. If
not OK, replace it.
13. REPLACE ECM
SYMPTOM(6)
• Malfunction of the IAC

motor
The cause is probably • Malfunction of the
• It is easy to turn off that the air/fuel mixture is throttle body
When the engine is cold, when the engine is inappropriate when the
it stalls (At idle) cold engine is cold, or that the • Malfunction of the
intake air volume is insuf- injector
• Engine is jitter at idle
ficient. • Malfunction of the
ignition system
• ECM
(a) With the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04A engine control
system - read and clear DTC) .
Is the DTC present?
2. CHECK VISUAL INSPECTION

(b) Check after opening the engine hood:
3. CHECK THE THROTTLE AND IDLE AIR CONTROL MOTOR
CAUTION
burning will be abnormal. And the usual reasons are: carbon and grease, grease beside the throttle air
path, carbon and grease with the idle air controlmotor.
(b) Start engine and run at idle.
(e) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value is 28
～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,
repair or replace it.
NO > Repair or replace harness or connectors.
4. CHECK THE ECT SENSOR
(a) Check the resistance accord with the standard: 04

20 ℃ : 2.1 ～ 2.7 kΩ.
80 ℃ : 0.26 ～ 0.36 kΩ.
ENGINE\MT20U2\READ THE DATA STREAM”.
NO > Replace the ECT sensor.
5. CHECK THE IAT SENSOR
(a) Check the resistance accord with the standard:

20 ℃ : 2.3 ～ 3.0 kΩ.
80 ℃ : 0.3 ～ 0.42 kΩ.
ENGINE\MT20U2\\READ THE DATA STREAM”.
NO > Replace the IAT sensor.
6. CHECK INJECTOR
(a) Using scan tool, select the item ”DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
NO > Repair or replace injector, harness or connectors.
CAUTION
WARNING


• If the pressure is less than 350 kPa, turn the ignition switch: ON, make the pump operate, check
the pressure again:
(1) If the pressure can be established, go to next step.
NO > Repair or replace the fuel supply pipe, pump,injector.
(a) Check whether the input pipe leakage or blocked.

(b) Turn ignition switch ON (Do not crank the engine). Make sure the pressure is established in the fuel
pipe. Check whether fuel leaks at fuel pipe connection.
YES > Repair or replace the intake fuel pipe.
NO > Replace the fuel pump.
(a) Perform the cylinder compression pressure test. The standard as following:
• Per cylinder pressure:1270 kPa 04
nism- timing belt, replacement”)

NO > Repair the engine mechanism faults.
13. REPLACE ECM
SYMPTOM(7)

air control motor
Defective ignition throttle body
The engine stalls when system, abnormal
The engine stalls when accelerating the accelerator pedal air-fuel ratio, poor
ignition system
is depressed compression, etc
are suspected • Malfunction of the
injector
• Poor acceleration
• ECM
NOTE
Start in idling mode: put into gear without pressing the accelerator pedal, disengage the clutch and
start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed,
ECM considers it as the idling mode. The control of idling mode is a cruise control without any load
signal, namely a steady speed control that the engine is controlled in target speed range. Speed-
raising control is done if with load signal. During starting, the load signal is input into ECM, the later
raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load.
This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and
easy to be shut off and the speed falls in idling mode, find the causes from the idling control.
(a) With the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04 engine control
Is the DTC present?

(b) Start engine and run at idle. 04
(c) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\ VIEW\ENGINE\491 GASOLINE
(e) Disconnect the idle air control motor connector, check whether there is 12 V exists. And the resistance 04
value is 28 ～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If nec-
esasary, repair or replace it.
(f) Remove the idle air control motor. Connect the connector.
• Check whether the idle air control motor can extend-retract when turning the switch off.
• Check whether the idle air control motor can move when turning the ignition switch on.
4. CHECK THROTTLE POSITION
(a) With the scan tool, check if the throttle is normal.

(b) Check whether the throttle open degree is normal when depressing the accelerator pedal.
NO > Adjust the throttle position.
5. CHECK THE LOAD SIGNAL
(a) Check whether the gear signal is sent to ECM.

(b) Check whether the A/C signal is sent to ECM.
(c) Check whether the load signal is sent to ECM.
NO > Repair the load signal harness.
6. CHECK THE IGNITION SYSTEM
(a) Engine runs at idle speed. Cut off one by one. Inspect if the idle speed changes.
CAUTION
It is better to use the active test function of the scan tool to perform the cutoff test. If without the scan
tool or the scan tool without the function, the brennschluss period shoul not be too long, if not, the
TWC will be damaged.
YES > Go to step14.



(a) Check ignitioin coil resistance, and clear connector

terminals.
And then clear the plug.


(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\ VIEW\ENGINE\491 GASOLINE
ENGINE\MT20U2\ACTIVE TEST”. 04
(c) Check whether the same engine RPM decling obviously and shortly in synchronism (touching the injec-
tor, can feel vibration, or with the voice-tool, touch the injector, the action voice should be heard).
NO > Repair or replace injector，harness or connectors. 04
WARNING


pressure again:
NO > Repair or replace the fuel supply pipe, pump, injector.

pipe. Check whether fuel leaks at fuel pipe connection.
nism- timing belt, replacement”)

17. REPLACE ECM
SYMPTOM(8)
• Malfunction of the A/F 04

When the accelerator is mixture system
The cause is probably
The reaction of depressed the vehicle is now
ignition system, A/F • Malfunction of fuel
acceleration is slow traveling or a temporary drop in
mixture or compression supply system
disturbance vehicle speed during such
pressure is defective • Poor compression
acceleration.
• ECM
04
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04Aengine control
Is the DTC present?

3. CHECK THE AIR FILTER
(a) Check whether the air filter dirty, grease and blocked.
NO > Clean or replace the filter. If it is not OK, go to next step.
4. CHECK IDLE
(a) Start engine and runs at idle.

(b) Check whether the idle speed is normal.
NO > Refer to the symptom chart - idle, eliminate the problems.

(d) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE
(e) Read the scan tool displayed MAP/IAT sensor data stream value.
NO > Clear and reinstall or repair MAP/IAT sensor.
6. CHECK TPS
(b) With the analogue mulitimeter to check TPS resistance (resistance should be continuity).
(c) Refer to engine DTC chart.


the pressure again:
(2) If the pressure cannot be established, go to step10.
8. CHECK INJECTOR

(b) Remove the injector and fuel rail assy. 04
CAUTION
If the spraying condition is abnormal just as the “cylindrical growth”, or the spraying quantity is not
equal much more under the same condition (more than 5 ml), then replace the injector.
04
WARNING
YES > Go to step11.
NO > Clean or replace the injector. If it is still not OK, go to next step.
(a) Using the fuel return blocker and clamping the return pipe, make the system fuel not return. Check
Is the fuel pressure established?
NO > Repair or replace the fuel supply pipe, pump and injector.

(b) Turn the ignition switch ON (Do not crank the engine). Make sure the pressure is established in the fuel
pipe. Check whether fuel leakage at fuel pipe connection.
11. CHECK EXHAUST SYSTEM
(a) Check the exhaust system and Three Way Catalytic Converter (TWC).
(b) Check whether the exhaust pipe blocked with the exhaust pressure meter.
NO > Replace or clean the exhaust system.
(a) Check whether the engine valve-timing gear mark is aligned, damaged, and the belt is loose.
nism - timing belt, replacement”)

15. REPLACE ECM
SYMPTOM(9)
• Malfunction of the 04
ignition system
Poor acceleration is the inability • Malfunction of air-fuel
to obtain an acceleration ratio control system
Defective ignition system,
corresponding to the degree of
abnormal air-fuel ratio, • Malfunction of the fuel
Poor Acceleration throttle opening (even though
poor compression, etc are supply system
acceleration is smooth) or the
suspected. • Poor acceleration
inability to reach maximum 04
speed • Clogged exhaust
system
• ECM
Is the DTC present?

3. CHECK TPS
(b) With the analogue mulitimeter to check TPS data.

(d) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\ MPX\ENGINE\491 GASOLINE
NO > Repair or replace the MAP/IAT sensor. If it is still not OK, go to step 12.


the pressure again:
6. CHECK INJECTOR

(d) Check whether every injector can spray even and standard quantity gasoline.
CAUTION
WARNING
04
YES > Go to step9.
NO > Repair or replace the injector. If it is still not OK, go to next step. 04

pipe. Check whether fuel leakage at fuel pipe connection.






NO > Perform the valve timing align operation or replace the timing belt. (Refer to “Chapter 15A engine
mechanism - timing belt, replacement”)

NO > Repair the engine mechanism faults. 04
15. REPLACE ECM
04-128 DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)
DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)

PRECAUTION
1. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the nagative battery cable to
(b) The ignition switch must be off without any special descriptions.
WARING
The ignition and illuminatioin switches must be off before removing or installing the negative battery
cable (the semiconductor maybe damaged without doing that).
CAUTION
3. EXPRESSIONS OF IGNITION SWITCH


Expression
4. OVERHAUL THE DIESEL ENGINE CONTROL SYSTEM FAILURE PRECAUTIONS.

(a) Do not disconnect battery from electric circuit while diesel engine is running at high speed in case the
instantaneous overvoltage damage the control units and sensors.
(b) The unit should be disconnected at the time for electric welding on the car body. It is special attention
that performing the repair work beside the control units or sensors.
out of order.
(e) Don’t check any electric apparatus connecting the unit with a test light.
(g) Control unit and sensor must be kept from moisture. No permission damaging the seal device of control
units and sensors and washing them more.
(h) Prevent human body static electricity from damaging control unit. The operator body must be grounded
when operator checks unit or replace chips.
order.
(j) We must remove and install control unit, actuators and independent sensors when the ignition switch is
OFF unless there is additional specification in the checking procedure.
(k) If the removed and installed control units, actuators and sensors are to be reinstalled, the system
should be checked after completing installation.
(l) When diagnosis, the ignition switch turns to ON position and the connectors are dissociated. Other
system will store DTC. After diagnosis, confirm DTC in all systems. Turn the ignition switch to OFF
position when the connectors are connected and disconnected.
DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ) 04-129
(m) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also
cause corrossion. Use the test wire, wire connector and measure wire and so on.
(n) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, do not insert by force. 04
(o) If check the common connectors when they are not in connection status (check male connectors):
• Be careful and do not short terminals circuit by using a probe. This will damage the interior circuit in
control unit.
(p) If check the common connectors when they are not in connection status (check formale connectors):
(q) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam- 04
age wire harness, sensor, control unit and other components so we must carefully handle when check-
ing.
(r) Do not check with the list order.
• If the check results are different from the standard value, then check related sensors ,actuators and
eliminated.
(s) Check resistance and continuity between terminals of ECM with multimeter.
(t) Ground inspection.
works.
(u) When inspecting a ground connection, follow these rules:

Good Contact.

• Inspect all mating surfaces for tarnish, dirt, rust, etc.
• If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of
the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in
one eyelet make sure no ground wires have excess wire insulation.
LOCATION
ENGINE ROOM
04
04
1 EGR Valve Control Unit 2 Data Link Connector (DLC)

ENGINE
1 Coolant Temperature Sensor For Fan 6 Fuel Delivery Valve Seat
2 Throttle Position Sensor 7 VE Pump
3 Inlet Pipe 8 Fuel Return Pump
4 Intake Manifild 9 EGR Coolant Temperature Sensor
5 Oil Dipstick
04
04
1 Coolant Temperature Sensor For Fan 6 Glow Plug
2 Generator 7 VE Pump
3 Vacuum Pump 8 Intake Manifold
4 Turbocharger 9 Injector
5 EGR Valve Assy
.

NOTE
1. VEHICLE IS SENT INTO REPAIR SHOP

2. GET INFORMATION ABOUT SYMPTOM FROM THE CUSTOMER

3. VISUAL CHECK

If the engine does not start, first perform the "CHECK FOR DTC" procedures and "CONDUCT BASIC”
Result Proceed To
Normal Step 6

6. BASIC CHECK
Result Proceed To
Result Proceed To
8. CHECK POWER SUPPLY CIRCUIT

Result Proceed To
04
04
YES > Go to step14.
11. CHECK PARTS

12. CONFIRM FAULT


YES > END.

CAUTIONS FOR CIRCUIT TROUBLESHOOTING

CAUTIONS FOR CIRCUIT TROUBLESHOOTING ARE AS FOLLOWS:
(a) Be sure to use the high-impedance digital multimeter; Be sure to use original conducting wire service
tool kit, including various kinds of connectors, contact probes, sealing elements, terminals, testing leads
and other tools for service connectors.
(b) Conduction testing. Select the conduction testing mode on the multimeter, which is marked with a diode
symbol. Disconnect both ends of the circuit or part to be tested during the testing. Contact one test pen
with one end of circuit or one terminal of part and contact the other test pen with the other end of circuit
or the other terminal of part. Read the measured value; If the circuit is continuity, the multimeter sounds
a buzze; If the circuit is open, the multimeter doesn’t sound a buzzer.
(c) Test for short-circuit grounding. The short-circuit grounding is a case in which it can’t be grounding
(ground) but actually is grounding. The testing sequences for short-circuit grounding are:
• Turn the ignition switch OFF.
• Unplug the connector to be tested. Remove the sensor from the harness connector when test it.
Remove the harness connector from the sensor when test the harness connector on EGR valve control
unit.
• Contact one test pen of the multimeter with the contact probe to be tested and the other test pen with
the ground.
• The read of multimeter must be larger than 1 MΩ, indicating the circuit is open rather than short.
• If the circuit isn’t open and the resistance value is less than 2 Ω, it shows that the conducting wire
tested must be shorted to ground.
• Repair or replace the part or harness.
(d) Testing for short between contact probes. Short between contact probes means the case in which there
should be no conduction between two contact probes but conduction exists. Testing sequences are:
• Turn the ignition switch OFF, remove the connector to be tested; If the contact probe and other sensors
form a circuit, remove the sensor.
• Contact one test pen of the multimeter with the proper contact probe to be tested at the connector
harness side, and the other test pen with the other contact probes at the connector harness side.
• The read of multimeter must be larger than 1MΩ, indicating the circuit is open; if the circuit isn’t open
and the resistance value is less than 2 Ω, it shows there must be short circuit between contact probes
tested.
• Check the inside of harness connector for wet vapor which may cause short circuit.
• Repair or replace the harness.
(e) Conduction testing. Conduction means that the resistance between two contact probes is less than a
definite value, namely the resistance should be less than 2 Ω. Testing sequences are:
• Remove the harness connector to be tested.
• Contact both test pens with contact probes of harness to be tested separately.
• For the conducted harness, the resistance should be less than 2 Ω.
• If the resistance is larger than 2 Ω, repair or replace the harness or connector.

(a) Turn the ignition switch OFF. Remove the burned fuse. 04
no circuit for short. But the temporally shorted circuit also 04
• Clipped harness
• Damaged harness
• Connectors or circuits with water
• Wrong operation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Circuit shorted

CAUTION
in the customer's complaint. Do not recur visits. Realize also that the most frequent cause of
intermittent incidents occurrences is poor electrical connections. Because of this, the conditions
under which the incident occurred may not be clear. Therefore, circuit checks made as part of the
standard diagnostic procedure may not indicate the specific malfunctioning area. In this case, the
maintenance staff must find out the situation in detail from the customer, asking the car owner for the
details of driving conditions, weather conditions, frequency of occurrence and symptom of failure,
extension.
• Relay, part and sensor: pat the sensor, relay and part
2. HEATING METHOD.
CAUTION 04
Don’t heat over 60 ℃ (the heating temperature should be in the limit of touching the part with hands);
3. SPRAYING METHOD.
failure occurs. 04
CAUTION
• Please take extra care to sprinkle water on vehicle leaking water, as the water leaked into
vehicle may damage control unit.
find out the trouble location quickly; this method is very practical and effective.
5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCAN TOOL.
• Use the function of data flow capture on the diagnostic scan tool. When seeing the data flow on the
diagnostic scan tool, make the rated data status to simulate the fault conditions based on the freeze-
frame on the diagnostic scan tool.
• The oscilloscope analyzer can collect the waveforms of EGR control system sensors, diagnose if the
sensor fails or not correctly by analyzing the sensor waveforms.
• Generally, there is no method to replace the known good parts tested on a faulty vehicle. Only by
knowing which parameter is the normal, it can be picked out as problematic or abnormal one.
7. OTHER METHODS
• Replace part. Before replacing control unit in part replacing method, take full diagnosis for other
external causes. Control unit is expensive product with high reliability.
CAUTION
When replacing and testing possible damaged control unit, install the possible damaged control unit
on a failure-free vehicle for testing; don’t install new control unit on a failed vehicle for testing to avoid
damaging the control unit.

1. If the failure can't be confirmed throug testing, do the troubleshooting analysis for all circuits
that are possible to cause failures. In many cases, carrying out the following preparation works
can find out the location causing failure effectively. So, it’s necessary to take this method during
engine troubleshooting.
CAUTION
• Troubleshooting working is a systematical project, so the diesel engine should be taken as a
whole (a system) rather than a set of components. To grasp the whole situation of failure
occurrence, make a complete understanding from the operators and observe the diesel engine,
take necessary checking and make analysis to finger the cause of the failure.
• Some failures of diesel engine, such as gas in diesel system, filter blocking, loose driving belt
and so on, can be cleared through necessary technical maintenance and adjustment. But some
failures, such as cylinder gasket damage, piston ring severe wear and valve face wear, can’t be
cleared with general methods of maintenance and adjustment as the mechanism defect. There
failures only can be cleared by removing and repairing the diesel engine or replacing parts.
2. The using condition should be known. Including as following.
No. Item
1 Is there any abnormal sound
2 Load or not
3 Accelerate or decelerate
4 Does the oil pressure or ECT change
6 The consumption of the oil, diesel, coolant
7 Check whether the exhaust thickness is normal
8 Check whether the electric accelerator pedal is sensitive
9 Check whether the deceleration is normal
10 Check whether the shut down is satisfaction
11 Check whether the cold starting is satisfaction
12 Check whether there is any misfire or stall
13 What kind of diesel is used, what the degree is, and where from
14 During idle or full speed running, whether there would be a surge or not
15 Check whether the long period idle can last

3. The maintenance history should be known. Including as following.
No. Item
1 Recently, Whether diesel engine has been repaired 04
2 Whether this trouble happen before
3 When the oil and diesel last changed
4 How long or how far the diesel engine run
5 Is there any metallic impurity, when to replace change oil filter 04

6 Any repaired items
4. Inspect the checking result finally, as following.
No. Item
1 Whether the diesel engines is clean
2 What the degree of tightness of belt is
3 There is external seepage of oil, diesel and water or not
4 Whether there had been hot phenomenon
5 Whether there is any temporary maintenance on diesel engine
6 What the sounding of the diesel engine is. And any surge of the belt pulley
7 Whether the component is not belong to the diesel engine or it is nonstandard
Oil level, coolant level and diesel level (if relate to the bearing, pay attention to the oil
8
condition)
9 When removing, pay attention to the carbon deposit, abnormal taste, etc.
13.
STANDARD NORMAL RESISTANC AS FOLLOWING

No. Item Normal Condition
1 Glow plug ≤ 0.45 Ω (23 ± 5 ℃ )
15.462 Ω (-20 ℃ )
5.986 Ω (0 ℃ )
2 Coolant temperature sensor for fan
2.500 Ω (20 ℃ )
0.323 Ω (80 ℃ )
3 EGR coolant temperature sensor 14 Ω (20 ℃ )
4 Preheating temperature sensor 860 ± 86 Ω (20 ℃ )
5 Vacuum regulator 14 ± 10% Ω （20 ℃）

6 KSB valve 7.1 ± 1 Ω （20 ℃）
7 Speed sensor 2.6 ± 0.4 kΩ （20 ℃）
8 Throttle position sensor Hall type （20 ℃）
9 Timming stroke sensor Hall type （20 ℃）
10 EGR valve lift sensor Hall type （20 ℃）
11 Fuel supply solenoid 11 ± 2 Ω （20 ℃）
12 Return fuel solenoid valve 7.1 ± 1 Ω （20 ℃）
13 Fuel inlet solenoid valve 11 ± 2 Ω （20 ℃）
14 Idle solenoid 40 Ω （20 ℃）
DIAGNOSTIC SYSTEM
1. THE FAILURE OF ENGINE CONTROLSYSTEM.
(a) BJ493ZQ diesel engine equiped with VE pump. When 04
diesel engine system failure, MIL lamp (1) illuminates.
When the MIL lights, based on relevant requirements of
national rules, it needs to be treated immediately. The
failure should be checked with diagnostic scan tool or
special equipment with corresponding functions.
04
SYMPTOM OF FAILURE
CAUTION
• If the trouble isn’t confirmed in checking and the cause of trouble can’t be confirmed in basic
checking, please take the troubleshooting in the sequence listed in the following list, then go to
related page for troubleshooting.
• Thorough analysis on the customer’s complaint is the key for successful troubleshooting. The
more information from the complaint, the quicker and easier the problem can be solved. The
failure symptom diagnosis list is organized in the thought of determining the failure location
and solving the problem by doing the easiest and most logical things. Complete all steps in
sequence from top to down. The list is impossible to contain all possible problems; but the
failure symptom diagnosis can be used to develop thoughts so as to find out the cause of
trouble and remove it.
DIESEL ENGINE PROBLEM SYMPTOMS TABLE

Symptom Suspect Area
• Battery
• Main relay
• Harness or connector
• Diesel quality
• Injection advance angle
Failed to start • Low pressure lines or pump
• Preheat system
• Feed pump
• Injector
• Diesel engine mechanism system
• VE pump
• Battery
Engine start
• Starter
• Solenoid
• Relay and strater switch
• Diesel quality
• Air in diesel system
• Preheat system
Hard start
• ECT sensor
• Low pressure lines
• High pressure lines
• Injector
• VE pump
• Air filter
• Diesel filter 04
• Diesel quality
Power Poor power • Turbocharger
• Throttle pedal
• EGR control system 04
• ECT sensor
• Injector
• VE pump
• Diesel quality
• Water in diesel system
• Diesel filter
• Feed pump
Idling stability • VE pump
Idle shaking
(Improper idling) • Injector
• Linkage betwee the diesel engine and VE pump
• Idle adjustment
• Each cylinder supply quantity
• The idle Improve device
• Accelerate system adjustment
• Air filter
• ECT sensor
• Diesel quality
• Turbocharger (poor pressure)
• EGR valve and control system
• Injector
Black smoke
• VE pump
• Supply quantity
• Injection timming
• Diesel engine overloaded
• Water in diesel cylinder or diesel

• Coolant
• Preheat system
• Diesel quality
• Inject pressure and spraying condition
Emission White smoke • Oil level is too high
• Breather
• Supercharger
• Injection timming
• VE pump
• Diesel quality
• The engine oil level inside the diesel engine pan
• The piston chamfer is installed in opposite direction during
installation to let engine oil into the combustion chamber
• The cylinder and piston ring is severe worn or the piston
ring gap is not aligned or the elasticity is decreased
Blue smoke • The piston ring is severe worn or broken causing the ring
seized
• The diesel engine lubrication oil is inhaled into the
combustion chamber through the valve guide
• The valve oil seal is damaged
• The valve oil seal seat and the valve guide aren’t aligned
or the gap
• The match between piston pin and connecting rod small

end bushing hole
• The gap between piston and cylinde

There is abnormal knocking
Abnormal noise
or impact sound during • The wear of connecting rod bearing shell and main
when running
running bearing shell makes the fit clearance
• The valve and the piston gap
• The gap between intake/exhaust valves

• Coolant
• Fan belt 04
• Fan silicone oil clutch
Over heat • Thermoster valve is stuck
• Coolant pump fault
• Radiator core
Abnormal • Oil quality
temperature
• Thermoster valve cannot close completely 04
Too cold
• Coolant temperature indicator
• Raditor
• Raditor hose connector
Lack of coolant
• Coolant pump
• Heater hose connector loose or hose damaged
• Turbo side seal

• The floating bearing
• The supercharger return tube
• The supercharger seal
• The turbine shaft rotor
Under-power
• The turbo blades and compressor blades
• The air filter
• The induction tunnel of the supercharging compensator
• Air intake and exhaust pipes
• The supercharger
• The junction part or inlet and outlet pipe

Pressure High diesel wastage • Performance of turbocharge
charging system • Piston ring
• Turbocharge seal ring

• The side of impeller blades of compressor of turbocharger
High oil wastage
• The screw at the junction of inlet and outlet oilpipe
• Oil quality
• The turbo end and the gas passage

Abnormal knocking • The compressor end and the gas passage
• The floating bearing
Vibration produced by • Turbocharge inner

friction between turbine, rotor • Floating bearing
and case • Turboshaft dynamic balancing
• The mount of diesel engine
• The transmission flying wheel or flexible connecting bolt

Attaching parts
Body serious • Accessories
vibration
• The diesel engine bottom guard plate
Diesel engine • The dynamic balance of rotating parts such as crankshaft

and crankshaft pulley
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS

CAUTION
Some symptom diagnosis steps require visual and observational check. Firstly carry out the visual
and observational check every time. The check can solve one problem without further test and can
save valuable time.
1. ASK THE VEHICLE OWNER FOR THE FOLLOWINGS AS RECEIVING THE VEHICLE.
(a) The time at which the trouble first occurs.
(b) The diesel engine temperature as the trouble occurred.
(c) The vehicle miles of travel
(d) The driving road and owner’s driving manner.
(e) The vehicle maintenance condition.
(f) The vehicle maintenance history.
(g) Whether the vehicle is equipped with optional device. Initial assessment can be done through the
understanding above to save the checking time.
2. ORIGINAL INSPECTION SHOULD BE DONE AT FIRST BEFORE THE CARRYING OUT THE
FAULT DIAGNOSIS BASED ON THE DIESEL ENGINE SYMPTOM.
(a) Be sure the diesel engine malfunction indicator lamp works normal. If it's abnormal, first troubleshoot
the malfunction indicator lamp.
(b) Be sure the customer’s complaint is current and the causes of failure exist.
(c) Confirm the maintenance record, the diesel engine compression pressure and the diesel fuel condition
during the vehicle maintenance.
3. OBSERVATIONAL VISUAL CHECK.
(a) Check the connection status of ground wire.
(b) Check if the diesel engine vacuum system connecting pipe is cracked, twisted, squashed or damaged
and if the connection is correct.
(c) Check if the diesel engine oil dipstick and the engine oil filler port are installed properly.
(d) Check if the diesel engine grounding (ground) is clean and the connection is firm.
(e) Check if the engine intake pipes leaking gas at the joint points.
(f) Check if the engine diesel fuel system high/low pressure oil pipes leak at the joints.
(g) Check if the engine diesel fuel goes bad and the water and diesel fuel are proper.
(h) Check if the connectors of engine sensors and actuators are in good contact and firm connection.
CAUTION
• There are many causes of trouble that the diesel engine gives off black smoke; the problems
with oil supply system, diesel qulity, combustion condition, air intake and exhaust system may
cause the trouble of diesel engine giving off black smoke.
• Although the problems with the oil supply system problem、 the combustion condition、 the air
intake system、 the exhaust system and other factors may be the cause of trouble that the
diesel engine gives off black smoke, for a diesel engine, the cause of trouble of giving off black
smoke may be only one factor among them.
• For the diesel engine equipped with turbocharger, one air leak source is the turbocharger intake
pipe, which is easy to neglect.
4. IF ONE SYSTEM FAILS, IT MAY LEAD TO MANY TROUBLE SYMPTOMS OF DIESEL ENGINE.
(a) For example, either blocked intake system or too long pipe may increase the intake resistance. The
intake resistance is too large and the intake system is blocked (For example, the air cleaner element is
blocked, the intake pipe makes the inhale resistance of supercharger increase because of settled dust), 04
thus leading to that the supercharging pressure of diesel engine falls and waves, further resulting in that
the diesel engine power falls, the engine runs unbalance and generates black smoke. Too high intake
temperature is also possible to cause the diesel engine to give off black smoke. Besides causing the
diesel engine to give off black smoke, the trouble of intake system also has the following symptoms.
• The diesel engine is short of power.
• The diesel engine consumption increases. 04
(b) If the intake system is installed improperly, for example, the exhaust pipe is too long or thin, the muffler
is improper, it may increase the exhaust resistance, cause restricted exhaust of diesel engine thus
leading to giving off black smoke. If the exhaust system has a problem, besides giving off black smoke,
the diesel engine also has the following symptoms:
• The diesel engine exhaust temperature increases.
• The diesel consumption increases.
(c) If the turbocharger fails, it arises many symptoms:
• The supercharger creates powerful vibrations and makes noise during running.
• The diesel engine is short of power and its forces drop.
• The diesel consumption increases
• Oil discharging at turbo end or pump impeller end leads to increasing engine oil consumption of diesel
engine. The turbocharger adopts full floating type slide bearing on the rotor shaft. If the rotor shaft is
worn and the rotor axial clearance especially the radial clearance is too large, the seal ring fails. Severe
wear can bring much oil-fouled and carbon-residue deposits in the exhaust pipe and the muffler, not
only increasing the exhaust resistance, lowering the supercharger speed and the diesel engine forces,
but also increasing the engine oil consumption of the diesel engine.
(d) Troubles with cylinder head parts: this moment the diesel engine is short of power and the performance
drops, and also there are symptoms such as air leak, giving off black smoke and abnormal knocking.
DIESEL ENGINE TROUBLESHOOTING LIST

DIESEL ENGINE CAN’T START (VE PUMP CAN SUPPLY - DIESEL CAN
REACH INJECTOR)
CAUTION
For successful start of diesel engine, it must be ensured with high enough speed, good cylinder
compression effort and good atomized diesel fuel injected in time. In addition, the temperature should
be high enough to make the atomized diesel reach the ignition status. In general, the possible causes
of engine unable to start are related to the electric system、 the supply system and the mechanical
parts of the diesel engine.
Suspect Area Trouble-Shooting
1. Poor connection, harness

• Check harness and connector. Repair or replace.
or connector damaged
Electrical control 2. Low battery • Check charging system. Charging battery or replace.
system
3. Starter • Repair or replace.
4. Main relay • Replace.
• Check whether the diesel supply line connector loose. If

1. Air in diesel supply
loose, replace it. (Refer to “Chapter 12B fuel - diesel filter,
system
replace filter”)
2. Diesel system lines are

blocked. The pressure is
Diesel supply • Check whether the diesel system is clear, leakage.
too low in high and low
system pressure system
3. Diesel filter • Check diesel filter or replace.
4. VE pump fault • Check and replace.
5. Injector fault • Check, repair or replace.
• Check the timing mark. Reinstall or replace it. (Refer to

1. Timing system “Chapter 15B diesel engine mechanism - engine timing
gear, overhaul")
Mechanism • Check valve clearance, spring. Check the sealing

system 2. Valve is unable to close performance of the valve guides and valve seats. Check
properly whether the valve seat is too deep. If the sealing ing is not
good, repair it.
• Replace the piston ring. Depending on actual need,

3. Wear-out of piston
replace it.
DIESEL ENGINE IS DIFFICULT TO START(VE PUMP CAN SUPPY - DIESEL

CAN REACH VE PUMP, BUT CAN’T REACH INJECTOR)
CAUTION 04
Suspect Area Trouble-Shooting 04

system
replace filter”)
2. Diesel supply system

lines are blocked. The
• Check whether the diesel supply system is clear, leakage.
pressure is too low in high
and low pressure system
Diesel supply
system 3. Diesel filter • Check diesel filter or replace.
4. VE pump • Check and replace.
5. Injector • Check, repair or replace.
6. Feed pump • Check, repair or replace.
7. Delivery seat leaking • Check, repair or replace.

DIESEL ENGINE IS DIFFICULT TO START(VE PUMP CAN’T SUPPLY - DIESEL

CAN’T REACH VE PUMP)
CAUTION

or connector
2. Low battery • Check charging system. Charging battery or replace.

Electrical
system 3. Starter or start switch • Repair or replace.
4. Main relay • Replace.
5. Cut-out solenoid valve • Repair or replace.

system
replace filter”)

• Check whether the diesel system is clear, leakage.
Supply system 3. Diesel filter • Check diesel filter or replace.
4. VE pump or vane • Repair or replace.
5. Feed pump • Check and replace (Internal leakage or no diesel).
6. No diesel • Refuel.
7. Fuel filter valve does not

• Replace.
seal
DIESEL ENGINE HARD TO START

CAUTION
In the case of sufficient battery power、 diesel tank with oil and starter in good condition, If diesel
04
engine starting difficulty or be unable to start, should focus on examination of the following areas: the
electric system、 the preheating system、 the supply system and the mechanical parts of the diesel
engine
1. Poor connection, harness 04

or connector
Electrical control 2. Low battery • Check charging system. Charging battery or replace.
system
3. ECT sensor • Repair or replace harness or ECT sensor.
4. Starter • Repair or replace.
1. The preheating system is

Preheating out of work caused by • Check fuse, harness,preheat relay, glow plug, KSB valve
system electrical components. and preheat control unit.
Glow plugs is out of work
• Check whether the diesel supply line connector is loose. If

system
replacement”)

pressure are too low in • Check whether the diesel system is clear, leakage.
high and low pressure
Fuel supply system
system
3. Diesel filter • Check or replace diesel filter.
4. VE pump wear or vane is

• Repair or replace.
stuck
• Check whether the spray of the injector is normal,

5. Injector dropping or clamping. Check whether the washer is
damaged.
• Check whether the filter is dirty, ash and blocking of the

1. Air filter intake (Usually when the intake is blocked. the exhaust will
emmit smoke when starting).

gear overhaul)
Mechanism • Check valve clearance, spring. Check the sealing

system 3. Valve is unable to close performance of the valve guides and valve seats. Check
properly whether the valve seat is too deep. If the seal ing is not
good, repair it.
4. Wear-out of piston • Replace the piston ring. Depending on actual need.
5. Camshaft and camshaft • Check whether the installation of the camshaft gear is
gear alignned.
6. Shaft wear • Check and replace.

DIESEL ENGINE IS SHORT OF POWER

CAUTION
For diesel engine short of power, the main features are: uneven running in low speed, exhaust pipe
giving off black smoke in high speed, abnormal sound. In case that the diesel engine hasn’t reached
the major repair, the short of power is mainly caused by the trouble of diesel supply system and poor
compression of cylinder.
1. Poor connection,
harness or connector
2. EGR control system • Check harness and connector. Repair or replace.

Electrical control
system 3. ECT sensor • Check harness and connector. Repair or replace.
4. Accelerator pedal
• Check the installation position.
position sensor
5. Main relay • Check main relay and related harness.
1. Diesel • Diesel quality.
• Check whether the diesel supply line connector is loose. If

2. Air in diesel system loose, replace it. (Refer to “Chapter 12B fuel - diesel filter,
replace filter”)
3. Diesel system lines

are blocked. The
pressure is too low in • Check whether the diesel system is clear.
high and low pressure
system
4. Blocking in diesel filter • Check or replace diesel filter.

Fuel supply system
• Check and replace VE pump.
5. VE pump
• Adjust the installation position.
• Check whether the spraying of the injector is normal,

6. Injector dropping or clamping. Check whether the washer is
damaged.
7. Valve stuck, valve

• Check and replace.
spring broken
8. Pressure compensator
diaphragm rupture or • Check and replace or adjust the installation position.
out of adjustment
1. The coolant • Check dirty on the radiator or cooling surface. Clear the
temperature is too high internal scale.
• Check the oil quantity. Depending on actual need, add it. if

Diesel engine is 2. The oil temperature is the shaft bearing or related components are worn-out
overheat too high caused by heat, overhaul diesel engine after finding out
the causes of fever of components.
3. The exhaust
• Check injector.
temperature is too high
• Check whether the air filter is dirty, deposition. The inlet

1. Inlet system (filter)
line is blocked. 04
2. EGR valve • Check whether EGR valve clamping.
• Check the intake and exhaust system. Check if there is

leaking or blocked between the air cleaner and the
turbocharger, the turbocharger and the cylinder head, the
turbocharger and the exhaust pipe.
• Check the pressure of turbocharger with the turbocharger 04
pressure meter; the pressure should meet specified value.
• Check of replace the turbocharger bearing, clean the
intake pipes, the case and the impeller; tighten the nuts
and clamps at the joints.
• Check the radial clearance of the turbocharger rotor: press
down the compressor impeller in radial direction with
Mechanism system hands, measure the minimum clearance between the
3. Turbocharger system compressor impeller and the compressor case with a
feeler gauge; the measured value should not be less than
0.10mm.Replace the floating bearing if the measured
value is less than 0.10mm.
• Check the axial clearance of the turbocharger rotor: fix a
magnet base on the turbo case outlet flange face, contact
the dial gauge with the turbo rotor axis end face, push or
pull the turbo rotor axially, the measured value is the axial
clearance value. The axial clearance of rotor on the new
supercharger should be ≤ 0.1mm, the operating limit ≤
0.25mm. Disassemble the assembly and replace the worn
parts if the axial clearance of the supercharger rotor is
greater than the operating limit value.

gear, overhaul”)
• Check valve clearance (when cold):

(a) Intake valve: 0.4 ± 0.05 mm
(b) Exhaust valve: 0.4 ± 0.05 mm
• The free length of valve spring: 48 mm, if it is out of the
range , replace it.
• Check the clearance between valve leveler and valve
Guide:
(a) Inlet valve: 0.039 ～ 0.071 mm
5. Valve is unable to
close properly (b) Outlet valve: 0.064 ～ 0.096 mm
• Check limit clearance between valve leveler and valve
Guide:
(a) Inlet valve: 0.20 mm
(b) Outlet valve: 0.25 mm
• Check the gas tightness of the valve seat, check if the
valve retainer sinks too deeply or is burnt to wear; if the
tightness is poor, repair and grind the matching surface of
valve seat to recover the tightness.
• Replace piston ring. Replace cylinder depending on wear

Mechanism system 6. Piston wear
condition.
• Check cylinder head bolts. Tighten them according to the

7. Cylinder gasket
specified torque or replace cylinder head gasket.
8. Exhaust pipe • Check the carbon deposition. Clear it.
9. Leakage at the juncted

surface between the • Tighten the cylinder head bolts according to the specified
cylinder head and torque.
body. The cylinder
head bolts loose. The • Overhaul cylinder head. Check whether the gasket is
cylinder gasket damaged. If not OK, replace it.
damaged
10. Crank link

mechanism(unsmooth
• Remove oil pan. Check whether the lower end of the
stagnation between
connecting rod axial runout . If it is not OK, remove piston
the piston pin in the
linkage. Overhaul it.
connecting-rod bush
and piston pin)
DIESEL ENGINE IDLE IS UNSTABLE

CAUTION
The problem is mostly intake system and diesel control system
04
1. Poor connection, harness • Check harness and connector. Repair or

or connector replace.
• Check harness and connector. Repair or

2. Cut-out solenoid valve 04
replace.
Electrical control system
3. EGR control system
replace.

4. ECT sensor
replace.
• Check whether the diesel supply line connector

1. Check the air existing in
is loose. If loose, replace it. (Refer to “Chapter
diesel
12B fuel - diesel filter, replace filter”)

• Check whether the diesel supply system is clear.
3. Diesel filter • Check or replace diesel filter.

Diesel supply system
• Low idle speed - adjustments, replace VE pump.
• The uneven cylinder diesel - adjust, repair or
replace.
4. VE pump
• Poor performance of the output valve - adjust,
repair or replace.
• Plunger wear - Replace.
• Check whether the spraying of the injector is

5. Injector
normal, dropping or clamping.
• Check whether the filter is dirty, ash and blocking

1. Filter
of the intake.
• Check the timing mark. Reinstall or replace it.

2. Timing system (Refer to “Chapter 15B diesel engine
mechanism - engine timing gear, overhaul”)
Mechanism system
• Check valve clearance, spring. Check the
3. Valve is unable to close sealing performance of the valve guides and
properly valve seats. Check whether the valve seat is too
deep. If the sealing is not good, repair it.
• Replace the piston ring. Depending on actual

4. Piston abrasion
need, replace it.
DIESEL ENGINE GIVES OFF BLACK SMOKE

CAUTION
It indicates that the air fuel ratio is incorrect if the electric control diesel engine gives off black smoke,
mainly because of insufficient air input and large quantity of fuel injected. For insufficient air input, it’s
reflected in air leak or blocking of intake system pipe, insufficient supercharging pressure, air flow
sensor trouble and so on. In addition, poor atomizing of injector also can lead to giving off black
smoke because of insufficient combustion. It shows that the diesel fuel isn’t burnt sufficiently if the
diesel engine gives off black smoke; the diesel fuel that isn’t burnt is exhausted in uncombined type
and forms the black smoke. The diesel engine giving off black smoke also goes with powerless
accelerating and short of power usually.
1. High pressure is
• Overhaul.
too high
• Low idle speed - adjustments, replace.

• The uneven cylinder diesel - adjust, repair or replace.
Fuel supply system 2. VE pump fault • Poor performance of the output valve - adjust, repair or
replace.
• Plunger wear - Replace.

3. Injector fault dropping or clamping. Check whether the washer is
damaged.
• Check whether the filter is dirty, ash and blocking of the

1. Filter intake (Usually when the intake is blocked. the exhaust will
emmit smoke when starting).

leak or block between the air cleaner and the
• Check the pressure of turbocharger with the turbocharger
• Check of replace the turbocharger bearing, clean the
• Check of rotor’s radial clearance: press the compressor
blades with a hand in radial direction and measure the
2. Check the minimum clearance between the compressor blade and
Mechanism system turbocharge compressor casing with thickness gauge. The measured
system value should not be less than 0.10, if not, replace the
turbocharger.
• Check of rotor’s axial clearance: fix a magnetic base on
outlet flange facing of turbocharger, let the dial indicator
touch the rotor spindle, and then push or pull the
turbocharger rotor in axial direction to get a clearance
value, the measured value is the clearance value. The
rotor’s axial clearance value of new turbocharger should
not be more than 0.1mm and operating limit value should
not be more than 0.25mm. If the axial clearance value of
turbocharger rotor exceeds the operating limit value,
replace the turbocharger.

gear overhaul")
• Check the valve clearance (measure the valve clearance

value with a plug gauge, adjust the valve clearance again
04
to specified value if it’s abnormal); the clearance values of
intake and exhaust valves in cold condition are:
• The free length of valve spring: 48 mm, if out of the range,
replace it
Guide:
04
4. Valve is unable to
close properly (a) Inlet valve: 0.039 ～ 0.071 mm
(b) Outlet valve: 0.064 ～ 0.096 mm
Mechanism system Guide:
• Check valve clearance, spring. Check the sealing
performance of the valve guides and valve seats. Check
whether the valve seat is too deep. If the sealing is not
good, repair it.
• Check clearance between piston and cylinder bush: 0.042

～ 0.060 mm.
• The limit clearance between piston and cylinder bush:
5. Piston abrasion 0.20 mm.
• If the clearance of the piston and the cylinder bush are
large, the pressure is low. The diesel combustion is not
full, then the black smoke will emit.
DIESEL ENGINE RUNS WITH ABNORMAL NOISE

CAUTION
• First, identify the type of the abnormal noise. Find out whether it is the knocking caused by
abnormal explosion or the clashing caused by abnormal motion. Then, checkout and diagnose
the noise source based on the noise characteristics and combining the construction principle.
• The diesel engine is strictly forbidden to continue running with abnormal noise; when an
abnormal noise is found, park the vehicle urgently, and do the checking and troubleshooting,
then run the engine again.
Suspect Area Troubleshooting
• The clearance between the piston-pin seat and the piston-

pin is within 0.002 ～ 0.015 mm, the maximum wear limit is
1. The elearance 0.03 mm; the clearance between the small end of
between piston pin connecting rod and the piston-pin is within 0.008 ～ 0.020
and connecting rod mm, the maximum wear limit is 0.05 mm.
small end bushing hole • If the clearance value is out of the specified range, replace
is too loose; there is the connecting rod small end bushing to make the value
slight but sharp sound within the range. When installing the stop ring of the piston
during idling running pin, check the external of the stop ring for crack or scar.
The stop ring opening should be out of alignment with the
mounting notch on the piston during installation.
2. The gap between • The fit clearance between the piston and the cylinder bush
piston and cylinder is
too large; an impact is within 0.042 ～ 0.060 mm, the clearance wear limit is
sound can be heard at 0.20 mm. Measure the fit clearance between the piston
engine body outer wall and the cylinder bush during maintenance; replace both
and it increases with the piston and the cylinder bush if the clearance exceeds
the speed increasing the wear limit.
3. The wear of
connecting rod bearing • Install the piston connecting rod assembly and crank
shell and main bearing assembly on the cylinder block, rotate the crankshaft,
shell makes the fit watch carefully if the crankshaft compensator and bottom
Mechanism system clearance too large. of connecting rod crash to the cylinder block. The radial
The body impact clearance between the connecting rod bearing shell and
sound can be heard at
the journal is within 0.029 ～ 0.075 mm, the maximum
the crank case during
wear limit is 0.03 mm; the axial clearance between the
running. The heavy
and power impact connecting rod and the crankshaft is within 0.175 ～ 0.29
sound can be heard if mm, the maximum wear limit is 0.35 mm; replace it if
the speed reduces damaged and install it upon specified clearance
suddenly
4. The valve hits the

piston; the clear, even
• Find out the cause of hitting, check the valve timing and
and rhythmic knocking
adjust the valve clearance
sound can be heard at
the cylinder head

5. The gap between to specified value if it’s abnormal); the clearance values of
intake/exhaust valves intake and exhaust valves in cold condition are:
is too large; the loud (a) Intake valve: 0.4 ± 0.05 mm
and rhythmic sound (b) Exhaust valve: 0.4 ± 0.05 mm
can be heard at the • Check the gas tightness of the valve seat, check if the
cylinder head valve retainer sinks too deeply or is burnt to wear; if the
TEMPERATURE OF COOLANT IS ABNORMAL IN DIESEL ENGINE COOLING

SYSTEM, COOLANT IS INSUFFICIENT
CAUTION 04
1. If the diesel engine is overheating, don’t stop the running of diesel engine immediately or fill it
with coolant suddenly. with running the engine with no-load, shut off the engine and check it
after the temperature of coolant in the cooling system drops.
2. Excessive high temperature of coolant may cause damage to the cylinder gasket. the causes
are the following.
(a) The diesel engine temperature is too high (over the critical line of engine temperature). 04
(b) The vehicle runs with the coolant temperature over 100 ℃ till the diesel engine stalls by itself.
(c) After the diesel engine stalls by itself as the temperature is too high, open the diesel engine hood, and
fill the engine with water after natural coolant (at this moment, never open the expansion valve cap to
avoid being burnt); generally, the cylinder gasket has been damaged and needs to be replaced.
3. Excessive high temperature of coolant may cause deformation to the cylinder head. the causes
are the following.
(a) When the temperature is too high and the vehicle continues running till the diesel engine stalls by itself,
if open the expansion water tank cover (avoid being burnt by fleeing steam with a washcloth or other
things) and fill it with water immediately, the cylinder head will be deformed.
4. If the diesel engine is overheating, don’t open the expansion water tank cover to avoid being
burnt. Do take good care of safety when adding coolant. Remove the overheating trouble
immediately, otherwise it may cause damage to other parts.
• Add coolant. Check whether the coolant leakage. Repair it

1. Coolant is too low
if necessary.
2. Coolant level is out of

• Check coolant concentration.
range
• Check the keeping pressure condition. If not OK, replace

3. Radiator cap fault
it.
4. Thermostat does not

• Check thermostat open degree. If it is not OK, replace it.
open
• Check whether the gasket damaged to be leakage. The

5. Water pump fault poor ability of pump was caused rotor clipping or
corrosion, if it is not OK, replace it.
6. Radiator core block or the

adherent substance and • Clear radiator and lines.
the rust chokes channel
7. Oil level is too low or poor

• Add or replace oil which meet requirements.
quality

close completely (coolant • Check thermostat open degree. If it is not OK, replace it.
temperature too low)
Cooling system
9. Coolant temperature • Check coolant temperature. Repair indicator harness or
indicator replace it.
10.Cooling fan system • Check or replace harness, relay or fan.
11. Radiator leaking • Repair or replace radiator.
12.Radiator hose connector

• Tighten up clamp or replace hose.
loose or damaged
13.Heating water tank hose

connector loose or • Tighten up clamp or replace hose.
damaged
14.Radiator heat sink

distortion or there is
• Check, clear and repair radiator blades.
foreign matter blocked
inside
15.Engine cylinder head

bolts for loose
16.Engine cylinder gasket

• Overhaul engine cylinder head, replace cylinder gasket.
damaged
17.Cylinder block or cylinder

• Overhaul engine. Replace cylinder block or cylinder head.
head cracks
TROUBLE WITH DIESEL ENGINE SUPERCHARGER SYSTEM

CAUTION
• Actually, the turbocharger unit is a kind of air compressor, increasing the air input of diesel
04
engine by compressing air; generally, the turbocharger drives the turbo in the turbo chamber by
use of the inertia force of gas exhausted by the diesel engine, then the turbo drives the coaxial
impeller which compresses the air from the air cleaner pipe, supercharges it and delivers it into
the cylinder. With the diesel engine speed increasing, the gas exhausting speed and the turbo
speed increase and the impeller compresses more air into the cylinder. The air with increased
pressure and density can burn more fuel, so increasing the fuel quantity and adjusting the
diesel engine speed will improve the diesel engine output. 04
• The turbocharger unit mainly consists of the turbo chamber and the supercharger. First, the air
intake port of the turbo chamber is connected with the exhaust manifold of diesel engine, while
the exhaust port with the exhaust pipe. Then, the intake port of supercharger is connected with
the pipe of air cleaner, the exhaust port with the intake manifold; at last, the turbo and the
impeller are installed in the turbo chamber and the supercharger respectively, the both are
coaxial and rigid coupled.
• Foreign matters are strictly prohibited into the intake and exhaust system during the diesel
engine troubleshooting, installing and removing processes. As the supercharger rotor rotates
with very high speed and the clearance between the rotor and the case is small, foreign matters
of whatever material and size will affect the running of rotor and cause damage to the blades. If
the blades are damaged, the supercharger produces abnormal vibration and noise; this
moment, stop the vehicle immediately for supercharger troubleshooting.

1. Foreign matters in engine
oil are piled at the turbo • Replace oil, replace booster compressor.
side seal
2. The engine oil
temperature is too high;
oil supplyment isn't • Check oil supply system, replace booster compressor.
enough; the floating
bearing is burnt out
3. The supercharger return
tube is blocked, deformed
leading to engine oil leaks • Repair or replace return tube.
at the turbo, compressor
shaft end
4. The supercharger seal is
• Replace seal.
damaged and fails
5. The turbine shaft rotor
• Repair, replace turbine shaft rotor.
loses balance
hands, measure the minimum clearance between the
Under-power compressor impeller and the compressor case with a
6. The turbo blades and
compressor blades are
rubbed and damaged
supercharger should be ≤ 0.1 mm, the operating limit ≤
0.25 mm. Replace the assembly if the axial clearance of
the supercharger rotor is greater than the operating limit
value.
7. The air filter is blocked • Clear or replace filter.
8. The induction tunnel of
the supercharging • Check or replace induction tunnel.
compensator is cracked
9. There is much dirt in air
• Clear, repair intake and exhaust pipes.
intake and exhaust pipes
10.The supercharger works • Check booster pressure.

abnormally or is damaged • Check or replace booster.
1. Leaking at the junction of
the air intake and exhaust • Check or replace components.
High diesel pipes
wastage
2. Booster compressor poor
• Clear, adjust or replace booster compressor.
performance

1. Turbocharge seal ring
• Replace seal ring.
worn or damaged
04
2. Leakage at the side of
impeller blades of • Check whether there is leakage or block between filter and
compressor of booster compressor, booster and cylinder head.
High oil turbocharger
consumption
3. The screw and washer at
the junction of inlet and
• Check or replace washer. 04
outlet oilpipe loose,
damaged
4. Poor oil quality • Replace oil.
1. There is much oil dirt in
the turbo end and the gas
• Clear or replace.
line becomes narrow
evidently
There is 2. There is much oil dirt in
abnormal the compressor end and
knocking or • Clear or replace.
the gas line becomes
impact sound narrow evidently
3. The floating bearing
wears severely; the turbo
• Repalce floating bearing.
and blade wheel is friction
with the case
1. Foreign matter enter into
• Clear or replace.
inner
Vibration 2. Floating bearing wears

• Replace floating bearing.
severely
3. Poor turboshaft dynamic
• Check or replace.
balancing
04-166 DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM (4D20)
DIESEL ENGINE CONTROL SYSTEM (4D20)

PRECAUTION
1. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the nagative battery cable to
(b) The ignition switch must be off without any special descriptions.
WARING
The ignition and illuminatioin switches must be off before removing or installing the negative battery
cable (the semiconductor maybe damaged without doing that).
CAUTION


Expression
4. OVERHAUL THE DIESEL ENGINE CONTROL SYSTEM FAILURE PRECAUTIONS.

(a) Do not disconnect battery from electric circuit while engine is running at high speed in case the instan-
taneous overvoltage damage the EGR valve electronic control module and sensors.
(b) The EGR valve electronic control module should be disconnected at the time for electric welding on the
car body. It is special attention that performing the repair work beside the EGR valve electronic control
module or sensors.
out of order.
(e) Don’t check any electric apparatus connecting the EGR valve electronic control module with a test light.
(g) EGR valve electronic control module and sensors must be kept from moisture. No permission damag-
ing the seal device of EGR valve electronic control module and sensors and washing them more.
(h) Prevent human body static electricity from damaging EGR valve electronic control module. The opera-
tor body must be grounded when operator checks EGR valve electronic control module or replace
chips.
(j) We must remove and install EGR valve electronic control module, actuators and independent sensors
when the ignition switch is OFF unless there is additional specification in the checking procedure.
DIAGNOSTICS - DIESEL ENGINE CONTROL SYSTEM (4D20) 04-167
(k) If the removed and installed EGR valve electronic control module, actuators and sensors are to be
reinstalled, the system should be checked after completing installation. Using the special diagnosis
tool, check DTC.
(l) When diagnosis, the ignition switch turns to ON position and the connectors are dissociated. Other 04
system will store DTC. After diagnosis, confirm DTC in all systems. Turn the ignition switch to OFF
position when the connectors are connected and disconnected.
(m) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also
cause corrossion. Use the test wire, wire connector and measure wire and so on.
(n) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, do not insert by force. 04
(o) If check the common connectors when they are not in connection status (check male connectors):
• Be careful and not short terminals circuit by using a probe. This will damage the interior circuit in EGR
valve electronic control module.
(p) If check the common connectors when they are not in connection status (check formale connectors):
(q) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam-
age wire harness, sensor, EGR valve electronic control module and other components So we must
carefully handle when checking.
(r) Do not check with the list order.
eliminated.
(s) Check resistance and continuity between terminals of ECM with multimeter.
(t) Ground inspection.
works.
(u) When inspecting a ground connection, follow these rules:

Good Contact.

• Inspect all mating surfaces for tarnish, dirt, rust, etc.
• If several wires are crimped into one ground eyelet terminal, check for proper crimps. Make sure all of
the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased in
one eyelet make sure no ground wires have excess wire insulation.
LOCATION
ENGINE ROOM
04
04
1 Data Link Connector (DLC) 2 Battery

ENGINE
1 EGR Solenoid Valve Assy 7 Speed Handle
2 Oil Dipstick 8 Inlet Pipe
3 Oil Pan 9 Return Fuel Solenoid Valve
4 Delivery Valve Seat 10 Fuel Inlet Solenoid Valve
5 Electronic Control VE Pump 11 Injector
6 Return Pipe 12 Warm Water Pipe
.

NOTE
04
1. VEHICLE IS SENT INTO REPAIR SHOP

2. GET INFORMATION ABOUT SYMPTOM FROM THE CUSTOMER
04
3. CONNECT THE DIAGNOSTIC SCANNER TO DLC

4. CHECK DTC AND DATA

5. ERASE DTC

6. VISUAL CHECK

Check result (if engine can not start,check following first).
Result Proceed To
Fault present The step 11
Normal Step 8

9. CHECK IF DTC PRESENT
Result Proceed To
Normal Step 11
10. Refer to DTC TABLE

11. BASIC CHECK
Result Proceed To
Result Proceed To
13. CHECK EGR VALVE ELECTRONIC CONTROL MODULE POWER SUPPLY CIRCUIT

Result Proceed To
YES > Go to step17.

16. CHECK PARTS

17. CONFIRM FAULT


YES > END.


CAUTIONS FOR CIRCUIT TROUBLESHOOTING ARE AS FOLLOWS:
(a) Be sure to use the high-impedance digital multimeter; Be sure to use original conducting wire service 04
tool kit, including various kinds of connectors, contact probes, sealing elements, terminals, testing leads
and other tools for service connectors.
(b) Conduction testing. Select the conduction testing mode on the multimeter, which is marked with a diode
symbol. Disconnect both ends of the circuit or part to be tested during the testing. Contact one test pen
with one end of circuit or one terminal of part and contact the other test pen with the other end of circuit
or the other terminal of part. Read the measured value; if the circuit is continuity, the multimeter sounds 04
a buzzer; if the circuit is open, the multimeter doesn’t sound a buzzer.
(c) Test for short-circuit grounding. The short-circuit grounding is a case in which it can’t be grounding
(ground) but actually is grounding. The testing sequences for short-circuit grounding are:
• Unplug the connector to be tested. Remove the sensor from the harness connector when test it.
Remove the harness connector from the sensor when test the harness connector on EGR valve
electronic control module.
• Contact one test pen of the multimeter with the contact probe to be tested and the other test pen with
the ground.
• The read of multimeter must be larger than 1 MΩ, indicating the circuit is open rather than short.
• If the circuit isn’t open and the resistance value is less than 2 Ω, it shows that the conducting wire
tested must be shorted to ground.
• Repair or replace the part or harness.
(d) Testing for short between contact probes. Short between contact probes means the case in which there
should be no conduction between two contact probes but conduction exists. Testing sequences are:
• Turn the ignition switch OFF, remove the connector to be tested; if the contact probe and other sensors
form a circuit, remove the sensor.
• Contact one test pen of the multimeter with the proper contact probe to be tested at the connector
harness side, and the other test pen with the other contact probes at the connector harness side.
• The read of multimeter must be larger than 1 MΩ, indicating the circuit is open; if the circuit isn’t open
and the resistance value is less than 2 Ω, it shows there must be short circuit between contact probes
tested.
• Check the inside of harness connector for wet vapor which may cause short circuit.
• Repair or replace the harness.
(e) Conduction testing. Conduction means that the resistance between two contact probes is less than a
definite value, namely the resistance should be less than 2 Ω.Testing sequences are:
• Remove the harness connector to be tested.
• Contact both test pens with contact probes of harness to be tested separately.
• For the conducted harness, the resistance should be less than 2 Ω.
• If the resistance is larger than 2 Ω, repair or replace the harness.

CAUTION
DTC stored caused by burned fuse.
no circuit for short. But the temporally shorted circuit also
• Clipped harness
• Damaged harness
• Connectors or circuits admission of water
• Wrong operation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Circuit shorted

CAUTION
04
04
extension.
2. HEATING METHOD.
CAUTION
Don’t heat over 60 ℃ (the heating temperature should be in the limit of touching the part with hands);
3. SPRAYING METHOD.
failure occurs.
CAUTION
• Please take extra care to sprinkle water on vehicle leaking water, as the water leaked into
vehicle may damage EGR valve electronic control module.
find out the trouble location quickly; This method is very practical and effective.
• The oscilloscope analyzer can collect the waveforms of EGR control system sensors, diagnose if the
sensor fails or not correctly by analyzing the sensor waveforms.
• Generally, there is no method to replace the known good parts tested on a faulty vehicle. Only by
knowing which parameter is the normal, it can be picked out as problematic or abnormal one.
6. OTHER METHODS.
• Before replacing EGR valve electronic control module or other electronic control modules in part
replacing method, take full diagnosis for other external causes. EGR valve electronic control module is
expensive product with high reliability.
CAUTION
When replacing and testing possible damaged EGR valve electronic control module, install the
possible damaged EGR valve electronic control module on a failure-free vehicle for testing; don’t
install new control modules on a failed vehicle for testing to avoid damaging the control module.

1. IF THE FAILURE CANNOT BE CONFIRMED THROUGH DTC TESTING. DO THE TROUBLESHOOTING
ANALYSIS FOR ALL CIRCUITS THAT ARE POSSIBLE TO CAUSE FAILURES. IN MANY CASES,
CARRYING OUT THE FOLLOWING PREPARATION WORKS CAN FIND OUT THE LOCATION CAUSING 04
FAILURE EFFECTIVELY. IT’S NECESSARY TO TAKE THIS METHOD DURING ENGINE
TROUBLESHOOTING.
CAUTION
• Troubleshooting working is a systematical project, so the diesel engine should be taken as a
whole (a system) rather than a set of components. To grasp the whole situation of failure 04
occurrence, make a complete understanding from the operators and observe the diesel engine,
take necessary checking and make analysis to finger the cause of the failure.
• Some failures of diesel engine, such as gas in diesel system, filter blocking, loose driving belt
and so on, can be cleared through necessary technical maintenance and adjustment. But some
failures, such as cylinder gasket damage, piston ring severe wear and valve face wear, can’t be
cleared with general methods of maintenance and adjustment as the mechanism defect. There
failures only can be cleared by removing and repairing the diesel engine or replacing parts.
2. HE DIESEL USING CONDITION SHOULD BE KNOWN. INCLUDING AS FOLLOWINGT.
No. Item
1 Is there any abnormal sound
2 Load or not
3 Accelerate or decelerate
4 Does the oil pressure or ECT change
6 The consumption of the oil, diesel, coolant
7 Check whether the exhaust thickness is normal
8 Check whether the electric accelerator pedal is sensitive
9 Check whether the deceleration is normal
10 Check whether the shut down is satisfaction
11 Check whether the cold starting is satisfaction
12 Check whether there is any misfire or stall
13 What kind of diesel is used, what the degree is, and where from
14 During idle or full speed running, whether there would be a surge or not
15 Check whether the long period idle can last

3. THE MAINTENANCE HISTORY SHOULD BE KNOWN. INCLUDING AS FOLLOWING.
No. Item
1 Recently, Whether diesel engine has been repaired
2 Whether this trouble happened before
3 When the oil and diesel last changed
4 How long or how far the diesel engine run
5 Is there any metallic impurity, when to replace change oil filter
6 Any repaired items
4. INSPECT THE CHECKING RESULT FINALLY, AS FOLLOWING.
No. Item
1 Whether the diesel engines is clean
2 What the degree of tightness of belt is
3 There is external seepage of oil, diesel and water or not
4 Whether there had been hot phenomenon
5 Whether there is any temporary maintenance on diesel engine
6 What the sounding of the diesel engine is. And any surge of the belt pulley
7 Whether the component is not belong to the diesel engine or it is nonstandard
Oil level, coolant level and diesel level (if relate to the bearing, pay attention to the oil
8
condition)
9 When removing, pay attention to the carbon deposit, abnormal taste, etc.
13.
EGR VALVE ELECTRONIC CONTROL MODULE TERMINAL

DIAGRAM
04
04
EGR VALVE ELECTRONIC CONTROL MODULE TERMINAL DEFINITION

1 B-L Timing solenoid valve 14 Y-W Timing signal
2 R-B Power supply 15 R Fuel supply solenoid valve
3 B-Y 5 V power supply 16 LG Temperature
4 W-O Lift signal 17 GR TP sensor
5 W-L 5 V power supply 18 G-O Clutch signal
6 GR RXD 19 W-B Ground
7 W-G TXD 20 B-W Start (ST)
8 L-W Preheat indicator 21 BR-B Fuel return relay
EGR vacuum solenoid

9 V Speed signal 22 L-R
valve
Fuel supply solenoid valve

10 R-B 23 LG Idle speed control
control
11 B-Y Glow plugs 24 BR-B Fuel return solenoid valve
12 G-L Idle speed control 25 G-O Ignition (ON)
13 R-L Glow plugs control - - -

STANDARD NORMAL RESISTANCE AS FOLLOW

1 Throttle position sensor Hall type (20 ℃ )

2 Timing stroke sensor Hall type (20 ℃ )
3 EGR Valve lift sensor Hall type (20 ℃ )
4 Timing solenoid valve 12 ～ 20 Ω (20 ℃ )
3.288 KΩ (20 ℃ )
1.586 KΩ (20 ℃ )
5 ECT sensor 0.8 KΩ (20 ℃ )
0.426 KΩ (20 ℃ )
0.24 KΩ (20 ℃ )
6 EGR vacuum solenoid valve 35.8 ± 0.5 Ω (20 ℃ )

DIAGNOSTIC SYSTEM
SYSTEM. 04
(a) 4D20 diesel engine equiped with electronic controL VE
pump. When diesel engine system failure, MIL(1)
illuminates. When the MIL lights, based on relevant
immediately. The failure should be checked with
diagnostic scan tool or special equipment with 04
corresponding functions.
NOTE
The following matters should be noted during the engine running and service processes.
• Turn the ignition switch ON, check whether the preheat indicator on the unified meter indicates are
normal. If the preheat indicator lights, it means that the coolant temperature is below 10 ℃ , the
preheating system is warming up. The operator can skip the warm-up process (When the starting is
trouble, can also warm-start as normal operation).
• If an engine failure that may involve the electronic control VE pump system is to be diagnosed and
cleared, first determine if the failure is related with the electronic control VE pump system. if the engine
fails but the malfunction indicator lamp doesn't light, the failure is unrelated to the electronic control VE
pump system generally.
2. READ DTC.
(a) The DTC (Diagnostic Trouble Code) record and data
related with sensors and actuators in EGR valve
electronic control module can be read by ZDY-3
diagnostic scanner. In additional, the actuator can be
positive driven by the diagnostic scanner under specified
conditions.
3. DLC- DATA LINK CONNECTOR.

(a) EGR valve electronic control module communicate with
DLC.

1 TXD terminal -
2 Battery positive Battery voltage
3 Battery negative 0V
4 RXD terminal -
4. POSITION SELECTOR SWITCH SETUP INSTRUCTIONS.
Position Function
1 Direction for use
2 486 (4D24) electronic control VE pump with EGR system
3 486 (4D22) electronic control VE pump with EGR system
4 4D20 electronic control VE pump with EGR system
5. ENGINE CONTROL SYSTEM SELF-DIAGNOTIC ITEM.
No. Check Item

1 Speed sensor
2 Throttle position sensor
3 EGR valve lift sensor
4 EGR coolant temperature sensor
5 Timing stroke sensor
6 EGR vacuum solenoid valve
7 Fuel supply solenoid valve
8 Return fuel solenoid valve
9 Timing solenoid valve
10 Idle speed increase solenoid valve
11 Fuel inlet solenoid valve
12 Glow plug

NOTE
The troubles are tested and determined by the diesel engine control system and stored in the diesel
04
engine EGR valve electronic control module; The system troubles can be current or history.
1. DTC DESCRIPTION:
(a) Current troubles: Exist in EGR valve electronic control module currently, for example: The circuit of
Engine Coolant Temperature (ECT) sensor is open. The current troubles must be repaired, otherwise,
they can’t be erased from memory.
(b) History troubles: have two storage types: 04
from EGR valve electronic control module.
• The trouble occurred once and didn’t exist, but it is possible to occur again. For example: Poor contact
of conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before
erased from the memory, or it can be processed referring to the troubleshoot methods for intermittent
malfunction.
CAUTION
• If the battery voltage is too low and the trouble code can’t be output normally from EGR valve
electronic control module, the battery voltage must be tested before checking and the voltage
should not be less than 11V.
• When the battery or EGR valve electronic control module connectors are disconnected, the
trouble code stored in EGR valve electronic control module will be erased.
• Before connecting or disconnecting ZDY-3 diagnostic scan tool, be sure to confirm the ignition
switch is in OFF position.
• Using the ZDY-3 scan tool, read DTC.
2. USING THE SCAN TOOL, PERFORM THE READING DTC PROCEDURE:

• Release the accelerator pedal
• A/C switch: OFF
• Transmission: N
(e) Select 4 position, read DTC.
(f) Check DTC and data stream.
• Simulate DTC set condition.
• Simulate the scan tool freeze-frame data.
(i) With the scan tool to read the DTC in EGR valve
electronic control module.
(j) If there are DTCs but the stream is normal or the function
is good, then refer to the diagnostics help. If there are DTC
but the stream is abnormal or the function is not good, then
perform diagnosis procedure refer to “Diagnostics trouble
code chart”.
DIAGNOSTIC SCAN TOOL MAIN FUNCTION

1. DIAGNOSIS.
2. ENGINE SPEED MEASUREMENT (RPM).
3. TPS VOLTAGE MEASUREMENT (V) (REFLECT THE SIZE OF THROTTLE OPENING).
4. COOLANT TEMPERATURE MEASUREMENT ( ℃ ).
5. POWER SUPPLY MEASUREMENT (V) (BATTERY VOLTAGE).
6. EGR VALVE ELECTRONIC CONTROL MODULE SOFTWARE VERSION NUMBER.
USAGE METHOD
CAUTION
READ DATA STREAM PROCEDURE.

(a) Wiring harness connection: Please set the power switch in the closed state before connecting the
wiring harness. Connect scan tool and DLC with the “EGR valve electronic control module diagnosis
cable”.
(b) Set the power switch in “-” position (press switch "-" end). A moment later, the appropriate information
should appear on the scan tool monitor.
(c) As the requirement, set the corresponding position according to the position selector switch setup
instructions on above table. With the aid of "button", can read all the information of the position on the
scan tool monitor in turn.
(d) 4 position is 4D20 electronic control VE pump system with EGR diesel engine related to fault diagnosis
and inspection of electrical characteristics. With the aid of "button" can be read in turn.
• DTC diagnosis (If no fault, the monitor display: "No", if fault exists, then automatically display the fault
code in a cycle in turn).
• Engine speed measurement (RPM).
• TPS voltage measurement (V) (Reflect the size of throttle opening).
• Coolant temperature measurement ( ℃ ).
• Power supply measurement (V) (Battery voltage).
• EGR valve electronic control module software version number.
COMPULSORY DIAGNOSIS FUNCTION (ACCESSIBILITY FOR THE

DIAGNOSIS OF LOW-TEMPERATURE HOT VEHICLE)
CAUTION 04
1. THE SCAN TOOL CAN PERFORM THE COMPULSORY INSPECTION OF 4D20 ELECTRONICAL
CONTROL VE PUMP WITH EGR SYSTEM DIESEL ENGINE PREHEATING, HIGH IDLE SPEED
CONTROL RELAY. 04
(b) Select scan tool to 4 position.
(c) Press the "button" to open scan tool power (the scan tool "power switch" from "0" placed "-"), when the
scan tool display "check the relevant relay> button to start", release button.
(d) When the button is pressed again to make the appropriate checks, and the corresponding information
displayed on the screen.
CONSIDERATIONS
1. WHEN DIAGNOSIS, PLEASE PROPERLY SET ACCORDING TO VEHICLE TYPE: ONLY SET
POSITION CORRECTLY, CAN GET THE CORRECT INFORMATION.
2. SCAN TOOL POWER IS TURNED ON FOR 2 SECONDS, IF THE SCREEN NO DISPLAY AND NO
LIGHT, PLEASE CHECK:
(a) Whether the scan tool cable connection is correct.
(b) Whether the ignition switch is in ON position.
(c) Check whether the diagnosis cable is correct.

Note
If a malfunction code is displayed during the DTC check in the check mode, check the circuit for the
codes listed in the table below. For details of each code, refer to the DTC chart.
• EGR valve lift sensor

1 EGR Valve Lift Sensor Or Circuit Fault • EGR valve lift sensor harness or
connectors
• EGR valve electronic control module
• EGR valve
2 EGR Valve Is Stuck And Does Not Close • EGR valve lift sensor harness or
connectors
• EGR valve
3 EGR Valve Seat Carbon And Close Lax • EGR valve lift sensor harness or
connectors

• Throttle position sensor installation
error
4 Throttle Position Sensor Or Circuit Fault
• Throttle position sensor harness or
connectors
• Speed sensor
• Speed sensor installation error
5 Speed Sensor Or Circuit Fault
• Speed sensor harness or connectors

6 Engine Coolant Temperature Sensor Or Circuit Fault • Engine coolant temperature sensor
7 Generator Or Circuit Fault • Generator D+ harness or connectors
• Starter switch
8 Startup, Starter Switch No Signal • Starter switch signal harness or
connectors
• Glow plug
9 Glow Plug Circuit Open Or Circuit Fault • Glow plug harness or connectors
• Fuel supply solenoid valve

10 Fuel Supply Solenoid Valve Circuit Open • Fuel supply solenoid valve harness or
connectors
• Flameout solenoid
11 Flameout Solenoid Circuit Open Or Circuit Fault • Flameout solenoid harness or 04
connectors
• Start solenoid valve

12 Start Solenoid Valve Circuit Open Or Circuit Fault • Start solenoid valve harness or
connectors
• EGR valve electronic control module 04
13 Battery power input circuit failure power harness or connectors
14 - -
• Glow plug relay

15 Glow Plug Relay Adhesion • Glow plug Relay harness or
connectors
• Glow plug relay

16 Glow Plug Relay No Power • Glow plug Relay harness or
connectors
17 - -
• Preheat fuel supply relay

18 Preheat Fuel Supply Relay Adhesion • Preheat fuel supply relay harness or
connectors
• Preheat fuel supply relay

19 Preheat Fuel Supply Relay No Power • Preheat fuel supply relay harness or
connectors
20 - -
• Flameout relay
21 Flameout Relay Adhesion
• Flameout relay harness or connectors
• Flameout relay
22 Flameout Relay No Power
• Flameout relay harness or connectors
23 - -
• Start solenoid relay

24 Start Solenoid Relay Adhesion • Start solenoid relay harness or
connectors
• Start solenoid relay

25 Start Solenoid Relay No Power • Start solenoid relay harness or
connectors
• High idle solenoid valve

26 High Idle Solenoid Valve Open Or Circuit Fault • High idle solenoid valve harness or
connectors
27 - -
• High idle solenoid valve relay

28 High Idle Solenoid Valve Relay Or Circuit Fault • High idle solenoid valve relay harness
or connectors
29 - -
• Battery
30 Battery Power No-load Voltage Is Lower Than 12V • EGR valve electronic control module
• Timing solenoid valve

31 Timing Solenoid Valve Or Circuit Fault • Timing solenoid valve harness or
connectors
• Timing stroke sensor

32 Timing Stroke Sensor Or Circuit Fault • Timing stroke sensor harness or
connectors

33 Timing Solenoid Valve Stuck And Out Of Work • Timing solenoid valve harness or
connectors
• Return fuel solenoid valve

34 Return Fuel Solenoid Valve Open Or Circuit Fault • Return fuel solenoid valve harness or
connectors
• Return fuel solenoid valve relay

35 Return Fuel Solenoid Valve Relay Adhesion • Return fuel solenoid valve relay
• Return fuel solenoid valve relay

• Return fuel solenoid valve power
36 Return Fuel Solenoid Valve Relay No Power
• FReturn fuel solenoid valve relay con-
trol harness or connectors

1 - EGR VALVE LIFT SENSOR OR CIRCUIT FAULT
04
2 - EGR VALVE IS STUCK AND DOES NOT CLOSE
3 - EGR VALVE SEAT CARBON AND CLOSE LAX
04
DESCRIPTION
EGR valve electronic control module is a sensor signal input interface, the actuator drive circuit of the
electronic control module. It receives and processes the sensor input signal of the engine condition. And send
control signals to the actuator. To ensure good fuel economy and emissions.
WIRING DIAGRAM

• Engine: running
• Open or short at EGR
• EGR valve electronic valve lift sensor
1 EGR valve lift sensor or circuit fault control module detect that harness or connctor
the voltage signal is out
of the range • EGR valve electronic
control module

• Engine: running • Open or short at EGR
2 EGR valve is stuck and can not close control module detect that harness or connctor
the voltage signal is out • EGR valve stuck
control module

• Engine: running • Open or short at EGR
3 EGR valve seat carbon and close lax control module detect that harness or connctor
the voltage signal is out • EGR valve carbon
control module
NOTE
• While performing electrical diagnosis & testing, assure the EGR valve electronic control module
ground is in good contact.
• While performing electrical diagnosis & testing, look for broken, bent or corroded terminals.
1. READ DTC

(b) Using the scan tool, perform the DTC confirming procedure.

1 The next step Open or short
2 The next step Open or short, EGR valve
3 The next step Open or short, EGR valve

2. CHECK HARNESS AND CONNECTOR (EGR VALVE LIFT SENSOR - GROUND)

04
(b) Disconnect the C092 EGR valve lift sensor connector.
below.
Standard voltage
04
C092 (1) - Ground 5V

NO > Repair or replace EGR valve lift sensor reference voltage harness or connector. If OK, replace EGR
valve electronic control module.
3. CHECK HARNESS AND CONNECTOR (EGR VALVE LIFT SENSOR - GROUND)

table below.

C092 (2) - Ground ＜2Ω

NO > Repair or replace EGR valve lift sensor harness or connector.
4. CHECK HARNESS AND CONNECTOR (EGR VALVE LIFT SENSOR - EGR VALVE ELECTRONIC
CONTROL MODULE)
(a) Disconnect the C091 EGR valve electronic control mod-

ule connector.
table below.

C092 (3) - C091 (4) ＜2Ω

NO > Repair or replace EGR valve lift sensor harness or connector.
5. CHECK EGR VALVE LIFT SENSOR
(a) Replace the on-vehicle EGR valve lift sensor with a known good one.
(b) Connect the C091 EGR valve electronic control module connector.
(c) Connect the C092 EGR valve lift sensor connector.
(d) Start and run engine. Depresses the accelerator pedal to full speed.
(e) Using the scan tool, perform the DTC confirming procedure.
YES > Repair or replace EGR valve lift sensor.
NO > Replace EGR valve electronic control module.
4 - THROTTLE POSITION SENSOR OR CIRCUIT FAULT
04
04
DESCRIPTION
EGR valve electronic control module provide 5V reference voltage signal and ground to the throttle
position sensor. Throttle position sensor sends a throttle feedback voltage signal to the EGR valve
electronic control module. Voltage signal from the off position about 1.0 ± 0.5 V variable to the fully
open about 4.3 ± 0.1 V.
WIRING DIAGRAM

• Engine: running
installation
Throttle position • EGR valve electronic control
4 • Open or short at throttle
sensor or circuit fault module detect that the
position sensor harness or
voltage signal is out of the
connctor
range
• EGR valve electronic control
module
NOTE
terminals.
1. READ DTC

(b) Using the scan tool, perform the DTC confirming procedure

2. CHECK HARNESS AND CONNECTOR (THROTTLE POSITION SENSOR - GROUND)
(b) Disconnect the C072 throttle position sensor connector.

below.
Standard voltage


NO > Repair or replace throttle position sensor reference voltage harness or connector for open or short. If it
is OK, replace EGR valve electronic control module.

04
table below.

C072 (1) - Ground ＜2Ω 04

(a) Connect the C072 throttle position sensor connector.

(b) Turn the ignition switch ON.
(c) Measure the voltage according to the value in the table
below.
Standard voltage

Full-open: 4.3 ± 0.1 V
C072 (2) - Ground
Full-closed: 1.0 ± 0.5 V

NO > Repair or replace throttle position sensor.
(a) Measure the voltage according to the value in the table

below.
Standard voltage

Full-open: 4.3 ± 0.1 V
C091 (17) - Ground
Full-closed: 1.0 ± 0.5 V

NO > Repair or replace throttle position sensor harness.
6. REPLACE EGR VALVE ELECTRONIC CONTROL MODULE
(a) Replace EGR valve electronic control module.

(c) Confirm no DTC and data normal.
5 - SPEED SENSOR OR CIRCUIT FAULT
1 VoH 04
2 VoL
3 100%
4 10%
5 Tf 04
6 Tr
DESCRIPTION
Speed sensor is used for the detection of electronic control VE pump speed. The speed sensor is
installed in fly block seat. Make use of the gear cutting magnetic field lines to generate pulse to
measure pump speed. And the signal is sent to EGR valve electronic control module.
WIRING DIAGRAM
• Speed sensor
• Engine: running • Speed sensor atstallation
• EGR valve electronic • Open or short at speed
5 Speed sensor or circuit fault control module detect that sensor harness or
the voltage signal is out connctor
control module
NOTE
terminals.
1. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - GROUND)

(b) Disconnect the C098 speed sensor connector.

below.
Standard voltage

C098 (1) - Ground 12 V

NO > Repair or replace speed sensor harness or connector. If OK, replace EGR valve electronic control mod-
ule.

table below.

C098 (2) - Ground ＜2Ω

NO > Repair or replace speed sensor harness or connector.
3. CHECK SPEED SIGNAL
(a) Connect the C098 speed sensor connector.

04
(b) Start and run engine.
(c) Using the oscilloscope, check the speed sensor
waveform in the C091, terminal 9 EGR valve electronic
control module connector ((1) - VoH, (2) - VoL).
04

YES > Replace EGR valve electronic control module.
4. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - EGR VALVE ELECTRONIC CONTROL
MODULE)

(b) Disconnect the C091 EGR valve electronic control mod-
ule connector.
table below.
Standard resistance

C098 (3) - C091 (9) ＜2Ω
C098 (3) - Ground ≥ 1 MΩ


below.
Standard voltage


6. CHECK HARNESS AND CONNECTOR (SPEED SENSOR)

table below.

C098 (1) - C098 (3)
≥ 1 MΩ
C098 (2) - C098 (3)

7. CHECK SPEED SENSOR

04
(b) Disconnect the C098 speed sensor connector.
table below.
Standard resistance

04
(1) - (2)
(2) - (3) Except 0 or ∞

(1) - (3)

NO > Replace speed sensor.
8. CHECK SPEED SENSOR
(a) Replace the on-vehicle speed sensor with a known good one.
(b) With the oscilloscope, check the speed sensor waveform.
YES > System is normal. Using the scan tool, clear the DTC in EGR valve electronic control module.
9. CHECK SPEED SENSOR SIGNAL TOOTH
(a) Inspect the speed sensor Installation clearance.

Clearance: Normal
(b) Check for a problem such as scrap, dirt, foreign body and loose with the speed sensor signal tooth.
NO > Remove any foreign obstacles, clean or replace speed sensor signal tooth.
10. CHECK TIMING
(a) Check whether the timing is correct.

NO > Install the timing tooth.

6 - ENGINE COOLANT TEMPERATURE SENSOR OR CIRCUITFAULT
Electric Appliance
1
Connector
2 Cabinet
3 NTC Resistance
DESCRIPTION
temperature is high, theresistance drops. The variations in resistance are reflected in the
2. The EGR valve electronic control module monitors the sensor voltage and uses this value to
calculate the engine coolant temperature.
WIRING DIAGRAM
04
04
• EGR coolant temperature

• Engine: running sensor
Engine coolant temperature • EGR valve electronic • Open or short at coolant
6 control module detect that temperature sensor
sensor or circuit fault
the voltage signal is out harness or connctor
control module
NOTE
terminals.
1. READ DTC AND DATA STREAM

(c) Perform data stream reading procedure.


2. CHECK HARNESS AND CONNECTOR (EGR COOLANT TEMPERATURE SENSOR - GROUND)

(b) Disconnect the C093 EGR coolant temperature sensor connector.

below.
Standard voltage


3. CHECK HARNESS AND CONNECTOR (EGR COOLANT TEMPERATURE SENSOR - GROUND)

table below.

C093 (1) - Ground ＜2Ω

4. INSPECT EGR COOLANT TEMPERATURE SENSOR

table below. 04
Standard resistance
3.288 KΩ (20 ℃ )
1.586 KΩ (40 ℃ ) 04
(1) - (2) 0.8 KΩ (60 ℃ )
0.426 KΩ (80 ℃ )
0.24 KΩ (100 ℃ )

NO > Replace EGR coolant temperature sensor.

15 - GLOW PLUG RELAY ADHESION

16 - GLOW PLUG RELAY NO POWER
DESCRIPTION
Preheating system ensure low-temperature starting performance of diesel engine. before cold starting
engine, preheating system heat compressed air through glow plug.This improve the starting
performance of the engine.
WIRING DIAGRAM
15 Glow plug relay adhesion • Glow plug relay

diagnostic circuit
• Engine: running • Open or short at glow
• EGR valve electronic plug relay circuit
16 Glow plug relay no power control module detect that • EGR valve electronic
the glow plug circuit fault control module
• EGR valve electronic
control module
NOTE
terminals.
1. READ DTC AND DATA STREAM

Is DTC present?
NO > System is normal.
2. PERFORM THE ACTIVE TEST ON SCAN TOOL 04
(a) Using scan tool, perform the compulsory diagnosis function test - preheat.
3. CONFIRM DTC
(a) Using the scan tool, perform the DTC confirming procedure.

15 The next step Short
4. CHECK PREHEAT FUSIBLE LINK BOX

(b) Check preheat fusible link box C096 (40A).
YES > Go to step 6.
5. CHECK HARNESS AND CONNECTOR (PREHEAT RELAY - GROUND)
(a) Disconnect the C056 preheat relay.

table below.

C056 (30) - Ground ≥ 1 MΩ

YES > Go to step 8.
NO > Replace preheat fusible, repair or replace harness or connector.
6. CHECK PREHEAT RELAY

(b) Disconnect the C056 preheat relay.
table below.
Standard resistance
≥ 1 MΩ
between terminal 85 - 86)
(30) - (87)
＜1Ω
terminal 85 - 86)

NO > Replace preheat relay.
7. CHECK HARNESS AND CONNECTOR (EGR VALVE ELECTRONIC CONTROL MODULE -
GROUND)

ule connector.
below.
Standard voltage (check for short)

C091 (11) - Ground 0V


GROUND)
(a) Turn the ignition switch OFF. 04

(b) Disconnect the C057 glow plug connector.
table below.
Tester Connection Specified Condition 04
C091 (11) - Ground ≥ 1 MΩ

9. CHECK HARNESS AND CONNECTOR (GLOW PLUG RELAY - EGR VALVE ELECTRONIC CON-
TROL MODULE)

table below.

C091 (11) - C056 (87) ＜2Ω

10. CHECK GLOW PLUG
(a) Replace the on-vehicle glow plug with a known good one.
YES > Repair or replace glow plug.
31 - TIMING SOLENOID VALVE OR CIRCUIT FAULT

DESCRIPTION
EGR valve electronic control module control the size of the timing through the output pulse signal. It
form the closed loop timing control with timing stroke sensor.
WIRING DIAGRAM

• Engine: running
• Open or short at timing
• EGR valve electronic solenoid valve harness
31 Timing solenoid valve or circuit fault control module detect that or connctor
open or short in the timing
solenoid valve circuit • EGR valve electronic
control module
NOTE
terminals.
1. READ DTC


No DTC Diagnoctic help Intermittent fault 04

2. CHECK TIMING SOLENOID VALVE

(b) Disconnect the C094 timing solenoid valve connector.
table below.
Standard resistance

(1) - (2) 12 ～ 20 Ω (20 ℃ )

3. CHECK HARNESS AND CONNECTOR (TIMING SOLENOID VALVE - GROUND)

table below.
Standard resistance

C094 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (TIMING SOLENOID VALVE - EGR VALVE ELECTRONIC
CONTROL MODULE)

ule connector.
table below.

C094 (2) - C091 (1) ＜2Ω


table below.

C094 (2) - Ground ≥ 1 MΩ


04
below.
Standard voltage

C094 (2) - Ground 0V 04


32 - TIMING STROKE SENSOR OR CIRCUIT FAULT

DESCRIPTION
The timing stroke sensor feedback the advance angle location. It form the closed loop control of
advance angle with timing solenoid valve. The timing stroke sensor is Hall sensor.
WIRING DIAGRAM
• Timing stroke
sensor
• Timing stroke
sensor installation
• Engine: running
• Open or short at
32 Timing stroke sensor or circuit fault • EGR valve electronic
timing stroke
control module detect that
sensor harness or
no signal.
connctor
• EGR valve
electronic control
module
NOTE
terminals.
1. CHECK HARNESS AND CONNECTOR (TIMING STROKE SENSOR - GROUND)

(b) Disconnect the C095 EGR timing stroke sensor connector.

below.
Standard voltage 04



table below.

C095 (2) - Ground ＜2Ω

(a) Connect the C095 EGR timing stroke sensor connector.

(b) Start and run engine.
below.
Standard voltage

C095 (1) - Ground 1～5V
(d) Check the timing stroke sensor waveform with the

oscilloscope.

NO > Go to step 8.
GROUND)
(a) Measure the voltage according to the value in the table

below.
Standard voltage

C091 (14) - Ground 1～5V

YES > Replace EGR valve electronic control module.
5. CHECK HARNESS AND CONNECTOR (TIMING STROKE SENSOR - EGR VALVE ELECTRONIC
CONTROL MODULE)

(b) Disconnect the C095 timing stroke sensor connector.
(c) Disconnect the C091 EGR valve electronic control mod-
ule connector.
table below.
Standard resistance

C095 (1) - C091 (14) ＜2Ω
C095 (1) - Ground ≥ 1 MΩ


(b) Measure the voltage according to the value in the table 04
below.
Standard voltage

04

7. CHECK HARNESS AND CONNECTOR (TIMING STROKE SENSOR)

table below.

C095 (1) - C095 (3)
≥ 1 MΩ
C095 (2) - C095 (3)

table below.

C095 (1) - C095 (2) ≥ 1 MΩ

8. CHECK TIMING STROKE SENSOR

(b) Disconnect the C095 timing stroke sensor connector.
table below.
Standard resistance

(1) - (2)
(2) - (3) Except 0 or ∞

(1) - (3)

NO > Replace timing stroke sensor.
9. REPLACE TIMING STROKE SENSOR AND CHECK SIGNAL
(a) Replace the on-vehicle timing stroke sensor with a known good one.
(b) With the oscilloscope, check the timing stroke sensor waveform.
YES > System is normal. Using scan tool, Clear DTC.
10. CHECK TIMING STROKE SENSOR SIGNAL TOOTH
(a) Inspect the timing stroke sensor Installation clearance.

(b) Check for a problem such as scrap, dirt, foreign body and loose with the timing stroke sensor signal
tooth.
NO > Remove any foreign obstacles, clean or replace timing stroke sensor signal tooth.
11. CHECK TIMING
(a) Check whether the timing is correct.

NO > Install the tooth.

34 - RETURN FUEL SOLENOID VALVE OPEN OR CIRCUIT FAULT

35 - RETURN FUEL SOLENOID VALVE ADHESION
04
36 - RETURN FUEL SOLENOID VALVE NO POWER
DESCRIPTION
Fuel return solenoid valve is a fuel return screw with solenoid valve. When cold start, the fuel return
solenoid valve coil is energized, the pressure increased, cause to the fuel supply angle in advance.
After starting, the fuel return solenoid valve circuit is disconnected, the fuel back into the fuel tank or
04
on the road, fuel return large quantitative, pressure drop, the advance angle returns back to seat.
WIRING DIAGRAM

Return fuel solenoid valve • Fuel supply solenoid
34 open or circuit fault valve fuse
• Engine: running • Return fuel solenoid valve
Return fuel solenoid valve
35 • EGR valve electronic • Return fuel solenoid valve
relay adhesion
control module detect that harness
open or short at the return • Return fuel solenoid valve
Return fuel solenoid valve fuel solenoid valve circuit. relay
36
relay no power • EGR valve electronic
control module
NOTE
• While performing electrical diagnosis & testing, look for broken, bent or corroded terminals.
1. READ DTC

Is DTC present?
NO > System normal.
2. Confirm DTC

35 The next step Short
3. CHECK FUEL SUPPLY SOLENOID VALVE FUSE

(b) Check fuel supply solenoid valve fuse 15A.
YES > Go to step 6.
4. CHECK HARNESS AND CONNECTOR (RETURN FUEL SOLENOID VALVE RELAY - GROUND)
(a) Disconnect return fuel solenoid valve relay R4 in body junction box.

table below.

R4 (5) - Ground ≥ 1 MΩ

YES > Go to step 8.
NO > Replace fuel supply solenoid valve fuse, repair or replace harness or connector.
5. CHECK RETURN FUEL SOLENOID VALVE RELAY

04
(b) Disconnect return fuel solenoid valve relay R4.
table below.
Standard resistance

04
≥ 1 MΩ
(3) - (5)
＜2Ω
terminal 1 and 2)

NO > Replace return fuel solenoid valve relay.
GROUND)

ule connector.
below.
Standard voltage

C091 (24) - Ground 0V


GROUND)

(b) Disconnect the C047 fuel return solenoid valve connec-
tor.
table below.

C091 (24) - Ground ≥ 1 MΩ

RETURN FUEL SOLENOID VALVE RELAY)

table below.

C091 (24) - R4 (3) ＜2Ω

9. CHECK FUEL RETURN SOLENOID VALVE
(a) Replace the on-vehicle fuel return solenoid valve with a known good one.
(b) Start engine.
(c) Using the scan tool, perform the DTC confirming procedure.
YES > Repair or replace fuel return solenoid valve.
LIST OF SYMPTOM OF FAILURE

CAUTION
• If the trouble isn’t confirmed in DTC (Diagnostic Trouble Code) checking and the cause of 04
trouble can’t be confirmed in basic checking, please take the troubleshooting in the sequence
listed in the following list, then go to related page for troubleshooting.
• Thorough analysis on the customer’s complaint is the key for successful troubleshooting. The
more information from the complaint, the quicker and easier the problem can be solved. The
failure symptom diagnosis list is organized in the thought of determining the failure location
and solving the problem by doing the easiest and most logical things. Complete all steps in 04
sequence from top to down. The list is impossible to contain all possible problems; but the
failure symptom diagnosis can be used to develop thoughts so as to find out the cause of
trouble and remove it.
DIESEL ENGINE PROBLEM SYMPTOMS TABLE


• Battery
• Timing
Room temperature (ambient • Diesel quality
temperature ≥ 5 ℃ ) hard • Low pressure lines
cold starting • Preheat system
• Injector
• Battery
• Starter
• Relay and strater switch
• Diesel quality
Engine start • Air in fuel system
• Preheat system
Hard starting
• ECT sensor
• Injector
• Battery
• Lubricating oil
Low temperature (ambient
• Diesel quality
temperature <5 ℃) hard cold
starting • Preheat system
• Fuel supply solenoid valve or circuit
• Air filter
• Diesel quality
• Failure turbocharger
Power Poor power • EGR control system
• Blocking or leakage in turbocharger
• ECT sensor
• Injector, electronic control VE pump
• Diesel quality
• Blocking or low pressure in low pressure lines
Idling stably
Idle shaking • Injector
(Improper idling)
• Electronic control VE pump
• Air filter block

• Diesel quality
• ECT sensor
• Turbocharger (poor pressure)
Black smoke
• EGR valve and control system
• Injector
• Diesel engine overloaded
• Water in diesel cylinder or diesel

• Preheat system
• Diesel quality
• Inject pressure and spraying condition is not normal
White smoke
• Oil level is too high
• Breather
• Supercharger
Smoking
That the exhaust pipe gives off blue smoke shows there is a
lot of engine oil getting into the combustion chamber and
burnt. Meanwhile the engine oil consumption of diesel engine
also rises sharply. The causes of trouble may be:
• Diesel quality
• The engine oil level inside the diesel engine pan is too
high
• The piston chamfer is installed in opposite direction during
installation to let engine oil into the combustion chamber
Blue smoke
• The cylinder and piston ring is severe worn or the piston
ring gap is not aligned or the elasticity is decreased
• The piston ring is severe worn or broken causing the ring
seized
• The diesel engine lubrication oil is inhaled into the
combustion chamber through the valve guide
• The valve oil seal is damaged
• The valve oil seal seat and the valve guide aren’t aligned
or the gap is too large
• The match between piston pin and connecting rod small

end bushing hole is too loose; there is slight but sharp
04
sound during idling running
• The gap between piston and cylinder is too large; an

impact sound can be heard at engine body outer wall and
it increase with the speed increasing
There is abnormal knocking • The wear of connecting rod bearing shell and main
Abnormal noise
or impact sound during bearing shell makes the fit clearance too large; the body 04
when running
running. impact sound can be heard at the crank case during
running; the heavy and power impact sound can be heard
if the speed reduces suddenly
• The valve hits the piston; the clear, even and rhythmic
knocking sound can be heard at the cylinder head
• The gap between intake/exhaust valves is too large; the

loud and rhythmic sound can be heard at the cylinder head
• Too low coolant

• Fan belt is loosen or broken
• Thermoster valve is stuck
Over heat
• Coolant pump fault
• Blocking in radiator core
• Oil is poor quality or scarce
Abnormal
temperature • Thermoster valve cannot close completely
Too cold
• Coolant temperature indicator
• Raditor leakage
• Raditor hose connector loose or hose damaged
Lack of coolant
• Coolant pump leakage
• Heater hose connector loose or hose damaged
• Foreign substances in engine oil are piled at the turbo side

seal
• The engine oil temperature is too high, oil supply isn't
enough, the floating bearing is burnt out
• The supercharger return tube is blocked, deformed
leading to engine oil leaks at the turbo, compressor shaft
end
• The supercharger seal is damaged and fails
Under-power
• The turbine shaft rotor loses balance
• The turbo blades and compressor blades are rubbed and
damaged
• The air filter is blocked
• The induction tunnel of the supercharging compensator is
cracked
• There is much dirt in air intake and exhaust pipes
• The supercharger works abnormally or is damaged
• Leakage at the junction part or dirt in inlet and outlet pipe

Pressure High diesel wastage • Poor performance of turbocharge
charging system • Piston ring wear out
• Turbocharge seal ring worn and damaged

• Leakage at the side of impeller blades of compressor of
turbocharger
High oil wastage
• The screw at the junction of inlet and outlet oilpipe is
loosen, the washer damaged
• Oil poor quality
• There is much oil dirt in the turbo end and the gas line
becomes narrow evidently.
Abnormal knocking • There is much oil dirt in the compressor end and the gas
line becomes narrow evidently
• The floating bearing wears severely, the turbo and blade
wheel have friction with the case.
Vibration produced by • Foreign matter enter into inner

friction between turbine , • Floating bearing severe wearing, cause up and down
rotor and case • Poor turboshaft dynamic balancing
• The mount of diesel engine is loose or the inner is broken

and damaged. Check the diesel engine bracket, mount、
insulation for damage.
• The transmission flying wheel or flexible connecting bolt is

Attaching parts loose.
Body serious
vibration • Accessories resonant vibration
• The diesel engine bottom guard plate impacts the oil pan
because of deformation.
Diesel engine • The dynamic balance of rotating parts such as crankshaft

and crankshaft pulley is disqualified.
DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS

CAUTION
Some symptom diagnosis steps require visual and observational check. Firstly carry out the visual
04
and observational check every time. The check can solve one problem without further test and can
save valuable time.
1. ASK THE MOTOR-VEHICLE OWNER FOR THE FOLLOWINGS AS RECEIVING THE VEHICLE.
(a) The time at which the trouble first occurs.
(b) The diesel engine temperature as the trouble occurred.
(c) The vehicle miles of travel 04
(d) The driving road and owner’s driving manner.
(e) The vehicle maintenance condition.
(f) The vehicle maintenance history.
(g) Whether the vehicle is equipped with optional device. Initial assessment can be done through the
understanding above to save the checking time.
2. ORIGINAL INSPECTION SHOULD BE DONE AT FIRST BEFORE THE CARRYING OUT THE
FAULT DIAGNOSIS BASED ON THE DIESEL ENGINE SYMPTOM.
(a) Be sure the diesel engine malfunction indicator lamp works normal. If it's abnormal, first troubleshoot
the malfunction indicator lamp.
(b) Be sure there is no diesel engine Diagnostic Trouble Code (DTC) stored in the diesel engine electronic
control module (EGR valve electronic control module).If it exists, check through corresponding DTC list
for troubleshooting. Read DTC (all current and history DCT should be recorded)—Erase DTC—Run
(the conditions of trouble occurrence should be represented this moment)—Read DTC again Read
DTC List in service manual and refer to the cause, effect and erasing method of DTC. Don’t neglect the
intermittent malfunction codes.
(c) Check the hot engine idling speed data of electronic control system with a diagnostic scanner and
confirm they are all within the normal range.
(d) Be sure the customer’s complaint is current and the causes of failure exist.
(e) Confirm the maintenance record, the diesel engine compression pressure and the diesel fuel condition
during the vehicle maintenance.
3. OBSERVATIONAL VISUAL CHECK.
(a) Check the connection status of EGR valve electronic control module ground wire.
(b) Check if the diesel engine vacuum system connecting pipe is cracked, twisted, squashed or damaged
and if the connection is correct.
(c) Check if the diesel engine oil dipstick and the engine oil filler port are installed properly.
(d) Check if the diesel engine grounding (ground) is clean and the connection is firm.
(e) Check if the engine intake pipes leak gas at the joint faces.
(f) Check if the engine diesel fuel system high/low pressure oil pipes leak at the joints.
(g) Check if the engine diesel fuel goes bad and the water and diesel fuel are proper.
(h) Check if the connectors of engine sensors and actuators are in good contact and firm connection.
CAUTION
• There are many causes of trouble that the diesel engine gives off black smoke. The problems
with oil supply system, diesel qulity, combustion system, air intake and exhaust system may
cause the trouble of diesel engine giving off black smoke.
• Although the problems with the oil supply system problem, the combustion system problem,
the air intake system and the exhaust system and other factors may be the cause of trouble that
the diesel engine gives off black smoke, for a diesel engine, the cause of trouble of giving off
black smoke may be only one factor among them.
• For the diesel engine equipped with turbocharger, one air leak source is the turbocharger intake
pipe, which is easy to neglect. The diesel engine intake pipe supplies the turbocharger with air.
4. IF ONE SYSTEM FAILS, IT MAY LEAD TO MANY TROUBLE SYMPTOMS OF DIESEL ENGINE.
(a) For example, either blocked intake system or too long pipe may increase the intake resistance. The
intake resistance is too large and the intake system is blocked (for example, the air cleaner element is
blocked, the intake pipe makes the inhale resistance of supercharger increase because of settled dust),
thus leading to that the supercharging pressure of diesel engine falls and waves, further resulting in that
the diesel engine power falls, the engine runs unbalance and generates black smoke. Too high intake
temperature is also possible to cause the diesel engine to give off black smoke. Besides causing the
diesel engine to give off black smoke, the trouble of intake system also has the following symptoms:
• The diesel engine consumption increases.
(b) If the intake system is installed improperly, for example, the exhaust pipe is too long or thin, the muffler
is improper, it may increase the exhaust resistance, cause restricted exhaust of diesel engine thus
leading to giving off black smoke. If the exhaust system has a problem, besides giving off black smoke,
the diesel engine also has the following symptoms:
• The diesel engine exhaust temperature increases.
(c) If the turbocharger fails, it arises many symptoms:
• The supercharger creates powerful vibrations and makes noise during running.
• The diesel engine is short of power and its forces drop.
• Oil discharging at turbo end or pump impeller end leads to increasing engine oil consumption of diesel
engine. The turbocharger adopts full floating type slide bearing on the rotor shaft. If the rotor shaft is
worn and the rotor axial clearance especially the radial clearance is too large, the seal ring fails. Severe
wear can bring much oil-fouled and carbon-residue deposits in the exhaust pipe and the muffler, not
only increasing the exhaust resistance, lowering the supercharger speed and the diesel engine forces,
but also increasing the engine oil consumption of the diesel engine.
(d) Troubles with cylinder head parts: this moment the diesel engine is short of power and the performance
drops, and also there are symptoms such as air leak, giving off black smoke and abnormal knocking.
DIESEL ENGINE TROUBLESHOOTING LIST

DIESEL ENGINE IS DIFFICULT TO START
Symptom Suspect Area Trouble-Shooting 04
1. Air in fuel supply • Check and tighten the fuel pipe connectors,
system exclude air.
2. Low battery • Check the charging system, charge or replace

battery.
04
3. ECT sensor • Check harness and connectors. repair or replace.
4. Starter • Check harness and connectors. repair or replace.
5. Fuel filter • Clear or replace.
• Repair fuel supply solenoid valve and harness.

• Repair fuel inlet solenoid valve and harness.
• Repair fuel return solenoid valve and harness.
6. Electronic control • Uneven supply of each cylinder - adjust, repair,
VE pump replacement.
Room temperature
• Poor performance of the fuel valve - adjust, repair,
(ambient temperature ≥ 5)
replacement.
hard cold starting
• Plunger wear - replace.
7. Check whether the

spray of the injector
• Replace.
is normal, dropping
or clamping.
8. Preheat system • Repair.
• Repair fuel supply timing solenoid valve.

9. Injection timing
• Repair fuel supply timing stroke sensor.
error
10.Severe wear of • Check valve clearance, spring. Check the sealing

cylinders and piston performance of the valve guides and valve seats.
rings • Replace the piston ring. Depending on actual need,
replace it.
1. Starter does not

run, or speed too • Repair starting cable, starter and battery.
low
• Repair fuel supply solenoid valve.

2. Electronic control
• Repair fuel inlet solenoid valve.
VE pump
• Repair fuel return solenoid valve.
Hard starting
3. Severe valve
• Repair valve clearance, valve timing, valve seal.
leakage
• Repair fuel supply timing solenoid valve and

harness.
4. Injection timing
• Repair fuel supply timing stroke sensor and
error
harness.
• EGR valve electronic control module.
Symptom Suspect Area Trouble-Shooting
1. The reasons for the

• Exclusion method at room temperature.
same temperature
2. Can not meet the

environmental
• Added fuel by the requirements.
requirements of the
fuel starting
3. Oil can not meet the

requirements of the • Add the oil by requirements.
Low temperature (ambient environment
temperature <5 ℃ ) hard cold
4. Old battery can not
starting • Use the battery marked currents greater than
meet the
380A, and the storage battery are always in full
requirements of
power state. At some special conditions, the
low-temperature
battery should be removed, and keep it indoors.
starting
5. Preheating system
• Use scan tool.
or circuit
6. Fuel supply
solenoid valve and • Repair or replace.
harness
DIESEL ENGINE IS SHORT OF POWER

CAUTION
For diesel engine short of power, the main features are: uneven running in low speed, exhaust pipe
04
giving off black smoke in high speed, abnormal sound. In case that the diesel engine hasn’t reached
the major repair, the short of power is mainly caused by the trouble of diesel supply system and poor
compression of cylinder.

• Check harness and connector. Repair or replace. 04
or connector damaged
2. EGR control system • Check harness and connector. Repair or replace.
3. ECT sensor • Check harness and connector. Repair or replace.
4. Accelerator pedal • Check and adjust.
Electrical control 5. Throttle position sensor • Check harness and connector. Repair or replace.
system
6. Speed sensor • Check harness and connector. Repair or replace.
7. Fuel supply solenoid

valve
8. Fuel inlet solenoid valve • Check harness and connector. Repair or replace.
9. Fuel return solenoid valve • Check harness and connector. Repair or replace.
10. Relay • Repair or replace relay, harness and connector.
1. Diesel • Diesel quality.
2. Air in diesel system • Check whether the diesel supply line connector loose.
3. Diesel system lines

blocking. The pressure
• Check whether the diesel system is clear
are too low in high and
low pressure system
4. Blocking in diesel filter • Check or replace diesel filter
• Uneven supply of each cylinder - adjust, repair,

replacement.
Diesel supply 5. Electronic control VE
• Poor performance of the fuel valve - adjust, repair,
system pump
replacement.
• Plunger wear - replace.

6. Injector fault dropping or clamping. Check whether the washer is
damaged
7. Valve stuck, valve spring

broken
8. Pressure compensator
diaphragm rupture or poor • Check and replace.
adjustment
• Check whether the air filter dirty, deposition. The inlet

1. Inlet system (filter)
blocking
2. EGR valve • Check whether EGR valve clamping

turbocharger and the exhaust pipe
• Check or replace the turbocharger bearing, clean the
Mechanism hands, measure the minimum clearance between the
system 3. Turbocharger system compressor impeller and the compressor case with a
supercharger should be ≤ 0.1mm, the operating limit ≤
0.25mm. Replace the assembly if the axial clearance of
value.

belt overhaul”）
• Check valve clearance (when cold):

04
• The free length of valve spring: 48 mm, if out of the range
, replace it.
Guide:
(a) Inlet valve: 0.039 ～ 0.071 mm
5. Valve is unable to close
properly (b) Outlet valve: 0.064 ～ 0.096 mm 04
Guide:
• Check the gas tightness of the valve seat, check if the
valve retainer sinks too deeply or is burnt to wear; if the
Mechanism • Replace piston ring. Replace cylinder depending on wear
system 6. Piston wear
condition.
• Check cylinder head bolts. Tighten them according to the

7. Cylinder gasket
specified torque. Or replace cylinder head gasket.
8. Exhaust pipe • Check the carbon deposition. Clear it.
9. Leakage at the juncted

surface between the • Tighten the cylinder head bolts according to the specified
cylinder head and body. torque
The cylinder head bolts • Overhaul cylinder head. Check whether the gasket is
loose. The cylinder gasket damaged. If not OK, replace it.
damaged
10. Crank link mechanism

（unsmooth stagnation • Remove oil pan. Check whether the lower end of the
between the piston pin in connecting rod axial runout . If not, remove piston linkage.
the connecting-rod bush Overhaul it.
and piston pin）
1. The coolant temperature • Check dirty on the radiator or cooling surface. Clear the
is too high internal scale.
• Check the oil quantity. Depending on actual need, add it. if

Diesel engine is 2. The oil temperature is too the shaft bearing or related components are worn-out
overheat high caused by heat, overhaul diesel engine after finding out
the causes of fever of components.
3. The exhaust temperature

• Check injector.
is too high
DIESEL ENGINE GIVES OFF ABNORMAL

CAUTION
It indicates that the air fuel ratio is incorrect if the electric control diesel engine gives off black smoke,
mainly because of insufficient air input and large quantity of fuel injected. For insufficient air input, it’s
reflected in air leak or blocking of intake system pipe, insufficient supercharging pressure, air flow
sensor trouble and so on. In addition, poor atomizing of injector also can lead to giving off black
smoke because of insufficient combustion. It shows that the diesel fuel isn’t burnt sufficiently if the
diesel engine gives off black smoke; the unburnt diesel is exhausted as uncombined type and forms
the black smoke. The diesel engine giving off black smoke also goes with powerless accelerating and
short of power usually.
1. Filter • Repair or replace the filter is dirty.
2. Ageing air hose • Replace ageing air hose.
• Repair fuel timing solenoid valve and harness.

• Repair timing stroke sensor and harness.
3. Injection advance angle
• VE pump.
• EGR valve electronic control module.
4. Uneven supply of each • Cam wear - repair or replace VE pump.

cylinder • Valve wear - repair or replace VE pump.
5. EGR system • Using the scana tool to check.

Black smoke pressure meter; the pressure should meet specified value.
• Check or replace the turbocharger bearing, clean the
• Check rotor’s radial clearance: press the compressor
blades with a hand in radial direction and measure the
6. Check the turbocharge minimum clearance between the compressor blade and
system compressor casing with thickness gauge. The measured
value should not be less than 0.10, if not, replace the
turbocharger.
• Check rotor’s axial clearance: fix a magnetic base on
outlet flange facing of turbocharger, let the dial indicator
touch the rotor spindle, and then push or pull the
turbocharger rotor in axial direction to get a clearance
value, the measured value is the clearance value. The
rotor’s axial clearance value of new turbocharger should
not be more than 0.1mm and operating limit value should
not be more than 0.25mm. If the axial clearance value of
turbocharger rotor exceeds the operating limit value,
replace the turbocharger.

04
intake and exhaust valves in cold condition are:
• The free length of valve spring: 48 mm, if out of the range,
replace it.
Guide:
04
7. Valve is unable to close
properly (a) Inlet valve: 0.039 ～ 0.071 mm
(b) Outlet valve: 0.064 ～ 0.096 mm
Black smoke Guide:
• Check valve clearance, spring. Check the sealing
performance of the valve guides and valve seats. Check
whether the valve seat is too deep. If the sealing is not
good, repair it.
• Check of clearance between piston and cylinder bush:

0.042 ～ 0.060 mm.
8. Cylinder and piston • The limit clearance between piston and cylinder bush:
abrasion 0.20 mm.
• If the clearance of the piston and the cylinder bush are
large, the pressure will be low. The diesel combustion is
not full. then the black smoke will emit.
1. Adding excess oil,

• Check the oil gauge, release of excess oil.
resulting in burning oil
2. Air filter block, resulting in

• Clean or replace air filter.
burning oil
3. Ageing air hose, resulting

• Replace air hose.
in burning oil
4. Turbocharger compressor
side leakage, resulting in • Replace turbocharger.
Blue smoke burning oil
5. valve leakage, resulting in

• Repair or replace valve seal.
burning oil
• Check clearance between piston and cylinder bush: 0.042

～ 0.060 mm.
6. Cylinder and piston • The limit clearance between piston and cylinder bush:
abrasion 0.20 mm.
• If the clearance between the piston and the cylinder bush
are large, the pressure will be low. The diesel combustion
is not full. then the black smoke will emit.
DIESEL ENGINE RUNS WITH ABNORMAL NOISE

Symptom Possible Cause Troubleshooting
• The clearance between the piston-pin seat and the piston-

pin is within 0.002 ～ 0.015 mm, the maximum wear limit is
0.03 mm; the clearance between the small end of
1. The match between
piston pin and connecting connecting rod and the piston-pin is within 0.008 ～ 0.020
rod small end bushing mm, the maximum wear limit is 0.05 mm.
hole is too loose; there is • If the clearance value is out of the specified range, replace
slight but sharp sound the connecting rod small end bushing to make the value
during idling running within the range. When installing the stop ring of the piston
pin, check the external of the stop ring for crack or scar.
The stop ring opening should be out of alignment with the
mounting notch on the piston during installation.
2. The gap between piston • The fit clearance between the piston and the cylinder bush
and cylinder is too large; is within 0.042 ～ 0.060 mm, the clearance wear limit is
an impact sound can be 0.20 mm. Measure the fit clearance between the piston
heard at engine body and the cylinder bush during maintenance; replace both
Diesel engine outer wall and it increase the piston and the cylinder bush if the clearance exceeds
runs with abnor- with the speed increasing the wear limit.
mal noise
3. The wear of connecting • Install the piston connecting rod assembly and crank
rod bearing shell and assembly on the cylinder block, rotate the crankshaft,
main bearing shell makes watch carefully if the crankshaft compensator and bottom
the fit clearance too large; of connecting rod crash to the cylinder block. The radial
the body impact sound clearance between the connecting rod bearing shell and
can be heard at the crank the journal is within 0.029 ～ 0.075 mm, the maximum
case during running; the wear limit is 0.03 mm; the axial clearance between the
heavy and power impact connecting rod and the crankshaft is within 0.175 ～ 0.29
sound can be heard if the mm, the maximum wear limit is 0.35 mm; replace it if
speed reduces suddenly damaged and install it upon specified clearance.
4. The valve hits the piston;

the clear, even and
• Find out the cause of hitting, check the valve timing and
rhythmic knocking sound
adjust the valve clearance.
can be heard at the
cylinder head

5. The gap between intake/ intake and exhaust valves in cold condition are:
exhaust valves is too (a) Intake valve: 0.4 ± 0.05 mm
large; the loud and (b) Exhaust valve: 0.4 ± 0.05 mm
rhythmic sound can be
heard at the cylinder head • Check the gas tightness of the valve seat, check if the
Diesel engine valve retainer sinks too deeply or is burnt to wear; if the
runs with abnor- tightness is poor, repair and grind the matching surface of
mal noise valve seat to recover the tightness.
6. Injection too early,metal

percussion sound crisp in • Adjust static injection timing.
the cylinder of
7. Timing gear wear, when

• Check the drive gear clearance, depending on wear,
sudden deceleration, the
replace the timing gear.
metal crash can be heard
TEMPERATURE OF COOLANT IS ABNORMAL IN DIESEL ENGINE COOLING

SYSTEM, COOLANT IS INSUFFICIENT
CAUTION 04
If the diesel engine is overheat, don’t stop the running of diesel engine immediately or fill it with
coolant suddenly. with running the engine with no-load, shut off the engine and check it after the
temperature of coolant in the cooling system drops.
1. Excessive high temperature of coolant may cause damage to the cylinder gasket; the causes
are the following.
(a) The diesel engine temperature is too high (over the critical line of engine temperature). 04
(b) The vehicle runs with the coolant temperature over 100 ℃ till the diesel engine stalls by itself.
(c) After the diesel engine stalls by itself as the temperature is too high, open the diesel engine hood, and
fill the engine with water after natural coolant (at this moment, never open the expansion valve cap to
avoid being burnt); Generally, the cylinder gasket has been damaged and needs to be replaced.
2. Excessive high temperature of coolant may cause deformation to the cylinder head. the causes
are.
(a) When the temperature is too high and the vehicle continues running till the diesel engine stalls by itself,
if open the expansion water tank cover (avoid being burnt by fleeing steam with a washcloth or other
things) and fill it with water immediately, the cylinder head will be deformed.
3. If the diesel engine is overheat, don’t open the expansion water tank cover to avoid being burnt.
Do Take good care of safety when adding coolant. Remove the overheating trouble immediately,
otherwise it may cause damage to other parts.
• Add coolant. Check whether the coolant leakage. Repair it

1. Coolant is too low
if necessary.
2. Coolant level is out of

• Check coolant concentration.
range
• Check the keeping pressure condition. If not OK, replace

3. Radiator cap fault
it.

• Check the thermostat open degree. If not OK, replace it.
open
• Check whether the gasket damaged to be leakage. The

5. Water pump fault poor ability of pump was caused rotor clipping or
corrosion, if not OK, replace it.
6. Radiator core block or the

adherent substance and • Clear radiator and lines.
the rust chokes channel
7. Oil level is too low or poor

• Add or replace oil which meet requirements.
quality
8. Coolant temperature • Check coolant temperature. Repair indicator harness or

Cooling system indicator replace it.
9. Cooling fan system • Check or replace harness, relay or fan.
10.Radiator leaking • Repair or replace radiator.
11. Radiator hose connector

• Tighten up clamp or replace hose.
loose or damaged
12.Heating water tank hose

connector loose or • Tighten up clamp or replace hose.
damaged
13.Radiator heat sink

distortion or there is
• Check, clear and repair radiator blades.
foreign matter blocked
inside
14.Engine cylinder head

bolts for loose
15.Engine cylinder gasket

• Overhaul engine cylinder head, replace cylinder gasket.
damaged
16.Cylinder block or cylinder

• Overhaul engine. Replace cylinder block or cylinder head.
head cracks
TROUBLE WITH DIESEL ENGINE SUPERCHARGER SYSTEM

CAUTION
• Actually, the turbocharger unit is a kind of air compressor, increasing the air input of diesel
04
engine by compressing air; generally, the turbocharger drives the turbo in the turbo chamber by
use of the inertia force of gas exhausted by the diesel engine, then the turbo drives the coaxial
impeller which compresses the air from the air cleaner pipe, supercharges it and delivers it into
the cylinder. With the diesel engine speed increasing, the gas exhausting speed and the turbo
speed increase and the impeller compresses more air into the cylinder. The air with increased
pressure and density can burn more fuel, so increasing the fuel quantity and adjusting the
diesel engine speed will improve the diesel engine output. 04
• The turbocharger unit mainly consists of the turbo chamber and the supercharger. First, the air
intake port of the turbo chamber is connected with the exhaust manifold of diesel engine, while
the exhaust port with the exhaust pipe. Then, the intake port of supercharger is connected with
the pipe of air cleaner, the exhaust port with the intake manifold. At last, the turbo and the
impeller are installed in the turbo chamber and the supercharger respectively, the both are
coaxial and rigid coupled.
• Foreign matters are strictly prohibited into the intake and exhaust system during the diesel
engine troubleshooting, installing and removing processes. As the supercharger rotor rotates
with very high speed and the clearance between the rotor and the case is small, foreign matters
of whatever material and size will affect the running of rotor and cause damage to the blades. If
the blades are damaged, the supercharger produces abnormal vibration and noise. This
moment, stop the vehicle immediately for supercharger troubleshooting.
• If the supercharger leaks oil, as long as the impeller of rotating shaft doesn’t scrape the inner
shell and rotates freely, don’t replace the supercharger which can continue to be used after the
trouble oil leak is removal.

1. Foreign substances in
engine oil are piled at the • Replace oil, repair booster compressor
turbo side seal
2. The engine oil
temperature is too high;
oil supply isn't enough; • Check oil supply system
the floating bearing is
burnt out
3. The supercharger return
tube is blocked, deformed
leading to engine oil leaks • Repair or replace return tube
at the turbo, compressor
shaft end
4. The supercharger seal is
• Replace seal
damaged and fails
5. The turbine shaft rotor
• Repair, replace turbine shaft rotor
loses balance
hands, measure the minimum clearance between the
Under-power compressor impeller and the compressor case with a
6. The turbo blades and
compressor blades are
rubbed and damaged
supercharger should be ≤ 0.1 mm, the operating limit ≤
0.25 mm. Replace the assembly if the axial clearance of
value.
7. The air filter is blocked • Clear or replace filter.
8. The induction tunnel of
the supercharging • Check or replace induction tunnel.
compensator is cracked
9. There is much dirt in air
• Clear, repair intake and exhaust pipes.
intake and exhaust pipes
10.The supercharger works • Check booster pressure.
abnormally or is damaged • Check or replace booster.
1. Leakage at the junction of
the air intake and exhaust • Check or replace components.
High diesel pipes
wastage
2. Booster compressor poor
• Clear, adjust or replace booster compressor.
performance

1. Turbocharge seal ring
• Replace seal ring.
wear out, damaged
04
2. Leakage at the side of
impeller blades of • Check whether there is leakage or block between filter and
compressor of booster compressor, booster and cylinder head.
High oil wastage turbocharger
3. The screw at the junction
of inlet and outlet oilpipe
• Check or replace washer. 04
loose, the washer
damaged
4. Poor oil quality • Replace oil.
1. There is much oil dirt in
the turbo end and the gas
• Clear.
passage becomes narrow
evidently.
There is 2. There is much oil dirt in
abnormal the compressor end and
knocking or • Clear.
the gas passage
impact sound becomes narrow evidently
3. The floating bearing
wears severely; the turbo
• Repalce floating bearing.
and blade wheel have
friction with the case.
1. Foreign matter enter into
• Clear.
inner
Vibration 2. Floating bearing severe

• Replace floating bearing.
wearing
3. Poor turboshaft dynamic
• Check.
balancing
04-242 DIAGNOSTICS - CNG ENGINE CONTROL SYSTEM (4GC1)
CNG ENGINE CONTROL SYSTEM (4GC1)

PRECAUTION
1. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the negative battery cable to
(b) The ignition switch must be turned off without any special descriptions.
WARNING
The ignition and illumination switches must be turned off before removing or installing the battery
negative cable (the semiconductor maybe damage without doing that).
CAUTION
Do not leave the ignition switch in the vehicle in case the doors are locked before disconnecting the
negative battery cable for the vehicle equipped with remote control central lock.
CAUTION
3. THE SAVING DATA SETTING WILL BE LOST IF DISCONNECTING THE NEGATIVE BATTERY
CABLE.
CAUTION
After connecting the negative battery cable, the audio system shoud be reset.


Expression
5. PRECAUTIONS FOR OVERHAULING THE ENGINE CONTROL SYSTEM FAILURE.

(a) Do not disconnect power circuit while engine is running at high speed in case the instantaneous over-
voltage damage the ECM and sensors.
(b) The ECM should be disconnected when welding on the vehicle body. It is special attention that perform-
ing the repair work beside the ECM or sensors.
out of order.
(e) Don’t check any electric appliance connecting the ECM with a test light.
(g) ECM and sensors must be kept from moisture. No permission damaging the seal device of ECM and
sensors and washing them more.
(h) Prevent human body static electricity from damaging ECM. The operator body must be grounded when
operator checks ECM or replace chips.
DIAGNOSTICS - CNG ENGINE CONTROL SYSTEM (4GC1) 04-243
(j) We must remove and install ECM, actuators and independent sensors when the ignition switch is OFF 04
unless there is additional specification in the checking procedure.
(k) If the removed and installed ECM, actuators and sensors are to be reinstalled, the system should be
checked after completing installation. Using the special diagnosis tool, check DTC.
(l) Check the ECM connector terminals with a digital multimeter.
• Connect the small probing pin to the probe of a digital multimeter.
• Check voltage value of terminals referring to the inspection sheet by backprobing ECM connectors 04
terminals.
(m) When diagnosis, turn the ignition switch ON and the connectors are dissociated. DTCs of other system
will be set. After diagnosis, confirm DTCs in all systems. Turn the ignition switch OFF when the
connectors are connected and disconnected.
(n) The test probe must not be probed in wire harness. This will reduce the waterproofness. And it also
cause corossion. Use the test wire, wire connector to measure wire and so on.
(o) Check the common connectors when they are in connection status by probing terminals in the wire
harness. If the connector is too small to check, do not insert by force.
(p) If check the common connectors when they are not in connection status (check male connectors):
• Do not short terminals circuit by using a probe. This will damage the interior circuits in ECM.
(q) If check the common connectors when they are not in connection status (check female connectors):
(r) We shall have a short harness or connectors without taking cautions by wrong insertion. This will dam-
age wire harness, sensor, ECM and other components. So we must carefully handle when checking.
(s) Do not check with the list order.
eliminated.
(t) Check resistance and continuity between terminals of ECM with multimeter.
(u) Ground inspection.
works.
(v) When inspecting a ground connection, follow these rules:

Good Contact.

• Inspect all mating surfaces for tarnish, dirt and rust, etc.
• If several wires are crimped into one ground eyelet terminal, check for improper crimps. Make sure all
of the wires are clean, securely fastened and providing a good ground path. If multiple wires are cased
in one eyelet make sure no ground wires have excess wire insulation.
LOCATION
ENGINE ROOM
04
04
1 Engine Control Module (ECM) 2 Data Link Connector (DLC)

ENGINE
1 Crankshaft Position Sensor 8 Throttle Position Sensor
2 Oil Indicator 9 Idle Air Control Motor
3 Ignition Control Module 10 Fuel Pressure Regulator
4 Coolant Temperature Sensor Manifold Absolute Pressure/Intake Air

11
Temperature (MAP/IAT) Sensor
5 CNG Injector
12 Oxygen Sensor
6 Accelerator Cable
7 Throttle Body

NOTE
04
1. VEHICLE GOES INTO REPAIR SHOP

2. COLLECT AND ANALYSE THE SYMPTOM DESCRIPTION OF CUSTOMER
04
3. CONNECT THE DIAGNOSTIC SCAN TOOL TO DLC

4. CHECK DTC AND DATA/FREEZE-FRAME DATA

5. ERASE DTC

6. VISUAL CHECK

Result Proceed To
Normal Step 9

9. Check IF DTC present
Result Proceed To
Normal Step 11
10. Refer to DTC

11. BASIC CHECK
Result Proceed To
Result Proceed To
13. CHECK ECM POWER SUPPLY CIRCUIT

Result Proceed To

16. CHECK PARTS

17. CONFIRM FAULT


YES > END.


CAUTION
DTC may be stored as the fuse burned down.
04
the switch and the load components circuit must be 04
no circuit for short. But the temporall y shorted circuit
also will cause the fuse burning.
• Clipped harness
• Damaged harness
• Connectors or circuits admission of water
• Wrong operation
1 Battery
2 Fuse
3 Load switch
4 Burned fuse
5 Circuit shorted

CAUTION
horizontal directions, check if the wiring harness connector
connecting the connector and corresponding parts is loose,
the terminal is dirty, rusty, worn or bended and if the
connection is loose because of the terminal extension.
• Harness: Shake the harness lightly in vertical or horizontal
directions, thoroughly check the harness breakaway
condition in the connector connecting vibration section and
engine/cab instruments.
2. HEATING METHOD.
CAUTION 04
Don’t heat over 60 ℃ (the heating temperature should be in the limit of touching the part with hands),
3. SPRAYING METHOD.
failure occurs. 04
CAUTION
• Please take extra care to sprinkle water on vehicle leaking water,as the water leaked into vehicle
may damage control module.
find out the trouble location quickly. This method is very practical and effective.
5. DATA FLOW CAPTURE WITH DIAGNOSTIC SCANNER.
• Use the function of data flow capture on the diagnostic scanner. When seeing the data flow on the
diagnostic scanner, make the rated data status to simulate the fault conditions based on the freeze-
frame on the diagnostic scanner.
7. OTHER METHODS.
• Replace parts: Before replacing ECM of other electronic control modules in part replacing method, take
full diagnosis for other external causes. ECM or other electronic control modules are expensive
products with high reliability.
CAUTION
When replacing and testing possible damaged ECM or control modules, install the possible damaged
ECM or control modules on a failure-free vehicle for testing. Don’t install new control modules on a
failed vehicle for testing to avoid damaging the control modules.

1. CHECK BATTERY VOLTAGE
CAUTION
When engine stops or the ignition switch is in OFF position, perform the test.
Result Proceed To
More than 11V The next step
Less than 11V Charge or change battery
2. CHECK IF THE ENGINE STARTS

NO > Go to fault symptom chart.
3. CHECK FILTER

NO > Replace or clean filter.
4. CHECK IDLE SPEED

NO > Go to fault symptom chart - “Unstable idle - The engine cannot keep stability”.
5. CHECK FUEL PRESSURE

NO > Eliminate fuel pressure fault, and go to next step.
6. CHECK IGNITION

YES > Go to fault symptom chart - “When driving - Poor Acceleration”.
NO > Eliminate ignition system fault.
13.
ECM TERMINAL DIAGRAM (ECM SIDE)
04
04
CHECK ECM TERMINAL WITH MULTIMETER

CAUTION
The normal standard voltage of per terminal as follow “normal condition”. The table also point out the
check condition.

55 No.1 Injector
70 No.2 Injector
Idle: depress accelerator suddenly Voltage: 11 ～ 14 V
56 No.3 Injector
71 No.4 Injector
54 Idle air control motor loop A
53 Idle air control motor loop B

Engine: warm condition, start engine Voltage: 0 ～ 3 V
33 Idle air control motor loop C
34 Idle air control motor loop D

47 Pump relay
Engine: idle 0～3V

63 EVAP solenoid
Engine: warm condition, 3000 RPM 0～3V


17
Continuity power supply Ignition switch: OFF Battery voltage
18
39 A/C request signal Engine running, depress A/C switch -
46 A/C feed back signal Engine running, depress A/C switch -
31 MIL Ignition switch: OFF → ON 0～3V
Ignition switch: OFF Battery voltage

58 Main relay
Ignition switch: ON 0～3V
Engine: warm condition, idle 0～3V

61 upsreeam oxygen sensor
Engine: 5000 RPM Battery voltage
IAT: 0 ℃ 3.2 ～ 3.8 V
IAT: 20 ℃ 2.3 ～ 2.9 V

Ignition switch:
27 IAT sensor
ON
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
62 Upstream oxygen sensor Engine: warm condition, 2000 RPM 0.1 ～ 0.9 V
1 Ignition signal Ignition switch: ON Battery voltage
ECT: 0 ℃ 3.2 ～ 3.8 V
ECT: 20 ℃ 2.3 ～ 2.9 V

Ignition switch:
43 ECT sensor
ON
ECT: 40 ℃ 1.3 ～ 1.9 V
ECT: 80 ℃ 0.3 ～ 0.9 V
TPS: idle 0.3 ～ 1.0 V

Ignition switch:
24 TPS
ON
Open widely 4.5 ～ 5.5 V
Ignition switch: ON
3 VSS 0～5V
Move forward slowly
Start motor 0.4 ～ 4.0 V

12 CKP sensor
Idle 1.5 ～ 2.5 V
73 Ground - 0V
4 - 0V
Ground
5 - 0V
11 Diagnostic signal Ignition switch: ON Pulse signal
ECM TERMINAL DEFINITION

1 BR Ignition signal 38 - -
2 BR-R CNG request 39 B-W A/C request signal 04
3 R-B VSS 40 - -
4 GR-B Sensor ground 41 - -
5 GR Sensor ground 42 G MAP signal
6 L-G Oxygen sensor (LO) 43 R-L ECT signal 04
Injection control diagnostic

7 L 44 - -
data
8 - - 45 B-Y Speed signal
9 - - 46 B-R A/C control
10 - - 47 L-W Pump control
11 BR-Y Diagnostic circuit 48 - -
12 L Speed signal (HI) 49 - -
13 Y MAP signal 50 BR Fan control (HI)
14 - - 51 - -
15 - - 52 BR-G Ignition control (2 - 3)
16 - - 53 W-Y Idle air control motor loop B
17 R Continuity power supply 54 Y-L Idle air control motor loop A
18 R Continuity power supply 55 G-Y Injector 1
19 - - 56 BR-R Injector 3
20 R-W 5V standard sensor power 57 - -
21 L-BR 5V standard sensor power 58 B Main relay
22 B IAT signal 59 - -
23 - - 60 - -
24 L-Y TPS signal 61 R-Y Upstream oxygen sensor
Upstream oxygen signal

25 - - 62 Y-R
(HI)
26 - - 63 B-L EVAP control
GR-
27 IAT signal 64 - -
BR
28 GR Revolution signal (LO) 65 R Fuel selection control
29 - - 66 - -
30 - - 67 V-W Fan control (LO)
Reduce pressure control

31 V MIL 68 R-Y
valve
32 Y Ignition control (1 - 4) 69 - -
33 V-G Idle air control motor loop C 70 G-R Injector 2
34 Y-B Idle air control motor loop D 71 GR-R Injector 4
35 L-R - 72 - -
36 G-W Power steering 73 B Ground
37 - - 74 - -
CHECK ECM HARNESS-SIDE TERMINAL WITH A DIGITAL MULTIMETER

Standard normal resistance and continuity as follow.

1 No.1 Injector
2 No.2 Injector
12.0 ± 0.4 Ω (20 ℃ )
3 No.3 Injector
4 No.4 Injector
5 Idle air control motor loop A, B terminal

53 Ω ± 10% (27 ℃ )
6 Idle air control motor loop C, D terminal
7 CKP sensor 540 Ω (20 ℃ )
8 EVAP solenoid valve 19 ～ 22 Ω (20 ℃ )
9 ECM ground Continuity
10 Heated oxygen sensor 12 Ω (20 ℃ )
11 ECT sensor 3560 ～ 2260 Ω (20 ～ 30 ℃ )
12 Primary resistance of ignition coil 11.3 ± 1.0 kΩ (23 ± 5 ℃ )

INJECTOR CONTROL UNIT TERMINAL DIAGRAM
04
04
INJECTOR CONTROL UNIT TERMINAL DIFINATION

1 GR-R ECM signal (4 cylinder) 9 V Power supply
2 BR-R ECM signal (3 cylinder) 10 L Injection diagnostic data
3 G-R ECM signal (2 cylinder) 11 - -
4 G-Y ECM signal (1 cylinder) 12 W-B Ground
5 B CNG injector (4 cylinder) 13 GR-R Fuel injector (4 cylinder)
6 V CNG injector (3 cylinder) 14 BR-R Fuel injector (3 cylinder)
7 W CNG injector (2 cylinder) 15 G-R Fuel injector (2 cylinder)
8 GR CNG injector (1 cylinder) 16 G-Y Fuel injector (1 cylinder)

DIAGNOSTIC SYSTEM
SYSTEM.
(a) Malfunction Indicator Lamp (MIL) (1) (OBD MIL)
illuminated. When the MIL lights, based on relevant
immediately, otherwise the system will limit the speed of
the engine so as to affect the normal operating of
vehicle.
(b) The failures should be checked with diagnostic scan tool
with corresponding functions.
2. READ DTC.
(a) The Diagnostic Trouble Code (DTC) record and data
related with sensors and actuators in ECM can be read
by KT600 diagnostic scan tool. Additional, the actuator
can be positive driven by the diagnostic scan tool under
specified conditions.
3. DLC - DATA LINK CONNECTOR.

(a) ECM communicate with DLC.

Diagnostic Pulse signal
7
communication (when commnicate)
16 Battery positive 9 ～ 14 V
NOTE
• Connect the diagnostic scanner cable to DLC. Turn
ignition switch ON. Try to open it. If error communication
displayedon screen, then the diagnostic scanner faults.
• If the diagnostic scanner communicates with other
vehicle normally, then check the DLC on the original
vehicle.
ENGINE CONTROL SYSTEM SELF-DIAGNOSTIC ITEM

No. Check Item
1 Fuel Injector 04
2 CNG Injector
3 Main Relay
4 Fuel Pump
5 Ignition Coil 04
6 Oxygen Sensor
7 EVAP Solenoid
8 Vehicle Speed Sensor
9 CKP Sensor
11 ECT Sensor
12 MAP/IAT Sensor
13 Filter Pressure/Intale Air Temperature Sensor
14 High Pressure Solenoid Valve Relay
15 Fan Relay
16 Fuel Selection Relay


NOTE
The troubles are tested and determined by the engine control system and stored in the diesel engine
electronic control module; the system troubles can be current or history.
1. DTC DESCRIPTION.
(a) Current troubles: Exist in ECM currently, for example: The circuit of Engine Coolant Temperature (ECT)
sensor is open. The current troubles must be repaired, otherwise, they can’t be erased from memory.
(b) History troubles: Have two storage types:
from ECM.
• The trouble occurred once and didn’t exist, but is possible to occur again. For example: Poor contact of
conducting wire. As the stored troubles are not current ones, it’s unnecessary to repair them before
being erased from the memory, or it can be processed referring to the troubleshoot methods for
intermittent malfunction.
CAUTION
• If the battery voltage is too low and the trouble code can’t be output normally from ECM, the
battery voltage must be tested before checking and the voltage should not be less than 11V.
• When the battery or ECM connectors are disconnected, the trouble code stored in ECM will be
erased.
• Before connecting or disconnecting KT600 smart diagnostic scan tool, be sure to confirm the
ignition switch is in OFF position.
• Using the KT600 smart scan tool, read DTC.
2. USING THE SCAN TOOL, PERFORM THE READING DTC PROCEDURE.

• The throttle: Closed
• A/C switch: OFF
• Transmission: N
BUS\ VIEW\ ENGINE\4GC1\DELPHI SYSTEM\MT20U2
CNG SYSTEM\ACTIVE TEST”.
(f) Check DTC and data stream. After recording, delete it. (If
DTC cannot be deleted, then perform the diagnosis
procedure refering to “Diagnostics trouble code check”.
Repair faults).
• Simulate DTC setting condition.
• Simulate the scan tool freeze data.
(i) Using the scan tool, read the DTC in ECM.
(j) If there are DTCs but the data stream is normal or the
function is good, then refer to the diagnostics help. If there
are DTCs but the stream is not normal or the function is
not good, then perform diagnosis procedure refering to 04
“Diagnostics trouble code chart”.
NOTE
Use the scan tool to delete DTCs. As soon as DTC is
detected, ECM will record the vehicle and driving
conditions as the type of freeze stream. When eliminating
faults, the catching function will help to confirm the 04
condition of the fault, such as warm condition, stop
condition and lean or rich A/F ration and other data.
3. DTC SETTING CONDITION:
(a) Engine speed
(b) Fuel injector
(c) VSS
(d) ECT sensor
(e) MAP sensor
(f) IAT sensor
(g) TPS
(h) EVAP
(i) Fuel pressure adjustment
(j) A/C switch
(k) CNG injector
(l) Pressure regulator
(m) Filter pressure/intake air temperature sensor
4. THE WAY OF CLEAR DTC
available.
(d) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\
MT20U2 CNG SYSTEM\CLEAR DTC”.
CAPTURING DATA
CAUTION
• Once DTC is captured and stored, ECM records the vehicle and driving conditions information
as a form of rated data. During troubleshooting, the rated data can help determine if the vehicle
was running or parked, and data of other sensors and actuators has been recorded when the
trouble occurred.
• If the DTC is detected but the trouble can’t reappear, confirm the freeze-frame rated data. ECM
records the engine condition in form of freeze-frame data at regular intervals. The diagnostic
scan tool can be used to read several sets of freeze-frame data respectively; KT600 diagnostic
scan tool provides powerful random data flow help function. Select “Read Data Flow” function
menu in engine system, enter the data flow testing result display interface, click “?Help” button
to eject the following windows:
(a) Driving Record Playback
(b) Calculator
(c) Data Range Reference
(d) Data Capture
(e) Data Comparisons
(f) Data Flow Settings
(g) Data/Waveform Display
(h) Driving Recorder Menu
(i) The data can be used to simulate the vehicle conditions as the failure occurs. It also can help determine
the cause of trouble and judge if it’s temporary fault. When the engine is running with trouble, select the
item “Auto Diagnosis\Foton\Light Bus\View\Engine\4GC1\DELPHI SYSTEM\MT20U2 CNG System\
Read Data Flow (Click “?Help”)\Data Capture\Click “Record”\Click “?Help”\Data Comparisons.
ANALYSIS OF DATA
PCHUD ANALYSIS SOFTWARE
1. DELPHI ANALYSIS SOFTWARE. 04
(a) Delphi provides PCHUD software, you can use an ordinary computer engine analysis and
troubleshooting. PCHUD is a tool software connected with an ordinary computer and engine ECM.
Ordinary computer can use it to read, record and analyze equipment Delphi vehicle engine electronic
control system and engine work and control parameters.
2. ACTUATOR ACTION CONTROL: CONTROL OF THE ACTUATOR ACTION, CHANGE SOME
04
PARAMETERS.
3. INTERFACE SETTING.
4. DATA RECORD.
5. DATA READ: READ THE GRAPHICS FILE.
6. DIAGNOSIS.
(a) Preparations.
• Run PCHUD software.
• Preheat the engine to normal temperature.
(b) Data collection.
• Start the engine, run to the specified idle.
• Click (CLR BLF) and (START RECORD) in turn.
• After 20 seconds, raise speed to 2000 RPM for 30 seconds.
• Release the throttle.
• Open A/C for 30 seconds.
• Press throttle to full, continuous 2 ～ 3 seconds.
• After 5 seconds, turn the ignition switch ON (not running). After 15 seconds, throttle to full open for 3
seconds. Then release the throttle for 3 seconds. Repeat it.
• Click (STOP RECORD).
(c) Store data.
(d) Record data to a file.
(e) Analysis and transmission of data.
• Can be off-line playback.
• LOG software analysis data available.
FAIL-SAFE CHART
NOTE
When the DTC listed below is detected, the ECM enters fail-safe mode and the MIL lights up.

• Unstable idle.
1 Injector • Lack of engine power.

2 Relay • System is out of work.
• Can not start engine.

• Noisy fuel pump operation.
3 Fuel pump

• Unstable idle.
• Lack of engine power.
4 Ignition coil
• Weak spark.

5 Oxygen sensor • Excessive exhaust emissions.
• Sluggish acceleration.

• The engine base fuel closed-loop control self-learning will be shut off.
6 EVAP solenoid valve
• The engine idle air control self-learning will be shut off.
• Unstable idle or high idle.

• The engine RPM will be limited.
7 VSS
• No VSS diaplay.

8 IAT sensor
• The IAT is equal to ECT.

• Engine is hard to start.
• The engine RPM will be limited after the engine starts.
• The highest RPM is less than 4000.
9 CKP sensor
• No ignition signal to the ECM.
• The tachometer does not work.
10 TPS
• The MIL light will turn on. 04
• Engine hard to start when cold.
• Engine hard to start when hot.
11 ECT sensor • If the sensor circuit is shorted to power, the engine will run under the
default values. 04
• The temperature gauge indicates too high.
• The temperature gauge indicates too low.
• The cooling fan operates continuously on high speed.
• The high temperature warning lamp will flash when the IP.

12 MAP/IAT sensor
• Unstable idle.

13 Pressure regulator
• Switch back to petrol mode.
DATA STREAM LIST/ACTIVE TEST

NOTE
• Through reading the data stream displayed on scan tool sreen, we can check the sensor,
actuator and switch data value but not removing any components. As first step, this way is the
best way to short diagnosis period .
• The following arranged the data stream under the normal condition. It only offer to reference.
Don’t judge a component normal or not only depend on these value.
1. READ DATA STREAM PROCEDURE.
(c) Connect the KT600 scan tool to the Data Link Connector (DLC) - use the most current software
available.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\
MT20U2 CNG SYSTEM\READ DATA STREAM”.
2. THE TABLE BELOW LISTS THE DATA FOUND IN INSPECTION ITEMS AT DIFFERENT STATES
BY KT600 WITHIN “DATA LIST” ITEMS.
(a) If no concrete specification of idle condition, the shift selector lever is in neutral position. The A/C and
accessories switch are in the OFF position.
(b) Injector driving time means time is taken by crankshaft at speed of less than 250 RPM and power
supply voltage of 11V.
(c) For new vehicle (within operation distance of 500 km), sometimes injector driving time is 10% more
than standard time.
(d) For new vehicle (within operation distance of 500 km), sometimes step length of IAC motor is more
than 30 steps than standard step length.

Engine suddenly
• Engine: Warm decelerate from 4000 ≤ 0.2 V 04
• A/F: Mixture is made RPM
leaner when
decelerating Engine suddenly
Oxygen sensor accelerate 0.6 ～ 1 V
• Engine: Warm Engine: Idle ≤ 0.4 V

• Check A/F with oxygen 04
sensor 2500 RPM 0.6 ～ 1 V
IAT: -20 ℃ -20 ℃
IAT: 0 ℃ 0℃
• Or engine is running
IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
Engine: Idle 0.3 ～ 1 V (0%)
TPS Ignition switch: ON TP open slowly Increase proportionally
Wide open 4.5 ～ 5.5 V
Power supply Ignition switch: ON System voltage
Engine: Stop OFF

Ignition switch Ignition switch: ON
Engine: Start ON
ECT: -20 ℃ -20 ℃
ECT: 0 ℃ 0℃
ECT sensor Ignition switch: ON ECT: 20 ℃ 20 ℃
ECT: 40 ℃ 40 ℃
ECT: 80 ℃ 80 ℃

Barometric sensor Ignition switch: ON
Engine: Idle A/C switch: OFF OFF

A/C switch (Turn A/C switch ON, A/C
compressor works) A/C switch: ON ON
ECT: 0 ℃ 60 ～ 90 ms
Injector Engine: Running ECT: 20 ℃ 30 ～ 5 ms
ECT: 80 ℃ 6.7 ～ 10.1 ms


Engine: Idle 2.2 ～ 3.4 ms
• ECT: 80 ～ 95 ℃
Injector 2500 RPM 1.9 ～ 3.1 ms
• Accessorie: OFF
• Transmission: Neutral Engine runs at high speed
Increase
suddenly
Engine: Idle 2 ～ 18 BTDC

Ignition coil • Engine: Warm
2500 RPM 27 ～ 47 BTDC
• ECT: 80 ～ 95 ℃ A/C switch: OFF 2 ～ 25 steps

• Accessorie: OFF
Idle air control motor • Transmission: Neutral
• Engine: Idle A/C switch: OFF → ON A/C switch: OFF → ON
• A/C works
Not activate (Compressor

A/C switch: OFF
clutch does not work)
A/C relay Engine: Warm and idle
Activate (Compressor
A/C switch: ON
clutch works)
• Engine: Running Compare the values read

• Tachometer: from tachometer and The same
Connection KT600 respectively
ECT: -20 ℃ 1275 ～ 1475 RPM

CKP sensor ECT: 0 ℃ 1225 ～ 1425 RPM
Engine: Idle ECT: 20 ℃ 1100 ～ 1300 RPM
ECT: 40 ℃ 950 ～ 1150 RPM
ECT: 80 ℃ 650 ～ 850 RPM

3. ACTIVE TEST.
CAUTION
any components. We can use the scan tool to perform the test. As the first step, this way is the best 04
available.
04
MT20U2 CNG SYSTEM\ACTIVE TEST”.
(e) Refer to the following chart, perform the active test. The following chart is the item which in the
“ACTIVE TEST” of the KT600 scan tool.
(f) When performing the function of the “ACTIVE TEST”, if there is fault phenomenon, check and repair.
(g) After repairing, using the KT600, perform again, confirm the DTC no longer appears.
(h) Disconnect KT600 scan tool.
(i) Restart engine to perform test. Confirm the faults have been eliminated.
Scanner Display Test Component Control Area Diagnosis Remark

MIL Control MIL ON/OFF -
EVAP Control EVAP solenoid valve ON/OFF -
Fuel pump relay Fuel pump relay ON/OFF -
Low fan Control low fan ON/OFF -
High fan Control high fan ON/OFF -
A/C relay Shut off A/C relay ON/OFF -
Injector (A/B/C/D) Shut off fuel injection ON/OFF -


Note
If a malfunction code is displayed during the DTC check in the check mode, check the harness or con-
nectors for the codes listed in the table below. For details of each code, refer to the DTC chart.
• MAP sensor
P0105-1 MAP Pressure Too High • Short in MAP sensor harness or
connectors
• ECM
• MAP sensor
P0105-2 MAP Pressure Too Low • MAP sensor harness or connectors
• ECM
• IAT sensor
P0110-1 Inlet Air Temperature Too Low • IAT sensor harness or connectors
• ECM
• IAT sensor
P0110-2 Inlet Air Temperature Too High • IAT sensor harness or connectors
• ECM
• ECT sensor
P0115-1 ECT Too Low • ECT sensor harness or connectors
• ECM
• ECT sensor
P0115-2 ECT Too High • ECT sensor harness or connectors
• ECM

P0120-1 Throttle Position Too High • Throttle position sensor harness or
connectors
• ECM

P0120-2 Throttle Position Too Low • Throttle position sensor harness or
connectors
• ECM
• 1-4 cylinder ignition coil driver harness or

P0351-1 Ignition Coil Short To The Battery connectors
• ECM

P0351-2 Ignition Coil Short To Ground Or Open connectors
• ECM

P0352-1 Ignition Coil Short To Battery connectors
• ECM

P0352-2 Ignition Coil Short To Ground Or Open connectors
• ECM
• Oxygen sensor
P0130-4 Oxygen Sensor No Signal • Oxygen sensor harness or connectors 04
• ECM
• Injector leak
• MAP sensor
• ECT sensor
• Ignition system
• Fuel pressure 04
P0170-1 Oxygen Sensor Signal Rich For A Long Time
• Oxygen sensor circuit or connector
• Oxygen sensor
• Relay
• ECM
• Air intake system

• Injector blocked
• MAP sensor
• ECT sensor
• Fuel pressure
• Gas leakage in exhaust system
P0170-2 Oxygen Sensor Signal Lean For A Long Time • Oxygen sensor harness or connectors
• Oxygen sensor
• Relay
• PCV valve and hose
• ECM
• Injector A
P0201-0 Injector A (1 cylinder) Circuit Fault • Injector A harness or connectors
• ECM
• Injector B
P0202-0 Injector B (3 cylinder) Circuit Fault • Injector B harness or connectors
• ECM
• Injector C
P0203-0 Injector C (4 cylinder) Circuit Fault • Injector C harness or connectors
• ECM
• Injector D
P0204-0 Injector D (2 cylinder) Circuit Fault • Injector D harness or connectors
• ECM
• CKP sensor
P0335-0 No 58X CKP Sensor Signal • CKP sensor harness or connectors
• ECM
• CKP sensor
• Open or short in CKP sensorharness or
connectors
P0335-8 58X CKP Sensor Circuit Fault
• Harness poor anti-interference ability
• 58X tooth
• ECM
• Canister solenoid harness or connectors

P0443-1 Canister Solenoid Valve Short To The Battery • Canister solenoid
• ECM
• Canister solenoid harness or connectors

P0443-2 Canister Solenoid Valve Short To Grouned Or Open • Canister solenoid
• ECM
• Low fan relay

P0480-1 Low Fan Relay Short To The Battery • Low fan relay harness or connectors
• ECM
• Low fan relay

P0480-2 Low Fan Relay Short To Ground Or Open • Low fan relay harness or connectors
• ECM
• High fan relay

P0481-1 High Fan Relay Short To The Battery • High fan relay harness or connectors
• ECM
• High fan relay

P0481-2 High Fan Relay Short To Ground Or Open • High fan relay harness or connectors
• ECM
• Speed sensor
P0500-0 Speed Sensor Circuit Fault • Speed sensor harness or connectors
• ECM

P0505-0 Idle Speed Control System Fault • Inlet air system
• ECM

P0650-1 MIL Short To The Battery
• ECM

P0650-2 MIL Short To Ground Or Open
• ECM
• Charging system
P0560-0 System Voltage High
• ECM
P1604-0 EEPROM Checksum Error • ECM
P1605-0 FLASH Checksum Error • ECM
• Immobilizer
P1610-0 Immobilizer Fault
• ECM
• Immobilizer
P0170-2 ECM-Immobilizer Communication Fault
• ECM
• Fuel pump relay
P0230-1 Fuel Pump Relay Short To Battery • Fuel pump relay harness or connector
• ECM
• Fuel pump relay

P0230-2 Fuel Pump Relay Short To Grouned Or Open • Fuel pump relay harness or connector 04
• ECM
• Camshaft position sensor

P0342-0 Camshaft Position Sensor Signal Low • Camshaft position sensor harness or
connector
• ECM
04
• Camshaft position sensor
P0343-0 Camshaft Position Sensor Signal High • Camshaft position sensor harness or
connectors
• ECM
• Front evaporator temperature sensor

P2000-1 Front Evaporator Temperature Too High • Front evaporator temperature sensor
• ECM
• Front evaporator temperature sensor

P2000-2 Front Evaporator Temperature Too Low • Front evaporator temperature sensor
• ECM
• Rear evaporator temperature sensor

P2001-1 Rear Evaporator Temperature Too High • Rear evaporator temperature sensor
• ECM
• Rear evaporator temperature sensor

P2001-2 Rear Evaporator Temperature Too Low • Rear evaporator temperature sensor
• ECM
• A/C rear cycle shut-off valve

P2100-1 A/C Rear Cycle Shut-off Valve Short To The Battery • A/C rear cycle shut-off valve harness or
connectors
• ECM
• A/C rear cycle shut-off valve

P2100-2 A/C Rear Cycle Shut-off Valve Short To Grouned • A/C rear cycle shut-off valve harness or
connectors
• ECM
• CNG temperature sensor

P0180 CNG Rail Temperature Sensor Short Fault • CNG temperature sensor harness or
connectors
• ECM

P0181 CNG Rail Temperature Sensor Open • CNG temperature sensor harness or
connectors
• ECM

P0182 CNG Rail Temperature Sensor Short To Ground • CNG temperature sensor harness or
connectors
• ECM

P0183 CNG Rail Temperature Sensor Short To Battery • CNG temperature sensor harness or
connectors
• ECM

P0184 CNG Rail Temperature Sensor Intermittent Open • CNG temperature sensor harness or
connectors
• ECM
• CNG bottle temperature sensor

P0185 CNG Bottle Temperature Sensor Short Fault • CNG bottle temperature sensor harness
or connectors
• ECM

P0186 CNG Bottle Temperature Sensor Open • CNG bottle temperature sensor harness
or connectors
• ECM

P0187 CNG Bottle Temperature Sensor Short To Ground • CNG bottle temperature sensor harness
or connectors
• ECM

P0188 CNG Bottle Temperature Sensor Short To Battery • CNG bottle temperature sensor harness
or connectors
• ECM

P0189 CNG Bottle Temperature Sensor Short To Battery • CNG bottle temperature sensor harness
or connectors
• ECM
• CNG rail pressure sensor

P0190 CNG Rail Pressure Sensor Short Fault • CNG rail pressure sensor harness or
connectors
• ECM

P0191 CNG Rail Pressure Sensor Open • CNG rail pressure sensor harness or
connectors
• ECM

P0192 CNG Rail Pressure Sensor Short To Ground • CNG rail pressure sensor harness or
connectors
• ECM

P0193 CNG Rail Pressure Sensor Short To Battery • CNG rail pressure sensor harness or
connectors
• ECM

P0194 CNG Rail Pressure Sensor Intermittent Open • CNG rail pressure sensor harness or 04
connectors
• ECM
• CNG bottle pressure sensor

P1290 CNG Bottle Pressure Sensor Short Fault • CNG bottle pressure sensor harness or
connectors
• ECM 04
P1291 CNG Bottle Pressure Sensor Open • CNG bottle pressure sensor harness or
connectors
• ECM

P1292 CNG Bottle Pressure Sensor Short To Ground • CNG bottle pressure sensor harness or
connectors
• ECM

P1293 CNG Bottle Pressure Sensor Short To Battery • CNG bottle pressure sensor harness or
connectors
• ECM

P1294 CNG Bottle Pressure Sensor Intermittent Open • CNG bottle pressure sensor harness or
connectors
• ECM
• CNG pressure indicator

P1295 CNG Pressure Indicator Fault • CNG pressure indicator harness or
connectors
• ECM
• CNG injector control unit

P1296 CNG Injector Control Unit Diagnostic Circuit Fault • CNG injector control unit diagnostic circuit
• ECM
• High pressure solenoid valve relay

P1297 High Pressure Solenoid Valve Relay Fault • High pressure solenoid valve relay
• ECM
• CNG Instryment Indicator

P1298 CNG Instryment Indicator Fault • CNG Instryment Indicator harness or
connectors
• ECM
• Fuel selection relay

P1299 Fuel Selection Relay Fault • Fuel selection relay harness or connectors
• ECM

P0115-1 - ECT TOO LOW
P0115-2 - ECT TOO HIGH
1 Electric Appliance Connector
2 Cabinet
3 NTC Resistance
DESCRIPTION
temperature is high, the resistance drops. The variations in resistance are reflected in the
2. The ECM monitors the sensor voltage and uses this value to calculate the engine coolant
temperature.
WIRING DIAGRAM
04
04
• Ignition switch:ON
turned “ON” or after engine starts • Open or short at
P0115-1 ECT too low • Sensor output voltage continues to be 0.2 ECT sensor
V or lower (corresponding to an intakeair circuit
temperature of 145 ℃ or higher) for 4 • ECM
seconds
• Ignition switch:ON
turned “ON” or after engine starts
P0115-2 ECT too high • Short at ECT
• Sensor output voltage continues to be sensor circuit
4.6V or higher (corresponding to an
• ECM
intakeair temperature of -45 ℃ or lower)
for 4 seconds
NOTE
terminals.
• If the ECM detects the DTC P0115-1 or P0115-2, it operates the fail–safe function in which the
engine coolant temperature is assumed to be a default value. At the same time, with the ignition
switch on, the cooling fans will operate at high speed. The fail–safe function will not untill the
ECM detects the acceptance condition.
Temperature Displayed Malfunction
-40 ℃ Open circuit
140 ℃ Short circuit

(b) With the KT600 scan tool, perform the DTC confirming procedure.
(c) Read sensor value displayed on the KT600 scan tool.
• P0115-1
The next step Open or shotrt to power
• -40 ℃
• P0115-2
Step 5 Shotrt to ground
• 140 ℃ or more
• P0117 or P0118 Diagnostic help Check for intermittent problems

If there is a short circuit, go to step 5.
2. READ VALUE (ENGINE COOLANT TEMPERATURE SENSOR TERMINAL)

(c) Connect terminals A and B of the E021 ECT sensor

connector on the wire harness side.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\
VIEW\ENGINE\4GC1\DELPHI SYSTEM\ MT20U2 CNG
SYSTEM\READ DATA STREAM\COOLANT TEMP”.
(f) Read ECT value displayed on the KT600 scan tool.
Temperature value: 140 ℃ or more

YES > Confirm good connection at sensor. If OK, replace ECT sensor.
(a) Disconnect the connection terminals A and B of the E021

ECT sensor connector on the wire harness side. 04
below.
Standard voltage

04
E021 (B) - Ground 5.0 ± 0.25 V

4. CHECK HARNESS AND CONNECTOR (ECT SENSOR - ECM)

table below.

E021 (A) - E001 (5) ＜2Ω

YES > Go to step 6.
5. READ VALUE (ENGINE COOLANT TEMPERATURE)

MT20U2 CNG SYSTEM\READ DATA STREAM\COOLANT TEMP”.
(e) Read ECT value displayed on the KT600 scan tool.
Temperature value: -40 ℃
YES > Replace ECT sensor.


table below.

E021 (A) - E021 (B)
≥ 1 MΩ
E021 (B) - Ground

YES > Replace ECM.
P0105-1 - MAP PRESSURE TOO HIGH

P0105-2 - MAP PRESSURE TOO LOW
04
04
DESCRIPTION
MT20U2 adopts speed-density air measurement method to check the air intake volume into the engine
so as to control the fuel injection pulse width for the precise control of engine power output.
Meanwhile, this system adopts intake pressure cylinder determination technology and the intake air
sensor is installed near the inlet opening of cylinder 4 intake manifold. At the moment when the throttle
is opened, there will be one instantaneous pressure drop at the sensor, of which the value is about 1
kPa. When the ECM detected and received this instantaneous pressure drop, the ECM will determine
the compression upper dead center signal after software diagnosis treatment (its functions is similar
with the camshaft position sensor of traditional electric injection system, also referred as phase
sensor).
WIRING DIAGRAM
• MAP sensor
• Short at MAP sensor signal
• No TPS faults circuit
P0105-1 MAP pressure too high • ECM detects that the MAP • Short at MAP sensor 5V
input signal is less than power circuit
acceptable value
• ECM
• MAP sensor
• MAP sensor loose connector
• Open or short at MAP sensor
• Engine: running signal circuit
• No TPS faults • Short at MAP sensor signal
P0105-2 MAP pressure too low • ECM detects that the MAP circuit
input signal is higher than • Open at MAP sensor 5V
acceptable value circuit
• Open at MAP sensor ground
circuit
• ECM
NOTE
terminals.
1. READ VALUE AND DTC ON KT600

(c) Read MAP value displayed on the KT600 scan tool.
Pressure Displayed And DTC Proceed To Malfunction
• P0105-1
The next step Short to voltage
• P0105-2
• P0105-1
• P1105-2 Diagnostic help Check for intermittent problems
• Pressure is normal




04
below.
Standard voltage

E010 (D) - Ground 5.0 ± 0.25 V
04

YES > Go to the next step.
(a) Connect terminals A and D of the E010 MAP sensor

connector on the wire harness side.
(b) Read MAP value displayed on the KT600 scan tool.
Standard voltage: 5.0 ± 0.25 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (MAP SENSOR - ECM)

table below.

E010 (B) - E001 (4) ＜2Ω

(a) Connect the E010 MAP sensor connector.

(c) Start engine.

below.
Standard voltage

E010 (D) - Ground 5V
• Idle: 1.3 V
• No load condition, opening
E010 (A) - Ground throttle slowly: 1.3 V
• Open quickly: 4 V, then
return back to 1.5 V


below.
Standard voltage

E010 (A) - Ground 0V

7. READ MAP SIGNAL VOLTAGE

04
(c) Connect terminals A and D of the E010 MAP sensor
connector.
04
(e) Using scan tool, select the item ”DIAGNOSIS\

FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI
SYSTEM\MT20U2 CNG SYSTEM\ READ DATA
STREAM\MAP SENSOR VOLTAGE VALUE”.
Standard: 4 V

8. REPLACE ECM
(a) Repalce ECM.

P0110-1 - INLET AIR TEMPERATURE TOO LOW

P0110-2 - INLET AIR TEMPERATURE TOO HIGH
DESCRIPTION
The IAT sensor has a thermistor that varies its resistance depending on the temperature of the intake
air. When the air temperature is low, the resistance in the thermistor increases. When the temperature
is high, the resistance drops. The variations in resistance are reflected as voltage changes to the ECM
terminal.
WIRING DIAGRAM
• 60 seconds since the ignition switch • IAT sensor 04
is turned “ON” or after engine starts • Open at IAT
P0110-1 Inlet air temperature too low • Sensor output voltage continues to sensor 5V
be 4.6V or higher (corresponding to reference circuit
an intake air temperature of -45 ℃ • ECM
• 60 seconds since the ignition switch • IAT sensor
is turned “ON” or after engine starts • Short at IAT
P0110-2 Inlet air temperature too high • Sensor output voltage continues to sensor 5V
be 0.2V or lower (corresponding to reference circuit
an intake air temperature of 125 ℃ • ECM
NOTE
terminals.
1. READ VALUE AND DTC (IAT)

(c) Read IAT value displayed on the KT600 scan tool.
Temperature: Same value as the actual intake air temperature.
• P0110-1
Step 5 Short to voltage
• About 45 ℃
• P0110-2
• About 45 ℃
• P0110-1 or P0110-2
• Temperature is normal


(b) Disconnect the E010 IAT sensor connector.
(c) Connect terminal B and C at the E010 IAT sensor connector.

(e) Using scan tool, select the item“DIAGNOSIS\FOTON\ LIGHT
BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\ MT20U2 CNG
SYSTEM\READ DATA STREAM\ IAT SENSOR VALUE”.
(f) Read IAT value.
Temperature value: About 140 ℃

YES > Confirm good connection at sensor. If OK, replace IAT sensor.
(a) Disconnect the connection terminals B and C of the E010

IAT sensor connector wire harness side connector.
below.
Standard voltage
E010 (C) - Ground 4.5 ～ 5.0 V

NO > Confirm good connection at sensor. If OK, replace ECM.
4. CHECK HARNESS AND CONNECTOR (IAT SENSOR - ECM)

table below.

E010 (B) - E001 (4) ＜2Ω

YES > Go to step 7.

(b) Disconnect the E010 ECT sensor connector. 04
(d) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI
SYSTEM\ MT20U2 CNG SYSTEM\READ DATA STREAM\IAT SENSOR VALUE”.
(e) Read IAT value.
Temperature value: About -40 ℃
Is the result normal? 04
YES > Replace IAT sensor.


table below.

E010 (A) - E010 (C)
≥ 1 MΩ
E010 (C) - Ground

7. REPLACE ECM
(a) Replace ECM.

P0120-1 - THROTTLE POSITION TOO HIGH

P0120-2 - THROTTLE POSITION TOO LOW
DESCRIPTION
MT20U2 Throttle Position Sensor (TPS) is used to provide throttle angle, angle speed and engine idle
position information to the ECM, based on which the ECM can obtain the engine load information,
operating mode (such as start, idle, reverse towing, partial load, full load) and acceleration &
deceleration information. This sensor is of 3-line type and the ECM will check the throttle open extent
by monitoring the voltage variation.
WIRING DIAGRAM
• 60 seconds since the ignition 04
switch is turned “ON” or after • TPS failed or maladjusted
P0120-1 Throttle position too high engine starts. • Short at TPS circuit
• The sensor output voltage • ECM
continues to be 2V or higher for
4 seconds.
• 60 seconds since the ignition • TPS failed or maladjusted
switch is turned “ON” or after
P0120-2 Throttle position too low • Open or short at TPS
engine starts.
circuit
• Sensor output voltage continues
• ECM
to be 0.2V or lower for 4
seconds.
NOTE
terminals.
1. READ VALUE AND DTC KT600 SCAN TOOL

(c) Read TPS value displayed on the KT600 scan tool.
• P0120-1 ( ＞ 2 V) Step 4 Short to voltage
• P0120-2 ( ＜ 0.2 V) The next step Open or short to ground
• P0120-1 or P0120-2
• Signal is normal



below.
Standard voltage
E007 (A) - Ground 4.5 ～ 5.0 V

3. READ TPS SIGNAL
(a) Connect terminals A and B at the E007 TPS connectoron

the wire harness side.
(b) Perform reading sensor data stream procedure with scan
tool.
Voltage value: 4 V

YES > Go to step 5.
4. CHECK HARNESS AND CONNECTOR (TPS - ECM)

(b) Disonnect the E007 TPS connector.
table below.

E007 (B) - E001 (5) ＜2Ω

(a) Connect the E007 TPS connector.

(b) Connect the E001 ECM connector. 04
below.
Standard voltage
04
E007 (A) - Ground • Ignition switch ON: 5.0 V
• Ignition switch ON (TP close

completely): 0.5 V (scan tool: 0%)
E007 (C) - Ground
• Ignition switch ON (TPis full
opening): 4.5 V (scan tool: 100%)


below.
Standard voltage

E007 (C) - Ground 0V

7. READ TPS SIGNAL

(b) Connect the E007 TPS connector.
(c) Connect terminals A and C at the E007 TPS connector.
(e) Using scan tool, select the item”DIAGNOSIS\FOTON \LIGHT

BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\MT20U2 CNG
SYSTEM\READ DATA STREAM\TPS VALUE”.
Voltage: 4 V

8. REPLACE ECM
(a) Replace ECM.

P0130-4 - OXYGEN SENSOR NO SIGNAL

P0170-1 - OXYGEN SENSOR SIGNAL RICH FOR A LONG TIME
04
P0170-2 - OXYGEN SENSOR SIGNAL LEAN FOR A LONG TIME
1 Air
2 Case
3 Solid electrolyte 04
4 Platinum electrode
5 Heater
6 Lining
7 Exhaust gas
8 Rich
9 Air-fuel ratio
10 Lean
DESCRIPTION
The Engine Control Module (ECM) supplies a voltage of about 0.45 V between the ECM terminals 62
and 6. The Oxygen (O2) sensor varies the voltage within a range of about 1V if the exhaust is rich,
down to about 0.1V if the exhaust is lean. The O2 sensor is like an open circuit and produces no
voltage when it is below 360°C. An open O2 sensor circuit or a cold O2 sensor causes “open loop”
operation.
WIRING DIAGRAM
• The engine controls system is in

closed loop
04
• The engine speed is below 6000 • Upstream oxygen
RPM sensor
• Upstream oxygen sensor feedback • Short at upstream
P0130-4 Oxygen sensor no signal
voltage continues to be 0.07 V or oxygen sensor
lower at least 40 seconds circuit
• DTC P0115-1, P0115-2, P0120- • ECM
1, P0120-2, P0351-1, P0352-1, 04
P0351-2, P0352-2 are not set
• Upstream oxygen sensor feedback • Upstream oxygen
voltage continues to be 4.8 V or sensor
Oxygen sensor signal rich for higher for at least 0.2 seconds • Short at upstream
P0170-1
a long time • DTC P0115-1, P0115-2, P0120- oxygen sensor
1, P0120-2, P0351-1, P0352-1, circuit
P0351-2, P0352-2 are not set • ECM
• Upstream oxygen sensor feedback • Upstream oxygen

voltage continues to be between sensor
Oxygen sensor signal lean 0.42 ～ 0.48 V • Open at upstream
P0170-2
for a long time • DTC P0115-1, P0115-2, P0120- oxygen sensor
1, P0120-2, P0351-1, P0352-1, circuit
P0351-2, P0352-2 are not set • ECM
NOTE
terminals.
VIEW\ENGINE\4GC1\DELPHI SYSTEM\MT20U2 CNG SYSTEM\READ DATA STREAM”.
DIAGNOSIC HELP
• Normally scan tool voltage varies between 0.1 to 1.0 V while in closed loop.
• Check upstream oxygen sensor harness, may be the upstream oxygen sensor is not well installed
and it touches the exhaust pipe.
• Check if there is intermittent ground existent between ECM and upstream oxygen sensor.
• Perform an injector balance test. Check if the lean mixture was caused by injector blocked.
• The vacuum leaking of crankcase causes lean mixture.
• The air outside enters into exhaust pipe and through the upstream oxygen sensor by the leaking of
exhaust manifold wsaher.

(c) Read upstream oxygen sensor value displayed on the KT600 scan tool.
• P0170-2 ( ＜ 0.21 V) Step 6 Short to ground
• P0170-1 ( ＞ 4.8 V) Step 7 Short to power
• P0130-4 (0.42 V ～ 0.48 V) The next step Open

If there is a short to groung circuit, go to step 6.
If there is a short to power circuit, go to step 7.
2. CHECK HARNESS AND CONNECTOR (UPSTREAM OXYGEN SENSOR - UPSTREAM OXYGEN
SENSOR)

(b) Disconnect the E017 upstream oxygen sensor connector.
below.
Standard voltage

E017 (1) - E017 (2) 0.45 V

YES > Replace upstream oxygen sensor.

(b) Connect the E017 upstream oxygen sensor connector 04
terminal 1 and ground.
below.
Standard voltage
04
E017 (2) - Ground 0.45 V

YES > Go to step 5.

table below.

E017 (2) - E001 (62) ＜2Ω

(a) Disconnect the E017 upstream oxygen sensor connec-

tor terminal 1 and ground.
table below.

E017 (1) - E001 (6) ＜2Ω


table below.

E017 (2) - Ground
≥ 1 MΩ
E017 (1) - E017 (2)


below.
Standard voltage



04
below.
Standard voltage

E017 (1) - Ground 0V 04

9. REPLACE ECM
(a) Replace ECM.

P0335-0 - NO 58X CKP SENSOR SIGNAL

P0335-8 - 58X CKP SENSOR CIRCUIT FAULT
1 Shielded cable
2 Permanent magnet
3 Sensor case
4 Mounting bracket
5 Soft magnet iron core
6 Coil
7 Air clearance
DESCRIPTION
The 58X reference signal is produced by the Crankshaft Position (CKP) sensor. The Engine Control
Module (ECM) uses the 58X reference signal to calculate engine RPM and CKP. The ECM constantly
monitors the number of pulses on the 58X reference circuit and compares them to the number of MAP
signal being received. If the ECM receives and incorrect number of pulses on the 58X reference
circuit, Diagnostic Trouble Code (DTC) P0335-0, P0335-8 will be set.
WIRING DIAGRAM
• CKP sensor
• Ignition switch ON 04
No 58X CKP sensor • CKP loose connector
P0335-0 • ECM received no or error
signal • Open or short at CKP sensor circuit
signal
• ECM
• CKP loose connector

• Ignition switch ON
58X CKP sensor • 58X tooth
P0335-8 • ECM received no or error
circuit fault • CKP sensor circuit
signal 04
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “DIAGNOSIS\FOTON\LIGHT
BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\MT20U2 CNG SYSTEM\READ DATA STREAM”.
1. READ VALUE AND DTC ON SCAN TOOL

(c) Read CKP sensor value displayed on the KT600 scan tool.
(e) Using scan tool, perform the CKP sensor waveform confirming procedure.
2. CHECK CKP SIGNAL WITH OSCILLOSCOPE
(a) Raise vehicle.
(b) Using oscilloscope, check the CKP sensor waveform.

YES > Go to step 5.
3. CHECK CKP SENSOR

(b) Disconnect the E013 CKP sensor connecrtor.
(c) Check the resistance according to the value in the table
below.
Standard resistance

E013 (A) - E013 (B) 560 Ω ± 10% (25 ± 5 ℃ )

NO > Replace CKP sensor.
4. CHECK CKP SENSOR WAVEFORM
(a) Replace the on-vehicle CKP sensor with a known good

one.
(b) Using oscilloscope, check the CKP sensor waveform.

NO > Go to step 7.
5. CHECK CKP SENSOR HARNESS AND CONNECTOR (CKP SENSOR - ECM)

table below.

E013 (B) - E001 (28)
＜2Ω
E013 (A) - E001 (12)

table below.
04
E013 (A) - Ground
≥ 1 MΩ
E013 (B) - Ground
04

6. CHECK CKP SENSOR HARNES AND CONNECTOR (CKP SENSOR - GROUND)

below.
Standard voltage

E013 (A) - Ground
0V
E013 (B) - Ground

7. CHECK CKP SENSOR SIGNAL PLATE

(b) Check for a problem such as scrap, dirt, foreign body
and loose with the 58X CKP signal plate and signal
tooth.
(c) Check the mounting clearance of the CKP sensor.

NO > Remove any foreign obstacles and clean 58X signal tooth. If there is fault present, replace 58X signal
plate.
8. REPLACE ECM
(a) Replace ECM.

P0480-1 - FAN RELAY SHORT TO THE BATTERY

P0480-2 - FAN RELAY SHORT TO GROUND OR OPEN
04
P0481-1 - FAN RELAY SHORT TO THE BATTERY
P0481-2 - FAN RELAY SHORT TO GROUND OR OPEN
04
DESCRIPTION
The coolant fans are used to reduce heat in the engine system. And the condensator after the A/C is
turned on.
WIRING DIAGRAM
• Fan relay (LO)

• Fan (LO): running
• Short at fan (LO) harness
Fan relay (LO) short to • ECM detects that faults con-
P0480-1 the battery • Short at low fan relay har-
tinues to be present at fan
ness
(LO) harness for 3 seconds
• ECM
• Fan relay (LO)

• Fan (LO): running • Short or open at fan (LO)
Fan relay (LO) short to • ECM detects that faults con- relay harness
P0480-2
ground or open tinues to be present at fan • Short or open at fan (LO)
(LO) harness for 3 seconds relay harness
• ECM
• Fan relay (HI)

• Fan (HI): running
• Short at fan (HI) harness
Fan relay (HI) short to the • ECM detects that faults con-
P0481-1 • Short at high fan relay har-
battery tinues to be present at fan
ness
(HI) harness for 3 seconds
• ECM
• Fan relay (HI)

• Fan (HI): running • Short or open at fan relay
Fan relay (HI) short to • ECM detects that faults con- (HI) harness
P0481-2
ground or open tinues to be present at fan • Short or open at fan relay
(HI) harness for 3 seconds (HI) harness
• ECM
NOTE
terminals.
• If any DTC is detected, using the scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS
1. PERFORM ACTIVE TEST BY SCAN TOOL (OPERATE FAN)

(c) Using the KT600 scan tool, perform the DTC confirming
procedure.
(e) Using scan tool, select the item”DIAGNOSIS\FOTON\
LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\
MT20U2 CNG SYSTEM\ ACTIVE TEST\ SECONDARY
FAN”.
Standard: value change

Fan (LO): ON Fan (LO) : Running 04
Fan (HI): ON Fan (HI): Running

NO > If fan (LO) is abnormal, go to next step. 04
If fan (HI) is abnormal, go to step 7.
2. INSPECT FUSE

(c) Inspect fuse.
Is the inspection normal?

NO > Go to step 5.
3. INSPECT FAN RELAY (LO)
(a) Remove the fan relay (LO) from fan relay box in engine
room.
table below.
Standard resistance
≥ 1 MΩ
Fan relay (LO) (3) - (5)
＜ 1Ω
(Apply battery voltage

NO > Replace fan (LO) relay.
4. CHECK HARNESS AND CONNECTOR (FAN RELAY (LO) - ECM)

table below.

Fan relay (LO) (1) - E001 (67) ＜2Ω


table below.

Fan relay (LO) (1) - Ground ≥ 1 MΩ


04
below.
Standard voltage

Fan relay (LO) (1) - Ground 0V 04

7. INSPECT FUSE

(c) Inspect fuse.

NO > Go to step 9.
8. INSPECT FAN RELAY (HI)
(a) Disconnect the fan relay (HI) from fan junction box in
engine room.
table below.
≥ 1 MΩ
Fan relay (HI) (3) - (5)
＜ 1Ω
terminal 1 and 2)

NO > Replace high fan relay.
9. CHECK HARNESS AND CONNECTOR (FAN RELAY (HI) - ECM)

table below.

Fan relay (HI) (1) - E001 (50) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (FAN RELAY (HI) - GROUND)

table below. 04

Fan relay (HI) (1) - Ground ≥ 1 MΩ
04

NO > Repair or replace harness or connector. Replace the fuse A009 (30 A).
11. CHECK HARNESS AND CONNECTOR (FAN RELAY (HI) - GROUND)

table below.
Standard voltage

Fan relay (HI) (1) - Ground 0V

12. REPLACE ECM
(a) Replace ECM.

P1297 - HIGH PRESSURE SOLENOID VALVE RELAY FAULT

WIRING DIAGRAM
DTC Detection
DTC No. DTC Definition Trouble Area
Condition
• High pressure 04
solenoid valve relay
• Engine: running
• High pressure sole-
• ECM detects that the
noid valve relay loose
high pressure solenoid
P1297 High pressure solenoid valve fault connector
valve relay input signal • Short or open at high
is less than acceptable pressure solenoid
value valve relay harness 04
• ECM
NOTE
terminals.
1. PERFORM ACTIVE TEST BY SCAN TOOL (HIGH PRESSURE SOLENOID VALVE RELAY)

(c). Engine runs at idle.
(d). Using scan tool, select the item ”DIAGNOSIS\FOTON\
LIGHT BUS\ VIEW\ENGINE\4GC1\DELPHI SYSTEM\
MT20U2 CNG SYSTEM\ACTIVE TEST\HIGH PRES-
SURE SOLENOID VALVE RELAY”.
Standard
High pressure solenoid valve
Pressure regulator: Operate
relay: ON
High pressure solenoid valve

Pressure regulator: Not operate
relay: OFF

2. INSPECT FUSE
(a). Turn the ignition switch OFF.

(b). Remove pump fuse (15A) in body junction box.
(c) Inspect pump fuse.

NO > Go to step 5.
3. CHECK PRESSURE SOLENOID VALVE RELAY
(a) Remove high pressure solenoid valve relay A027.

(b). Measure the resistance according to the value in the
table below.
Standard resistance
≥ 1 MΩ
(3) - (5)
＜ 1Ω
terminal 1 and 2)

NO > Relace relay.
4. CHECK HARNESS AND CONNECTOR (PRESSURE SOLENOID VALVE RELAY - ECM)

04
table below.
Standard resistance
A027 (2) - E001 (68) ＜2Ω 04

5. CHECK HARNESS AND CONNECTOR (PRESSURE SOLENOID VALVE RELAY - GROUND)

table below.
A027 (2) - Ground ≥ 1 MΩ

NO > Repair or replace harness or connector. Replace pump fuse (15A).
6. CHECK HARNESS AND CONNECTOR (PRESSURE SOLENOID VALVE RELAY - GROUND)
(a). Turn the ignition switch ON.

(b). Measure the voltage according to the value in the table
below.
Standard voltage


7. REPLACE ECM
(a) Replace ECM.

(d). Confirm no DTC and data normal.
P1299 - FUEL SELECTION RELAY FAULT

WIRING DIAGRAM
04
04
• Fuel selection relay

• Fuel selection relay loose
• Engine: running connector
P1299 Fuel selection relay fault • ECM detects that the fuel
• Short or open at fuel
selection relay circuit fault
selection relay harness
• ECM
NOTE
terminals.
DESCRIPTION
When the vehicle is running and the volume of CNG is low, the system will automatically switch to gasoline
state. When the engine is converted to gasoline run-time or the engine flameout, CNG system solenoid valves
closed. System backs to gasoline mode.
1. PERFORM ACTIVE TEST BY SCAN TOOL
(a). Connect the KT600 scan tool to the DLC.

(b). Start the engine and warm it to normal operating
temperature.
(c). Using the KT600 scan tool, perform reading relay data
stream procedure.
(d). Engine runs at idle.
(e) Using scan tool, select the item ”DIAGNOSIS \FOTON\
MT20U2 CNG SYSTEM\ ACTIVE TEST\FUEL SELEC-
TION RELAY”.
Standard: value change

Fuel selection relay: ON Fuel selection relay: Closed
Fuel selection relay: OFF Fuel selection relay: Open

2. INSPECT FUSE
(a). Turn the ignition switch OFF.

04
(b). Remove pump fuse (15A) in body junction box.
(c). Inspect pump fuse.
04

NO > Go to step 5.
3. INSPECT FUEL SELECTION RELAY
(a). Remove fuel selection relay A026.

table below.
Standard resistance
≥ 1 MΩ
between terminal 1 - 2)
(3) - (5)
＜ 1Ω
terminal 1 - 2)

NO > Replace fuel selection relay.
4. CHECK HARNESS AND CONNECTOR (FUEL SELECTION RELAY - ECM)
(a). Disconnect the E001 ECM connector.

table below.
A026 (2) - E001 (65) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (FUEL SELECTION RELAY - GROUND)
(a). Measure the resistance according to the value in the

table below.
A026 (2) - Ground ≥ 1 MΩ

6. CHECK HARNESS AND CONNECTOR (FUEL SELECTION RELAY - GROUND)
(a). Turn the ignition switch ON.

04
(b). Measure the voltage according to the value in the table
below.
Standard voltage (check for short)

A026 (2) - Ground 0V 04

7. REPLACE ECM
(a) Replace ECM.

(d). Confirm no DTC and data normal.

When a malfunction is not confirmed by a DTC (DiagnosticTrouble Code) check and the causes of problems
cannot be identified through a basic inspection, troubleshoot according to the priority order indicated in the
table below.
GASOLINE ENGINE CONTROL SYSTEM SYMPTOM

Symptom Check Order
Communication fault with KT600 KT600 fails to communicate with ECM 1
Engine cranks, but will not start 2

Starting
When engine is cold, it starts difficultly, and body shock 3
Unstable idle, (Rough idle, hunting) 4

Idling stably (Improper idling)
Idle speed is high. (Improper idle speed) 5
When the engine is cold, it stalls (At idle) 6

Idling stably (Engine stalls)
The engine stalls when accelerating 7
Acceleration reaction is slow, acceleration disturbance 8

Driving
Poor acceleration capability 9
ENGINE CONTROL SYSTEM SYMPTOM DESCRIPTION

Item Symptom
The starter is used to crank the engine, but there is
Failed to start no combustion within the cylinders, and the engine
Starting does not start
Hard starting Engine starts after cranking a while
Hunting Engine speed does not remain constant

Idling stably
Incorrect idle speed The engine does not idle at the usual correct speed
Engine stall easily when ECT is low after it start for

Engine will stall when it is cold (Idle)
a while
Idling stably
The engine stalls when the accelerator pedal is
Engine stalls when moving
depressed
Hesitation is the delay in response of the vehicle

speed that occurs when the accelerator is
Acceleration reaction is slow, depressed in order to accelerate from the speed at
acceleration disturbance which the vehicle is now traveling or a temporary
drop in vehicle speed during such acceleration.
Driving Serious hesitation is called “sag”
Poor acceleration is the inability to obtain an

acceleration corresponding to the degree of throttle
Poor acceleration capability opening
(Even though acceleration is smooth) or the inability
to reach maximum speed
ENGINE SYMPTOM DIAGNOSTIC

CAUTION
Some symptom diagnostics require visual and additional inspection. Perform these inspections first.
04
These inspections can deal with the problem that needn’t to be check deeply. And it can save the
service time.
1. INQUIRY CUSTOMER ABOUT THE FAULT AFTER TAKING OVER VEHICLE.
(a) The faults appear at first time.
(b) Engine temperature when the faults appear.
(c) Vehicle roadhaul. 04
(d) The road condition the customer usually drives.
(e) The vehicle maintenance log.
(f) The vehicle maintenance record.
(g) Is there any aftermarket retrofit device on vehicle? After the inspection, the checking time will be
shorted.
2. PERFORM THE PRIMARY INSPECTION.
(a) Confirm the engine MIL is normal. If it is not good, repair it first.
(b) Confirm that no DTC exists in the ECM. If DTC exists, refer to the DTC chart to eliminate the fault.
(c) With the scan tool to inspect the engine control system hot data stream. And confirm them in the nor-
mal range.
(d) Confirm the fault and the reason.
(e) When repairing the vehicle, confirm the repair record.
3. VISUAL INSPECTION.
(d) Check the ignition system for any broken or aging spark plug wires and verify the engine firing order is
correct.
(e) Check the engine ground cable and verify a clean and tight connection.
(f) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
CAUTION
The carbon deposits in the back of the valve will cause the poor engine acceleration, unsteady idling,
starting difficulty in cold temperature, ect.
4. VALVE, CARBON DEPOSITS IN THE COMBUSTION CHAMBER.
Determined by the ECI (Electronic Controlled Injection) engine control features, the cylinder carries out
the fuel injection first and then the ignition at each running. The ignition is cut off immediately the engine
is shut off, but the petrol injected in this running cycle can’t be recovered and is attached on the intake
valve and the combustion chamber wall. The petrol is volatile, but the waxes and colloids in the petrol
remain. In the long term, the waxes and colloids become thick and hard after repeatedly heated, so the
carbon deposits are formed. If the engine burns oil or the filled petrol quality is poor and with many
impurities, the valve carbon deposits are more severe and the formation rate is faster. As the carbon
deposit structure is similar to the sponge, after the valve carbon deposits are formed, part of fuel
injected into the cylinder every time will be attached, making the air-fuel mixture strength actually into
the cylinder thin, which causes poor engine running, difficult starting, rough idling, poor accelerating,
backfire during emergency fueling, exhaust exceeding the standards, consumption increasing and
other abnormal symptoms. If the carbon deposits are more severe, they may lead to improperly sealed
valve, and the cylinder can't work without cylinder pressure, or even the valve is adhered and can’t
return. Now the motion interference occurs between the valve and the piston which would damage the
engine finally.
5. CARBON DEPOSITS IN THE INTAKE MANIFOLD.

As the running of each piston in the whole engine is not synchronous, when the engine is shut off,
some intake valves in some cylinders can’t be fully closed, the unburned fuel evaporates and is
oxidized continuously thus to form some softer black carbon deposits in the intake pipe, especially at
the rear of the throttle valve. On the one hand, the carbon deposits make the intake pipe wall coarse;
the air forms a spiral vortex at the coarse section, affecting the air intake effect and the quality of air-fuel
mixture. On the other hand, the carbon deposits block the idling aisle, making the idling speed control
device clamped or exceeding its regulation range, leading to low idling speed and rough idling.
6. IF THE CARBON DEPOSIT IN THE CYLINDER IS TOO MUCH, USUALLY IT WILL CAUSE THE
HIGH PRESSURE. BUT THE VEHICLE HAS MORE MILEAGE, THERE IS MUCH MORE CARBON
DEPOSIT IN THE CYLINDER. BECAUSE OF THE WEAR, THE CYLINDER PRESSURE WILL
DECLINE. SO IT IS NOT THE GOOD WAY TO JUDGE IF THERE IS THE CARBON DEPOSIT IN
THE CYLINDER. THE GOOD AS FOLLOWING.
(a) With the electronic endoscopy.
(b) Inspect the feedback voltage.　　
(c) Disassembly way.
7. CARBON DEPOSIT.
It’s a gradual process from the carbon deposit formation to aggregation and to affecting engine normal
running. when the engine cold starting is hard and the idling is rough, it shows that the carbon deposits
are quite serious, if further it will cause misfire and cylinder fuel cut, until the engine unable to start.
When the cold starting is hard, check the engine at once, clean the valve carbon deposits in time after
removing other factors to avoid damage caused by removing the cylinder cover.
8. PAY ATTENTION TO THE FOLLOWING FOR THE DANGER OF THE CARBON DEPOSIT.
(a) Fill with the high quality gasoline.
(b) Do not idle long.
(c) Run at high speed usually.
SYMPTOM (1)
Symptom Diagnostic Logic Suspect Area

04
• No power supply • ECM power supply
Communication fault with KT600 • Open in the harness of ECM and • Open in the harness of ECM and
scan tool KT600 scan tool KT600
• ECM • ECM
04
1. CHECK DATA STREAM

(b) Connect the KT600 scan tool to the Data Link Connector
(DLC) .
(c) Turn the ignition switch ON. Using the most current
software available, press the POWER key to start the
KT600.
(d) Using scan tool, select the item “DIAGNOSIS\FOTON\
MT20U2 CNG SYSTEM\READ DATA STREAM”.
(e) With the KT600 scan tool, read data stream displayed on
the screen.
Is the ECM data stream can be read?

2. CHECK OTHER MODULE DATA STREAM
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ ABS\READ DATA STREAM”.
(b) Read the data stream on the scan tool.
If the ABS data stream can be read?
YES > Go to step 4.
3. CHECK HARNESS OR CONNECTOR (DLC COMMUNICATION - ECM)

(b) Disconnect ECM connector.
(c) Check the continuity between the DLC A010 terminal 7 - ECM connector terminal 11.
Resistance: ＜ 2 Ω
(d) Using the multimeter, check the continuity between the DLC A010 terminal 7 and ground.
(e) Turn the ignition switch ON, using the multimeter,check the voltage between DLC A010 terminal 7 and
ground.
Voltage: 0 V
4. CHECK ECM POWER AND GROUND
(a) Check ECM power.

(b) Check ECM ground.
5. REPLACE ECM
(a) Replace ECM.(Refer to “ Chapter 11D engine control system - ECM, replacement”)
SYMPTOM (2)
• Malfunction of the igni- 04

The cause is tion system
• Engine run normally probably that a • Malfunction of the fuel
spark plugs are pump system
• Battery is normal
fouled defective, or
Engine cranks, but will not start • MIL is normal that the supply of • Malfunction of the
• No phenomenon of fuel to the injector
burning when crank- combustion • Leakage or malfunc-
tion of intake air sys- 04
ing the engine chamber is
defective tem
• ECM
NOTE
If the engine can’t be started with starting symptom, it shows the ignition system, fuel system and
control system don’t fully lose the functions even though work normally. The cause of this starting
failure is nothing but may be that the high tension sparks are too weak, the ignition is improper, the air-
fuel mixture is too thin or thick, or the cylinder pressure is too low. In general, first check the ignition
system, then the air intake system, the fuel system, the control system, the engine cylinder pressure at
last.
1. INSPECTION MIL AND DTC
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04 engine control
Is the DTC present?
2. VISUAL INSPECTION




YES > Go to step 6.

And clear the plug.


6. CHECK CKP SENSOR
(a) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI

SYSTEM\ MT20U2 CNG SYSTEM\READ DATA STREAM”.
(b) Read the displayed CKP sensor value. It should be within the specified value.
NO > Check whether the sensor installation is correct (Refer to “Chapter 11D engine control system CKP
sensor - overhaul”), repair or replace harness or connector or damaged component.
Can the engine start? 04
YES > Check throttle body and idle air path. Clear the carbon deposit. Disconnect the idle air control motor con-
nector, check whether there is 12 V. And the resistance value is 28 ~ 33 Ω when the temperature is 20 ℃ .
Check whether the idle air control motor is clip. If necesasary, repair or replace it.
CAUTION
04
burning will not be normal. And the usual reasons of unnormal burning are: carbon and grease, grease
beside the throttle air path, carbon and grease with the idle air control motor.

(c) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI
(d) Turn ignition switch: ON. Read the displayed ECT and MAP/IAT sensor value. It should reach the spec-
ified value.
NO > Clear, repair or replace the harness or connector. If the MAP value is still abnormal, go to step 15.
9. CHECK THE FUEL SYSTEM CIRCUIT
(a) Turn the ignition switch : ON

(b) Check whether the pump relay and pump operate normally.
NO > Repair or replace the fuel pump harness or connector.
(a) Release the fuel system pressure. (Refer to “Chapter 12D fuel system - precaution”)
(b) Check the fuel system pressure. (Refer to “Chapter 12D fuel system - precaution”)
• If the pressure is less than 350 kPa, turn ignition switch ON, make the pump operate, check the
pressure again:

(d) Check whether every injector can spray even and standard
quantity gasoline.
CAUTION
If the spraying condition is abnormal just as the “cylindrical
injector.
WARNING
operation area.
system components.
YES > Go to step14.
NO > Clear the injector. Check the injector operation condition again. If it is not OK, replace it. Confirm the
fault is not present. If not OK, go to next step.
(a) Using the fuel return blocker, clamp the return pipe, make the system fuel can not return. Check
Is the fuel pressure establish?

(b) Turn the ignition switch ON (Do not crank the engine) , make sure the fuel pressure can establish in the
fuel pipe. Check whether fuel leaks at fuel pipe connection.
YES > Go to step16.
(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose. If the
jumping over teeth exists.
NO > Perform the valveitimming align operation. (Refer to “Chapter 15D engine mechanism- timing belt，
replacement”) .

• Disassemble the engine faulty parts.
NO > Repair the engine inner mechanism faults. Clear or remove the carbon deposit and check the engine
cylinder head. Check valves, carbon deposit of manifold. For example: the clearance between the cylin-
der and the piston ring. The leakage of the cylinder gasket, and loose of the valve guides, carbon
deposit of the valve.
17. REPLACE ECM
SYMPTOM (3)
• A/F is not correct • Ignition system

• Carbon deposit at • Supply fuel system
valve • Injector
• Engine runs normally • Operation condition is • Leakage of the inlet
• MIL is normal not equal between system
Engine starts difficultly • It needs several times every cylinder
when it is cold (idle) • Cylinder compression
for engine starts suc- • ECT sensor is fault pressure
cessfully when it is • Others：
cold. • Engine management
1. MAP/IAT sensor system
2. Idle step motor • Battery
3. Fuel quality • ECM
NOTE
Hard engine starting refers to that the starter is able to drive the engine to run in normal speed with
clear starting symptom, but the engine only run after continuous starting or the starter driving for a
long time. For the failure of hard starting, determine whether the occurrence is in cold starting or hot
starting, or both of them. The cause of this failure is from the fuel injection system generally; check it
in the following method.
Is the DTC present?

(b) Check following after opening the engine hood.
• Filter
• Leakage of the intake manifold
3. CHECK BATTERY
(a) Check the battery voltage when cranking the engine.

Battery voltage: ≥ 9.6 V
NO > Charge battery or replace it.
4. CHECK STARTER
(a) Check whether the starter or the starter circuit is fault.

5. CHECK CKP SENSOR

04
(b) Read the displayed CKP sensor value. It should reach the specified value.
NO > Check whether the sensor installation is correct (Refer to “Chapter 11D engine control system CKP
sensor, overhaul”), repair or replace harness or connector or damaged part.
6. CHECK ECT SENSOR

(b) Or with the multimeter to check the ECT sensor or feedback voltage. Or with a 1.5 kΩ resistance,
replace the ECT sensor. Start engine. If OK, it means that the ECT sensor is abnormal.
NO > Repair or replace the ECT sensor.
7. CHECK MAP SENSOR
(a) Check MAP sensor after starting engine successfully.

Pressure value: 35 ～ 55 kPa
NO > Eliminate the leakage of intake system.
Can the engine start?
YES > Check throttle body and idle air path. Clear the carbon deposit. Go to next step.
NO > Go to step 10.
(a) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value
(b) Remove the idle air control motor to test:

SYSTEM\MT20U2 CNG SYSTEM\READ DATA STREAM”.
(d) Turn the ignition switch: ON. Read the displayed ECT and MAP/IAT sensor value. It should be within
the specified value.
NO > Clear or repair or replace the harness or connector. If the MAP value is still abnormal, go to step 15.

12D fuel system - precaution”)
(b) Check the fuel system pressure. (Refer to “Chapter 12D

the pressure again:
12. INSPECTION INJECTOR
(a) Remove the injector connector.

04
(d) Check whether every injector can spray evenly and
CAUTION
If the spraying condition is abnormal just as the “cylindrical 04
under the same condition(more than 5 ml), then replace the
injector.
WARNING
operation area.
system components.
ignition sources.
YES > Go to step15.
NO > Repair or replace injector. If it is not OK, go to next step.
(a) Using the fuel return blocker, and clamp the return pipe, make the system fuel not return. Check

(b) Turn the ignition switch ON (Do not crank the engine). Make sure the fuel pressure can establish in the
fuel pipe. Check whether fuel leakage at fuel pipe connection.



YES > Go to step18.

And clear the plug.


NO > Perform the valve timing align operation or replace the valve-timing belt.(Refer to “Chapter 15D engine
mechanism- timing belt”)

21. REPLACE ECM
SYMPTOM (4)
that the ignition system, ignition system
air-fuel ratio, IAC motor • Malfunction of air-fuel
or compression pressure ratio control system
Unstable idle (Rough idle, The engine cannot keep is defective. Because the • Malfunction of the IAC
hunting) stability range of possible causes system
is broad, inspection is
• Poor compression
narrowed down to simple
items • Drawing air into intake
air system
• ECM
NOTE
The unstable idle is the usually faulty. It has many kinds of types. It includes unstable, misfire, etc.
When performing the diagnosis and elimination, analyse according to the specific symptom.
Is the DTC present?

• Check whether the exhaust pipe emit black smoke. Check whether there is unburned petrol fumes.
(b) Start engine and runs at idle. 04
SYSTEM\ MT20U2 CNG SYSTEM\ACTIVE TEST”.
air control motor, the engine RPM changes from high to low in synchronism (Touching the idle air con-
trol motor, can feel vibration).
(e) Disconnect the idle air control motor connector, Check whether there is 12 V. And the resistance value is 04
28 ～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clipped. If necesa-
sary, repair or replace it.
(f) Remove the idle air control motor. Connect the connector and check as following:
• Check whether the idle air control motor can extend-retract when turning the switch on.
• Check whether the idle air control motor can move when turning the ignition switch off.
(a) Engine runs at idle speed. Brennschluss one by one. Inspect if the idle speed changes.
CAUTION
It is better that use the active test function of the scan tool to perform the brennschluss test. If without
the scan tool or the scan tool without the function, the brennschluss period not be too long, if not, the
Three Way Catalytic Converter (TWC) will be damaged.
YES > Go to step12.



YES > Go to step 8.

And clear the plug.



NO > Repair, clear or replace harness or connectors. Every injector can spray evenly and standard quantity
gasoline. If not OK, replace it.
CAUTION
WARNING

12D fuel system - precaution”) 04
04

pressure again:

(b) Turn the ignition switch ON (Do not crank the engine). Apply pressure on the fuel pipe. Check whether
fuel leaks at fuel pipe connection.
12. CHECK INTAKE AND EXHAUST SYSTEM

(d) Check the engine ground cable and verify a clean and tight connection.
(e) Check the sensors and actuators electrical connectors and verify good contact and tight connection.
(f) Check the PCV valve.
(g) Check whether the EVAP system leakage.
(h) Checkif the fuel pressure regulator vacuum pipe broken, kinked or crack.
(i) Check whether the Three Way Catalytic Converter (TWC) is blocked.
(j) Check whether the throttle body gasket leakage.
(k) Check whether the intake manifold gasket leakage.
NO > Repair or replace the faulty components.
(a) Check whether the installation of the MAP/IAT is normal?

(f) With the 3 kinds of the basic types: idle test, accerlerate suddenlly test and blocked test in exhaust
system. Test the vaccum rate in the intake manifold.
NO > Clear and reinstall or repair MAP/IAT sensor. If it is not OK, go to step 15.
14. CHECK OXYGEN SENSOR
(a) Engine idle. Inspect the displayed scan tool data stream. When the temperature is normal after the
engine enter into the closed-loop control, inspect if the oxygen sensor operate normally.
(b) Oxygen sensor normal value: 0 ～ 1 V. Change 5 ～ 8 times in 10 seconds periodically.
YES > Go to step17.
NO > Perform the valve timing align operation or replace timing belt. (Refer to “Chapter 15D engine mecha-
nism - timing belt, replacement”)

• Disassemble the faulty faults.
NO > Repair the engine inner mechanism faults. 04
18. REPLACE ECM
SYMPTOM (5)

Idle is too high (The The cause is probably air control motor
Engine idle speed too
engine does not idle at that the intake air volume • Malfunction of the
high
the usual correct speed) during idle is too great throttle body
• ECM
Is the DTC present?

• Check whether the exhaust pipe emits black smoke. Check whether there is unburned petrol fumes.
• Check whether the throttle cable is adjusted appropriately.
3. CHECK THE ACCELERATOR PEDAL
(a) Check whether the accelerator pedal cable blocked.

NO > Adjust or replace the accelerator cable.
4. CHECK THE RELATED ACCESSORIES
(a) Check the fuel pressure vacuum regualtor installation is reliable.

(b) Check whether the PCV vacuum pipe installation is reliable.
(c) Check whether the braking system vacuum booster pipe installation is reliable.
NO > Adjust or replace.
5. CHECK IDLE
(a) Engine runs at idle speed. Gear in N position. Depress brake pedal. Inspect if the idle speed is too high.
NO > Go to step 7. 04
6. CHECK THE VACUUM BOOSTER
(a) Blocking the vacuum pipe, inspect if the idle become normal.
YES > Go to next step. 04
NO > Repair or replace the vacuum booster.
7. CHECK PCV VALVE
(a) Clipping the PCV vacuum pipe, inspect if the idle become normal.
(b) Check whether the PCV valve clip. If the opening degree is normal.
NO > Replace PCV valve.
(a) Start engine and run at idle.

(b) Using scan tool, select the item “DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI
(c) Perform the idle air control motor test. When the scan tool control the rotation of expansion of the idle
air control motor, the engine RPM changes from high to low in synchronism (Touching the idle air con-
trol motor, can feel vibration).
(d) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value
(e) Remove the idle air control motor to test:
9. CHECK INTAKE SYSTEM
(a) Check the vacuum system for any broken, linked or incorrectly linked vacuum pipes or hoses.
(b) Check the intake air pipe for being jammed, leaking, or damaged.
NO > Repair or replace.
(a) Check whether the installation of the MAP/IAT sensor is normal.

(d) Turn the ignition switch ON. Read the displayed ECT and MAP/IAT sensor value. It should be within the
specified value.
NO > Replace the MAP\IAT sensor.


YES > Go to step13.
NO > Repair or replace:
• If the pressure is less than 350 kPa. Go to next step.
12. CHECK INJECTOR

CAUTION
If the spraying condition ia abnormal just as the “cylindrical growth”, or the 4 injectors spraying quan-
WARNING
04
YES > Replace the injector washer.
NO > Clean or replace the injectpor. 04
13. REPLACE ECM
SYMPTOM(6)
• Malfunction of the IAC

motor
that the air/fuel mixture is throttle body
The cause is probably
When the engine is cold, inappropriate when the
that the intake air volume • Malfunction of the
it stalls (At idle) engine is cold, or that the
during idle is too great injector
intake air volume is insuf-
ficient. • Malfunction of the
ignition system
• ECM
(a) With the KT600 scan tool, perform the reading DTC procedure. (Refer to “Chapter 04 engine control
Is the DTC present?

• Check whether the throttle cable is adjusted appropriately.
CAUTION
burning will be abnormal. And the usual reasons are: carbon and grease, grease beside the throttle air
path, carbon and grease with the idle air control motor.
(b) Start engine and run at idle.
(e) Disconnect the idle air control motor connector, check whether there is 12 V. And the resistance value is 28 04
～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If necesasary,
repair or replace it.
NO > Repair or replace harness, connectors or idle control motor.
04
4. CHECK THE ECT SENSOR

20 ℃ : 2.1 ～ 2.7 kΩ.
80 ℃ : 0.26 ～ 0.36 kΩ.
SYSTEM\ MT20U2 CNG SYSTEM\READ THE DATA STREAM”.
NO > Replace the ECT sensor.
5. CHECK THE IAT SENSOR

20 ℃ : 2.3 ～ 3.0 kΩ.
80 ℃ : 0.3 ～ 0.42 kΩ.
SYSTEM\ MT20U2 CNG SYSTEM\READ THE DATA STREAM”.
NO > Replace the IAT sensor.

NO > Repair or replace harness, connectors or injector.
CAUTION
WARNING



the pressure again:
(a) Check whether the input pipe leakage or blocked.

(b) Turn ignition switch ON (Do not crank the engine). Apply pressure on the fuel pipe. Check whether fuel
NO > Perform the valve timing align operation or replace the timing belt. (Refer to “Chapter 15D engine
mechanism- timing belt, replacement”)

13. REPLACE ECM
SYMPTOM(7)
• Malfunction of the Idle air control

motor
• Malfunction of the throttle body
Defective ignition sys- • Malfunction of the ignition system
The engine stalls
tem, abnormal air-fuel • Malfunction of air-fuel ratio
The engine stalls when when the accelera-
ratio, poor compres- control system
accelerating tor pedal is
sion, etc are sus- • Malfunction of the fuel supply
depressed
pected system
• Poor acceleration
• Clogged exhaust system
• ECM
NOTE
Start in idling mode: put into gear without pressing the accelerator pedal, disengage the clutch and
start the engine. This moment, as the throttle valve is closed and the idling electric shock is closed,
ECM considers it as the idling mode. The control of idling mode is a cruise control without any load
signal, namely a steady speed control that the engine is controlled in target speed range. Speed-
raising control is done if with load signal. During starting, the load signal is input into ECM, the later
raises the engine speed, enhances the dynamic property and keeps the idling from the effect of load.
This moment the starting is smoothly and hard to be shut off generally. If the starting is wobbled and
easy to be shut off and the speed falls in idling mode, find the causes from the idling control.
(a) With the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04 engine control
Is the DTC present?

(b) Start engine and run at idle. 04
(e) Disconnect the idle air control motor connector, check whether there is 12 V exists. And the resistance 04
value is 28 ～ 33 Ω when the temperature is 20 ℃ . Check whether the idle air control motor is clip. If nec-
esasary, repair or replace it.
(f) Remove the idle air control motor. Connect the connector.
• Check whether the idle air control motor can extend-retract when turning the switch off.
• Check whether the idle air control motor can move when turning the ignition switch on.
4. CHECK THROTTLE POSITION
(a) With the scan tool, check if the throttle is normal.

(b) Check whether the throttle open degree is normal when depressing the accelerator pedal.
NO > Adjust the throttle position.
5. CHECK THE LOAD SIGNAL
(a) Check whether the gear signal is sent to ECM.

(b) Check whether the A/C signal is sent to ECM.
(c) Check whether the load signal is sent to ECM.
NO > Repair the load signal harness.
(a) Engine runs at idle speed. cutoff one by one. Inspect if the idle speed changes.
CAUTION
It is better to use the active test function of the scan tool to perform the cutoff test. If without the scan
tool or the scan tool without the function, the brennschluss period shoul not be too long, if not, the
TWC will be damaged.
YES > Go to step14.







SYSTEM\ MT20U2 CNG SYSTEM\ACTIVE TEST”. 04
(c) Check whether the same engine RPM decling obviously and shortly in synchronism (touching the injec-
tor, can feel vibration, or with the voice-tool, touch the injector, the action voice should be heard).
NO > Repair, clear or replace harness or connectors. Every injector can spray evenly and standard quantity 04
gasoline. If not OK, replace it.
CAUTION
WARNING


pressure again:


17. REPLACE ECM
SYMPTOM(8)
• Malfunction of the Idle 04

air control motor
when the accelerator is throttle body
depressed in order to The cause is probably • Malfunction of the
accelerate from the ignition system, air- ignition system
Acceleration reaction is slow,
speed, the vehicle is now fuel mixture or com-
acceleraton disturbance • Malfunction of air-fuel
traveling or a temporary pression pressure is 04
drop in vehicle speed dur- defective ratio control system
ing such acceleration. • Malfunction of fuel
supply system
• Poor compression
• ECM
Is the DTC present?

3. CHECK THE AIR FILTER
(a) Check whether the air filter dirty, grease and blocked.
YES > Clean or replace the filter.
4. CHECK IDLE
(a) Start engine and runs at idle.

(b) Check whether the idle speed is normal.
NO > Refer to the symptom chart - idle, eliminate the problems.

(e) Read the scan tool displayed MAP/IAT sensor data stream value.
NO > Repair or replace MAP/IAT sensor.
6. CHECK TPS

(c) Refer to engine DTC chart.
NO > Repair or replace TPS.


the pressure again:
(2) If the pressure cannot be established, go to step10. 04
8. CHECK INJECTOR

04
CAUTION
WARNING
YES > Go to step11.
NO > Repair or replace the injector.
(a) Using the fuel return blocker, and clamp the return pipe, make the system fuel not return. Check

(b) Turn the ignition switch ON (Do not crank the engine). Apply pressure on the fuel pipe. Check whether
fuel leakage at fuel pipe connection.
11. CHECK EXHAUST SYSTEM
(a) Check the exhaust system and Three Way Catalytic Converter (TWC).
(b) Check whether the exhaust pipe blocked with the exhaust pressure meter.
NO > Replace or clean the exhaust system.
• Per cylinder pressure: 1270 kPa
YES > Go to step14.
(a) Check whether the engine valve-timing gear mark is aligned, damaged. And the belt is loose.
mechanism - timing belt, replacement”)

15. REPLACE ECM
SYMPTOM(9)
• Malfunction of the 04
ignition system
Poor acceleration is the inability to • Malfunction of air-fuel
Defective ignition ratio control system
obtain an acceleration
system, abnormal air-
corresponding to the degree of • Malfunction of the fuel
Poor Acceleration fuel ratio, poor
throttle opening (even though supply system
compression, etc are
acceleration is smooth) or the • Poor acceleration
suspected. 04
inability to reach maximum speed • Clogged exhaust
system
• ECM
(a) Using the KT600 scan tool, perform the reading DTC procedure. (Refer to ”Chapter 04-4 engine con-
trol system - read and clear DTC”)
Is the DTC present?

3. CHECK TPS

NO > Repair or replace TPS.

NO > Repair or replace the MAP\IAT sensor.


the pressure again:
6. CHECK INJECTOR

CAUTION
WARNING

YES > Go to step9.
NO > Clean or replace the injector. 04
Is the fuel pressure established? 04

leakage at fuel pipe connection.







YES > Go to step14.

15. REPLACE ECM
04
04-368 DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM

PRECAUTION
1. ELECTRONIC CONTROL.
(a) Before removing or installing any electrical device, please disconnect the negative cable to prevent
damage to the device or personal injury.
(b) Make sure ignition switch is OFF if no specific instructions.
NOTE
If equipped with central locking, do not leave ignition switch in the car before disconnecting the
battery negative cable.
2. REMOVE INSTRUMENT CLUSTER OR DISCONNECT THE NEGATIVE CABLE WILL RESULT IN
LOSS OF DATA.
NOTE
Total odometer will not be cleared.
3. WHEN THE BATTERY TERMINAL IS REMOVED, ALL THE MEMORIES OF THE CLOCK, RADIO,
DTCS, ETC. WILL BE ERASED. SO BEFORE REMOVING IT, CHECK THEM AND NOTE THEM
DOWN.
NOTE
When service is finished, reset the clock and audio systems.


Expression
5. NOTES ABOUT ANTI-LOCK BRAKE SYSTEM.

(a) The system will resumes its normal state temporarily or competely by removing and reinstalling the
suspicious faulty components when the connector terminals or the installing state of the components go
out of order.
(b) In order to identify the faulty position, we must check the vehicle condition while vehicle goes out of
order. For example, we check the faults through the DTC. And we record these fault states before
(c) The sensor and ABS module can be removed or installed with the ignition switch in OFF position.
(d) After repairing the anti-lock brake system is completed, check the ABS warning light.
(e) Never use the multimeter to measure the terminal of ABS module.
DIAGNOSTICS - ANTI-LOCK BRAKE SYSTEM 04-369
LOCATION
04
04
1 Speed Sensor 3 ABS Module
Load Sensing Proportioning And By-Pass 4 Hydraulic Regulator

2
Valve
1 Instrument Cluster Stop Lamp Switch 3 Brake Switch
2 Ignition Switch 4 Parking Brake Switch

ABS MODULE CONNECTOR
04
04
No. Wiring Color Difinition No. Wiring Color Difinition
1 Y-G Sensor signal 7 G-W Brake signal
2 L-W Sensor signal 8 R Parking brake
3 P Limit switch input 9 - -
4 - - 10 R-B Power supply
5 W-B Ground 11 Y-R ABS warning light
6 G Pressure relief valve 12 LG Stop valve


NOTE
If a malfunction code is displayed during the DTC checking, check the circuit listed below. For details
of each code, turn to the relevant troubleshooting page in the DTC chart.
DTC No. Detection Item (DTC Definition) Trouble Area
• Speed sensor
2 Speed Sensor Measuring Circuit Open • Speed sensor circuit harness or connectors
• ABS module
• Speed sensor
3 Speed Sensor Measuring Circuit Short • Speed sensor circuit harness or connectors
• ABS module
• Stop valve
4 Stop Valve Driver Circuit Open • Stop valve harness or connectors
• ABS module
• Stop valve
5 Stop Valve Driver Circuit Short • Stop valve harness or connectors
• ABS module
• Pressure relief valve

6 Pressure Relief Valve Driver Circuit Open • Pressure relief valve harness or connectors
• ABS module

7 Pressure Relief Valve Driver Circuit Short • Pressure relief valve harness or connectors
• ABS module
10 Malfunction In ABS Module • ABS module


Use the table below to help you find the cause of the problem. The numbers indicate the priority of the
likely cause of the problem. Check each part in order. If necessary, replace these parts.
04
Symptom Suspect Area Reference
1. Brake pipe -
2. Brake fluid -
Chapter 34 axle and propeller shaft - dif-

3. Differential ferential assy, check and adjustment 04
4. Front brake Chapter 35 brake - front brake, overhaul
5. Rear brake Chapter 35 brake - rear brake, overhaul
6. Hydraulic regulator -
assembly
Chapter 04 diagnostics - instrument

7. Parking light switch cluster, ABS warning light is inoperative/
always on
ABS is inoperative. Chapter 04 diagnostics - instrument
8. Brake fluid level sensor cluster, ABS warning light is inoperative/
always on
Chapter 04 diagnostics - instrument

9. Brake switch cluster, ABS warning light is inoperative/
always on
Chapter 04 diagnostics - anti-lock brake

10. Speed sensor system, ABS system is inoperative

11. Stop valve system, ABS system is inoperative

12. Pressure relief valve system, ABS system is inoperative

13. ABS module system, ABS system is inoperative
1. Brake fluid Chapter 35 brake - brake fluid, bleeding
2. Brake pipe -
3. Front brake Chapter 35 brake - front brake, overhaul

ABS does not operate effectively
4. Rear brake Chapter 35 brake - rear brake, overhaul
5. LSP&BV Chapter 35 brake - LSP&BV adjustment
6. ABS module -

1. ABS warning light system, ABS warning light is always on

ABS warning light is always on. 2. Instrument cluster system, ABS warning light is always on

3. ABS module system, ABS warning light is always on

1. ABS warning light system, ABS warning light is inoperative

ABS warning light is inoperative. 2. Instrument cluster system, ABS warning light is inoperative

3. ABS module system, ABS warning light is inoperative
Chapter 35 brake - speed sensor,

1. Speed sensor replacement

2. Stop valve system, ABS warning light is intermittent
on
ABS warning light is intermittent on. Chapter 04 diagnostics - anti-lock brake
3. Pressure relief valve system, ABS warning light is intermittent
on

4. ABS module system, ABS warning light is intermittent
on
PRE - CHECK
1. DIAGNOSIS SYSTEM.
(a) Turn the ignition switch ON. ABS warning light illuminates, 04
ABS module self-test the whole system for about 1.5
seconds, then the self-test finishes. ABS warning light goes
out, that means the system is normal.
(b) When the ignition switch is ON, if the ABS light flashes
continuously, it means that the brake pedal switch is
pressed. If the brake pedal is closed at that time, after 04
release the brake pedal, the ABS warning light should
be off, that means the system is normal. Otherwise,
check whether the brake pedal switch is closed in a
abnormal state.
(c) If the ABS warning light always illuminates at normal
condition, that means the system is fault.
2. READ DIAGNOSTIC TROUBLE CODE (DTC) .

(a) When the fault occurs, ABS warning light will illuminate
continually. At this time, if the brake pedal (1) is pressed
3 times continually in 3 seconds, ABS module will output
DTC. If no DTC outputs, repeat the operation until the
DTC outputs.
(b) ABS warning light flashing is divided into 2 kinds, one is
long and another is short. The short flashing times
between two long flashing add a long flashing to form a
DTC.
3. CLEAR DTC.
(a) Turn the ignition switch OFF, the implementation of display program will be stopped, and the DTC also
be cleared.
4. TROUBLESHOOTING SIGN.
(a) After troubleshooting, connect the connector, turn the ignition switch ON.
• If the ABS warning light illuminates for about 1.5 seconds, then goes out, which means the system back
to normal, fault has been eliminated.
• If the ABS warning light still illuminates, it means that fault has not been really eliminated or other faults
are still present. According to the DTC table to troubleshoot.
2 - SPEED SENSOR MEASURING CIRCUIT OPEN

3 - SPEED SENSOR MEASURING CIRCUIT SHORT
WIRING DIAGRAM
DTC No. DTC Definition DTC Detecting Condition Suspect Area
• Speed sensor
• Vehicle at the speed of 20km/h or • Speed sensor
more, pulses are not input for 15 connector
Speed sensor measuring
2 circuit open
second • Open in speed sensor
• ABS module detects speed sensor circuit
circuit fault • Signal tooth
• ABS module
• Speed sensor
• Vehicle at the speed of 20km/h or • Speed sensor
more, pulses are not input for 15 connector
Speed sensor measuring
3 circuit short
second • Short in speed sensor
• ABS module detects speed sensor circuit
circuit fault • Signal tooth
• ABS module
1. READ DTC
(a) Turn the ignition switch ON. 04

Is the inspection result normal？
YES > System is normal.
NO > DTC 2 or 3 is present, go to next step.
04
2. INSPECT SPEED SENSOR

(b) Raise vehicle.
(c) Inspect whether the ABS speed sensor installation is

correct.
(d) Inspect whether the ABS speed sensor connector is
loose.
(e) Inspect whether the ABS speed sensor tightening bolt is
loose.
(f) Remove ABS speed sensor to inspect whether the
speed sensor is damaged or the surface is dirty.
(g) Disconnect the T002 ABS speed sensor connector.
(h) Replace the on-vehicle ABS speed sensor with a known

good one.
(i) With the KT600 scan tool, perform the DTC confirming
procedure.

YES > Repair or replace ABS speed sensor.
(a) Disconnect the S001 ABS module connector.

table below.
Standard resistance (Check for short)

T002 (1) - Ground
≥ 1 MΩ
T002 (2) - Ground

4. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - SPEED SENSOR)

table below.
Standard resistance

T002 (1) - T002 (2) ≥ 1 MΩ

5. CHECK HARNESS AND CONNECTOR (SPEED SENSOR - ABS MODULE)

table below.
Standard resistance (Check for open)

T002 (1) - S001 (1)
＜2Ω
T002 (2) - S001 (2)


04
below.
Standard voltage

T002 (1) - Ground 04
0V
T002 (2) - Ground

YES > Replace ABS module.
4 - STOP VALVE DRIVER CIRCUIT OPEN

5 - STOP VALVE DRIVER CIRCUIT SHORT
WIRING DIAGRAM
• Stop valve
• ABS is in operation • Stop valve connector
Stop valve driver
4 circuit open • ABS module detects stop valve cir- • Open in stop valve circuit
cuit fault • Hydraulic regulator
• ABS module
• Stop valve
• ABS is in operation • Stop valve connector
Stop valve driver
5 circuit short • ABS module detects stop valve cir- • Short in stop valve circuit
cuit fault • Hydraulic regulator
• ABS module
1. READ DTC

04
2. CHECK HYDRAULIC REGULATOR

(b) Disconnect the T001 hydraulic regulator connector.
(c) Replace the on-vehicle hydraulic regulator with a known good one.
(e) With the KT600 scan tool, perform the DTC confirming procedure.
YES > Replace hydraulic regulator.
3. CHECK HARNESS AND CONNECTOR (HYDRAULIC REGULATOR - ABS MODULE)

table below.

S001 (5) - T001 (3)
＜2Ω
S001 (12) - T001 (1)

4. CHECK HARNESS AND CONNECTOR (HYDRAULIC REGULATOR - HYDRAULIC REGULATOR)

table below.

T001 (1) - T001 (2)
T001 (1) - T001 (3) ≥ 1 MΩ

T001 (1) - T001 (4)

table below.

T001 (2) - T001 (3)
≥ 1 MΩ
T001 (3) - T001 (4)

5. CHECK HARNESS AND CONNECTOR (HYDRAULIC REGULATOR - GROUND)

table below.
Standard resistance

T001 (1) - Ground
≥ 1 MΩ
T001 (2) - Ground
T001 (3) - Ground ＜2Ω


04
below.
Standard voltage

T001 (1) - Ground 04
0V
T001 (2) - Ground

6 - PRESSURE RELIEF VALVE DRIVER CIRCUIT OPEN

7 - PRESSURE RELIEF VALVE DRIVER CIRCUIT SHORT
WIRING DIAGRAM

• Pressure relief valve connector
• ABS is in operation
Pressure relief valve • Open in pressure relief valve
6 driver circuit open • ABS module detects pres- circuit
sure relief valve circuit fault
• Hydraulic regulator
• ABS module

• Pressure relief valve connector
• ABS is in operation
Pressure relief valve • Short in pressure relief valve
7 driver circuit short • ABS module detects pres- circuit
sure relief valve circuit fault
• Hydraulic regulator
• ABS module
1. READ DTC

04


table below.

S001 (5) - T001 (3)
＜2Ω
S001 (6) - T001 (4)


table below.

T001 (4) - T001 (1)
T001 (4) - T001 (2) ≥ 1 MΩ

T001 (4) - T001 (3)

table below.

T001 (1) - T001 (3)
≥ 1 MΩ
T001 (2) - T001 (3)

NO > Repair or replace harness.

table below.
Standard resistance

T001 (4) - Ground
≥ 1 MΩ
T001 (2) - Ground
T001 (3) - Ground ＜2Ω


04
below.
Standard voltage

T001 (2) - Ground 04
0V
T001 (4) - Ground

ABS WARNING LIGHT IS ALWAYS ON

WIRING DIAGRAM
1. CHECK ABS MODULE

(b) Disconnect the S001 ABS module connector.
Standard: ABS warning light doesn’t illuminate.

2. CHECK INSTRUMENT CLUSTER

(b) Disconnect the C011 instrument cluster connector. 04
Standard: ABS warning light doesn’t illuminate.
NO > Repair or replace instrument cluster.
3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ABS MODULE) 04

table below.

C011 (A9) - Ground ≥ 1 MΩ

ABS WARNING LIGHT IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
04
(b) Disconnect instrument cluster fuse (7.5A).
(c) Inspect instrument cluster fuse (7.5A).
04

NO > Go to step 4.
2. CHECK HARNESS AND CONNECTOR (ABS MODULE - ABS MODULE）

below.
Standard voltage

S001 (11) - S001 (5) Battery voltage

3. CHECK HARNESS AND CONNECTOR (ABS MODULE - GROUND)

table below.

S001 (5) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - GROUND)
(a) Disconnect the C012 instrument cluster connector.

table below.

C012 (B9) - Ground ≥ 1 MΩ
(c) Check resistance between terminal B9, the C012 instrument cluster connector and instrument cluster
fuse seat.
Standard: ＜ 2 Ω
NO > Repair or replace harness or connector. Replace instrument cluster fuse (7.5A).
5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ABS MODULE)

04
table below.

C011 (A9) - S001 (11) ＜2Ω 04

below.
Standard voltage

C011 (A9) - Ground 0V

YES > Repair or replace instrument cluster.
ABS WARNING LIGHT IS INTERMITTENT ON (ABS MODULE

CHECK FAULT INTERMITTENTLY)
WIRING DIAGRAM

(b) Raise the vehicle.

correct.
loose. 04
loose.
(f) Remove ABS speed sensor, inspect whether the speed
sensor is damaged or the surface is dirty.
(g) Disconnect the T002 ABS speed sensor connector.
(h) Replace the on-vehicle ABS speed sensor with a known

good one.
(i) With the KT600 scan tool, perform the DTC confirming
procedure.

YES > Repair or replace ABS speed sensor.

table below.

T002 (1) - Ground
≥ 1 MΩ
T002 (2) - Ground


table below.

T002 (1) - T002 (2) ≥ 1 MΩ


table below.

T002 (1) - S001 (1)
＜2Ω
T002 (2) - S001 (2)


04
below.
Standard voltage

T002 (1) - Ground 04
0V
T002 (2) - Ground



table below.

S001 (3) - T001(2)
S001 (5) - T001(3)

＜2Ω
S001 (6) - T001(4)
S001 (12) - T001(1)

8. CHECK HARNESS AND CONNECTOR (HYDRAULIC REGULATOR)

table below.

T001 (1) - T001 (2)
T001 (1) - T001 (3) ≥ 1 MΩ

T001 (1) - T001 (4)

table below.
Standard resistance (Check for short or open)

T001 (1) - Ground
T001 (2) - Ground ≥ 1 MΩ

T001 (4) - Ground
T001 (3) - Ground ＜2Ω


below.
Standard voltage

T001 (1) - Ground
T001 (2) - Ground 0V

T001 (4) - Ground

ABS IS INOPERATIVE
WIRING DIAGRAM
04
04
1. INSPECT FUSE

(b) Disconnect ABS fuse (15A).
(c) Disconnect pump fuse (15A).
(d) Inspect the ABS fuse and pump fuse.

NO > Replace ABS fuse and pump fuse. Repair or replace the harness between ABS fuse/pump fuse and
ABS relay. Repair or replace the harness between ABS fuse and ABS module. If the fuse is still burned,
replace the body junction box.
2. CHECK HARNESS AND CONNECTOR (ABS MODULE - ABS MODULE)

below.
Standard voltage

S001(10) - S001 (5) Battery voltage

YES > Go to step 6.

04
table below.

S001(5) - Ground ＜2Ω 04

4. INSPECT ABS RELAY
(a) Remove ABS relay.

table below.
Standard resistance
≥ 1 MΩ
R4 (3) - R4 (5)
＜ 2Ω
terminal 1 and 2)

NO > Replace ABS relay.
5. CHECK HARNESS AND CONNECTOR (ABS MODULE - ABS RELAY)

table below.
Standard resistance (Check for short or open)

S001 (10) - R4 (3) ＜2Ω
R4 (3) - Ground ≥ 1 MΩ

(b) Disconnect the S001 ABS module connector.

(d) Release brake pedal.
below.
Standard voltage

S001(7) - Ground 0V

(a) Release parking brake.

04
(b) Disconnect fluid level sensor connector.
table below.

04
S001(8) - Ground ≥ 1 MΩ

(a) Inspect and add brake fluid to normal level.

(b) Connect fluid level sensor connector.
(c) Disconnect parking light switch.
table below.

S001(8) - Ground ≥ 1 MΩ


(b) Raise the vehicle.

correct.
loose.
loose.
(f) Remove ABS speed sensor, inspect whether the speed
sensor is damaged or the surface is dirty.

NO > Replace speed sensor.

(b) Disconnect the T002 speed sensor connector.

table below.
Standard resistance

(1) - (2) 1.2 ~ 1.65 KΩ

NO > Replace ABS speed sensor.

table below.

T002 (1) - Ground
≥ 1 MΩ
T002 (2) - Ground


table below. 04

T002 (1) - T002 (2) ≥ 1 MΩ
04


table below.

T002 (1) - S001 (1)
＜2Ω
T002 (2) - S001 (2)


below.
Standard voltage

T002 (1) - Ground
0V
T002 (2) - Ground



table below.
Standard resistance

(1) - (3) 2.3 ± 5%
(3) - (4) 4.4 ± 5%

NO > Replace hydraulic regulator.

table below.

S001 (3) - T001(2)
S001 (5) - T001(3)

＜2Ω
S001 (6) - T001(4)
S001 (12) - T001(1)

NO > Replace hydraulic regulator.

table below.

T001 (1) - T001(2)
T001 (1) - T001(3) ≥ 1 MΩ

T001 (1) - T001(4)

table below.
04
T001 (2) - T001(3)
T001 (2) - T001(4) ≥ 1 MΩ

T001 (3) - T001(4)
04

table below.
Standard resistance

T001 (1) - Ground
T001 (2) - Ground ≥ 1 MΩ

T001 (4) - Ground
T001 (3) - Ground ＜2Ω


below.
Standard voltage

T001 (1) - Ground
T001 (2) - Ground 0V

T001 (4) - Ground

04-408 DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM
HEATER AND AIR CONDITIONING SYSTEM

PRECAUTION
1. DO NOT DEPOSIT REFRIGERANT IN AN ENCLOSED AREA OR NEAR AN OPEN FLAME.
2. ALWAYS WEAR SAFETY GOGGLES.
3. AVOID CONTACTING WITH LIQUID REFRIGERANT R-134A.
If liquid refrigerant is in your eyes or on your skin:
(a) Wash the area with lots of cold water.
(b) Apply clean petroleum jelly to the skin.
(c) Immediately go to a hospital or see a physician for professional treatment.
4. DO NOT HEAT CONTAINER OR EXPOSE THE CONTAINER TO OPEN FLAME.
5. DO NOT DROP DOWN CONTAINER OR APPLY PHYSICAL SHOCKS TO IT.
6. DO NOT OPERATE COMPRESSOR WITHOUT ENOUGH REFRIGERANT IN REFRIGERANT SYSTEM.
(a) If there is not enough refrigerant in the A/C system, oil lubrication will be insufficient and the
compressor may be damaged.
7. DO NOT OPEN HIGH PRESSURE MANIFOLD VALVE WHILE COMPRESSOR IS OPERATING.
(a) Open and close only the low pressure valve.
If the high pressure valve is opened, refrigerant flowing in the reverse direction will cause the charging
cylinder to rupture.
8. BE CAREFUL NOT TO OVERCHARGE SYSTEM WITH REFRIGERANT.
(a) If refrigerant is overcharged, it will cause problems such as insufficient cooling, poor fuel economy,
engine overheating, etc.
9. DO NOT OPERATE ENGINE AND COMPRESSOR WITH NO REFRIGERANT.


Expression

DIAGNOSTICS - HEATER AND AIR CONDITIONING SYSTEM 04-409
BASIC INSPECTION
Step Condition Action
Check the refrigerant. Yes Go to next step 04
1 • Open the cap of release valve.Press the
release valve. No Charge the refrigerant system
Check the A/C switch. Yes Go to next step

• Start the engine.
2 04
• Check the A/C switch. No Go to problem symptoms table
Check the A/C clutch field coil. Yes Go to next step

3 • Check the A/C clutch field coil.
Is the check result normal? No Go to problem symptoms table
Check compressor belt. Yes Go to next step

4 • Check compressor belt.
Check the compressor. Yes Go to next step

5 • Check the compressor cluth for noisy.
Check the condenser. Yes Go to next step

• Check the dirt between the condenser
6 and radiator.
• Check condenser fan No Clear the dirt or repalce the condenser
Check pressure A/C liquid line. Yes Go to problem symptoms table

7 • Check the line for inhibition or leakage.
Is the check result normal? No Replace the pressure A/C liquid line
LOCATION
1 Front Heater Control Panel 4 Instrument Panel
2 Blower Assy 5 Front Fog Lamp Switch
3 Outside Mirror Switch 6 Rear Fog Lamp Switch

04
04
1 Accumulator Assy 3 Condenser Assembly
2 Condenser Fan 4 Evaporator Assembly


Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely
cause of the problem. Check each part in order. If necessary, replace these parts.
1. Fuse -
2. A/C relay -
Chapter 61 heater and air conditioning -

A/C system is inoperative 3. A/C amplifier front evaporator, overhaul

4. A/C compressor compressor, overhaul
5. Wire harness -
1. Fuse -
2. Relay -

3. Blower switch front blower, replacement
Air flow control: Front blower motor
is inoperative Chapter 61 heater and air conditioning -
4. Front blower motor resistor front blower, replacement

5. Front blower motor front blower, replacement
6. Wire harness -
1. Fuse -
2. Relay -
3. Rear evaporator blower Chapter 61 heater and air conditioning -

switch rear evaporator, replacement
Air flow control: Rear evaporator Chapter 61 heater and air conditioning -
4. Rear evaporator resistor rear evaporator, replacement
motors are inoperative
5. Rear A/C switch A/C controller, replacement

6. A/C amplifier front evaporator, overhaul
7. Wire harness -

1. Blower switch(front control) front blower, replacement
04
2. Front blower motor resistor front blower, replacement

Air flow control: Front air flow is 3. Front blower motor front blower, replacement
insufficient
Chapter 61 heater and air conditioning - 04
4. Front A/C controller A/C controller, replacement

5. Front A/C air output pipe heater hose, replacement
6. Wire harness -
1. Rear evaporator blower Chapter 61 heater and air conditioning -

switch rear evaporator, replacement

Air flow control: Rear air flow is 2. Rear evaporator resistor rear evaporator, replacement
insufficient
3. A/C amplifier front evaporator, overhaul
4. Wire harness -
1. Fuse -
2. Relay -

3. A/C compressor compressor, overhaul
Temperature Control: Temperature Chapter 61 heater and air conditioning -

control is inoperative 4. A/C amplifier front evaporator, overhaul
5. Refrigerant -

6. A/C pressure line A/C pipe, replacement
7. Wire harness -
A/C SYSTEM IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(a) Disconnect the battery negative cable. 04
(b) Inspect the A/C fuse (15 A) in body junction box (C035).
04

NO > Replace the fuse.
2. INSPECT A/C MAIN RELAY
(a) Disconnect the battery negative cable.

(b) Remove A/C main relay.
(c) Inspect the A/C main relay according to the value(s) in

the table below.

1–2 Continuity
3–5 ＜2Ω
(Apply battery voltage to terminal 1 and 2)

NO > Replace the A/C main relay.
3. Inspect A/C CUT-OFF RELAY

(b) Remove the K003 A/C cut-off relay.
(c) Inspect the A/C cut-off relay according to the value(s) in

the table below

1–2 Continuity
3–4 ≥ 1 ΜΩ

NO > Replace the A/C cut-off relay.
4. INSPECT FRONT A/C SWITCH

(b) Disconnect the C017 front A/C switch connector.
(c) Replace the front A/C switch with a new one.
YES > Replace the front A/C switch.
5. INSPECT BLOWER SWITCH

(b) Disconnect the C016 blower switch connector.
(c) Replace the blower switch with a new one.
YES > Replace the blower switch.
6. CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - GROUND)

(b) Disconnect the C017 A/C amplifier connector.
(c) Measure the resistance according to the value(s) in the

table below.

K001 (15) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - GROUND)

(b) Disconnect the C016 blower switch connector. 04
table below.

04
C016 (8) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - BLOWER SWITCH)

(b) Disconnect the C052 junction connector.
(c) Disconnect the C016 blower switch connector.
(d) Measure the resistance according to the value(s) in the

table below.

C052 (8) - C016 (5) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (A/C FUSE - JUNCTION CONNECTOR)


table below.

A/C fuse (15 A) - C051 (5) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - A/C CUT-OUT RELAY)

(c) Disconnect the K003 A/C cut-out relay.

table below.

C051 (12) - K003 (4) ＜2Ω

11. CHECK HARNESS AND CONNECTOR (A/C CUT-OUT RELAY - A/C AMPLIFIER)

(b) Remove the K003 A/C cut-out relay. 04
(c) Disconnect the C017 A/C amplifier connector.

table below.
K003 (3) - K001 (4) ＜2Ω

12. CHECK HARNESS AND CONNECTOR (FRONT A/C SWITCH - A/C AMPLIFIER)


table below.

C017 (5) - K001 (11) ＜2Ω

YES > Relace the A/C amplifier.
AIR FLOW CONTROL: FRONT BLOWER MOTOR IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE

(b) Inspect the front heater fusible link (40 A) in body
junction box (C035).
04

2. INSPECT FRONT HEATER RELAY

(b) Remove the front heater relay.
(c) Inspect the front heater relay according to the value(s) in

the table below.

1–2 Continuity
3–5 ＜2Ω

NO > Replace the front heater relay.
3. INSPECT FRONT BLOWER MOTOR RESISTOR

(b) Disconnect the C027 front blower motor resistor connector.
(c) Replace the front blower motor resistor with a new one.
YES > Replace the front blower motor resistor.
4. CHECK HARNESS AND CONNECTOR (FRONT HEATER RELAY - FRONT BLOWER MOTOR)

(b) Disconnect the C028 front blower motor.
(c) Remove the front heater relay.

table below.

Front heater relay (5) - C028 (1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR RESISTOR - GROUND)


table below.

C027 (4) - Ground ＜2Ω

6. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH- GROUND)

(b) Disconnect the C016 blower switch connector. 04
table below.

04
C016 (8) - Ground ＜2Ω

AIR FLOW CONTROL: REAR EVAPORATOR MOTORS ARE

INOPERATIVE
WIRING DIAGRAM
1. INSPECT FUSE

(b) Inspect the rear evaporator fusible link (30 A) in body
(c) Inspect the rear evaporator motors fuse (7.5 A).
04

2. INSPECT REAR EVAPORATOR MOTOR RELAY

(b) Remove the K006 rear evaporator motor relay.
(c) Check the rear evaporator motor relay according to the

value(s) in the table below.

3–5 Continuity
1–2 ＜2Ω

NO > Replace the rear evaporator motor relay.
3. INSPECT REAR A/C SWITCH

(b) Disconnect the L001 rear A/C switch connector.
(c) Replace the rear A/C switch with a new one.
YES > Replace the rear A/C switch.
4. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - GROUND)

(c) Connect the battery negative cable.
(d) Start the engine.
(e) Press the rear evaporator motor switch.
(f) Measure the voltage according to the value(s) in the

table below.

K006 (2) - Ground
Battery voltage
K006 (3) - Ground

5. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - REAR A/C
SWITCH)

(c) Disconnect the L001 rear A/C switch.

table below.

K006 (1) - L001 (7) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - A/C AMPLIFIER)

(b) Remove the K006 rear evaporator motor relay. 04

table below.
K006 (1) - K001 (12) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR A/C SWITCH - REAR EVAPORATOR BLOWER
SWITCH)

(b) Remove the L001 rear A/C switch connector.
(c) Disconnect the L002 rear evaporator blower switch connector.

table below.

L001 (8) - L002 (3) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR BLOWER SWITCH - GROUND)

(b) Disconnect the L002 rear evaporator blower switch connector.

table below.

L002 (4) - Ground ＜2Ω

9. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR RELAY - REAR
EVAPORATOR MOTOR)

(c) Disconnect the L005 rear evaporator motor LH connector.
(d) Disconnect the L006 rear evaporator motor RH connector.
(e) Measure the resistance according to the value(s) in the

table below.

K006 (5) - L005 (2)
＜2Ω
K006 (5) - L006 (2)

10. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR MOTOR - REAR EVAPORATOR
BLOWER SWITCH)

(c) Disconnect the L005 rear evaporator motor LH connector.
(d) Disconnect the L006 rear evaporator motor RH connector.

table below.
04

L005 (1) - L002 (1)
＜2Ω
L006 (1) - L002 (1)

YES > Replace the rear evaporator blower switch.
AIR FLOW CONTROL: FRONT AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
1. INSPECT FRONT BLOWER MOTOR RESISTOR

(c) Replace the front blower motor resistor with a new one.
2. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR - FRONT BLOWER MOTOR
RESISTOR)

(b) Disconnect the C028 front blower motor connector.
(c) Disconnect the C027 front blower motor resistor connector.

table below.

C028 (2) - C027 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - GROUND)


table below.

C016 (8) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FRONT BLOWER MOTOR RESISTOR - BLOWER

SWITCH)

(c) Disconnect the C027 front blower motor resistor connector.

table below.

C016 (1) - C027 (3)
＜2Ω
C016 (2) - C027 (2)

AIR FLOW CONTROL: REAR AIR FLOW IS INSUFFICIENT

WIRING DIAGRAM
04
04
1. INSPECT REAR EVAPORATOR RESISTOR

(b) Disconnect the L007 rear evaporator resistor connector.
(c) Replace the rear evaporator resistor with a new one.
YES > Replace the rear evaporator resistor.
2. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - GROUND)


table below.

L007 (2) - Ground ＜2Ω

3. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - REAR EVAPORATOR
BLOWER SWITCH)

(c) Disconnect the L002 rear evaporator blower switch connector.

table below.

L007 (3) - L002 (2) ＜2Ω


RESISTOR)

(b) Disconnect the L005 rear evaporator motor LH connector.
(c) Disconnect the L006 rear evaporator motor RH connector.
(d) Disconnect the L007 rear evaporator resistor connector.

table below.
04

L005 (1) - L007 (1)
＜2Ω
L006 (1) - L007 (1)

BLOWER SWITCH)

(b) Disconnect the L005 rear evaporator motor LH connector.
(c) Disconnect the L006 rear evaporator motor RH connector.
(d) Disconnect the L002 rear evaporator blower switch connector.

table below.

L005 (1) - L002 (1)
＜2Ω
L006 (1) - L002 (1)

6. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR RESISTOR - GROUND)

table below.

L007 (2) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REAR EVAPORATOR BLOWER SWITCH - GROUND)

table below.

L002 (4) - Ground ＜2Ω

YES > Replace the rear evaporator blower switch.
TEMPERATURE CONTROL: TEMPERATURE CONTROL IS

INOPERATIVE
WIRING DIAGRAM 04
04
1. INSPECT COMPRESSOR
(a) Start the engine and hold it at idle speed. 04

(b) Set the blower switch to LOW.
(c) Press the A/C switch to get the compressor clutch engaged.
(d) Check the compressor.
Does the compressor work correctly?
YES > Go to step 6. 04
2. INSPECT EFI & A/C RELAY

(b) Remove the EFI & A/C relay.
(c) Inspect the EFI & A/C relay according to the value(s) in
the table below.

1–2 Continuity
3–5 ＜2Ω

NO > Replace the EFI & A/C relay.
3. CHECK HARNESS AND CONNECTOR (EFI & A/C RELAY - GROUND)

(e) Measure the voltage according to the value(s) in the

table below.
Standard voltage

EFI & A/C relay (2) - Ground
Battery voltage
EFI & A/C relay (5) - Ground

4. CHECK HARNESS AND CONNECTOR (EFI & A/C RELAY - A/C CLUTCH FIELD COIL)

(c) Disconnect the E022 A/C clutch field coil connector.

table below.

EFI & A/C relay (3) - E022 (1) ＜2Ω

YES > Replace the A/C clutch field coil.
5. INSPECT FRONT A/C SWITCH

(b) Disconnect the C017 front A/C switch connector. 04
(c) Replace the front A/C switch with a new one.
6. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - GROUND) 04


table below.

C016 (8) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (FRONT A/C SWITCH - GROUND)


table below.

C017 (1) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - GROUND)

(b) Disconnect the C017 A/C amplifier connector.

table below.

K001 (15) - Ground ＜2Ω

9. CHECK HARNESS AND CONNECTOR (A/C AMPLIFIER - A/C PRESSURE SWITCH)

(b) Disconnect the K001 A/C amplifier connector.
(c) Disconnect the C034 A/C pressure switch connector.

table below.

K001 (4) - C034 (1)
＜2Ω
K001 (6) - C034 (3)

YES > Replace the A/C amplifier.
DIAGNOSTICS - LIGHTING SYSTEM 04-443
LIGHTING SYSTEM
PRECAUTION
1. PRECAUTION FOR USING BATTERY DURING INSPECTION. 04
(a) While using the battery during inspection, do not bring the positive and negative tester probes too close
to each other as a short circuit may occur.
2. PRECAUTION FOR HEADLIGHT BULB REPLACEMENT.
(a) If even a thin film of oil is left on the surface of the halogen light, the bulb may be damaged because the
light will burn at a higher temperature.
04
(b) Handle any halogen light with great care. Dropping, hitting or damaging the bulb, in any way, may result
in exploding and shattering because the internal pressure is high.
(c) Always prepare a new bulb for immediate replacement. While replacing the bulb, the lens may attract
dust and moisture if removed from the vehicle for too long.
(d) Always use a bulb of the same wattage for replacement.
(e) Firmly reinstall the socket after bulb replacement. The lens may become cloudy or the light cavity may
fill with water through the gaps around the socket.


Expression

04-444 DIAGNOSTICS - LIGHTING SYSTEM
BASIC INSPECTION
Yes Go to next step
Check the battery voltage.
1 • The voltage should be above 12 V. Charge or replace battery. Refer to “Chapter
Is the check result normal? No 20A/20B starting and charging - battery,
replacement”
Check the LO-beam lamps. Yes Go to next step

• Turn the ignition switch ON.
2
• Check the LO-beam lamps. No Go to problem symptoms table
Check the HI-beam lamps. Yes Go to next step

3 • Turn the ignition switch ON.
Check the "Flash" lamps. Yes Go to next step

Check the turn signal lamps. Yes Go to next step

Check the hazard lamps. Yes Go to next step

Check the Indoor Lamps. Yes Check harness and connector

LOCATION
04
04
1 Rear Dome Light Assy 5 Front Combination Lamp Assy LH
2 Front Combination Lamp Assy RH 6 Rear Combination Lamp Assy LH
3 Front Fog Lamp Assy RH 7 License Lamp Assy
4 Front Fog Lamp Assy LH 8 Rear Combination Lamp Assy RH

PROBLEM SYMPTOMS TABLE - 09 LATE PRODUCTION

1. Headlamp 04

Chapter 64 lighting - front combination lamp bulb LH,
LO-beam headlamp is 1. Bulb replacement
inoperative (One side)
2. Wire harness - 04
1. Bulb replacement
2. Relay -
LO-beam headlamps are
inoperative (Both sides) -
3. Wire harness
Chapter 51 steering column - combination switch assy,

4. Combination switch replacement

HI-beam headlamp is 1. Bulb replacement
2. Wire harness -
1. Relay -
HI-beam headlamps are Chapter 51 steering column - combination switch assy,

inoperative (Both sides) 2. Combination switch replacement
3. Wire harness -

1. Combination switch replacement
LO-beam and HI-beam
headlamps are inopera- Chapter 64 lighting - front combination lamp bulb LH,
2. Bulb replacement
tive (One side)
3. Wire harness -
1. Relay -
LO-beam and HI-beam
headlamps are inopera- 2. Combination switch replacement
tive (Both sides)
3. Wire harness -
2. Fog lamp
1. Bulb Chapter 64 lighting - front fog lamps LH,

replacement
Front fog lamps are inoperative Chapter 51 steering column - combination switch
2. Combination switch assy, replacement
3. Wire harness -

Chapter 51 steering column - combination switch
Front fog lamps are always on -
2. Front fog lamp relay
3. Wire harness -
Chapter 64 lighting - rear combination lamp bulb

1. Bulb LH, replacement
Rear fog lamps are inoperative Chapter 64 lighting - rear fog lamp switch,
2. Rear fog lamp switch replacement
3. Wire harness -

Rear fog lamps are always on Chapter 64 lighting - rear fog lamp switch,
3. Wire harness -
1. Fuse -
2. Relay -
3. Front fog lamp switch -

All fog lamps are inoperative
5. Wire harness -
3. Turn signal and hazard warning lamp
1. Fuse -
Hazard warning lamps are inoperative Chapter 83 instrument panel -

(Turn signal lamps are normal) 2. Hazard switch instrument cluster, replacement
3. Wire harness -
1. Fuse -
Chapter 51 steering column -

Turn signal lamps are inoperative
2. Combination switch combination switch assy,
(Hazard warning lamps are normal)
replacement
3. Wire harness -

1. Combination switch combination switch assy,
Hazard warning and turn signal lamps are
replacement
inoperative
2. Wire harness -

1. Combination switch (light combination switch assy,
Turn signal lamps are inoperative (One control) 04
replacement
side)
2. Wire harness -
Chapter 83 instrument panel -

1. Hazard switch instrument cluster, replacement
Chapter 51 steering column - 04

Hazard warning lamps are always on combination switch assy,
2. Combination switch
replacement
3. Wire harness -
4. Stop lamp
1. Fuse -
Stop lamps are inoperative (Both sides) 2. Stop lamp switch Chapter 35 brake - brake pedal, replacement
3. Wire harness -
Chapter 64 lighting - rear combination lamp

1. Bulb bulb LH, replacement
Stop lamp is inoperative (One side)
2. Wire harness -
1. Bulb
High-mounted stop lamp is inoperative
2. Wire harness -
5. Buck-up lamp

Chapter 64 lighting - rear combination
1. Bulb lamp bulb LH, replacement
Back-up lamp is inoperative (One side)
2. Wire harness -
1. Fuse -
Chapter 41 transmission - input shaft

2. Back-up lamp switch and reverse idler gear shaft, replace-
Back-up lamps are inoperative ment

4. Wire harness -
6. Interior lamp

Chapter 64 lighting - front indoor lamp
1. Bulb assy, replacement
Front dome lamp is inoperative Chapter 64 lighting - front indoor lamp

2. Front dome lamp switch assy, replacement
3. Wire harness -
Chapter 64 lighting - rear indoor lamp

1. Bulb assy, replacement
Rear dome lamp is inoperative Chapter 64 lighting - rear indoor lamp

2. Rear dome lamp switch assy, replacement
3. Wire harness -
Chapter 64 lighting - Sliding door step

1. Front door ajar switch lamp, replacement
Sliding door step lamps are inoperative Chapter 64 lighting - Sliding door step
2. Bulb lamp, replacement
3. Wire harness -
7. Interior illumination system
1. Fuse
Illuminated system is not inoperative
2. Wire harness
Chapter 83 instrument panel - instru-

1. Instrument cluster ment cluster, replacement
Instrument cluster illumination is inoperative
2. Wire harness -
Chapter 83 instrument panel - dash-

1. Combined display board, replacement
Combined display illumination is inoperative
2. Wire harness -

1. Cigarette lighter board, replacement
Cigarette lighter illumination is inoperative
2. Wire harness -

1. Front A/C controller board, replacement
Front A/C controller illumination is inoperative
2. Wire harness -

1. Electronic clock board, replacement
Blower switch illumination is inoperative
2. Wire harness -

1. Audio board, replacement
Audio illumination is inoperative 04
2. Wire harness -

1. Hazard switch board, replacement
Hazard switch illumination is inoperative
2. Wire harness -
04
8. Parking lamp, tail lamp and license lamp
Chapter 64 lighting - front combination lamp
Front parking lamps are inop- 1. Bulb
bulb LH, replacement
erative
2. Wire harness -
Chapter 64 lighting - rear combination lamp

1. Bulb
Tail lamps are inoperative bulb LH, replacement
2. Wire harness -
1. Fuse -
2. Relay -
License lamp is inoperative Chapter 51 steering column - combination
(light control) switch assy, replacement
4. Wire harness -
1. Fuse -
2. Relay -
Parking lamps, tail lamps and
license lamp are inoperative 3. Combination switch Chapter 51 steering column - combination
(light control) switch assy, replacement
4. Wire harness -
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
1. INSPECT BULB

(b) Disconnect the C006 front combination lamp LH connector.
(c) Replace the front combination lamp LH bulb with a new one.
YES >Replace the front combination lamp LH bulb.
2. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP LH - COMBINATION
SWITCH)

(b) Disconnect the C008 combination switch (light control) connector.
(c) Disconnect the C006 front combination lamp LH connector.

table below.

C006 (1) - C008 (A3) ＜2Ω

YES > Replace the combination switch.
LO-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
1. INSPECT COMBINATION SWITCH

(c) Inspect the combination switch according to the value(s)

in the table below.
Specified
Condition Tester Connection
Condition
Set the combination A13 - A11

switch to OFF ≥ 1 MΩ
A3 - A9

switch to LO-beam ＜2Ω
A3 - A9

NO > Replace the combination switch.
04
2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - JUNCTION CONNECTOR)

(c) Disconnect the C055 junction connector.
(d) Measure the resistance according to the value(s) in the 04

table below.

C008 (A9) - C055 (2) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP - COMBINATION SWITCH)

(d) Disconnect the C003 front combination lamp RH

table below.

C008 (A3) - C006 (1)
＜2Ω
C008 (A3) - C003 (1)

YES > Replace the front combination lamp bulb.
HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
1. INSPECT BULB

YES > Replace the front combination lamp LH bulb.
SWITCH)


table below.

C006 (2) - C008 (A12) ＜2Ω

HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM


in the table below.
Specified
Condition

A12 - A9

A12 - A9

04


table below.

C008 (A9) - C055 (2) ＜2Ω



table below.

C008 (A12) - C006 (2)
＜2Ω
C008 (A12) - C003 (2)

YES > Replace front combination lamp bulb.
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE (ONE

SIDE)
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuse (15 A) in body junction box(C035).


YES > Go to step 3.
04
2. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP LH - GROUND)


table below. 04

C006 (3) - Ground ≥ 1 ΜΩ

YES > Replace the fuse.


in the table below.
Specified
Condition
A13 - A11

A13 - A11
A12 - A9

switch to LO-beam A3 - A9
＜2Ω
switch to HI-beam A12 - A9



table below.

C008 (A9) - C055 (2)
＜2Ω
C008 (A11) - C055 (2)

5. CHECK HARNESS AND CONNECTOR (FRONT HEADLAMP LH FUSE - FRONT COMBINATION
LAMP LH)


table below.

Headlamp fuse LH (15 A) - C006 (3) ＜2Ω


SWITCH)


table below.
04
C008 (A3) - C006 (1)
＜2Ω
C008 (A12) - C006 (2)

YES > Replace front combination lamp LH bulb.
ALL HEADLAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the headlamp fuse (30 A) in body junction

box(C035).
(c) Inspect the headlamp fuse LH (15 A) in body junction
box(C035).
(d) Inspect the headlamp fuse RH (15 A) in body junction
box(C035).

YES > Go to step 4.
NO > If the headlamp fuse (30 A) is blown, go to next step.
If the headlamp fuse LH or headlamp fuse RH is bolwn, go to step 3. 04
2. CHECK HARNESS AND CONNECTOR (HEADLAMP RELAY - GROUND)

(b) Remove the headlamp relay.
(c) Measure the resistance according to the value(s) in the 04

table below.

Headlamp relay (2) - Ground
≥ 1 ΜΩ
Headlamp relay (5) - Ground

3. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP - GROUND)

(c) Disconnect the C003 front combination lamp RH

table below.

C006 (3) - Ground
≥ 1 ΜΩ
C003 (3) - Ground

4. INSPECT HEADLAMP RELAY

(c) Inspect headlamp relay according to the value(s) in the

table below.

1–2 Continuity
＜2Ω
3–5 (Apply battery voltage to
terminals 1 and 2)

NO > Replace the headlamp relay.
5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - GROUND)


table below.

C008 (A9) - Ground
＜2Ω
C008 (A11) - Ground

YES > Go to step 8.

(b) Disconnect the C008 combination switch (light control) connector. 04

table below.
C008 (A11) - C055 (2)

＜2Ω
C008 (A9) - C055 (2)

7. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - GROUND)


table below.

C055 (1) - Ground ＜2Ω

YES > Replace the junction connector。
8. CHECK HARNESS AND CONNECTOR (HEADLAMP RELAY - COMBINATION SWITCH)

(c) Disconnect the C008 combination switch (light control) connector.

table below.

Headlamp relay (1) - C008 (A13)
＜2Ω

9. CHECK HARNESS AND CONNECTOR (HEADLAMP FUSE - FRONT COMBINATION LAMP)

(c) Disconnect the C003 front combination lamp RH.

table below.

Headlamp fuse LH (15 A) - C006 (3 )
＜2Ω
Headlamp fuse RH (15 A) - C003 (3 )

FRONT FOG LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FRONT FOG LAMP SWITCH

(b) Disconnect the C036 front fog lamp switch connector.
(c) Inspect front fog lamp switch according to the value(s) in

the table below.
Tester Specified
Condition
Connection Condition
Press front fog lamp switch 1-4 ＜2Ω
Release front fog lamp switch 1-4 ≥ 1 MΩ


NO > Replace the front fog lamp switch.
2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP - GROUND)

(b) Disconnect the C004 front fog lamp LH connector.
(d) Press the parking lamp switch.
(e) Press the front fog lamp switch.

table below.
Standard voltage

C004 (1) - Ground Battery voltage

NO > Go to step 5.

(c) Disconnect the C001 front fog lamp RH connector.

table below.

C004 (2) - Ground
＜2Ω
C001 (2) - Ground

4. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

(b) Remove the fog lamp relay. 04
(c) Disconnect the C004 front fog lamp LH connector.
(d) Disconnect the C001 front fog lamp RH connector.

table below.
Standard resistance (check for open) 04
Fog lamp relay (3) - C004 (1)
＜2Ω

YES > Replace the front fog lamp switch.
5. CHECK HARNESS AND CONNECTOR (FOG LAMP RELAY - FRONT FOG LAMP SWITCH)

(b) Remove the fog lamp relay.
(c) Disconnect the C036 front fog lamp switch connector.
table below.

Front fog lamp relay (1) - C036 (1) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP SWITCH - JUNCTION CONNECTOR)


table below.

C036 (4) - C055 (6) ＜2Ω



table below.

C055 (1) - Ground ＜2Ω

YES > Replace the junction connector.
FRONT FOG LAMPS ARE ALWAYS ON

WIRING DIAGRAM
04
04


the table below.
Tester Specified
Condition


2. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP SWITCH - GROUND)


table below.

C036 (1) - Ground ≥ 1 MΩ


(e) Connect the battery negative cable.
(f) Press the parking lamp switch.
(g) Measure the voltage according to the value(s) in the

table below.
Standard voltage

C004 (1) - Ground
0V
C001 (1) - Ground

YES > Replace the fog lamp relay.
REAR FOG LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT REAR FOG LAMP SWITCH

(b) Disconnect the C037 rear fog lamp switch connector.

the table below.
Tester Specified
Condition
Press rear fog lamp switch 1-4 ＜2Ω
Release rear fog lamp switch 1-4 ≥ 1 MΩ


2. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP - GROUND)

(b) Disconnect the J002 rear fog lamp LH connector.
(c) Disconnect the J001 rear fog lamp RH connector.
(d) Connect the battery negative cable.
(e) Press the parking lamp switch.
(f) Press the front fog lamp switch.
(g) Press the rear fog lamp switch.
(h) Measure the voltage according to the value(s) in the

table below.
Standard voltage

J002 (2) - Ground
Battery voltage
J001 (2) - Ground

NO > Go to step 4.


table below.

J002 (1) - Ground
＜2Ω
J001 (1) - Ground

YES > Replace the rear fog lamp bulb.
4. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP SWITCH - REAR FOG LAMP)

(b) Disconnect the C037 rear fog lamp switch connector. 04
(c) Disconnect the J002 rear fog lamp LH connector.
(d) Disconnect the J001 rear fog lamp RH connector.

table below.
C037 (4) - J002 (2)
＜2Ω
C037 (4) - J001 (2)

5. CHECK HARNESS AND CONNECTOR (FOG LAMP RELAY - REAR FOG LAMP SWITCH)

(c) Disconnect the C037 rear fog lamp switch connector.

table below.

Fog lamp relay (3) - C037 (1) ＜2Ω

YES > Replace the front fog lamp relay.
REAR FOG LAMPS ARE ALWAYS ON

WIRING DIAGRAM


the table below.
Tester Specified
Condition


04

(d) Connect the battery negative cable. 04

table below.
Standard voltage

J002 (2) - Ground
0V
J001 (2) - Ground

ALL FOG LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the tail fuse (15 A) in body junction box(C035).

(c) Inspect the front fog lamp fuse (15 A) in body junction
box(C035).
04

2. INSPECT TAIL LIGHT RELAY

(b) Remove the tail relay and fog lamp relay.
(c) Inspect the relay according to the value(s) in the table

below.

1–2 Continuity
＜2Ω
terminals 1 and 2)

NO > Replace the relay.


the table below.
Tester Specified
Condition

4. CHECK HARNESS AND CONNECTOR (FOG LAMP RELAY - FRONT FOG LAMP)


table below.

Front fog lamp relay (3) - C004 (1)
＜2Ω
Front fog lamp relay (3) - C001 (1)

5. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP SWITCH)


table below.



table below.

C036 (4) - Ground ＜2Ω

YES > Go to step 8.


table below.

C036 (4) - C055 (6) ＜2Ω



table below.

C008 (A11) - Ground ＜2Ω



table below.

C008 (A11) - C055 (2) ＜2Ω

04


table below. 04

C055 (1) - Ground ＜2Ω

11. CHECK HARNESS AND CONNECTOR (TAIL LIGHT RELAY - COMBINATION SWITCH)

(b) Remove tail light relay.

table below.

Tail light relay (1) - C008 (A2) ＜2Ω

HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL

LAMPS ARE NORMAL)
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the hazard &horn fuse (15 A) in body junction

box(C035).
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - GROUND)

(b) Disconnect the C015 hazard switch connector.

table below.

C015 (8) - Ground ≥ 1 ΜΩ

3. INSPECT HAZARD SWITCH

(c) Inspect the hazard switch according to the value(s) in the

table below.
Tester Specified
Condition
Release the hazard switch 7 - 10
7-8 ＜2Ω
Press the the hazard switch
5-6-9

NO > Replace the hazard switch.
4. CHECK HARNESS AND CONNECTOR (HAZARD & HORN FUSE - HAZARD SWITCH)


table below.

Hazard & horn fuse (15 A) - C015 (8) ＜2Ω

YES > Go to step 7.
5. CHECK HARNESS AND CONNECTOR (HAZARD & HORN FUSE - JUNCTION CONNECTOR)

(b) Disconnect the C051 junction connector. 04
table below.

04
Hazard & horn fuse (15 A) - C051(14) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - HAZARD SWITCH)

(c) Disconnect the C015 hazard switch connector.

table below.

C051 (7) - C015 (8) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - TURN SIGNAL FLASHER RELAY)

(b) Disconnect the C042 turn signal flasher relay connector.

table below.

C042 (1) - C015 (9) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - INSTRUMENT CLUSTER)

(b) Disconnect the C011 instrument cluster connector.
(c) Disconnect the C013 instrument cluster connector.
(d) Disconnect the C015 hazard switch connector.

table below.

C015 (5) - C011 (A7)
＜2Ω
C015 (6) - C013 (C10)

9. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - JUNCTION CONNECTOR)

(b) Disconnect the C015 hazard switch connector. 04

table below.
C015 (5) - C054 (6)

＜2Ω
C015 (6) - C054 (14)

YES > Replace the turn signal flasher relay.
TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD WARNING

LAMPS ARE NORMAL)
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the turn signal fuse (10 A) in body junction

box(C035).
04

YES > Go to step 3.


table below.

C015 (10) - Ground ≥ 1 ΜΩ



table below.
Tester Specified
Condition
7-8 ＜2Ω
5-6-9



in the table below.
Specified
Condition
Turn combination A1 - A5
switch OFF ≥ 1 MΩ
A1 - A8
Set combination
A1 - A5
switch to LEFT
＜2Ω
Set combination
A1 - A8
switch to RIGHT

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD SWITCH)

table below.

04
Turn signal fuse (10 A) - C015 (10) ＜2Ω

YES > Go to step 8.
6. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - JUNCTION CONNECTOR)


table below.

Turn signal fuse (10 A) - C051(2) ＜2Ω



table below.

C051 (8) - C015 (10) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FLASHER RELAY - COMBINATION
SWITCH)

(c) Disconnect the C008 combination switch connector.

table below.

C042 (1) - C008 (A1) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT COMBINATION LAMP

LH)

(b) Disconnect the C008 combination switch connector.

table below.
04
C008 (A5) - C005 (1)
＜2Ω
C008 (A5) - C005 (3)



table below.

C008 (A5) - C054 (5)
＜2Ω
C008 (A8) - C054 (7)

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the hazard &horn fuse (15 A) in body junction

box(C035).
(c) Inspect the turn signal fuse (10 A) in body junction
box(C035).
04

YES > Go to step 4.
NO > If the hazard & horn fuse is blown, go to next step.
If the turn signal fuse is blown, go to step 3.


table below.

C015 (8) - Ground ≥ 1 ΜΩ



table below.

C015 (10) - Ground ≥ 1 ΜΩ



table below.
Tester Specified
Condition
7-8 ＜2Ω
5-6-9

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FLASHER RELAY - GROUND)

(c) Disconnect the C042 turn signal flasher relay connector.

table below.
C042 (3) - Ground ＜2Ω



table below.

C015 (7) - C042 (2)
＜2Ω
C015 (9) - C042 (1)


SWITCH)


table below.

C008 (A1) - C042 (1) ＜2Ω

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04


in the table below.
Specified
Condition
A1 - A8
Set combination
A1 - A5
switch to LEFT
＜2Ω
Set combination
A1 - A8
switch to RIGHT

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - COMBINATION LAMP)


table below.

C008 (A5) - C005 (1)
＜2Ω
C008 (A5) - C005 (3)


(b) Disconnect the C008 combination switch connector. 04

table below.
C008 (A5) - C054 (5) ＜2Ω

HAZARD WARNING LAMPS ARE ALWAYS ON

WIRING DIAGRAM


table below.
Tester Specified 04
Condition
7-8 ＜2Ω
Press the hazard switch
5-6-9



table below.
Standard voltage




table below.
Standard voltage


STOP LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the stop lamp fuse (15 A) in body junction

box(C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - GROUND)

(b) Disconnect the C044 stop lamp switch connector.

table below.

C044 (1) - Ground ≥ 1 ΜΩ

3. INSPECT STOP LAMP SWITCH

(c) Inspect the stop lamp switch according to the value(s) in

the table below.
Tester Specified
Condition
Release stop lamp switch 1-2 ≥ 1 MΩ
Press stop lamp switch 1-2 ＜2Ω

NO > Replace stop lamp switch.
4. CHECK HARNESS AND CONNECTOR (STOP LAMP FUSE - STOP LAMP SWITCH)

(b) Disconnect the C044 stop lamp switch connector. 04
table below.

04
Stop lamp fuse (15 A) - C044(1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)

(c) Disconnect the F002 rear combination lamp LH connector.
(d) Disconnect the F001 rear combination lamp RH connector.

table below.

C044 (2) - F002 (3)
＜2Ω
C044 (2) - F001 (3)

YES > Replace the stop lamp bulb.
STOP LAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP - GROUND)

(b) Disconnect the F002 rear combination lamp LH connector.

table below.

F002 (4) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP)


table below.
C044 (2) - F002 (3) ＜2Ω

HIGH-MOUNTED STOP LAMP IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (HIGH-MOUNTED STOP LAMP - GROUND)

(b) Disconnect the J006 high-mounted stop lamp connector.

table below.
04
J006 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH-MOUNTED STOP LAMP)

(c) Disconnect the J006 high-mounted stop lamp connector.

table below.

C044 (2) - J006 (1) ＜2Ω

YES > Replace the high-mounted stop lamp bulb.
BACK-UP LAMP IS INOPERATIVE(ONE SIDE)

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP - GROUND)

(b) Disconnect the J004 rear combination lamp RH connector.

table below.
04
J004 (1) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - BACK-UP LAMP)

(b) Disconnect the G001 back-up lamp switch connector.
(c) Disconnect the J004 rear combination lamp RH connector.

table below.

G001 (1) - J004 (2) ＜2Ω

YES > Replace the back-up lamp bulb.
BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the instrument cluster fuse (15 A) in body

junction box(C035).
04

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - GROUND)


table below.

G001 (2) - Ground ≥ 1 ΜΩ

3. INSPECT BACK-UP LAMP SWITCH

(c) Inspect the back-up lamp switch according to the

Tester Specified
Condition
Release back-up
1-2 ≥ 1 MΩ
lamp switch
Press back-up
1-2 ＜2Ω
lamp switch

NO > Replace the back-up lamp switch.
4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER FUSE - BACK-UP LAMP
SWITCH)


table below.

Instrument cluster fuse (7.5 A) - G001(2) ＜2Ω

YES > Go to step 7.
5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER FUSE - JUNCTION

CONNECTOR)


table below.
Instrument cluster fuse(7.5 A) - C050(12) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - BACK-UP LAMP SWITCH)


table below.

C050 (13) - G001 (2) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REAR COMBINATION LAMP
RH)

(c) Disconnect the J004 rear combination lamp LH connector.
(d) Disconnect the J005 rear combination lamp RH connector.

table below.

G001 (1) - J004 (2)
＜2Ω
G001 (1) - J005 (2)

FRONT DOME LIGHT IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FRONT DOME LIGHT

(b) Disconnect the F003 front dome light connector.
(c) Replace the front dome light with a new one.
(e) Turn the front dome light switch ON.
YES > Replace the front dome light.
2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT DOME LIGHT)


table below.

C050 (1) - F003 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (FRONT DOME LIGHT - INSTRUMENT CLUSTER)


table below.

F003 (2) - C014 (D3) ＜2Ω

4. INSPECT INSTRUMENT CLUSTER

table below.

04
D3 - D4
＜2Ω
D3 - D5

NO > Replace instrument cluster.
5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FRONT DOOR AJAR SWITCH)

(c) Disconnect the A008 front door ajar switch LH connector.
(d) Disconnect the A004 front door ajar switch RH connector.

table below.

C014 (D4) - A004 (1)
＜2Ω
C014 (D5) - A008 (1)

YES > Replace the door ajar switch.
REAR DOME LIGHT IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT REAR DOME LIGHT

(b) Replace rear dome light with a new one.
YES > Replace rear dome light.
2. INSPECT REAR DOME LIGHT SWITCH

(b) Disconnect the F004 rear dome light switch connector.\
(c) Inspect the rear dome switch according to the value(s) in
the table below.
Specified
Condition
Release dome light switch 1-4 ≥ 1 MΩ
Press dome light switch 1-4 ＜2Ω

NO > Replace the rear dome light switch.
3. INSPECT DOOR AJAR SWITCH

(b) Replace sliding door ajar switch RH with a new one. 04
YES > Replace sliding door ajar switch.
4. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR DOME LIGHT)
04
(b) Disconnect the F004 rear dome light switch connector.

table below.

C050 (1) - F004 (1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (REAR DOME LIGHT - INSTRUMENT CLUSTER)


table below.

F004 (2) - C014 (D10) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - REAR DOME LIGHT SWITCH)

(c) Disconnect the C033 rear dome light switch connector.

table below.

C014 (D9) - C033 (1) ＜2Ω

7. CHECK HARNESS AND CONNECTOR( REAR DOME LIGHT SWITCH - GROUND)

(b) Disconnect the C033 rear dome light switch connector.

table below.

C033 (4) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SLIDING DOOR AJAR SWITCH
RH)

(b) Disconnect the F005 sliding door ajar switch RH connector.

table below.
04
C014 (D8) - F005 (1) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - REAR HATCH AJAR SWITCH)

(b) Disconnect the F005 rear hatch ajar switchconnector.

table below.

C014 (D7) - J008 (1) ＜2Ω

YES > Replace the instrument cluster.
STEP LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT STEP LAMP

(b) Disconnect the M001 step lamp LH connector.
(c) Replace step lamp LH with a new one.
Does step lamp work correctly?
YES > Replace step lamp LH.
2. INSPECT SLIDING DOOR AJAR SWITCH

(b) Disconnect the F005 sliding door ajar switch RH connector. 04
(c) Replace sliding door ajar switch RH with a new one.
YES > Replace sliding door ajar switch RH.
3. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - STEP LAMP) 04

(c) Disconnect the M001 step lamp LH connector.
(d) Disconnect the N001 step lamp RH connector.

table below.

C050 (1) - M001 (1)
＜2Ω
C050 (1) - N001 (1)

4. CHECK HARNESS AND CONNECTOR (STEP LAMP - INSTRUMENT CLUSTER)

(b) Disconnect the M001 step lamp connector.
(c) Disconnect the N001 step lamp RH connector.
(d) Disconnect the C014 instrument cluster connector.

table below.

M001 (2) - C014 (D10)
＜2Ω
N001 (2) - C014 (D10)

5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - DOOR AJAR SWITCH)

(c) Disconnect the F005 sliding door ajar switch RH connector.
(d) Disconnect the J008 rear hatch ajar switchconnector.

table below.

C014 (D7) - J008 (1)
＜2Ω
C014 (D8) - F005 (1)

YES > Replace Instrument Cluster.
ILLUMINATED SYSTEM IS NOT INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the tail fuse (15 A) in body junction box(C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR ( JUNCTION CONNECTOR - GROUND)


table below.

C053 (1) - Ground ≥ 1 ΜΩ


(b) Remove the tail light relay. 04
(c) Inspect the tail light relay according to the value(s) in the
table below.

04
1–2 Continuity
＜2Ω
terminals 1 and 2)

NO > Replace the tail light relay.
4. CHECK HARNESS AND CONNECTOR (TAIL FUSE - JUNCTION CONNECTOR)


table below.

Tail fuse (15 A) - C053 (1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR ( JUNCTION CONNECTOR - GROUND)


table below.

C055 (1) - Ground ＜2Ω



table below.

C008 (A11) - C055 (2) ＜2Ω


(c) Remove the tail light relay.

table below.

INSTRUMENT CLUSTER ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - JUNCTION CONNECTOR)


table below.

C014 (D2) - C055 (3) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - INSTRUMENT CLUSTER)


table below.
C053 (6) - C014 (D1) ＜2Ω

YES > Replace the Instrument cluster.
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY - GROUND)

(b) Disconnect the P002 combined display.

table below.
04
P002 (10) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - COMBINED DISPLAY)


table below.

C053 (2) - P002 (11) ＜2Ω

YES > Replace the combined display.
CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - JUNCTION CONNECTOR)

(b) Disconnect the C024 cigarette lighter connector.

table below.

C055 (5) - C024 (2) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (CIGARETTE LIGHTER - JUNCTION CONNECTOR)

(b) Disconnect the C024 cigarette lighter connector.

table below.

C024 (1) - C053 (6) ＜2Ω

YES > Replace the cigarette lighter.
FRONT A/C SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (FRONT A/C SWITCH - JUNCTION CONNECTOR)


table below.

C017 (1) - C055 (5) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT A/C SWITCH)


table below.

C053 (3) - C017 (3) ＜2Ω

YES > Replace the front a/c switch.
BLOWER SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - JUNCTION CONNECTOR)


table below.

C016 (3) - C055 (5) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - BLOWER SWITCH)


table below.

C053 (3) - C016 (4) ＜2Ω

AUDIO ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR(AUDIO - GROUND)

(b) Disconnect the C021 audio connector.

table below.
04
C021 (7) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR(junction connector -AUDIO)

(b) Disconnect the C021 audio connector.

table below.

C053 (4) - C021 (10) ＜2Ω

YES > Replace the audio.
HAZARD SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM


table below.

C015 (3) - C055 (4) ＜2Ω



table below.

C053 (5) - C015 (2) ＜2Ω

YES > Replace the hazard switch.
FRONT PARKING LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (FRONT PARKING LAMP - GROUND)

(c) Disconnect the C002 front combination lamp RH connector.

table below.

C005 (5) - Ground
＜2Ω
C002 (5) - Ground

2. CHECK HARNESS AND CONNECTOR(junction connector - FRONT PARKING LAMP)

(d) Disconnect the C002 front combination lamp RH connector.

table below.

C053 (5) - C005 (2)
＜2Ω
C053 (2) - C002 (2)

TAIL LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
(c) Disconnect the F001 rear combination lamp RH connector.

table below.

F002 (4) - Ground
＜2Ω
F001 (4) - Ground

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR COMBINATION LAMP)


table below.

C053 (2) - F002 (2)
＜2Ω
C053 (2) - F001 (2)

YES > Replace the tail lamp bulb.
LICENSE LAMP IS INOPERATIVE

WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND)

(b) Disconnect the J003 license lamp connector.

table below.
04
J003 (1) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - LICENSE LAMP)


table below.

C053 (2) - J003 (2) ＜2Ω

YES > Replace the license lamp.
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP ARE

INOPERATIVE
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the tail lamp fuse (15 A) in body junction box
(C035).
04

YES > Go to step 3.


table below.

C053 (1) - Ground ≥ 1 ΜΩ


(b) Remove the tail light relay.

below.

1–2 Continuity
＜2Ω
terminals 1 and 2)

NO > Replace the tail light relay.
4. CHECK HARNESS AND CONNECTOR (TAIL FUSE - JUNCTION CONNECTOR)


table below.

Tail fuse (15 A) - C053 (1) ＜2Ω

5. INSPECT JUNCTION CONNECTOR

04
table below.

1-5 04
＜2Ω
1-2

NO > Replace the junction connector.


table below.

C008 (A11) - C055 (2) ＜2Ω



table below.

C055 (1) - Ground ＜2Ω



table below.


PROBLEM SYMPTOMS TABLE - EARLY PRODUCTION

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the
1. Headlamp 04

Chapter 64 lighting - front combination lamp bulb
LO-beam headlamp is inoper- 1. Bulb LH, replacement
ative (One side)
2. Wire harness - 04
2. Relay -
LO-beam headlamps are
inoperative (Both sides) -
3. Wire harness


HI-beam headlamp is 1. Bulb LH, replacement
2. Wire harness -
1. Relay -
HI-beam headlamps are Chapter 51 steering column - combination switch

inoperative (Both sides) 2. Combination switch assy, replacement
3. Wire harness -

LO-beam and HI-beam
headlamps are inoperative Chapter 64 lighting - front combination lamp bulb
(One side)
3. Wire harness -
1. Relay -
LO-beam and HI-beam
headlamps are inoperative 2. Combination switch assy, replacement
(Both sides)
3. Wire harness -
2. Fog lamp
1. Bulb -

Front fog lamps are inoperative 2. Combination switch assy, replacement
3. Wire harness -

Front fog lamps are always on -
2. Front fog lamp relay
3. Wire harness -

Rear fog lamps are inoperative Chapter 64 lighting - rear fog lamp switch,
3. Wire harness -
Chapter 64 lighting - rear fog lamp switch,

Rear fog lamps are always on
2. Wire harness -
1. Fuse -
2. Relay -
3. Front fog lamp switch -

All fog lamps are inoperative
5. Wire harness -
3. Turn signal and hazard warning lamp
1. Fuse -
Hazard warning lamps are
Chapter 83 instrument panel - instrument
inoperative (Turn signal lamps are 2. Hazard switch cluster, replacement
normal)
3. Wire harness -
1. Fuse -
Turn signal lamps are inoperative Chapter 51 steering column - combination

(Hazard warning lamps are normal) 2. Combination switch switch assy, replacement
3. Wire harness -
Chapter 51 steering column - combination

Hazard warning and turn signal 1. Combination switch switch assy, replacement
lamps are inoperative
2. Wire harness -
1. Combination switch (light Chapter 51 steering column - combination

Turn signal lamps are inoperative control) switch assy, replacement
(One side)
2. Wire harness -

1. Hazard switch cluster, replacement
04
Hazard warning lamps are always Chapter 51 steering column - combination
on 2. Combination switch switch assy, replacement
3. Wire harness -
4. Stop lamp
04
1. Fuse -
Chapter 35 brake - brake pedal,

Stop lamps are inoperative (Both sides) 2. Stop lamp switch replacement
3. Wire harness -

Stop lamp is inoperative (One side)
2. Wire harness -
Chapter 88 exterior and interior trim -

1. Bulb spoiler assy, replacement
High-mounted stop lamp is inoperative
2. Wire harness -
5. Buck-up lamp

Back-up lamp is inoperative (One side)
2. Wire harness -
1. Fuse -
Chapter 41 transmission - input shaft and

2. Back-up lamp switch reverse idler gear shaft, replacement
Back-up lamps are inoperative (Both
sides) Chapter 64 lighting - rear combination
4. Wire harness -
6. Interior lamp

Chapter 64 lighting - front indoor lamp assy,
1. Bulb replacement
Front dome lamp is inoperative Chapter 64 lighting - front indoor lamp assy,
2. Front dome lamp switch replacement
3. Wire harness -

Chapter 64 lighting - rear indoor lamp assy,
1. Bulb replacement
Rear dome lamp is inoperative Chapter 64 lighting - rear indoor lamp assy,
2. Rear dome lamp switch replacement
3. Wire harness -
Chapter 64 lighting - Sliding door step lamp,

1. Front door ajar switch replacement
Sliding door step lamps are Chapter 64 lighting - Sliding door step lamp,
inoperative 2. Bulb replacement
3. Wire harness -
7. Interior illumination system
1. Fuse -
Illuminated system is not
inoperative -
2. Wire harness

Instrument cluster illumination is 1. Instrument cluster cluster, replacement
inoperative
2. Wire harness -
Chapter 83 instrument panel - dashboard,

Combined display illumination is 1. Combined display replacement
inoperative
2. Wire harness -
Front A/C switch illumination is 1. Front A/C switch

inoperative
2. Wire harness

Blower switch illumination is 1. Electronic clock replacement
inoperative
2. Wire harness -

1. Radio replacement
Radio illumination is inoperative
2. Wire harness -
8. Parking lamp, tail lamp and license lamp

Chapter 64 lighting - front combination 04
1. Bulb
Front parking lamps are inoperative lamp bulb LH, replacement
2. Wire harness -

1. Bulb
Tail lamps are inoperative lamp bulb LH, replacement
04
2. Wire harness -
1. Fuse -
2. Relay -
License lamp is inoperative Chapter 51 steering column -
(light control) combination switch assy, replacement
4. Wire harness -
1. Fuse -
2. Relay -
Parking lamps, tail lamps and
license lamp are inoperative 3. Combination switch Chapter 51 steering column -
(light control) combination switch assy, replacement
4. Wire harness -
LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
1. INSPECT BULB

YES > Replace the front combination lamp LH bulb.
SWITCH)


table below.

C006 (1) - C008 (A3) ＜2Ω


WIRING DIAGRAM


in the table below.
Specified
Condition

A3 - A9

A3 - A9

04


table below.

C008 (A9) - C068 (3) ＜2Ω



table below.

C068 (1) - Ground ＜2Ω



table below.

C008 (A3) - C006 (1)
＜2Ω
C008 (A3) - C003 (1)

HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04
1. INSPECT BULB

(c) Replace the front combination lamp bulb with a new one.
SWITCH)


table below.

C006 (2) - C008 (A12) ＜2Ω

HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04


in the table below.
Specified
Condition

A3 - A9

A3 - A9



table below.

C008 (A9) - C068 (3) ＜2Ω



table below.

C068 (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR ( FRONT COMBINATION LAMP - COMBINATION SWITCH)


table below.
C008 (A12) - C006 (2)
＜2Ω
C008 (A12) - C003 (2)

LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE (ONE

SIDE)
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the fuse (15 A) in body junction box (C035).


YES > Go to step 3.
04


table below. 04

C006 (3) - Ground ≥ 1 ΜΩ



in the table below.
Specified
Condition
A13 - A11
Set the A3 - A9
combination ≥ 1 MΩ
switch to OFF A13 - A11
A12 - A9
Set the A13 - A11

combination
switch to A3 - A9
LO-beam
＜2Ω
Set the A13 - A11
combination
switch to A12 - A9
HI-beam



table below.

C008 (A9) - C068 (3)
＜2Ω
C008 (A11) - C067 (2)



table below.

C067 (1) - Ground
＜2Ω
C068 (1) - Ground

6. CHECK HARNESS AND CONNECTOR (FRONT HEADLAMP LH FUSE - FRONT COMBINATION

LAMP LH)


table below.
Headlamp fuse LH (15 A) - C006 (3) ＜2Ω

SWITCH)


table below.

C008 (A3) - C006 (1)
＜2Ω
C008 (A12) - C006 (2)

ALL HEADLAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the headlamp fuse ( 15 A) LH in body junction

box(C035).
(c) Inspect the headlamp fuse (15 A) RH in body junction
box(C035).

YES > Go to step 3.
NO > If the headlamp fuse is blown, go to next step.
04
2. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP - GROUND)


table below.

C006 (3) - Ground
≥ 1 ΜΩ
C003 (3) - Ground

3. INSPECT HEADLAMP RELAY

(c) Inspect headlamp relay according to the value(s) in the

table below.

1–2 Continuity
＜2Ω
terminals 1 and 2)

NO > Replace the headlamp relay.


table below.

C008 (A9) - Ground
＜2Ω
C008 (A11) - Ground

YES > Go to step 8.

(d) Disconnect the C068 junction connector.

table below.

C008 (A11) - C067 (2)
＜2Ω
C008 (A9) - C068 (3)



table below.
C067 (1) - Ground

＜2Ω
C068 (1) - Ground

7. CHECK HARNESS AND CONNECTOR (HEADLAMP RELAY. - COMBINATION SWITCH)


table below.

＜2Ω

8. CHECK HARNESS AND CONNECTOR (HEADLAMP FUSE - FRONT COMBINATION LAMP)


table below.

Headlamp fuse LH (15 A) - C006 (3 )
＜2Ω
Headlamp fuse RH (15 A) - C003 (3 )

FRONT FOG LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04


the table below.
Tester Specified
Condition



(e) Press the front fog lamp switch.

table below.
Standard voltage


NO > Go to step 5.

(c) Disconnect the C001 front fog lamp RH connector.

table below.

C004 (2) - Ground
＜2Ω
C001 (2) - Ground

4. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP)

table below.
04
＜2Ω

YES > Replace the front fog lamp switch.
5. CHECK HARNESS AND CONNECTOR (FRONT FOG LAMP RELAY - FRONT FOG LAMP
SWITCH)

table below.

Front fog lamp relay (1) - C036 (1) ＜2Ω



table below.

C036 (4) - C067 (5) ＜2Ω



table below.

C067 (1) - Ground ＜2Ω

FRONT FOG LAMPS ARE ALWAYS ON

WIRING DIAGRAM
04
04


the table below.
Tester Specified
Condition




table below.

C036 (1) - Ground ≥ 1 MΩ


(e) Connect the battery negative cable.
(f) Press the parking lamp switch.
(g) Measure the voltage according to the value(s) in the

table below.
Standard voltage

C004 (1) - Ground
0V
C001 (1) - Ground

YES > Replace the fog lamp relay.

WIRING DIAGRAM
04
04


the table below.
Tester Specified
Condition



(b) Disconnect the F011 rear fog lamp LH connector.
(c) Disconnect the F010 rear fog lamp RH connector.
(f) Press the front fog lamp switch.
(g) Press the rear fog lamp switch.
(h) Measure the voltage according to the value(s) in the

table below.
Standard voltage

F011 (2) - Ground
Battery voltage
F010 (2) - Ground

NO > Go to step 4.


table below.

F011 (6) - Ground
＜2Ω
F010 (6) - Ground

YES > Replace the rear fog lamp bulb.
4. CHECK HARNESS AND CONNECTOR (REAR FOG LAMP SWITCH - REAR FOG LAMP)

(b) Disconnect the C001 rear fog lamp switch connector. 04
(c) Disconnect the F011 rear fog lamp LH connector.
(d) Disconnect the F010 rear fog lamp RH connector.

table below.
C037 (4) - F011 (2)
＜2Ω
C037 (4) - F010 (2)

5. CHECK HARNESS AND CONNECTOR (FOG LAMP RELAY - REAR FOG LAMP SWITCH)

(c) Disconnect the C037 rear fog lamp switch connector.

table below.

Rear fog lamp switch (3) - C037 (1) ＜2Ω


WIRING DIAGRAM


the table below.
Tester Specified 04
Condition



table below.
Standard voltage

F011 (2) - Ground
0V
F010 (2) - Ground

ALL FOG LAMPS ARE INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the tail fuse (15 A) in body junction box (C035).
(c) Inspect the fog lamp fuse (15 A) in body junction box
(C035).
04


(b) Remove the tail relay and fog lamp relay.

below.

1–2 Continuity
＜2Ω
terminals 1 and 2)



the table below.
Tester Specified
Condition

4. CHECK HARNESS AND CONNECTOR ( FOG LAMP RELAY - FRONT FOG LAMP)


table below.

＜2Ω

5. CHECK HARNESS AND CONNECTOR(FOG LAMP RELAY - FRONT FOG LAMP SWITCH)


table below.



table below.

C036 (4) - Ground ＜2Ω

YES > Go to step 8.


table below.

C036 (4) - C067 (5) ＜2Ω



table below.

C008 (A11) - Ground ＜2Ω



table below.
C008(A11) - C067(2) ＜2Ω



table below.

C067(1) - Ground ＜2Ω



table below.


HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL

LAMPS ARE NORMAL)
WIRING DIAGRAM 04
04
1. INSPECT FUSE
(b) Inspect the hazard & horn fuse ()15 A in body junction box
(C035).

YES > Go to step 3.


table below.

C015 (8) - Ground ≥ 1 ΜΩ


table below.
Tester Specified
Condition
04
7-8 ＜2Ω
5-6-9

4. CHECK HARNESS AND CONNECTOR (HAZARD & HORN FUSE - HAZARD SWITCH)


table below.

Hazard & horn fuse (15 A) - C015 (8) ＜2Ω



table below.

C042 (2) - C015 (9) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (HAZARD SWITCH - REAR COMBINATION LAMP)

(d) Disconnect the F011 rear combination lamp LH connector.

table below.

C015 (5) - F011 (4)
＜2Ω
C015 (6) - F010 (4)

TURN SIGNAL LAMPS ARE INOPERATIVE (HAZARD WARNING

LAMPS ARE NORMAL)
WIRING DIAGRAM 04
04
1. INSPECT FUSE
(b) Inspect the turn signal fuse (10 A) in body junction box (C035).

YES > Go to step 3.


table below.

C015 (10) - Ground ≥ 1 ΜΩ


table below.
Tester Specified
Condition
04
7-8 ＜2Ω
5-6-9



in the table below.
Specified
Condition
A1 - A8
Set combination
A1 - A5
switch to LEFT
＜2Ω
Set combination
A1 - A8
switch to RIGHT

5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - HAZARD SWITCH)


table below.


YES > Go to step 8.


table below.




table below.
C069 (12) - C015 (10) ＜2Ω

SWITCH)


table below.

C042 (2) - C008 (A1) ＜2Ω


LH)


table below.

C008 (A5) - C005 (1)
＜2Ω
C008 (A5) - C005 (3)

RH)


table below.

C008 (A8) - C002 (1)
＜2Ω
C008 (A8) - C002 (3)

HAZARD WARNING AND TURN SIGNAL LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the hazard & horn fuse (15 A) in body junction
box (C035).
(c) Inspect the turn signal fuse (10 A) in body junction box
(C035).

YES > Go to step 4.
NO > If the hazard & horn fuse isblown, go to next step.
If the turn signal fuse is blown, go to step 3.


table below.

C015 (8) - Ground ≥ 1 ΜΩ


table below.

04
C015 (10) - Ground ≥ 1 ΜΩ



table below.
Tester Specified
Condition
7-8 ＜2Ω
5-6-9

Replace the hazard switch.
5. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FLASHER RELAY - GROUND)


table below.

C042 (3) - Ground ＜2Ω



table below.

C015 (7) - C042 (2)
＜2Ω
C015 (9) - C042 (1)


SWITCH)


table below.
04
C008 (A1) - C042 (2) ＜2Ω

TURN SIGNAL LAMPS ARE INOPERATIVE (ONE SIDE)

WIRING DIAGRAM


in the table below.
Specified 04
Condition
A1 - A8
Set combination
A1 - A5
switch to LEFT
＜2Ω
Set combination
A1 - A8
switch to RIGHT

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT COMBINATION LAMP)


table below.

C008 (A5) - C005 (1)
＜2Ω
C008 (A5) - C005 (3)

3. CHECK HARNESS AND CONNECTOR (FRONT COMBINATION LAMP LH- GROUND)


table below.

C005 (4) - Ground
＜2Ω
C005 (6) - Ground

HAZARD WARNING LAMPS ARE ALWAYS ON

WIRING DIAGRAM
04
04


table below.
Tester Specified
Condition
7-8 ＜2Ω
Press the hazard switch
5-6-9



table below.
Standard voltage



(b) Disconnect the C042 turn signal flasher relay connector. 04

table below.
Standard voltage 04

STOP LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the stop lamp fuse (15 A) in body junction box
(C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - GROUND)

table below.

04
C044 (1) - Ground ≥ 1 ΜΩ

3. INSPECT STOP LAMP SWITCH

(c) Inspect the stop lamp switch according to the value(s) in

the table below.
Tester Specified
Condition
Release stop lamp switch 1-2 ≥ 1 MΩ
Press stop lamp switch 1-2 ＜2Ω

NO > Replace stop lamp switch.
4. CHECK HARNESS AND CONNECTOR (STOP LAMP FUSE - STOP LAMP SWITCH)


table below.

Stop lamp fuse (15 A) - C044 (1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - STOP LAMP)


table below.

C044 (2) - F011 (3)
＜2Ω
C044 (2) - F010 (3)

STOP LAMP IS INOPERATIVE (ONE SIDE)

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (REAR COMBINATION LAMP LH - GROUND)


table below.

F011 (6) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - REAR COMBINATION LAMP LH)


table below.

C044 (2) - F011 (3) ＜2Ω

HIGH-MOUNTED STOP LAMP IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (HIGH-MOUNTED STOP LAMP - GROUND)

(b) Disconnect the J006 high-mounted stop lamp connector.

table below.

J006 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (STOP LAMP SWITCH - HIGH-MOUNTED STOP LAMP)

(c) Disconnect the J006 high-mounted stop lamp connector.

table below.
Specified
Tester Connection
Condition
C044 (2) - J006(1) ＜2Ω

YES > Replace the high-mounted stop lamp bulb.
BACK-UP LAMP IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP - GROUND)


table below.

F011 (6) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - BACK-UP LAMP)


table below.

G001 (1) - F011 (1) ＜2Ω

BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the turn signal fuse (15 A) in body junction

box(C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - GROUND)


table below.

G001 (2) - Ground ≥ 1 ΜΩ


(b) Disconnect the G001 back-up lamp switch connector. 04
(c) Inspect the back-up lamp switch according to the
Tester Specified
Condition
04
Release back-up lamp switch 1-2 ≥ 1 MΩ
Press back-up lamp switch 1-2 ＜2Ω

4. CHECK HARNESS AND CONNECTOR (TURN SIGNAL FUSE - BACK-UP LAMP SWITCH)


table below.

Turn signal fuse (10 A) - G001 (2) ＜2Ω

YES > Go to step 7.


table below.
Standard resistance (check for open)0


6. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - BACK-UP LAMP SWITCH)


table below.

C069 (6) - G001 (2) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - REAR COMBINATION LAMP)


table below.
G001 (1) - F011 (1)
＜2Ω
G001 (1) - F010 (1)

FRONT DOME LIGHT IS INOPERATIVE

WIRING DIAGRAM

(c) Replace the front dome light with a new one.
(e) Turn the front dome light switch ON.
Is the inspect result normal?
2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT DOME LIGHT)

(b) Disconnect the F003 front dome light connector. 04

table below.
C069 (9) - F003 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (FRONT DOME LIGHT - FRONT DOOR AJAR SWITCH LH)

(c) Disconnect the C051 front door ajar switch LH connector.

table below.

F003 (2) - C051 (1) ＜2Ω

YES > Replace the front door ajar switch LH.

WIRING DIAGRAM

(b) Replace rear dome light with a new one.
YES > Replace rear dome light.

(c) Inspect the rear dome switch according to the value(s) in

the table below.
Specified
Condition Tester Connection 04
Condition
Release dome light switch 1-4 ≥ 1 MΩ
Press dome light switch 1-4 ＜2Ω
04

NO > Replace the rear dome light switch.
3. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR DOME LIGHT)


table below.

C069 (9) - F004 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (REAR DOME LIGHT - REAR DOME LIGHT SWITCH)


table below.

F004 (2) - C044 (1) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (REAR DOME LIGHT SWITCH - JUNCTION CONNECTOR)


table below.

C044 (4) - C067 (5) ＜2Ω



table below.
Specified
Tester Connection
Condition
C067 (1) - Ground ＜2Ω

STEP LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT STEP LAMP

(b) Disconnect the M001 step lamp LH connector.
(c) Replace step lamp RH with a new one.
Does step lamp work correctly?
YES > Replace step lamp RH.
2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - STEP LAMP)

(c) Disconnect the N001 step lamp RH connector.

table below.

C069 (9) - N001 (1) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (STEP LAMP - SLIDING DOOR AJAR SWITCH)

(b) Disconnect the N001 step lamp RH connector.
(c) Disconnect the C090 sliding door ajar switch connector.

table below.

N001 (2) - C090 (1) ＜2Ω

YES > Replace the sliding door ajar switch LH.

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the tail fuse (15 A) in body junction box (C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (FRONT A/C SWITCH - GROUND)


table below.

C017 (3) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (TAIL FUSE - FRONT A/C SWITCH)

(b) Disconnect the C017 front A/C switch connector. 04
table below.

04
Tail fuse (15 A) - C017 (3) ＜2Ω



table below.

C067 (1) - Ground ＜2Ω



table below.

C008 (A11) - C067 (2) ＜2Ω


(c) Remove the tail light relay.

table below.



WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - JUNCTION CONNECTOR)


table below.

C062 (B2) - C067 (6) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - INSTRUMENT CLUSTER)


table below.

Tail fuse (15 A) - C062 (B1) ＜2Ω


WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY - JUNCTION CONNECTOR)


table below.

P002 (10) - C067 (10) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - COMBINED DISPLAY)


table below.

Tail fuse (15 A) - P002 (11) ＜2Ω


WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (FRONT A/C SWITCH - JUNCTION CONNECTOR)


table below.

C017 (1) - C067 (7) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - FRONT A/C SWITCH)


table below.

Tail fuse (15 A) - C017 (3) ＜2Ω

BLOWER SWITCH ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (BLOWER SWITCH - JUNCTION CONNECTOR)


table below.

C016 (3) - C067 (9) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - BLOWER SWITCH)


table below.

Tail fuse (15 A) - C016 (4) ＜2Ω

RADIO ILLUMINATION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (RADIO - JUNCTION CONNECTOR)

(b) Disconnect the C021 radio connector.

table below.

C067 (4) - C021 (7) ＜2Ω

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - RADIO)

(b) Disconnect the C021 radio connector.

table below.

Tail fuse (15 A) - C021 (10) ＜2Ω

YES > Replace the radio.
FRONT PARKING LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (FRONT PARKING LAMP - GROUND)


table below.

C005 (5) - Ground
＜2Ω
C002 (5) - Ground

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - FRONT PARKING LAMP)


table below.

Tail fuse (15 A) - C005 (2)
＜2Ω
Tail fuse (15 A) - C002 (2)

TAIL LAMPS ARE INOPERATIVE

WIRING DIAGRAM
04
04


table below.

F011 (6) - Ground
＜2Ω
F010 (6) - Ground

2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - REAR COMBINATION LAMP)


table below.

Tail fuse (15 A) - F011 (5)
＜2Ω
Tail fuse (15 A) - F010 (5)

YES > Replace the tail lamp bulb.
LICENSE LAMP IS INOPERATIVE

WIRING DIAGRAM
04
04
1. CHECK HARNESS AND CONNECTOR (LICENSE LAMP - GROUND)


table below.

J003 (1) - Ground ＜2Ω

YES > Go step next step.
2. CHECK HARNESS AND CONNECTOR (TAIL FUSE - LICENSE LAMP)


table below.

Tail fuse (15 A) - J003 (2) ＜2Ω

YES > Replace the license lamp.
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE LAMP ARE

INOPERATIVE
WIRING DIAGRAM 04
04
1. INSPECT FUSE
(b) Inspect the tail lamp fuse (15 A) in body junction

box(C035).

YES > Go to step 3.


table below.

C005 (2) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH -JUNCTION CONNECTOR)


table below.

C008 (A11) - C067 (2) ＜2Ω


table below.

04
C067 (1) - Ground ＜2Ω



table below.
Specified
Tester Connection
Condition

04-670 DIAGNOSTICS - WIPER AND WASHER
WIPER AND WASHER

PRECAUTION


Expression
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to
prevent damage to the device or personal injury.
DIAGNOSTICS - WIPER AND WASHER 04-671
LOCATION
04
04
1 Front Wiper Arm Assy LH 4 Front Wiper Blade Assy RH
2 Front Wiper Arm Assy RH 5 Rear Washer Bottle And Pump Assy
3 Front Wiper Blade Assy LH 6 Windshield Washer Bottle And Pump Assy
1 Rear Wiper Arm Assy 3 Instrument Cluster Assy
2 Rear Wiper Blade Assy 4 Wiper And Washer Switch Assy

SYSTEM DESCRIPTION
1. System Description
When ignition switch is ON/ST, the current flows through wiper fuse in body junction box to pin 5 of
junction connector C052. Then system is powered on. 04
2. Front Wiper Switch HI
When the front wiper switch of combination switch is in HI position, the current flows from pin 12 of
junction connector C052 to pin B18 of combination switch, and output from pin B13 of instrument
cluster to pin 1 of front wiper motor. The power grounds at pin 5 of front wiper motor. This enables front
wiper to operate at high speed.
04
3. Front Wiper Switch INT
When the front wiper switch of combination switch is set at INT, the current flows from pin 12 of junction
connector C052 to pin 3 of front INT wiper relay, and output from pin 2 of front INT wiper relay to pin
B12 of combination switch, and output from pin B16 of combination switch to pin 6 of junction connector
C055. The power grounds at pin 1 of junction connector C055.
The current flows output from pin 1 of front INT wiper relay, to pin B4 of combination switch, and output
from pin B7 of combination switch, to pin 2 of front wiper motor, and through wiper motor, the power is
ground at pin 5 of front wiper motor. This enables front wiper to operate in the intermittent mode.
4. Rear Washer Switch INT
When the rear washer switch of combination switch is set at INT, the current flows from pin 7 of junction
connector C052 to pin 3 of rear wiper relay, and output from pin 2 of rear wiper relay to pin B10 of
combination switch, and output from pin B16 of combination switch to pin 6 of junction connector C055,
then ground at pin 1 of junction connector C055.
The current outputs from pin 4 of rear wiper relay to pin 4 of rear wiper motor, and through the rear
wiper motor to ground at pin 2 of rear wiper motor. This enables rear wiper to operate in intermittent
mode.
BASIC INSPECTION
Yes Go to next step
replacement”
Check the wiper motor in HIGH position. Yes Go to next step

• Set the wiper and washer switch in HIGH
2 position.
Does the wiper motor operate in high No Go to problem symptoms table
mode?
Check the wiper motor in LOW position. Yes Go to next step

• Set the wiper and washer switch in LOW
3 position.
Does the wiper motor operate in low No Go to problem symptoms table
mode?
Check the wiper motor in INT position. Yes Check wiper and washer switch
• Set the wiper and washer switch in INT
4 position.
Does the wiper motor operate in No Go to problem symptoms table
intermittent mode?

04
1. Fuse -

2. Wiper and washer switch combination switch, replacement
Wipers are inoperative - windshield
Chapter 65 wiper and washer - 04
3. Windshield wiper motor wiper motor, replacement
4. Wire harness -
Chapter 65 wiper and washer -

Wipers are inoperative at low speed Chapter 51 steering column -
- windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Wipers are inoperative at high Chapter 51 steering column -
speed - windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Wipers are inoperative in Chapter 51 steering column -
intermittent mode - windshield 2. Wiper and washer switch combination switch, replacement
3. Wire harness -

Washer pump is inoperative - Chapter 65 wiper and washer -
windshield 2. Windshield wiper motor wiper motor, replacement
3. Wire harness -

When the wiper and washer switch
is OFF, the wiper blade does not Chapter 51 steering column -
retract
3. Wire harness -

1. Rear window wiper motor wiper motor, replacement
Wiper is inoperative - rear window Chapter 51 steering column -

3. Wire harness -

1. Rear window wiper motor wiper motor, replacement
Wiper is inoperative in intermittent Chapter 51 steering column -
mode - rear window 2. Wiper and washer switch combination switch, replacement
3. Wire harness -
1. Washer pump - rear window -
Washer pump is inoperative - rear Chapter 51 steering column -

window 2. Wiper and washer switch combination switch, replacement
3. Wire harness -
WIPERS ARE INOPERATIVE - WINDSHIELD

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the wipe and washer fuse in body junction box
(C035): 20 A.

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (WINDSHIELD WIPER - GROUND)

(b) Disconnect the C029 front wiper motor connector.

table below.

C029 (4) - Ground ≥ 1 ΜΩ


(b) Disconnect the C009 combination switch (wiper and washer control) connector. 04

table below.
C009 (B16) - C055 (6) ＜2Ω



table below.

C055 (1) - Ground ＜2Ω

5. INSPECT FRONT WIPER MOTOR

(c) Inspect the front wiper motor in LOW mode.
Specified
Condition
Apply battery Battery (+) - 2
Front wiper motor
voltage to
operates at low
terminal 2 and Battery (-) - Ground speed
ground
(d) Inspect the front wiper motor in HIGH mode.
Specified
Condition
Apply battery Battery (+) - 1
Front wiper motor
voltage to
operates at high
terminal 1 and Battery (-) - Ground speed
ground

NO > Replace front wiper motor.

(b) Disconnect the C009 combination switch (wiper and washer control) connector.
(d) Measure the voltage according to the value(s) in the

table below.
Standard voltage

C009 (B18) - Ground Battery voltage

7. CHECK HARNESS AND CONNECTOR (WIPER FUSE - JUNCTION CONNECTOR)

table below.

04
Wiper fuse (20 A) - C052 (5) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - COMBINATION SWITCH)


table below.

C052 (12) - C009 (B18) ＜2Ω

WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD

WIRING DIAGRAM

(c) Inspect combination switch (wiper and washer control)

according to the value(s) in the table below.
Tester Specified 04
Condition
Set the wiper and washer
B18 - B7 ≥ 1 MΩ
switch to OFF

B18 - B7 ＜2Ω
switch to LOW



table below.
Standard voltage


YES > Go to step 5.


table below.

Wiper fuse (20 A) - C052 (5) ＜2Ω



table below.

C052 (12) - C009 (B18) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WIPER MOTOR)

(c) Disconnect the C029 front wiper motor connector.

table below.
C009 (B7) - C029 (2) ＜2Ω

YES > Replace the front wiper motor.
WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD

WIRING DIAGRAM


Tester Specified 04
Condition
B18 - B13 ≥ 1 MΩ
switch to OFF

B18 - B13 ＜2Ω
switch to HIGH



table below.
Standard voltage


YES > Go to step 5.


table below.

Wiper fuse (20 A) - C052 (5) ＜2Ω



table below.

C052 (12) - C009 (B18) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WIPER MOTOR)

(c) Disconnect the C029 front wiper motor connector.

table below.
C009 (B13) - C029 (1) ＜2Ω

YES > Replace the front wiper motor.
WIPERS ARE INOPERATIVE IN INTERMITTENT MODE -

WINDSHIELD
WIRING DIAGRAM
1. INSPECT FRONT WIPER MOTOR

(c) Inspect the windshield wiper motor in INT mode.
Specified
Condition 04
Apply battery Battery(+) - 2 Front wiper
voltage to terminal motor operates
2 and ground Battery(-) - Ground at low speed

NO > Replace the front wiper motor.


Specified
Condition
Set the wiper and washer B4 - B7

B12 - B16
Set the wiper and washer B4 - B7

switch to INT ＜ 2Ω
B12 - B16
Is the inspecrtion result normal?

3. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT INT WIPER RELAY)


table below.

C052 (12) - Front int wiper relay (3) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (FRONT INT WIPER RELAY - COMBINATION SWITCH)

(c) Remove the front INT wiper relay.

table below.

Front INT wiper relay (2) - C009 (B12)
＜2Ω
Front INT wiper relay (1) - C009 (B4)

5. CHECK HARNESS AND CONNECTOR (FRONT INT WIPER RELAY - FRONT WIPER MOTOR)

(b) Disconnect the C029 front wiper motor connector. 04
(c) Remove the front INT wiper relay.

table below.
Front INT wiper relay (5) - C029 (3) ＜2Ω

YES > Replace the front INT wiper relay.
WASHER PUMP IS INOPERATIVE - WINDSHIELD

WIRING DIAGRAM


Specified 04
Condition
B8 - B16 ≥ 1 MΩ
switch to OFF

B8 - B16 ＜2Ω
switch to WASH

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT WASHER PUMP)

(c) Disconnect the C007 front washer pump connector.

table below.

C052 (13) - C007 (2) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - FRONT WASHER PUMP)

(b) Disconnect the C007 front washer pump connector.
(c) Disconnect the C009 combination switch (wiper and washer control) connector.

table below.

C009 (B8) - C007 (1) ＜2Ω


table below.

C052 (5) - C052 (13) ＜2Ω

YES > Replace the front washer pump.
WHEN THE WIPER SWITCH IS OFF, THE WIPER BLADE DOES NOT
RETRACT
WIRING DIAGRAM 04
04


Specified
Condition
B4 - B7 ≥ 1 MΩ
switch to OFF

B4 - B7 ＜2Ω
switch to LOW

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT WIPER MOTOR)


table below.

C052 (6) - C029 (4) ＜2Ω


04
table below.

C052 (5) - C052 (6) ＜2Ω 04

YES > Replace the front INT wiper relay.
WIPER IS INOPERATIVE - REAR WINDOW

WIRING DIAGRAM


Specified 04
Condition
B1 - B16 ≥ 1 MΩ
switch to OFF
Set the rear wiper and

B1 - B16 ＜2Ω
washer switch to ON

2. CHECK HARNESS AND CONNECTOR (REAR WIPER MOTOR - GROUND)

(b) Disconnect the J009 rear wiper motor connector.

table below.

J009 (2) - Ground ＜2Ω

3. INSPECT REAR WIPER MOTOR

(c) Inspect rear wiper motor according to the value(s) in the

table below.
Specified
Condition
Apply battery Battery (+) - 4 Rear wiper motor
voltage to operates at normal
terminal 2 and 4 Battery (-) - 2 speed

NO > Replace the rear wiper motor.
4. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR WIPER RELAY)

(b) Disconnect the C031 rear wiper relay connector.

table below.

C052 (7) - C031 (3) ＜2Ω

5. CHECK HARNESS AND CONNECTOR ( REAR WIPER RELAY - COMBINATION SWITCH)

(b) Disconnect the C031 rear wiper relay connector. 04

table below.
C031(6) - C009 (B1) ＜2Ω

6. CHECK HARNESS AND CONNECTOR ( REAR WIPER RELAY - REAR WIPER MOTOR)

(c) Disconnect the J009 rear wiper motor connector.

table below.

C031(4) - J009 (4) ＜2Ω

YES > Replace the rear wiper relay.
WIPER IS INOPERATIVE IN INTERMITTENT MODE - REAR

WINDOW
WIRING DIAGRAM


Specified 04
Condition
Set rear wiper and
B10 - B16 ≥ 1 MΩ
washer switch to OFF
Set rear wiper and

B10 - B16 ＜2Ω
washer switch to ON

2. CHECK HARNESS AND CONNECTOR (COMBINATION SWITCH - REAR WIPER RELAY)

(c) Disconnect the C031 rear wiper relay connector.

table below.

C009 (B10) - C031 (2) ＜2Ω

3. INSPECT REAR WIPER MOTOR

(c) Inspect rear wiper motor according to the value(s) in the

table below.
Specified
Condition
Apply battery Battery (+) - 4 Rear wiper motor
voltage to operates at normal
terminal 2 and 4 Battery (-) - 2 speed

NO > Replace the rear wiper motor.
4. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - REAR WIPER MOTOR)

(c) Disconnect the J009 rear wiper motor connector.

table below.

C031(4) - J009(4) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (REAR WIPER RELAY - GROUND)

(b) Disconnect the J009 rear wiper motor connector. 04
table below.

04
J009 (2) - Ground ＜2Ω

YES > Replace the rear wiper relay.
WASHER PUMP IS INOPERATIVE - REAR WINDOW

WIRING DIAGRAM


Specified 04
Condition
Set rear wiper and
washer switch to B2 - B16
WASH 1
B16 - B1 ＜2Ω
Set rear wiper and
washer switch to B1 - B2
WASH 2
B1 - B16
B2 - B16
Set rear wiper and B2 - B1
washer switch to ≥ 1 MΩ
OFF B2 - B16
B1 - B16

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR WIPER MOTOR)

(b) Disconnect the F009 rear wiper motor connector.

table below.

C052 (7) - F009 (2) ＜2Ω

3. CHECK HARNESS AND CONNECTOR (REAR WIPER MOTOR - COMBINATION SWITCH)

(b) Disconnect the F009 rear wiper motor connector.

table below.

F009 (1) - C009 (B2) ＜2Ω

YES > Replace the rear wiper motor.
DIAGNOSTICS - AUDIO SYSTEM 04-711
AUDIO SYSTEM
PRECAUTION
1. IT IS FORBIDDEN TO REFIT THE AUDIO SYSTEM. 04
2. THE RADIO WAVE BANDS USED IN RADIO BROADCASTING ARE AS FOLLOWS.
Radio wave AM FM
Modulation method Amplitude modulation Frequency modulation
Designation AM1 AM2 FM1 FM2 FM3 04

Frequency 522 ～ 1620 KHz 87.5 ～ 108 MHz
3. POWER OFF.
prevent the device damage or personal injury.
(b) Ignition switch must be off if no specific instructions.
04-712 DIAGNOSTICS - AUDIO SYSTEM
LOCATION
1 Front Speaker Assy RH 3 Radio Assy
2 Radio Antenna Assy 4 Front Speaker Assy LH

TERMINALS OF RADIO
04
04
Terminal No. Wiring Color Terminal Description

1 LG Speaker FR+
2 P Speaker FL+
3 BR Power supply
4 R Power supply
5 L Speaker FR-
6 V Speaker FL-
7 W- B Ground
8 - -
9 - -
10 G Illumination
BASIC INSPECTION
Yes Go to next step
1 • The voltage should be above 12V. Charge or replace battery. Refer to “Chapter
replacement”
Check radio antenna. Yes Go to next step

• Check whether the antenna is pulled out
and pulled out to end.
2 • Check whether the antenna is covered
with obstacles. No Repair or replace the radio antenna assy.
• Check whether the antenna is bended or
deformation.
Check radio. Yes Go to next step

3 • Press the radio power button, check
whether the radio work well. No Go to problem symptoms table
Check speaker. Yes Go to next step

4 • Set the radio volume level above 5 VOL,
check whether the speaker sounds. No Go to problem symptoms table
Yes Go to problem symptoms table

Check the radio broadcasting signal.
5 Move the vehicle to the place where the
Is the check result normal? No
signal is strong.

04
1. Fuse -
2. Wire harness -
Radio does not work
3. Junction connector -
04
4. Radio Chapter 66 audio system - radio system, replacement
1. Setting impropriety Chapter 04 diagnositics - audio system, radio reception poor
2. Radio broadcasting Chapter 04 diagnositics - audio system, radio reception poor

Radio reception is poor signal
3. Antenna malfunction Chapter 04 diagnositics - audio system, radio reception poor
1. Setting impropriety Chapter 04 diagnositics - audio system, sound quality poor
2. Radio broadcasting Chapter 04 diagnositics - audio system, sound quality poor

signal
Poor sound quality
3. Antenna malfunction Chapter 04 diagnositics - audio system, sound quality poor
4. Speaker Chapter 04 diagnositics - front speaker assy, replacement
Chapter 04 diagnositics - audio system, speaker does not

1. Setting impropriety work
2. Speaker Chapter 04 diagnositics - front speaker assy, replacement

Speaker does not work
3. Wire harness -

RADIO DOES NOT WORK

WIRING DIAGRAM
1. INSPECT FUSE
(b) Check dome light fuse (7.5 A) in engine room junction

box (C035).
(c) Check Radio & Cigarette fuse (15 A) in engine room
04

YES > Go to step 4.
NO > If the dome light fuse is blown, go to next step.
If the radio & cigarette fuse is blown, go to step 3.
2. CHECK HARNESS AND CONNECTOR (RADIO - GROUND)
(a) Disconnect the C021 radio connector.

NOTE
Do not drop the radio.

table below.

C021(4) - Ground ≥ 1 ΜΩ


NOTE

table below.

C021 (3) - Ground ≥ 1 ΜΩ

4. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - RADIO)

NOTE

table below.
Dome light fuse (7.5 A) - C021 (4) <2Ω

NO > Go to step 6.
5. CHECK HARNESS AND CONNECTOR (RADIO & CIGARETTE FUSE - RADIO)

table below. 04

Radio & Cigarette fuse(15 A) - C021 (3) <2Ω
04

YES > Go to step 8.
6. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - JUNCTION CONNECTOR)
(a) Disconnect the C050 junction connector.

table below.

Dome light fuse (7.5 A) - C050 (8) <2Ω

7. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - RADIO)

table below.

C050 (2) - C021 (4) <2Ω


table below.

C021 (7) - Ground <2Ω

YES > Replace the radio.
RADIO RECEPTION IS POOR

1. CHECK RADIO SETTING 04

(b) Press the radio power button.
(c) Adjust the volume level above 5 VOL.
(d) Turn the button and search the radio station.
04
Check whether the radio setting is correct?
NO > Reset the radio.
2. CHECK THE RADIO BROADCASTING SIGNAL
(a) Move the vehicle to the place where the signal is strong.
(c) Press the radio power button.
(d) Adjust the volume level above 5 VOL.
(e) Turn the button and search the radio station.
Check whether the radio reception is good?
NOTE
• There is great difference in the size of the service area for AM, FM monaural, and FM stereo
broadcasting. Thus it may happen that FM broadcast cannot be received even though AM comes in
very clearly. Not only does FM stereo have the smallest service area, but also it picks up static and
other types of interference most easilly.
• AM broadcasts are susceptible to other types of interference, especially at night. This is because AM
radio waves bounce off the ionosphere at night. These radio waves then interfere with the signals from
the same transmitter that reach the vehicle’s antenna directly.
• When a signal from broadcast transmitter antenna bounces off Mountains, tall buildings or other
obstruction, it will interfere with the signal that is received directly.
3. CHECK RADIO ANTENNA
(a) Check whether the antenna is pulled out to the end.

(b) Check whether the antenna is bended or deformation.
(c) Check whether the antenna is breakage.
(d) Check whether the antenna connnector is intalled correct.
Adjust and check the radio antenna. Is the check result normal?
YES > Repair or replace the radio antenna.
NO > Replace the radio.
POOR SOUND QUALITY

1. CHECK RADIO SETTING

2. CHECK THE RADIO BROADCASTING SIGNAL
(a) Move the vehicle to the place where the signal is strong.
(c) Press the radio power button.
(d) Adjust the volume level above 5 VOL.
(e) Turn the button and search the radio station.
Check whether the radio reception is good?
3. CHECK RADIO ANTENNA
(a) Check whether the antenna is pulled out to the end.

(b) Check whether the antenna is bended or deformation.
(c) Check whether the antenna is breakage.
(d) Check whether the antenna connnector is intalled correct.
Adjust and check the radio antenna. Is the check result normal?
YES > Repair or replace the radio antenna.
4. CHECK SPERKER

(b) Remove the speaker. (Refer to “Chapter 66 audio system - front speaker assy, replacement”)
(c) Check whether the speaker is around with obstacles.
(d) Check whether the speaker cone diaphragm accumulates dust.
(e) Check the speaker cone diaphragm for damage.
(f) Replace the old speaker with a troubleprool one and check the system.
Check whether the radio sound quality is good?
YES > Repair or replace the speaker.
SPEAKER DOES NOT WORK

WIRING DIAGRAM
04
04
1. CHECK RADIO SETTING

2. CHECK SPEAKER

(b) Remove the speaker. (Refer to “Chapter 66 audio system - front speaker assy, replacement”)
(c) Check the speaker for damage.
YES > Replace the speaker.

table below.
C021 (2) - Ground ≥ 1 ΜΩ


table below.
C021 (6) - Ground ≥ 1 ΜΩ

5. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

table below.
C021 (2) - C040 (1) <2Ω

6. CHECK HARNESS AND CONNECTOR (RADIO - SPEAKER)

table below. 04
C021 (6) - C040 (2) <2Ω

04

7. CHECK SPEAKER

(b) Replace the old speaker with a troubleprool one and check the system.
YES > Replace the speaker.
04-726 DIAGNOSTICS - HORN SYSTEM
HORN SYSTEM
LOCATION
1 Horn Switch 3 Horn
2 Body Junction Box

DIAGNOSTICS - HORN SYSTEM 04-727

04
1. Horn fuse -
2. Horn relay -
Horn is inoperative 3. Horn switch Chapter 51 steering column - steering wheel, replacement
04
4. Horn Chapter 81 communication system - horn, replacement
5. Wire harness -
1. Horn relay -
Horn is always on 2. Horn switch Chapter 51 steering column - steering wheel, replacement
3. Wire harness -
HORN IS INOPERATIVE
WIRING DIAGRAM
1. INSPECT FUSE
(b) Inspect the hazard & horn fuse in body junction box
(C305):15 A.

YES > Go to step 3.

table below.

04
C051 (14) - Ground ≥ 1 ΜΩ

3. INSPECT HORN RELAY

(b) Remove the horn relay.
(c) Inspect horn relay.

Standard resistance：
Condition Tester Connection Specified Condition

Constant 1-2 Continuity

NO > Replace horn relay.
4. CHECK HARNESS AND CONNECTOR (HORN RELAY - COMBINATION SWITCH)


table below.

Horn relay (1) - C008 (A10) ＜2Ω

5. INSPECT HORN SWITCH
(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(b) Check the horn switch for corrosion or damaged pins.
(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(d) Press the horn switch.
Does the horn sound?
YES > Repair or replace the horn switch.

(d) Connect a fused (5A) jumper wire between the C008

combination switch connector, pin A10 and ground.

YES > Repair or replace harness or connector.
7. CHECK HARNESS AND CONNECTOR (HORN - GROUND)

(b) Disconnect the C010 horn connector. 04
table below.

04
C010 (2) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (HORN RELAY - HORN)

(c) Disconnect the C010 horn connector.

table below.

Horn relay (3)- C010 (1) ＜2Ω

YES > Replace horn.
HORN IS ALWAYS ON
WIRING DIAGRAM
1. INSPECT HORN RELAY

(c) Inspect horn relay.

Standard resistance
Condition Tester Connection Specified Condition

1-2 Continuity
Constant
2-3 ≥ 1 ΜΩ

NO > Replace horn relay.
2. INSPECT HORN SWITCH
(a) Remove the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(b) Check the horn switch for corrosion or damaged pins. 04
(c) Replace the horn switch. (Refer to“Chapter 51 steering column - steering wheel, replacement”)
(d) Press horn switch.
YES > Repair or replace the horn switch.
04


table below.

C008 (A10) - Ground ≥ 1 ΜΩ

4. CHECK HARNESS AND CONNECTOR (HORN - GROUND)


table below.
Standard voltage


YES > Replace horn.
04-734 DIAGNOSTICS - COMBINED DISPLAY
COMBINED DISPLAY
PRECAUTION


Expression
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the nagative battery cable to pre-
vent damage to the device or personal injury.
DIAGNOSTICS - COMBINED DISPLAY 04-735
LOCATION
04
04
1 Combined Display 2 Front Control Panel

TERMINALS OF COMBINED DISPLAY
Terminals No. Wiring Color Terminal Description

1 R-B Power supply
2 W-B Ground
3 P Reverse radar
4 - -
5 G-R Ambient sensor
6 L-R In-vehicle sensor
7 - -
8 - -
9 G Illumination
10 W-B Ground
11 O Reverse radar
12 - -
13 G-B Ambient sensor
14 L-B In-vehicle sensor
15 - -
16 - -
BASIC INSPECTION
04
Yes Go to next step
Check battery voltage.
1 • The voltage should be above 12 V. Charge or replace battery. Refer to
Is the check result normal? No “Chapter 20 Starting and Charging -
battery, replacement”
Check combined display illumination. Yes Go to next step

• Turn the ignition switch ON. 04
2
• Turn on the parking lamp. No Go to problem symptoms table
Does the combined display illuminate?
Check combined display indication. Yes Go to problem symptoms table

3
• Set the shift lever in reverse position. No Replace combined display
Does the combined display work correctly?

1. Fuse -
Chapter 04 diagnostics - combined display,

Combined display is inoperative 2. Combined display combined display is inoperative
3. Wire harness -

1. In-vehicle sensor in-vehicle temperature does not display or
display incorrectly
In-vehicle temperature does not Chapter 04 diagnostics - combined display,
display or display incorrectly in-vehicle temperature does not display or
2. Combined display
display incorrectly
3. Wire harness -

1. Ambient sensor ambient temperature does not display or
display incorrectly
Ambient temperature does not Chapter 04 diagnostics - combined display,
display or display incorrectly ambient temperature does not display or
2. Combined display
display incorrectly
3. Wire harness -

1. Combined display reverse data does not display or display
incorrectly
Reverse data does not display or Chapter 04 diagnostics - combined display,
display incorrectly reverse data does not display or display
2. Reversing radar controller
incorrectly
3. Wire harness -
COMBINED DISPLAY IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the radio & cigarette fuse (15 A) in body junction
box (C035).

YES > Go to step 3.

(b) Disconnect the P002 combined display connector.
(c) Measure the resistance according to the value (s) in the

table below.

P002 (1) - Ground ≥ 1 ΜΩ

3. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY FUSE - COMBINED DISPLAY )


table below.

Radio & Cigarette Fuse(15 A) - P002 (1) ＜2Ω


(b) Disconnect the P002 combined display connector. 04
table below.

04
P002 (2) - Ground
＜2Ω
P002 (10) - Ground

YES > Replace the conbined display.
IN-VEHICLE TEMPERATURE DOES NOT DISPLAY OR DISPLAY

INCORRECTLY
WIRING DIAGRAM
1. INSPECT IN-VEHICLE SENSOR
(a) Immerse the in-vehicle sensor in water, and then heat the water gradually.
(b) Inspect the in-vehicle sensor according to the value(s) in

the table below.
Condition Standard Resistance (KΩ)
0℃ 6.143 ± 8%
25 ℃ 2.186 ± 3%

NO > Replace the in-vehicle sensor.
2. CHECK HARNESS AND CONNECTOR (IN-VEHICLE SENSOR - COMBINED DISPLAY)

(b) Disconnect the P003 in-vehicle sensor connector. 04
(c) Disconnect the P002 combined display connector.
(d) Measure the resistance according to the value (s) in the

table below.
P003 (3) - P002 (14)

＜2Ω
P003 (1) - P002 (6)


(b) Disconnect the P003 in-vehicle sensor connector.

table below.

P002 (6) - Ground
≥ 1 ΜΩ
P002 (14) - Ground

AMBIENT TEMPERATURE DOES NOT DISPLAY OR DISPLAY

INCORRECTLY
WIRING DIAGRAM
1. INSPECT AMBIENT SENSOR
(a) Immerse the ambient sensor in water, and then gradually heat the water.
(b) Inspect the ambient sensor according to the value(s) in

the table below.
Condition Standard Resistance (KΩ)
0℃ 6.143 ± 8%
25 ℃ 2.186 ± 3%

NO > Replace the ambient sensor.
2. CHECK HARNESS AND CONNECTOR (AMBIENT SENSOR - COMBINED DISPLAY)

(b) Disconnect the D005 ambient sensor connector. 04

table below.
D005 (1) - P002 (13)

＜2Ω
D005 (2) - P002 (5)


(b) Disconnect the D005 ambient sensor connector.

table below.

P002 (5) - Ground
≥ 1 ΜΩ
P002 (13) - Ground

REVERSE DATA DOES NOT DISPLAY OR DISPLAY INCORRECTLY

WIRING DIAGRAM
1. INSPECT REVERSE RADAR CONTROL UNIT

(b) Replace the reverse radar control unit.
YES > Replace the reverse radar control unit.
2. CHECK HARNESS AND CONNECTOR (COMBINED DISPLAY - REVERSE RADAR CONTROL
UNIT)

(c) Disconnect the P001 reverse radar control unit connector.

table below.

P002 (3) - P001 (12)
＜2Ω
P002 (11) - P001 (13)

04
3. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - GROUND)


table below. 04

P002 (3) - Ground
≥ 1 ΜΩ
P002 (11) - Ground

04-748 DIAGNOSTICS - REVERSE RADAR SYSTEM

PRECAUTION
1. UNDER THE FOLLOWING CONDITIONS, THE DETECTION FUNCTION MAY NOT FUNCTION
PROPERLY:
(a) The sensor is covered with foreign matter, such as mud or snow (detection function returns to normal
when the sensor is cleaned).
(b) The sensor is frozen (detection function returns to normal when the temperature of the sensor is going
high).
(c) The sensor is covered with a hand.
(d) In very cold weather where a malfunction display appears, the sensor may not be able to detect
obstacles.
2. THE DETECTION RANGE MAY BE AFFECTED BY THE FOLLOWING CONDITIONS:
(a) The sensor is covered with foreign matter, such as mud or snow.
(b) The vehicle is in an excessively hot or cold area.
3. UNDER THE FOLLOWING CONDITIONS, A DETECTION ERROR MAY OCCUR:
(a) Driving on a bumpy road, an unpaved road, or in tall grass.
(b) Ultrasonic waves from items such as another vehicle's horn, motorcycle engine sounds, a large
vehicle's air brake sound, or another vehicle's sonar are transmitted near the vehicle.
(c) It is raining heavily or the sensor comes into contact with water (sprayed).
(d) The vehicle is tilted at a large angle.
(e) The vehicle is equipped with a commercial fender pole or a wireless mechanism antenna.
(f) The sensor is covered with foreign matter, such as mud or snow.
(g) The vehicle is moving toward a high curb or the corner of a pointed object.
4. THE SENSOR CANNOT DETECT SOME OBJECTS SUCH AS THE FOLLOWING:
(a) Thin objects, such as wires and ropes.
(b) Materials that absorb ultrasonic waves, such as cotton, snow, etc.
(c) Objects with sharp edges.
(d) Short objects.
(e) Tall, overhanging objects.
5. OTHER NOTICES:
(a) The sensor cannot detect objects directly under the bumper. (The sensor may detect low objects and
thin poles, and then lose track of the objects.)
(b) The sensor may not be able to detect obstacles that are too close to the sensor.
(c) The sensor may not be able to detect obstacles if it is dropped or subjected to a strong impact.
DIAGNOSTICS - REVERSE RADAR SYSTEM 04-749
LOCATION
04
04
1 Reverse Radar Sensor LH 3 Reverse Radar Sensor RH
2 Reverse Radar Sensor MID

SYSTEM DESCRIPTION
1. GENERAL.
This system uses ultrasonic sensors to send ultrasonic waves. The reverse radar sensors receive the
echo. The reverse radar control unit then informs the driver of the distance between the sensors and
the obstacles as well as their positions by indicating them on the combined display and by clearance
warning buzzer.
2. FUNCTION OF COMPONENTS.
Components Function
Reverse radar sensor Detects the distance between the vehicle and an obstacle.
Sounds from the buzzer to motify the driver for the distance between the vehicle
Clearance warning buzzer
and the obstacle.
1. Displays the location of the obstacle and the approximate distance between the
vehicle and the obstacle.
Combined display
2. Informs the driver if the reverse radar sensors malfunction, or if they are frozen
or dirty.
1. Judges the approximate distance between the vehicle and the obstacle based
on the signals from the reverse radar sensor and sends it to the combined
Reverse radar control unit
display.
2. Sounds the clearance warning buzzer.
Back-up lamp switch Sends the back-up signal to the reverse radar control unit.
3. INITIALIZATION FUNCTION OF REVERSE RADAR CONTROL UNIT.

(b) Set shift lever in reverse position.
• If all the reverse radar sensors work correctly, the clearance warning buzzer sounds once for 0.5 sec-
ond. The interval time is 0.5 second.
• If one reverse radar sensor works incorrectly, the clearance warning buzzer sounds twice for 0.5 sec-
ond. The interval time is 0.5 second.
• If two reverse radar sensors work incorrectly, the clearance warning buzzer sounds three times for 0.5
second. The interval time is 0.5 second.
• If three reverse radar sensors work incorrectly, the clearance warning buzzer sounds four times for 0.5
second. The interval time is 0.5 second.
4. DETECTION RANGE OF REVERSE RADAR SENSOR.

(a) Detection range of reverse radar sensor (both sides).
04
04
(b) Detection range of reverse radar sensor (middle).
5. DISTANCE TO AN OBSTACLE, FREQUENCY AND MODE OF CLEARANCE WARNING BUZZER.
NO. DISTANCE MODE FREQUENCY

A 90 - 150 cm Long & Intermittent 1 Hz
B 60 - 90 cm Short & Intermittent 2 Hz
C 40 - 60 cm Rapid & Intermittent 4 Hz
D 40 ± 5 cm Continual Continual
6. TERMINALS OF REVERSE RADAR CONTROL UNIT.

1 R Power supply
2 - -
3 - -
4 BR Reverse radar sensor LH
5 W-R Reverse radar sensor MID
6 GR - R Reverse radar sensor RH
7 W-B Ground
8 Y-R Reverse radar sensor LH
9 W-B Ground
10 Y Reverse radar sensor LH
11 GR Reverse radar sensor RH
12 P Combined display
13 o Combined display
14 - -
15 - -
16 W-B Reverse radar sensor MID


04
Chapter 04 diagnostics - reverse radar
1. Fuse system, reverse radar system is
inoperative at all

2. Reverse radar control unit system, reverse radar system is 04
Reverse radar system is inoperative inoperative at all
at all Chapter 04 diagnostics - reverse radar
3. Combined display system, reverse radar system is
inoperative at all

4. Wire harness system, reverse radar system is
inoperative at all

1. Reverse radar sensor system, self-check function is inoperative
Self-check function is inoperative
2. Reverse radar control unit system, self-check function is inoperative

system, reverse radar system is operative
1. Reverse radar sensor when the shift lever is out of reverse posi-
tion

Reverse radar system is operative
when the shift lever is out of reverse 2. Reverse radar control unit when the shift lever is out of reverse posi-
position
tion

3. Back-up Lamp switch when the shift lever is out of reverse posi-
tion

system, reverse radar system is inopera-
1. Reverse radar sensor tive within specified distance (back-up
lamp is normal)

Reverse radar system is inoperative
within specified distance (Back-up 2. Reverse radar control unit tive within specified distance (back-up
lamp is normal)
lamp is normal)

3. Wire harness tive within specified distance (back-up
lamp is normal)

1. Reverse radar sensor but there is no obstacle behind the vehi-
cle (back-up lamp is normal)

Reverse radar system is operative but
there is no obstacle behind the 2. Reverse radar control unit but there is no obstacle behind the vehi-
vehicle (Back-up lamp is normal)

3. Wire harness but there is no obstacle behind the vehi-

system, buzzer is inoperative or operative
1. Reverse radar sensor incorrectly within specified distance
(combined display is normal)

Buzzer is inoperative or operative
incorrectly within specified distance 2. Reverse radar control unit incorrectly within specified distance
(Combined display is normal)

3. Wire harness incorrectly within specified distance

system, combined display is inoperative
1. Combined display within specified distance (back-up lamp
is normal)

Combined display is inoperative
within specified distance (Back-up 2. Reverse radar control unit within specified distance (back-up lamp
lamp is normal)
is normal)

3. Wire harness within specified distance (back-up lamp
is normal)
REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the instrument cluster fuse (7.5 A) in body junc-

tion box (C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (BACK-UP LAMP SWITCH - IGNITION SWITCH)


table below.

G001 (2) - Ground ≥ 1MΩ


(b) Disconnect the P001 reverse radar control unit connector.

table below.

P001 (7) - Ground
＜2Ω
P001 (9) - Ground


(c) Inspect the back-up lamp switch.
Tester Specified
Condition
Connection condition
Set shift lever in reverse
1-2 ＜2Ω 04
position
Set shift lever out of

1-2 ≥ 1 ΜΩ
reverse position

5. CHECK HARNESS AND CONNECTOR (FUSE - BACK-UP LAMP SWITCH)


table below.
Specified
Tester Connection
Condition
Instrument cluster fuse (7.5 A) - G001 (2) ＜2Ω

6. CHECK HARNESS AND CONNECTOR ( BACK-UP LAMP SWITCH - REVERSE RADAR CONTROL
UNIT)


table below.

G001 (1) - P001 (1) ＜2Ω

YES > Replace the reverse radar.
SELF-CHECK FUNCTION IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT REVERSE RADAR SENSOR

(b) Disconnect the R001 reverse radar LH connector.
(c) Disconnect the R002 reverse radar MID connector.
(d) Disconnect the R003 reverse radar RH connector.
(e) Replace the reverse radar sensor with a new one.
(f) Turn the ignition switch ON.
(g) Set the shift lever in reverse position.
Does the reverse radar work correctly?
YES > Replace the reverse radar sensor.
2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR SENSOR - GROUND)


table below.

R001 (4) - Ground
R002 (4) - Ground ＜2Ω

R003 (4) - Ground

3. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - REVERSE RADAR
SENSOR)

(e) Disconnect the P001 reverse radar control unit connector.
(f) Measure the resistance according to the value(s) in the

table below.
04
P001 (10) - R001 (2)
＜2Ω
P001 (8) - R001 (3)
04
(g) Measure the resistance according to the value(s) in the

table below.

P001 (16) - R002 (2)
＜2Ω
P001 (5) - R002 (3)
(h) Measure the resistance according to the value(s) in the

table below.

P001 (11) - R003 (2)
＜2Ω
P001 (6) - R003 (3)
(i) Measure the resistance according to the value(s) in the

table below.

P001 (4) - R001 (1)
P001 (4) - R002 (1) ＜2Ω

P001 (4) - R003 (1)

REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE SHIFT

LEVER IS OUT OF REVERSE POSITION
WIRING DIAGRAM

(c) Inspect the back-up lamp switch.
Tester Specified
Condition
Connection condition
Set shift lever in reverse
1-2 ＜2Ω
position
Set shift lever out of

1-2 ≥ 1 ΜΩ
reverse position

NO > Replace the back-up lamp switch. 04

(b) Disconnect the P001 reverse radar control unit connector.
04
table below.
Standard voltage

P001 (7) - Ground
0V
P001 (9) - Ground


NO > Replace the reverse radar sensor.
REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN SPECIFIED

DISTANCE
WIRING DIAGRAM

(f) Turn the ignition switch ON. 04


table below.

R001 (4) - Ground
R002 (4) - Ground ＜2Ω

R003 (4) - Ground

SENSOR)

(b) Disconnect the D001 reverse radar sensor LH connector.
(c) Disconnect the D003 reverse radar sensor MID connector.
(d) Disconnect the D004 reverse radar sensor RH connector.

table below.

P001 (10) - R001 (2)
＜2Ω
P001 (8) - R001 (3)

table below.

P001 (16) - R002 (2)
＜2Ω
P001 (5) - R002 (3)

table below.

P001 (11) - R003 (2)
＜2Ω
P001 (6) - R003 (3)

table below.

P001 (4) - R001 (1)
P001 (4) - R002 (1) ＜2Ω

P001 (4) - R003 (1)

REVERSE RADAR SYSTEM IS OPERATIVE BUT THERE IS NO

OBSTACLE BEHIND VEHICLE
WIRING DIAGRAM 04
04

SENSOR)


table below.

P001 (10) - R001 (2)
＜2Ω
P001 (8) - R001 (3)

table below.

P001 (16) - R002 (2)
＜2Ω
P001 (5) - R002 (3)

table below.
04
P001 (11) - R003 (2)
＜2Ω
P001 (6) - R003 (3)
04

table below.

P001 (4) - R001 (1)
P001 (4) - R002 (1) ＜2Ω

P001 (4) - R003 (1)

BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY WITHIN

SPECIFIED DISTANCE
WIRING DIAGRAM

(f) Turn the ignition switch ON. 04
2. CHECK HARNESS AND CONNECTOR ( REVERSE RADAR SENSOR - GROUND)


table below.

R001 (4) - Ground
R002 (4) - Ground ＜2Ω

R003 (4) - Ground

SENSOR)


table below.

P001 (10) - R001 (2)
＜2Ω
P001 (8) - R001 (3)

table below.

P001 (16) - R002 (2)
＜2Ω
P001 (5) - R002 (3)

table below.

P001 (11) - R003 (2)
＜2Ω
P001 (6) - R003 (3)

table below.

P001 (4) - R001 (1)
P001 (4) - R002 (1) ＜2Ω

P001 (4) - R003 (1)

COMBINED DISPLAY IS INOPERATIVE WITHIN SPECIFIED DISTANCE

WIRING DIAGRAM
04
04
1. INSPECT COMBINED DISPLAY

(c) Remove the combined display and replace it with a new one.
(e) Set shift lever in reverse position.
2. CHECK HARNESS AND CONNECTOR (REVERSE RADAR CONTROL UNIT - COMBINED
DISPLAY)


table below.

P001 (12) - P002 (3)
＜2Ω
P001 (13) - P002 (11)

DIAGNOSTICS - POWER WINDOWS 04-775
POWER WINDOWS
PRECAUTION
1. EXPRESSIONS OF IGNITION SWITCH 04


Expression
Ignition switch on (ACC) ACC On (ACC) 04
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the negative cable from battery
to prevent damage to the device or personal injury.
NOTE
To prevent locking the key in the vehicle, do not leave the key in the vehicle when disconnecting the
negative battery cable.
(b) Ignition switch must be off if no specific instructions.
3. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER
AND THE CLOCK TO ‘0’.
NOTE
The total odometer can not be reset to ‘0’.
4. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE
IS DISCONNECTED.
NOTE
After reconnecting the negative battery cable, the audio system will need to be reset (Refer to “Audio
instructions”).
04-776 DIAGNOSTICS - POWER WINDOWS
LOCATION
1 Main Power Window Lock/Unlock Switch 3 Power Window Switch RH
2 Power Window Controller

TERMINALS OF MAIN POWER WINDOW LOCK/UNLOCK SWITCH
04
04
Terminal No. Wiring Color Description

1 G-W Power window switch RH
2 W-R Ground
3 R-L Power supply
4 R-W Power window switch RH
5 - -
6 Y-W Power window controller
7 L-Y Power window controller
8 B Power window controller

TERMINALS OF POWER WINDOW SWITCH RH
Terminal No. Wiring Color Description

1 L-R Power window motor RH
2 R-L Main power window lock/unlock switch
3 L Power supply
4 G-R Main power window lock/unlock switch
5 L-W Power window motor RH

TERMINALS OF POWER WINDOW CONTROLLER
04
04
Terminal No Wiring Color Description

1 L-B Power window motor LH
2 L Main power window lock/unlock switch
3 L-W Power window motor LH
4 R-B Main power window lock/unlock switch
5 - -
6 W-B Ground
7 L Main power window lock/unlock switch
8 R-L Main power window lock/unlock switch

BASIC INSPECTION
Check the battery voltage. Yes Go to next step.
• The battery voltage should be over than
1 Charge or replace the battery. Refer to
12 V. No
Is the check result normal？ “Chapter 20A starting and charging - battery”.
Check the front power window motor LH. Yes Go to next step.
• Push or pull the front window switch
2
LH to operate the fornt window LH No Go to the problem symptoms table.
open and close.
Is the check result normal？
Check power window auto open operation. Yes Go to next step.

3 • Push or pull the front window switch
LH to operate the fornt window LH No Go to the problem symptoms table.
auto open.
Check power window motor RH. Yes Go to next step.

LH to operate the fornt window RH No Go to the problem symptoms table.
open and close.
Check power window motor RH. Yes Replace power window motor.
RH to operate the fornt window RH No Go to the problem symptoms table.
open and close.

Use the table below to help you to find the cause of the problem. The numbers indicate the priority of the likely
04
Chapter 04 diagnostics - power window,
1. Power, ground circuits all power windows are inoperative
2. Main power window lock/ Chapter 04 diagnostics - power window,

unlock switch all power windows are inoperative
All power windows are inoperative. 04
3. Power window motor LH Chapter 04 diagnostics - power window,
and RH all power windows are inoperative

4. Harness all power windows are inoperative

1. Power, ground circuits front power window LH is inoperative

unlock switch front power window LH is inoperative
Front power window LH is Chapter 04 diagnostics - power window,

inoperative. 3. Power window controller front power window LH is inoperative

4. Power window motor LH front power window LH is inoperative

5. Harness front power window LH is inoperative

unlock switch front power window LH does not open
Front power window LH does not Chapter 04 diagnostics - power window,

open. 2. Power window controller front power window LH does not open

3. Harness front power window LH does not open

unlock switch front power window LH does not close
Front power window LH does not Chapter 04 diagnostics - power window,

close. 2. Power window controller front power window LH does not close

3. Harness front power window LH does not close

1. Power, ground circuits front power window RH is inoperative

unlock switch front power window RH is inoperative
Front power window RH is Chapter 04 diagnostics - power window,

inoperative. 3. Power window switch RH front power window RH is inoperative

4. Power window motor RH front power window RH is inoperative

5. Harness front power window RH is inoperative

1. Power window switch RH front power window RH is inoperative
(using power window switch RH)
Front power window RH is Chapter 04 diagnostics - power window,

inoperative (using power window 2. Harness front power window RH is inoperative
switch RH). (using power window switch RH)

3. Power window motor RH front power window RH is inoperative
(using power window switch RH)
1. Foreign body Clear foreign body
2. The door glass Replace the door glass weatherstrip

Power window open / close is slow.
weatherstrip
3. The power window motor Replace the power window motor

ALL POWER WINDOWS ARE INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the power door/window fusible link (30 A) in body

(c) Inspect the instrument cluster fuse (7.5 A) in body junc-
tion box (C035).

2. INSPECT POWER WINDOW RELAY

(b) Remove the power window relay.

table below.

2-1
＜2Ω
5-3

3. CHECK HARNESS AND CONNECTOR (POWER WINDOW RELAY - GROUND)

(b) Remove the power window relay. 04
table below.

04
Power window relay (1) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (POWER WINDOW RELAY - MAIN POWER WINDOW
LOCK/UNLOCK SWITCH)

(b) Disconnect the D004 main power window lock/unlock switch connector.
(c) Remove the power window relay.

table below.

Power window relay (3) - D004 (3) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (POWER WINDOW RELAY - POWER WINDOW SWITCH RH)
(a) Disconnect the H004 power window switch RH connector.
(b) Measure the resistance according to the value (s) in the

table below.

Power window relay (3) - H004 (3) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (POWER WINDOW CONTROLLER - GROUND)
(a) Disconnect the C026 power window controller connector.

table below.

C026 (6) - Ground ＜2Ω

7. CHECK HARNESS AND CONNECTOR (MAIN POWER WINDOW LOCK/UNLOCK SWITCH -

GROUND)
(a) Disconnect the D004 main power window lock/unlock switch connector. 04
table below.

D004 (2) - Ground ＜2Ω 04

YES > Replace the main power window lock/unlock switch.
FRONT POWER WINDOW IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE

tion box (C035).


table below.

2-1 04
＜2Ω
5-3



table below.


LOCK/UNLOCK SWITCH)

(c) Disconnect the D004 main power window lock/unlock switch connector.

table below.



table below.

C026 (6) - Ground ＜2Ω


POWER WINDOW CONTROLLER)
(b) Disconnect the C026 power window controller connector.

table below.
D004 (8) - C026 (4)
D004 (7) - C026 (8) ＜2Ω

D004 (6) - C026 (7)

7. CHECK HARNESS AND CONNECTOR (POWER WINDOW RELAY - POWER WINDOW CONTROLLER)

(c) Disconnect the C026 power window controller connector.

table below.

Power window controller (3) - C026 (2) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (POWER WINDOW CONTROLLER - POWER WINDOW

MOTOR LH)

(b) Disconnect the D003 power window motor LH connector.

table below.

D003 (1) - C026 (3)
＜2Ω
D003 (2) - C026 (1)

9. INSPECT POWER WINDOW MOTOR LH
(a) Disconnect the D003 power window motor LH connector.

table below.

1-2 ＜2Ω

NO > Replace the power window motor LH.
10. INSPECT POWER WINDOW CONTROLLER

04
table below.

1-6 04
≥ 1 MΩ
3-6

YES > Replace the power window controller.
FRONT POWER WINDOW LH DOES NOT CLOSE

WIRING DIAGRAM
1. INSPECT FUSE

tion box (C035).


table below.

2-1 04
＜2Ω
5-3

3. CHECK HARNESS AND CONNECTOR (POWER WINDOW RELAY- GROUND)


table below.


LOCK/UNLOCK SWITCH)


table below.


5. INSPECT MAIN POWER WINDOW LOCK/UNLOCK SWITCH
(a) Disconnect the D004 main power window lock/unlock switch connector.
(b) Operate the power window LH open and close.

table below.
Tester Connection Condition Specified Condition

Down
3-7 ＜2Ω
(Switch LH)

table below.

3-6
Auto Down ＜2Ω
3-7

NO > Replace the main power window lock/unlock switch.


table below.
D004 (7) - C026 (8)

＜2Ω
D004 (6) - C026 (7)



table below.

C026 (6) - Ground ＜2Ω



table below.

1-2 ＜2Ω

MOTOR LH)

(c) Disconnect the D003 power window motor LH connector.

table below.

D003 (1) - C026 (3)
＜2Ω
D003 (2) - C026 (1)


(b) Disconnect the C026 power window controller connector. 04
table below.

04
Power window relay (3) - C026 (2) ＜2Ω



table below.

1-6
≥ 1 MΩ
3-6

FRONT POWER WINDOW LH DOES NOT OPEN

WIRING DIAGRAM
1. INSPECT FUSE

tion box (C035).


table below.

04
2-1
＜2Ω
5-3



table below.


LOCK/UNLOCK SWITCH)


table below.


(b) Operate the window LH open and close.

table below.

3-8 Up (Switch LH) ＜2Ω



table below.
D004 (8) - C026 (4) ＜2Ω



table below.

1-2 ＜2Ω


MOTOR LH)


table below.

D003 (1) - C026 (3)
＜2Ω
D003 (2) - C026 (1)



table below.

C026 (6) - Ground ＜2Ω


(b) Disconnect the C026 power window controller connector. 04
table below.

04
Power window controller (3) - C026 (2) ＜2Ω


table below.

1-6
≥ 1 MΩ
3-6

FRONT POWER WINDOW RH IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT FUSE

tion box (C035).
04



table below.

2-1
＜2Ω
5-3



table below.



(c) Disconnect the H004 power window switch RH connector.

table below.


5. INSPECT POWER WINDOW MOTOR RH
(a) Disconnect the H003 power window motor RH connector.

04
table below.

1-2 ＜2Ω
04

NO > Replace the power window motor RH.
6. CHECK HARNESS AND CONNECTOR (POWER WINDOW MOTOR RH - POWER WINDOW
SWITCH RH)

(b) Disconnect the H004 power window switch RH connector.

table below.

H003 (1) - H004 (5) ＜2Ω
H003 (2) - H004 (1) ＜2Ω

(b) Operate power window open and close.

table below.

2-4 Up (Switch
RH) ＜2Ω
1-3

table below.

2-1 Down
(Switch RH) ＜2Ω
4-3

8. INSPECT POWER WINDOW SWITCH RH

(b) Operate power window open and close.

table below.

1-2
Up ＜2Ω
3-5

table below.
04
1-2
Close ＜2Ω
4-5
04
(e) Measure the resistance according to the value (s) in the

table below.

3-1
Down ＜2Ω
4-5

NO > Replace the power window switch RH.
POWER WINDOW SWITCH RH)


table below.

D004 (1) - H004 (4)
＜2Ω
D004 (4) - H004 (2)

GROUND)


table below.

D004 (2) - Ground ＜2Ω

FRONT WINDOW RH IS INOPERATIVE (USING THE FRONT POWER

WINDOW SWITCH RH)
WIRING DIAGRAM 04
04
1. INSPECT FUSE

tion box (C035).

2. INSPECT POWER RELAY


table below.

2-1
＜2Ω
5-3


table below.

04



table below.


5. INSPECT POWER WINDOW MOTOR RH

table below.

1-2 ＜2Ω

NO > Replace the power window motor RH.
6. CHECK HARNESS AND CONNECTOR (POWER WINDOW MOTOR RH - POWER WINDOW
SWITCH RH)

(b) Disconnect the H003 power window motor RH connector.

table below.

H003 (1) - H004 (5)
＜2Ω
H003 (2) - H004 (1)

7. INSPECT POWER WINDOW SWITCH RH

(a) Operate the power window RH open and close. 04
table below.

1-2 04
Up ＜2Ω
3-5

table below.

1-2
Close ＜2Ω
4-5

table below.

3-1
Down ＜2Ω
4-5

NO > Replace the power window switch RH.

POWER WINDOW SWITCH RH)
(b) Disconnect the H004 power window switch RH connector.

table below.

D004 (1) - H004 (4)
＜2Ω
D004 (4) - H004 (2)

GROUND)


table below.

D004 (2) - Ground ＜2Ω

YES > Replace the main power window lock/unlock switch.
DIAGNOSTICS - OUTSIDE MIRROR 04-819
OUTSIDE MIRROR
LOCATION
04
04
1 Outside Mirror Assy LH 3 Instrument Cluster
2 Outside Mirror Assy RH 4 Outside Mirror Remote Control Switch

04-820 DIAGNOSTICS - OUTSIDE MIRROR
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH

OUTSIDE MIRROR DEFROST SWITCH

1 R-G Outside mirror motor LH
2 - -
3 - -
4 - -
5 LG Outside mirror motor LH
6 GR-R Outside mirror motor
7 R-Y Outside mirror motor RH
8 BR-W Outside mirror motor RH
9 W-B Ground
10 GR Power
BASIC INSPECTION
Yes Go to next step 04
replacement”
Check the outside mirror. Yes Go to next step

• Turn the ignition switch ON. 04
2 • Adjust the outside mirror LH and the out-
side mirror RH. No Go to problem symptoms table
Does the outside mirror work correctly?
Check the outside mirror. Yes Go to problem symptoms table

3 Replace the outside mirror. Refer to “Chapter
• Fold the outside mirrors. No
Does the outside mirror work correctly? 82 windshield - outside mirror, replacement”

Use the table below to help you find the cause of the problem. The numbers indicate the probability of the
1. Fuse -
Chapter 85 door lock - front door

Mirrors are inoperative (Both sides) 2. Outside mirror defrost switch lock - replacement
3. Wire harness -

1. Outside mirror defrost switch lock - replacement
A single mirror is inoperative Chapter 82 windshield - outside

2. Outside mirror mirror, replacement
3. Wire harness -

Mirror adjustment UP/DOWN is Chapter 82 windshield - outside
inoperative 2. Outside mirror motor mirror, replacement
3. Wire harness -

Mirror adjustment LEFT/RIGHT is Chapter 82 windshield - outside
inoperative 2. Outside mirror motor mirror, replacement
3. Wire harness -
MIRRORS ARE INOPERATIVE (BOTH SIDES)

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the radio & cigarette fuse (15 A) in body junction
box(C035).

YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH -
GROUND)

(b) Disconnect the C020 outside mirror remote control switch connector.

table below.

C020 (10) - Ground ≥ 1 ΜΩ


GROUND)


table below.
C020 (9) - Ground ＜2Ω

4. CHECK HARNESS AND CONNECTOR (OUTSIDE MIRROR REMOTE CONTROL SWITCH - RADIO
& CIGARETTE FUSE)


table below.
Specified
Tester Connection
Condition
Radio & cigarette fuse (15 A) - C020 (10) ＜2Ω

YES > Replace the outside mirror remote control switch.
A SINGLE MIRROR IS INOPERATIVE

WIRING DIAGRAM
1. INSPECT OUTSIDE MIRROR REMOTE CONTROL SWITCH

(c) Inspect outside mirror remote control switch according to

the value(s) in the table below.
Tester Specified 04
Item Condition
10 - 6
Left
1-9
10 - 1
Right
Outside 6-9
Mirror LH ＜2Ω
10 - 5
Up
6-9
10 - 6
Down
5-9

NO > repalce outside mirror remote control switch.
OUTSIDE MIRROR LH)

(b) Disconnect the D005 outside mirror connector.
(c) Disconnect the C020 outside mirror remote control switch connector.

table below.

D005 (2) - C020 (5)
＜2Ω
D005 (3) - C020 (6)


OUTSIDE MIRROR LH)


table below.

D005 (3) - C020 (6)
＜2Ω
D005 (4) - C020 (1)

YES > Replace the outside mirror.
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE

WIRING DIAGRAM
04
04


the value(s) in the table below
Tester Specified
Item Condition
10 - 5
Up
Outside 6-9
Mirror LH ＜2Ω
10 - 6
Down
5-9

NO > Repalce the outside mirror remote control switch.
OUTSIDE MIRROR LH)


table below.

C020 (5) - D005 (2)
＜2Ω
C020 (6) - D005 (3)

YES > Replace the outside mirror LH.
MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE

WIRING DIAGRAM
04
04


the value(s) in the table below
Tester Specified
Item Condition
10 - 6
Left
1-9
Outside Mirror LH ＜2Ω
10 - 1
Right
6-9

NO > Replace outside mirror remote control switch.
OUTSIDE MIRROR LH)


table below.

C020 (6) - D005 (3)
＜2Ω
C020 (1) - D005 (4)

YES > Replace the outside mirror.
DIAGNOSTICS - REAR WINDOW DEFROSTER SYSTEM 04-833
REAR WINDOW DEFROSTER SYSTEM

LOCATION
04
04
1 Rear Window Defrost Grid 3 Instrument Cluster
2 Rear Window Defrost Switch 4 Front Dome Lamp Switch

04-834 DIAGNOSTICS - REAR WINDOW DEFROSTER SYSTEM
SYSTEM DESCRIPTION
1. GENERAL
The defrost system's thin heater wires are attached to the inside of the rear window and defog the
window surface quickly. The rear window defrost switch controls the operation of the rear window
defrost grid. The rear window defrost grid only operates when the rear window defrost switch is ON.
2. FUNCTION OF MAIN COMPONENTS
Component Description
Receives rear defrost activation signals from rear window defrost switch
Rear window defrost relay
and supplies power to rear window defrost grid.
Rear window defrost grid Receives power from rear window defrost relay and heats defrost grid.
BASIC INSPECTION
04
Yes Go to next step
Check battery voltage.
replacement”
Yes Go to next step

04
Check ignition switch.
Repair or replace ignition switch. Refer to
2 • The ignition switch should work correctly. “Chapter 91 vehicle control system - assy,
removal & installation and disassembly &
reassembly”
Check rear window defrost fuse. Yes Go to next step

3 • Check the rear window defrost fuse.
Check rear window defrost switch. Replace rear window defrost switch. Refer to
• Press the rear window defrost switch. Yes “Chapter 83 instrument panel - instrument
4 • The rear window defrost switch should cluster, replacement”
work correctly.
Is the check result normal? No Go to next step
Check rear window defrost grid. Replace rear window defrost grid. Refer to
• Press the rear window defrost switch. Yes “chapter 82 Windshield - windshield,
5 • The rear window defrost grid should work replacement”
correctly.

1. Fuse -
2. Rear window defrost relay -
Chapter 83 instrument panel -

Defroster system is inoperative 3. Rear window defrost switch instrument cluster, replacement
Chapter 82 Windshield - rear win-

4. Rear window defrost grid dow glass, replacement
5. Wire harness -
DEFROSTER SYSTEM IS INOPERATIVE

WIRING DIAGRAM
04
04
1. INSPECT FUSE
(b) Inspect the rear defroster fuse (15 A) in body junction

box(C035).
(c) Inspect the instrument cluster fuse (7.5 A) in body
junction box(C035).

YES > Go to step 3.
NO > If the instrument cluster fuse is blown, go to next step.
If the rear defroster fuse is blown, replace the fuse.
2. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST SWITCH - GROUND)

(b) Disconnect the C019 rear window defrost switch.

table below.

C019 (2) - Ground ≥ 1 ΜΩ

3. INSPECT REAR WINDOW DEFROST SWITCH

(c) Inspect the rear window defrost switch according to the

Position Tester Connection Specified Condition

Release 3-6 ≥ 1 ΜΩ
Press 3-6 ＜2Ω

NO > Replace the rear window defrost switch.
4. INSPECT REAR DEFROSTER RELAY

(b) Remove the rear defroster relay.
(c) Inspect the rear defroster relay according to the value(s)

in the table below.

04
1–2 Continuity
3–5 ＜2Ω
04
NO > Replace the rear defroster relay.

table below.

C019 (3) - Ground ＜2Ω


table below.
Standard voltage


YES > Go to step 9.
7. CHECK HARNESS AND CONNECTOR (INSTRUMENT FUSE - JUNCTION CONNECTOR)


table below.
Specified
Tester Connection
Condition
Instrument cluster fuse (7.5 A) - C050 (12) ＜2Ω

8. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR WINDOW DEFROST
SWITCH)


table below.

C050 (14) - C019 (2) ＜2Ω


(b) Disconnect the C019 rear window defrost switch. 04

table below.
Standard voltage

10. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - REAR WINDOW DEFROST
SWITCH)

(c) Disconnect the C019 rear window defrost switch.

table below.

C050 (6) - C019 (6) ＜2Ω

11. CHECK HARNESS AND CONNECTOR (REAR WINDOW DEFROST GRID - GROUND)

(b) Disconnect the J011 rear window defrost grid.

table below.

J011 (1) - Ground ＜2Ω

12. CHECK HARNESS AND CONNECTOR (REAR DEFROSTER RELAY - REAR WINDOW DEFROST
GRID)

(b) Disconnect the J010 rear window defrost grid.
(c) Remove the rear defroster relay.

table below.

Rear defroster relay (3) - J010 (1) ＜2Ω

YES > Replace the rear window defrost grid.
DIAGNOSTICS - INSTRUMENT CLUSTER 04-843
INSTRUMENT CLUSTER
PRECAUTION
1. POWER OFF. 04
(b) Make sure ignition switch off if no specific instructions.
2. DISCONNECTING THE NEGATIVE BATTERY CABLE WILL RESET BOTH THE TRIP ODOMETER
AND THE CLOCK TO ‘ 0 ’.
04
NOTE
The total odometer can not be reset to ‘ 0 ’.
3. THE AUDIO SYSTEM WILL LOSE STORED MEMORY DATA IF THE NEGATIVE BATTERY CABLE
IS DISCONNECTED.
NOTE
instructions”).
Switch Type Ignition Switch (position) Engine (condition)


Expression

04-844 DIAGNOSTICS - INSTRUMENT CLUSTER
LOCATION (4 CONNECTORS)
1 Instrument Cluster 3 Fuel Level Sensor
2 Speedometer Sensor
INSTRUMENT CLUSTER INFORMATION
04
04
GAUGES
No Content Description
1 Fuel gauge The fuel gauge indicates the approximate fuel level in the tank.
Receving signal from coolant temperature indicator, the ECT

2 ECT gauge
gauge indicates the engine coolant temperature.
Receiving signal from the ECM, the tachometer indicates

16 Tachometer
engine revolutions per minute (RPM).
According to the signal received from the speedometer sen-

19 Speedometer
sor, the speedometer indicates the vehicle running speed.
WARNING / INDICATOR LIGHTS
3 ABS warning light Warning light will turn on when ABS is detected malfunction.
Engine oil pressure Engine oil pressure warning light will be illuminated when
4
warning light receiving signal from the engine oil pressure switch.
Coolant fluid level warning Coolant fluid level warming light turns on when coolant level is
5
light lower than specification.
Engine oil pressure Engine oil pressure indicator light turns on according to the
6
indicator light signal from engine oil pressure warning switch.
Left turn signal/hazard Left turn signal/hazard indicator light flashes when the turn
7
indicator light signal switch or hazard switch is activated.
SRS warning light will turn on when SRS is detected malfunc-

8 SRS warning light
tion.
Seat belt warning light turns on when receiving the seat belt
9 Seat belt warning light
warning signal.
High beam indicator light turns on when high beam is on and

10 High beam indicator light
receive headlamp relay signal.
Brake warning light turns on when receiving signals from park-

11 Brake warning light
ing brake switch or brake fluid level sensor.
12 Charging warning light Charging warning light turns on when charging system is fault.
Right turn signal/hazard Right turn signal/hazard indicator light flashes when the turn
13
Door ajar warning light turns on when receiving the door ajar
14 Door ajar warning light
signal.
ECM will turn on the MIL when engine electric control system
15 MIL
has problem.
Fuel level warning light turns on when fuel level lower than
17 Fuel level warning light
specified level.
LIQUID CRYSTAL DISPLAY
18 Odometer Display driving distance and can not be reset to “0”.
TERMINALS OF INSTRUMENT CLUSTER
04
04
Terminals No Wiring Color Description

A1 Y-R Fuel gauge signal, to fuel level sensor.
A2 P ECT gauge signal, to coolant temperature indicator.
A3 W-B ECT gauge ground.
A4 W-B Tachometer ground.
A5 - -
A6 - -
A7 G-B To combination switch.
Coolant Fluid level warning light signal, to coolant level

A8 V-W
sensor.
C011
A9 R-L ABS warning light signal, to ABS unit.
A10 - -
Engine oil pressure warning light signal, to engine oil

A11 P-L
pressure switch.
A12 - -
A13 - -
A14 - -
A15 - -
A16 - -
B1 - -
B2 - -
B3 - -
B4 - -
B5 - -
C012
B6 BR - W Speedometer signal, to speedometer sensor.
B7 R-B Speedometer signal, to speedometer sensor.
B8 - -
B9 R-L To ignition switch.
B10 Y-G Fuel level warning light signal, to fuel level sensor.

Brake warning light signal, to parking brake switch and
C1 B
brake fluid level sensor.
04
C2 B-R To ignition switch.
C3 - -
C4 V MIL signal, to ECM.
C5 - -
04
C6 Y Charging warning light signal, to generator.
C013
C7 - -
Door ajar warning light signal, to remote keyless entry

C8 Y-G
receiver.
C9 R-G High beam indicator light signal, to combination switch.
C10 G-Y Right turn signal, to combination switch.
C11 W-B Left turn, right turn, high beam indicator light ground.
C12 B-Y Tachometer signal, to ECM.
D1 G To power supply.
D2 W-B Ground
D3 W Door ajar warining light signal, to front dome light.
Door ajar warining light signal, to front door ajar switch

D4 L-R
RH.
Door ajar warining light signal, to front door ajar switch

D5 L-W
LH.
D6 - -
C014 D7 R-L Door ajar warining light signal, to rear hatch ajar switch.
Door ajar warining light signal, to sliding door ajar switch

D8 Y
RH.
D9 - -
Door ajar warining light signal, to rear dome light, sliding

D10 R-Y
door step light LH, sliding door step light RH.
D11 - -
D12 - -
D13 - -
BASIC INSPECTION
NOTE
Do not perform basic inspection until engine temperature reaches the specified value. If on-road test is
needed， must have at least two people to perform the test.
Step Conditions Action

Yes Go to next step.
1 • The battery voltage should above 12 V. Charge or replace the battery.
Is the check result normal？ No Refer to “Chapter 20A starting
and charging - battery”.
Check tachometer. Yes Go to next step.

• Connect hand-held tester, reading the engine
rotating speed data.
• Reading engine rotating speed data with 1000 ～
2 Go to the problem symptoms
2000 r/min and 3000 ～ 6000 r/min. No
• The variation of error in ± 100 ～ 200 r/min，± 150 table.
～ 300 r/min.
Check speedometer. Yes Go to next step.

• Connect hand-held tester, reading the vehicle
speed data.
• Reading vehicle speed data with 20 ～ 100 Km/h，
120 Km/h and 140 Km/h.
• The variation of error in + 5， + 6， + 7 Km/h.
3 • The pointer should be without jump when vehicle Go to the problem symptoms
is at constant speed or constant acceleration. No
table.
NOTE
Tire wear and incorrect tire pressure will lead
inaccurate data.
Check engine oil pressure warning light. Yes Go to next step.

• Engine oil pressure warning light should be illumi-
4 nated. Go to the problem symptoms
• After engine starts, engine oil pressure warning No
table.
light should go off.
Check charging warning light. Go to the problem symptoms

Yes
• Turn the ignition switch ACC. table.
5 • Charging warning light turns on.
• Charging warning light should turn off after engine Refer to “Chapter 20A starting
starts. No
and charging - generator”.

04
SYSTEM
1. Instrument cluster illumi- Chapter 04 diagnostics - lighting, problem

nation circuits symptoms table
The instrument cluster background
illumination is inoperative 04
2. Instrument cluster cluster, replacement
GAUGES
Chapter 04 diagnostics - instrument cluster, mal-
1. Speedometer sensor function in speedometer
Chapter 04 diagnostics - instrument cluster, the

Malfunction in speedometer 2. Speedometer circuits instrument cluster is inoperative

3. Speedometer instrument cluster is inoperative

1. CKP sensor function in tachometer

Malfunction in tachometer 2. Tachometer circuits function in tachometer

3. Tachometer function in tachometer

1. Fuel level sensor function in fuel gauge

Malfunction in fuel gauge 2. Fuel gauge circuits function in fuel gauge

3. Fuel gauge function in fuel gauge
1. Coolant temperature Chapter 04 diagnostics - instrument cluster, mal-

indicator function in ECT gauge
Malfunction in ECT gauge Chapter 04 diagnostics - instrument cluster, mal-

2. ECT gauge circuits function in ECT gauge

3. ECT gauge function in ECT gauge
WARNING LIGHTS
1. Engine electronic control Chapter 04 diagnostics - gasoline engine control sys-

system tem, diagnostic trouble code chart
2. Malfunction indicator light Chapter 04 diagnostics - diesel engine control system,

MIL never/always on
circuits diagnostic trouble code chart
Chapter 04 diagnostics - diesel engine control system,

3. Instrument cluster diagnostic trouble code chart
Chapter 04 diagnostics - instrument cluster, brake

1. Brake fluid level sensor warning light never/always on

2. Parking brake switch warning light never/always on
Brake warning light
never/always on Chapter 04 diagnostics - instrument cluster, brake
3. Brake warning light
circuits warning light never/always on

4. Instrument cluster warning light never/always on
Chapter 04 diagnostics - anti-lock brake system,

1. ABS system problem symptoms table
ABS warning light Chapter 04 diagnostics - anti-lock brake system,

never/always on 2. ABS warning light circuits problem symptoms table

3. Instrument cluster problem symptoms table
Chapter 04 diagnostics - instrument cluster, coolant

1. ECT sensor fluid level warning light never/always on
2. Engine coolant fluid level Chapter 04 diagnostics - instrument cluster, coolant

Coolant fluid level sensor fluid level warning light never/always on
warning light never/
always on 3. Coolant fluid level Chapter 04 diagnostics - instrument cluster, coolant
warning lightcircuits fluid level warning light never/always on
4. Instrument cluster Chapter 04 diagnostics - instrument cluster, coolant

fluid level warning light never/always on
1. Engine oil pressure switch Chapter 04 diagnostics - supplemental restraint

system, SRS warning light never/always on
Engine oil pressure Chapter 04 diagnostics - instrument cluster, engine
warning light never/ 2. Engine oil pressure warn-
ing light circuits coolant temperature warning light never/always on
always on
3. Instrument cluster Chapter 04 diagnostics - instrument cluster, engine
coolant temperature warning light never/always on
INDICATOR LIGHTS
Chapter 04 diagnostics - lighting, problem 04
1. Fuses symptoms table
Chapter 04 diagnostics - lighting, problem

2. Combination switch symptoms table
Turn signal/hazard Chapter 04 diagnostics - lighting, problem
indicator light never/ 3. Hazard switch symptoms table
always on 04
4. Turn signal/hazard indicator light Chapter 04 diagnostics - lighting, problem
circuits symptoms table

5. Instrument cluster symptoms table


High beam indicator
light never/always on Chapter 04 diagnostics - lighting, problem
3. High beam indicator light circuits symptoms table

Chapter 04 diagnostics - instrument cluster,

1. Door ajar switch door ajar indicator never/always on
Door ajar indicator light Chapter 04 diagnostics - instrument cluster,

never/always on 2. Door ajar indicator light circuits door ajar indicator never/always on

3. Instrument cluster door ajar indicator never/always on
MALFUNCTION IN SPEEDOMETER
WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - GROUND)

(b) Disconnect the G002 speedometer sensor connector.

table below.
G002 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SPEEDOMETER SENSOR)

(c) Disconnect the G002 speedometer sensor connector.

table below.
C012 (B6) - G002 (3)

＜2Ω
C012 (B7) - G002 (1)

3. INSPECT SPEEDOMETER SENSOR

(b) Remove the speedometer sensor.
(c) Rotate the speedometer sensor axle.

(d) Measure the resistance between the speedometer
sensor pin 1 and pin 3.
Pulse signal: Pulse of resistance signal pre revolu-
tion.

NO > Replace the speedometer sensor.
MALFUNCTION IN TACHOMETER
WIRING DIAGRAM
NOTE
An abnormal running engine will lead the tachometer pointer instable.
Check if the engine has normal start.
YES > Go to step 1.
NO > Refer to “Chapter 04 diagnostics - gasoline engine control system, problem symptoms table”
1. CHECK HARNESS AND CONNECTOR (TACHOMETER - GROUND)


table below.
C011 (A4) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECM)


table below.
C013 (C12) - E001 (45) ＜2Ω
(e) Start the engine until the engine temperature reaches to

normal condition.
(f) Measure the pulse signal between the instrument cluster

connector C013, pin 12 and ground.
Pulse signal: Appr 33.3 Hz (1000 r / min)

MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT

NEVER OR ALWAYS ON
WIRING DIAGRAM
• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank).
• Fuel level warning light will be illuminated when fuel level lower than 345 mm ( ≤ 7 ～ 10 L) or fuel level
sensor resistance greater than 96.5 ± 4 Ω.
• Fuel level warning light will turn off when fuel level higher than 345 mm ( ＞ 7～ 10 L) or fuel level sensor
resistance smaller than 96.5 ± 4 Ω.
1. INSPECT FUEL LEVEL SENSOR

(b) Disconnect the U001 fuel level sensor connector.
(c) Measure the resistance between the fuel level sensor

U001 pin 1 and pin 2.
(d) Remove the fuel level sensor and measure the resis-
tance following the table below.
Position Empty Warn threshold 1/4 1/2 3/4 Full
Resis-
110 ± 7 96.5 ± 4 84.3 ± 4 32.5 ± 4 18.2 ± 4 3.4 ± 1 04
tance(Ω)

NO > Replace the fuel level sensor.。
2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND) 04


table below.
U001 (3) - Ground ＜2Ω


table below.
Standard voltage

U001 (1) - Ground 5V

NO > Replace the fuel level sensor.
4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FUEL LEVEL SENSOR)

(b) Disconnect the C011 instrument cluster connectors.
(c) Disconnect the C012 instrument cluster connectors.
(d) Measure the resistanceaccording to the value(s) in the

table below.

C011 (A1) - U001 (1)
＜2Ω
C012 (B10) - U001 (2)

MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE

WIRING DIAGRAM
04
04
• Ensure engine coolant level within specified value.
• Ensure engine coolant temperature normal.
1. INSPECT ECT INDICATOR

(b) Remove ECT indicator.
CAUTION
Whenever remove the ECT indicator, ensure the engine is cold (Engine coolant temperature lower than
40 ℃ ).
(c) Measure the ECT sensor resistance following the table below.
Temperature ( ℃ ) 50 85 110 115
Resistance (Ω) 226 ± 35 64 ± 8 28 26.4 ± 2

NO > Replace the ECT indicator.
2. CHECK HARNESS AND CONNECTOR (ECT INDICATOR - GROUND)

(b) Disconnect the E025 ECT indicator connector.

table below.
Standard voltage

YES > Replace the ECT indicator.
3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECT INDICATOR)

(c) Disconnect the E025 ECT indicator connector.

table below.
C011 (A2) - E025 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (ECT GAUGE - GROUND)

table below.

04

BRAKE WARNING LIGHT NEVER / ALWAYS ON

WIRING DIAGRAM
• Check if the brake fluid (or clutch) level is too low. If the brake fluid (or clutch) level is low, fill the brake
fluid reservoir with genuine FOTON specified fluid.
• Fix four tires.
• Pull and release the parking brake.
Check if the brake warning light never or always on.
YES > (Always on) Go to step 1.
NO > (Never on) Go to step 4.
1. INSPECT PARKING BRAKE SWITCH

(b) Release the parking brake.
(c) Disconnect the C043 parking brake switch connector.
Check if the brake warning light turns off.
YES > Replace the parking brake switch.
2. INSPECT BRAKE FULID LEVEL SENSOR

(b) Disconnect the C039 brake fulid level sensor. 04
YES > Replace the brake fulid levle sensor.
3. CHECK HARNESS AND CONNECTOR (BRAKE FULID LEVEL SENSOR - JUNCTION 04
CONNECTOR)

(b) Disconnect the C039 brake fulid level sensor.

table below.
C039 (2) - C055 (6) ＜2Ω

YES > Replace the brake fulid level sensor.


table below.
C055 (1) - Ground ＜2Ω

5. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND)

(b) Disconnect the C043 parking brake switch connector.
(c) Pull the parking brake.

table below.

C043 (1) - Ground ＜2Ω

NO > Replace the parking brake switch.
6. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - PARKING BRAKE SWITCH)


table below.
C013 (C1) - C043 (1) ＜2Ω


table below.

04
C055 (1) - Ground ＜2Ω



table below.
C055 (6) - Ground ＜2Ω

9. CHECK HARNESS AND CONNECTOR (BRAKE FULID LEVEL SENSOR- JUNCTION

CONNECTOR)


table below.
C039 (2) - C055 (6) ＜2Ω



table below.

1-2 ＜2Ω

NO > Replace the brake fulid level sensor.
11. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - BRAKE FULID LEVEL SEN-
SOR)

(c) Disconnect the C039 brake fulid level sensor.

table below.
04
C013 (C1) - C039 (1) ＜2Ω

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS ON

WIRING DIAGRAM
• When turning the ignition switch ON, the engine oil pressure warning light will turn on.
• Engine oil pressure warning light will turn off after engine starts.
• Engine oil pressure warning light will turn on when the engine oil pressure is lower than 0.050 ± 0.011
MPa.
• Engine oil pressure warning light will turn off when the engine oil pressure is higher than 0.050 ± 0.011
MPa.
NOTE
If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immedi-
ately. Check oil level, if oil level is out of specification, it needs to be repaired first.
Check if engine oil pressure warning light is always on or never.
1. INSPECT ENGINE OIL PRESSURE WARNING LIGHT

(b) Disconnect the E024 engine oil pressure switch connector.
Check if the engine oil pressure warning light turns off.
YES > Replace the engine oil pressure switch.
2. CHECK HARNESS AND CONNECTOR (ENGINE OIL PRESSURE SWITCH - GROUND)

(b) Disconnect the E024 engine oil pressure switch connector. 04
table below.
Standard resistance (check for short

04
E024 (1) - Ground ≥ 1 MΩ

3. INSPECT ENGINE OIL PRESSURE SWITCH


table below.
Standard voltage
E024 (1) - Ground Battery voltage

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE OIL PRESSURE

SWITCH)


table below.
C011 (A11) - E024 (1) ＜2Ω


WIRING DIAGRAM
04
04
• Engine coolant temperature warning light will turn on.
• Engine coolant temperature warning light will turn off.
Check if engine coolant temperature warning light never or always on.
YES > (Never on) Go to step 1.
NO > (Always on) Go to step 3.
1. INSPECT COOLANT FLUID LEVEL WARNING LIGHT

(b) Disconnect the A006 engine coolant fluid level sensor connector.
Check if the coolant fluid level warning light turns off.
YES > Replace the engine coolant fluid level sensor.
2. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT FLUID LEVEL SENSOR - GROUND)

table below.
Standard voltage

A006 (3) - Ground Battery voltage



table below.

A006 (2) - Ground ＜2Ω

4. INSPECT ENGINE COOLANT FLUID LEVEL SENSOR

(b) Disconnect the A006 engine coolant fluid level sensor connector. 04
table below.

04
A006 (2) - A006 (3) ＜2Ω

NO > Replace the engine coolant fluid level sensor.
5. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE COOLANT FLUID
LEVEL SENSOR)


table below.

A006 (3) - C011 (A8) ＜2Ω

DOOR AJAR WAINING LIGHT NEVER / ALWAYS ON

WIRING DIAGRAM
• Close all doors.
• Turn the ignition switch ON. Door ajar warning light will turn off.
04
• Door ajar warning light will turn on when any door is open.
Check if door ajar warning light always/never on.
1. INSPECT DOOR AJAR SWITCH 04
(b) Close all doors.
(c) Following sequence disconnect each connector.
• Disconnect the A004 front door ajar switch LH connector.
• Disconnect the A008 front door ajar switch RH connector.
• Disconnect the F005 sliding door ajar switch connector .
• Disconnect the J008 rear hatch ajar switch connector.
Check if the door ajar warning light turns off.
YES > Replace the door ajar switch which is fault.
(a) Disconnect the F003 front dome light connector.

(a) Disconnect the C033 rear dome light switch connector.

YES > Replace the rear dome light switch.
(a) Disconnect the F004 rear dome light connector.

YES > Replace the rear dome light.
5. INSPECT STEP LAMP RH
(a) Disconnect the N001 step lamp RH connector.

YES > Replace the step lamp RH.
6. INSPECT POWER DOOR LOCK CONTROL UNIT
(a) Disconnect the C038 power door lock control unit connector.
YES > Replace the power door lock control unit.
NO > Replace the instrument cluster.
7. INSPECT FUSE
(b) Inspect the dome light fuse (7.5 A) in body junction box
(C035).

NO > Go to step 11.
8. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - JUNCTION CONNECTOR)


table below.
Dome light fuse (7.5 A) - C050 (8) ＜2Ω


04


table below. 04

C050 (1) - C050 (8) ＜2Ω

10. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - INSTRUMENT CLUSTER)


table below.

C050 (1) - C013 (C7) ＜2Ω

11. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FRONT DOME LIGHT)


table below.

C014 (D3) - F003 (2) ＜2Ω

12. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FRONT DOOR AJAR SWITCH
RH)

(b) Disconnect the A004 front door ajar switch RH connector.

table below.

C014 (D4) - A004 (1) ＜2Ω

LH)
(a) Disconnect the C014 instrument cluster connector. 04

(b) Disconnect the A008 front door ajar switch LH connector.

table below.
C014 (D5) - A008 (1) ＜2Ω

14. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - SLIDING DOOR AJAR SWITCH
RH)

(b) Disconnect the F005 sliding door ajar switch RH connector.

table below.
C014 (D8) - F005 (1) ＜2Ω

15. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - REAR HATCH AJAR SWITCH)

(b) Disconnect the J008 rear hatch ajar switch connector.

table below.

C014 (D7) - J008 (1) ＜2Ω

16. CHECK HARNESS AND CONNECTOR (REAR DOME LIGHT SWITCH - GROUND)
(a) Disconnect the C033 rear dome light switch connector.

table below.

C033 (4) - Ground ＜2Ω

17. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - REAR DOME LIGHT SWITCH
SWITCH)
(a) Disconnect the C014 instrument cluster connector.。 04

(b) Disconnect the C033 rear dome light switch connector.

table below.
C014 (D9) - C033 (1) ＜2Ω

18. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - REAR DOME LIGHT)

(b) Disconnect the F004 rear dome light connector.

table below.
C014 (D10) - F004 (2) ＜2Ω

19. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - STEP LAMP RH)

(b) Disconnect the N001 step lamp RH connector.

table below.
C014 (D10) - N001 (2) ＜2Ω

20. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - POWER DOOR LOCK CON-
TROL UNIT)

(b) Disconnect the C038 power door lock control unit connector.

table below.

C013 (C8) - C038 (14) ＜2Ω

LOCATION (3 CONNECTORS)
04
04
1 Instrument Cluster 3 Fuel Level Sensor
2 Speedometer Sensor
GAUGES
According to the signal received from the speedometer sen-
1 Speedometer
sor, the speedometer indicates the vehicle speed.
5 Fuel gauge The fuel gauge indicates the approximate fuel level in the tank.
Receving signal from coolant temperature indicator, the ECT

6 ECT gauge
gauge indicates the engine coolant temperature.
WARNING / INDICATOR LIGHTS
Left turn signal/hazard Left turn signal/hazard indicator light flashes when the turn 04
2
High beam indicator light turns on when high beam is on and

3 High beam indicator light
receive headlamp relay signal.
Right turn signal/hazard Right turn signal/hazard indicator light flashes when the turn
4
04
Low pressure alarm light turns on according to the vacuum
7 Low pressure alarm light
alarm signal.
Fuel filter water trap Fuel filter water trap warning light turns on according to the fuel
8
warning light filter signal.
The ECM will illuminate preheat indicator when engine coolant

9 Preheat indicator
temperature lower than specified value.
Engine oil pressure Engine oil pressure indicator light turns on according to the
10
indicator light signal from engine oil pressure warning switch.
11 Charging warning light Charging warning light turns on when charging system is fault.
Brake warning light turns on when receiving signals from park-

12 Brake warning light
ing brake switch or brake fluid level sensor.
ECM will turn on the MIL when engine electric control system
13 MIL
has problem.
Low fuel warning light turns on when fuel level lower than
14 Low fuel warning light
specified level
Coolant fluid level warning Coolant fluid level warming light turns on when coolant level is
16
light lower than specification.
17 ABS warning light Warning light will turn on when ABS is detected malfunction.
Rear fog lamp indicator Rear fog lamp indicator light will turn on when rear fog switch
18
light is pressed.
LIQUID CRYSTAL DISPLAY
15 Odometer Display driving distance and can not be reset to “0”.
TERMINALS OF INSTRUMENT CLUSTER


A1 Y-O Low pressure alarm light signal, to vacuum alarm.
04
A2 Y-R Fuel gauge signal, to fuel level sensor.
A3 W-B ECT gauge ground.
A4 Y-G ECT gauge signal, to coolant temperature indicator.
A5 Y-G Low fuel warning light signal, to fuel level sensor.

04
A6 - -
C061 Brake warning light signal, to parking brake switch and

A7 B
brake fluid levle sensor.
A8 L-W Charging warning light signal, to generator.
A9 - -
Engine oil pressure warning light signal, to engine oil

A10 Y-B
pressure switch.
A11 L-W Preheat indicator signal, to preheat control unit.
A12 Y-G Fuel filter water trap warning light signal, to fuel filter.
B1 - -
B2 W-B Illumination ground.
B3 - -
B4 - -
B5 - -
C062
B6 - -
B7 W-B Left turn, right turn, high beam indicator light ground.
B8 G-B Left turn signal, to combination switch.
B9 R-G High beam indicator light signal, to combination switch.
B10 G-Y Right turn signal, to combination switch.
C1 Y-R ABS warning light signal, to ABS unit.
C2 R-L To power supply.
C3 - -
Coolant Fluid level warning light signal, to coolant level

C4 L-Y
C063 sensor.
C5 - -
C6 R Speedometer signal, to speedometer sensor.
C7 W-B Speedometer signal, to speedometer sensor.
C8 W-B Fuel gauge ground.

BASIC INSPECTION
NOTE
Do not perform basic inspection until engine temperature reaches the specified value. If on-road test is
needed， must have at least two people to perform the test.
Step Conditions Action

Yes Go to next step.
1 • The battery voltage should above 12 V. Charge or replace the battery.
Is the check result normal？ No Refer to “Chapter 20A starting
and charging - battery”.
Check tachometer. Yes Go to next step.

• Connect hand-held tester, reading the engine
rotating speed data.
• Separate reading engine rotating speed data with
2 Go to the problem symptoms
1000 ～ 2000 r/min， 3000 ～ 6000 r/min. No
• The variation of error in ± 100 ～ 200 r/min，± 150 table.
～ 300 r/min.
Check speedometer. Yes Go to next step.

• Connect hand-held tester, reading the vehicle
speed data.
• Separate reading vehicle speed data with 20 ～
100 Km/h， 120 Km/h ， 140 Km/h.
• The variation of error in + 5， + 6， + 7 Km/h.
3 • The pointer should be without jump when vehicle Go to the problem symptoms
is at constant speed or constant acceleration. No
table.
NOTE
Tire wear and incorrect tire pressure will lead
inaccurate data.
Check engine oil pressure warning light. Yes Go to next step.

• Engine oil pressure warning light should be illumi-
4 nated. Go to the problem symptoms
• After engine starts, engine oil pressure warning No
table.
light should go off.
Check charging warning light. Go to the problem symptoms

Yes
• Turn the ignition switch ACC. table.
5 • Charging warning light turns on.
• Charging warning light should turn off after engine Refer to “Chapter 20A starting
starts. No
and charging - generator”.

04
SYSTEM
1. Instrument cluster illumi- Chapter 04 diagnostics - lighting, problem

The instrument cluster back- nation circuits symptoms table
ground illumination is 04
inoperative Chapter 83 instrument panel - instrument
2. Instrument cluster cluster, replacement
GAUGES
1. Speedometer sensor malfunction in speedometer

Malfunction in speedometer 2. Speedometer circuits instrument cluster is inoperative

3. Speedometer instrument cluster is inoperative

1. CKP sensor malfunction in tachometer

Malfunction in tachometer 2. Tachometer circuits malfunction in tachometer

3. Tachometer malfunction in tachometer

1. Fuel level sensor malfunction in fuel gauge

Malfunction in fuel gauge 2. Fuel gauge circuits malfunction in fuel gauge

3. Fuel gauge malfunction in fuel gauge
1. Coolant temperature Chapter 04 diagnostics - instrument cluster,

indicator malfunction in ECT gauge
Malfunction in ECT gauge 2. ECT gauge circuits Chapter 04 diagnostics - instrument cluster,
malfunction in ECT gauge
3. ECT gauge Chapter 04 diagnostics - instrument cluster,

malfunction in ECT gauge
WARNING LIGHTS
1. Brake fluid level sensor warning light never/always on

2. Parking brake switch warning light never/always on
Brake warning light
never/always on Chapter 04 diagnostics - instrument cluster, brake
3. Brake warning light
circuits warning light never/always on


1. ABS system problem symptoms table
ABS warning light Chapter 04 diagnostics - anti-lock brake system,

never/always on 2. ABS warning light circuits problem symptoms table

3. Instrument cluster problem symptoms table
Chapter 04 diagnostics - instrument cluster, coolant

1. ECT sensor fluid level warning light never/always on
2. Engine coolant fluid level Chapter 04 diagnostics - instrument cluster, coolant

sensor fluid level warning light never/always on
Coolant fluid level
warning light never/
3. Engine coolant Chapter 04 diagnostics - instrument cluster, coolant
always on
temperature warning light fluid level warning light never/always on
circuits
4. Instrument cluster Chapter 04 diagnostics - instrument cluster, coolant

fluid level warning light never/always on
Chapter 04 diagnostics - supplemental restraint

1. Engine oil pressure switch system, SRS warning light never/always on
Engine oil pressure Chapter 04 diagnostics - instrument cluster, engine
warning light mever/ 2. Engine oil pressure
warning light circuits coolant temperature warning light never/always on
always on
Chapter 04 diagnostics - instrument cluster, engine
3. Instrument cluster coolant temperature warning light never/always on
Chapter 04 diagnostics - instrument cluster, low fuel

1. Fuel level sensor warning light never/always on
Low fuel warning light 2. Low fuel warning light Chapter 04 diagnostics - instrument cluster, low fuel
never/always on circuits warning light never/always on
Chapter 04 diagnostics - instrument cluster, low fuel

INDICATOR LIGHTS
Chapter 04 diagnostics - lighting, problem 04

Turn signal/hazard indicator light Chapter 04 diagnostics - lighting, problem

3. Hazard switch symptoms table
never/always on 04
4. Turn signal/hazard Chapter 04 diagnostics - lighting, problem
indicator light circuits symptoms table



High beam indicator light never/
always on Chapter 04 diagnostics - lighting, problem
3. High beam indicator light
circuits symptoms table

MALFUCTION IN SPEEDOMETER
WIRING DIAGRAM
1. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - GROUND)

(b) Disconnect the G002 speedometer sensor connector.

table below.
G002 (2) - Ground ＜2Ω

2. CHECK HARNESS AND CONNECTOR (SPEEDOMETER SENSOR - INSTRUMENT CLUSTER)

(c) Disconnect the G002 speedometer sensor connector.

table below.
C063 (C6) - G002 (3)

＜2Ω
C063 (C7) - G002 (1)

3. INSPECT SPEEDOMETER SENSOR

(b) Remove the speedometer sensor.
(c) Rotate the speedometer sensor axle.

(d) Measure the resistance between the speedometer
sensor pin 1 and pin 3.
Pulse signal: pulse of resistance signal pre revolu-
tion.

NO > Replace the speedometer sensor.
MAIFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT

NEVER OR ALWAYS ON
WIRING DIAGRAM
• Turn the ignition switch ON and ensure fuel tank have enough fuel (more than 1/4 in fuel tank).
• Fuel level warning light will be illuminated when fuel level is lower than 345 mm ( ≤ 7 ～ 10 L) or fuel
level sensor resistance greater than 96.5 ± 4 Ω.
• Fuel level warning light will turn off when fuel level is higher than 345 mm ( ＞ 7 ～ 10 L) or fuel level
sensor resistance smaller than 96.5 ± 4 Ω.

(c) Measure the resistance between the fuel level sensor

U001 pin 1 and pin 2.
(d) Remove the fuel level sensor and measure the resis-
tance following the table below.
Position Empty Warn threshold 1/4 1/2 3/4 Full
Resistance(Ω) 110 ± 7 96.5 ± 4 84.3 ± 4 32.5 ± 4 18.2 ± 4 3.4 ± 1


NO > Replace the fuel level sensor.。
04
2. CHECK HARNESS AND CONNECTOR (FUEL LEVEL SENSOR - GROUND)


table below. 04
U001 (3) - Ground ＜2Ω


table below.
Standard voltage

U001 (1) - Ground 5V

NO > Replace the fuel level sensor.


table below.

C067 (1) - Ground ＜2Ω



table below.

C067 (1) - C067 (6) ＜2Ω

6. CHECK HARNESS AND CONNECTOR (FUEL GAUGE - JUNCTION CONNECTOR)


table below.
04
C063 (C8) - C067 (6) ＜2Ω
04

7. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - FUEL LEVEL SENSOR)

(b) Disconnect the C061instrument cluster connector.

table below.

C061 (A2) - U001 (1)
＜2Ω
C061 (A5) - U001 (2)

MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE

WIRING DIAGRAM
• Ensure engine coolant temperature normal.
1. INSPECT ECT INDICATOR

(b) Remove ECT indicator.
CAUTION
Whenever remove the ECT indicator, ensure the engine is cold (Engine coolant temperature lower than
40 ℃ ).
(c) Measure the ECT indicator resistance following the table below.
Temperature ( ℃ ) 50 85 110 115
Resistance (Ω) 226 ± 35 64 ± 8 28 26.4 ± 2

NO > Replace the ECT indicator.
2. CHECK HARNESS AND CONNECTOR (ECT INDICATOR - GROUND)

(b) Disconnect the E025 ECT indicator connector. 04

table below.
Standard voltage

YES > Replace the ECT indicator.
3. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ECT INDICATOR)

(c) Disconnect the E025 ECT indicator connector.

table below.
C061 (A4) - E025 (1) ＜2Ω

4. CHECK HARNESS AND CONNECTOR (ECT GAUGE - GROUND)

table below.

BRAKE WARNING LIGHT NEVER / ALWAYS ON

WIRING DIAGRAM
04
04
• Check if the brake fluid (or clutch) level is too low. If the brake fluid (or clutch) level is low, fill the brake
fluid reservoir with genuine FOTON specified fluid.
• Fix four tires.
• Pull and release the parking brake.
Check if the brake warning light never or always on.
1. INSPECT PARKING BRAKE SWITCH

(b) Release the parking brake.
(c) Disconnect the C043 parking brake switch connector.
YES > Replace the parking brake switch.

YES > Reolace the brake fulid levle sensor.
3. CHECK HARNESS AND CONNECTOR (BRAKE FULID LEVEL SENSOR - JUNCTION

CONNECTOR)


table below.
C039 (2) - C067 (5) ＜2Ω

YES > Replace the brake fulid level sensor.


table below.

C067 (1) - Ground ＜2Ω

5. CHECK HARNESS AND CONNECTOR (PARKING BRAKE SWITCH - GROUND)

(b) Disconnect the C043 parking brake switch connector. 04
(c) Pull the parking brake.

table below.
C043 (1) - Ground ＜2Ω

NO > Replace the parking brake switch.
6. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - PARKING BRAKE SWITCH)


table below.
C061 (A7) - C043 (1) ＜2Ω



table below.
C067 (1) - Ground ＜2Ω



table below.
C067 (5) - Ground ＜2Ω

9. CHECK HARNESS AND CONNECTOR (BRAKE FULID LEVEL SENSOR- JUNCTION

CONNECTOR)


table below.
04
C039 (2) - C067 (5) ＜2Ω



table below.
C039 (1) - C039 (2) ＜2Ω

NO > Replace the brake fulid level sensor.
11. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - BRAKE FULID LEVEL SEN-
SOR)

(c) Disconnect the C039 brake fulid level sensor.

table below.
C061 (A7) - C039 (1) ＜2Ω

ENGINE OIL PRESSURE WARNING LIGHT NEVER / ALWAYS ON

WIRING DIAGRAM
04
04
• When turning the ignition switch ON, the engine oil pressure warning light will turn on.
• Engine oil pressure warning light will turn off after engine starts.
• Engine oil pressure warning light will turn on when the engine oil pressure is lower than 0.050 ± 0.011
MPa.
• Engine oil pressure warning light will turn off when the engine oil pressure is higher than 0.050 ± 0.011
MPa.
NOTE
If the engine oil pressure warning light is always on after engine starts. Do not shut off engine immedi-
ately. Check oil level, if oil level is out of specification, it needs to be repaired first.
Check if engine oil pressure warning light is always on or never.
1. INSPECT ENGINE OIL PRESSURE WARNING LIGHT

Check if the engine oil pressure warning light turns off.
2. CHECK HARNESS AND CONNECTOR (ENGINE OIL PRESSURE SWITCH - GROUND)


table below.
E024 (1) - Ground ≥ 1 MΩ

3. INSPECT ENGINE OIL PRESSURE SWITCH


table below.
Standard voltage
E024 (1) - Ground Battery voltage

4. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE OIL PRESSURE

SWITCH)


table below.
04
C061 (A11) - E024 (1) ＜2Ω


WIRING DIAGRAM
• Engine coolant temperature warning light will turn on.
• Engine coolant temperature warning light will turn off.
Check if engine coolant temperature warning light never or always on.
YES > (Never on) Go to step 1.
NO > (Always on) Go to step 3.
1. INSPECT COOLANT FLUID LEVEL WARNING LIGHT

(b) Disconnect the C064 engine coolant fluid level sensor connector.
Check if the coolant fluid level warning light turns off.

04
table below.
Standard voltage
C064 (2) - Ground Battery voltage 04



table below.
C065 (1) - Ground ＜2Ω



table below.
C065 (1) - C065 (8) ＜2Ω

5. CHECK HARNESS AND CONNECTOR (ENGINE COOLANT FLUID LEVEL SENSOR - JUNCTION
CONNECTOR)


table below.
C064 (3) - C065 (8) ＜2Ω

6. INSPECT ENGINE COOLANT FLUID LEVEL SENSOR

(b) Disconnect the C064 engine coolant fluid level sensor connector. 04
table below.

04
C064 (2) - C064 (3) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (INSTRUMENT CLUSTER - ENGINE COOLANT FLUID
LEVEL SENSOR)


table below.
C064 (2) - C063 (C4) ＜2Ω

04-916 DIAGNOSTICS - POWER DOOR LOCKS
POWER DOOR LOCKS

PRECAUTION


Expression
2. POWER OFF.
(a) Before removing or installing any electrical device, please disconnect the negative battery cable to pre-
vent damage to the device or personal injury.
NOTE
To prevent the key locked in the vehicle, do not leave the key in the vehicle when disconnecting the
negative battery cable.
(b) If no specific instructions, the ignition switch must be off.
3. Disconnecting the negative battery cable will reset both the trip odometer data and the clock to
‘ 0 ’.
NOTE
The total odometer data can not be reset to ‘ 0 ’.
4. The audio system will lose stored memory data if the negative battery cable is disconnected.
NOTE
instructions”).
DIAGNOSTICS - POWER DOOR LOCKS 04-917
LOCATION
04
04
1 Front Door Lock Actuator LH 3 Sliding Door Lock Actuator
2 Front Door Lock Actuator RH 4 Rear Hatch Lock Actuator

TERMINALS OF POWER DOOR LOCK CONTROL UNIT
Terminal No. Wiring Clolor Description

1 W-L Power supply
2 - -
3 - -
4 - -
5 G-W Signal input (Lock)
6 G-B Signal input (Unlock)
7 L-H Load output
8 L-Y Load output
9 - -
10 W-H Ground
TERMINALS OF REMOTE KEYLESS ENTRY RECEIVER
04
04
Terminal No. Wiring Clolor Description

1 W-H Junction connector
2 - -
3 - -
4 - -
5 - -
6 - -
7 G-H Key lock switch (Lock)
8 R Power supply
9 - -
10 - -
11 - -
12 - -
13 - -
14 Y-G Instrument panel
15 G-W Key lock switch (Unlock)

BASIC INSPECTION
Check the battery voltage. Yes Go to next step

1 • The battery voltage should be above 12V. Charge or replace the battery. Refer to
“Chapter 20A starting and charging - battery”
Check basic function Yes Go to next step

• Using the key in driver‘s door cylinder to
lock, all doors should be locked.
2
• Using the key in driver‘s door cylinder to No Go to problem symptoms table.
unlock, all doors should be unlocked.
Check remote control function Yes Go to problem symptoms table.

• When all doors are closed, using the key
to lock the doors, all doors should be
locked.
3
• When all doors are closed, using the key No Replace the key.
to unlock the doors, all doors should be
unlocked.

cause of the problem. Check each part in order. If necessary, replace these parts
04
Chapter 04 diagnostics - power door
1. Power, ground circuits locks, the function of power door locks is
inoperative (using the key)

The function of power door locks 04
2. Power door lock control unit locks, the function of power door locks is
is inoperative (using the key)

3. Harness locks, the function of power door locks is

1. Harness locks, one door is inoperative (using the
key)

One door is inoperative (using
2. Door lock actuator locks, one door is inoperative (using the
the key)
key)

3. Power door lock control unit locks, one door is inoperative (using the
key)

1. Power door lock control unit locks, door does not open (using the
remote key)

2. Harness locks, door does not open (using the
remote key)

Door does not open (using the
3. Door lock actuator locks, door does not open (using the
remote key)
remote key)

4. Key locks, door does not open (using the
remote key)

5. Remote keyless entry receiver locks, door does not open (using the
remote key)

1. Power door lock control unit locks, doors does not close (using the
remote key)

2. Harness locks, doors does not close (using the
remote key)

Doors do not close (using the
3. Door lock actuator locks, doors does not close (using the
remote key)
remote key)

4. Key locks, doors does not close (using the
remote key)

5. Remote keyless entry receiver locks, doors does not close (using the
remote key)
THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE

(USING THE KEY)
WIRING DIAGRAM 04
04
• Before operating this inspection procedure, make sure the door open warning light is operating nor-
mally.
• If the door open warning light is inoperative, repair it. Refer to “Chapter 04 diagnostics - instrument
cluster, problem symptoms table”
• This inspection procedure is an example of front door LH, other doors inspection procedure are similar.
1. INSPECT FUSE


YES > Go to step 3.
2. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT - GROUND)


table below.
C030 (1) - Ground ≥ 1 MΩ

3. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT FUSE - POWER
DOOR LOCK CONTROL UNIT)


table below.
Specified 04
Tester Connection
Condition
Power door lock control unit fuse (30 A) - C030 (1) ＜2Ω



table below.
C030 (10) - Ground ＜2Ω

5. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT - FRONT DOOR
LOCK ACTUATOR LH)

(c) Disconnect the D002 front door lock actuator LH connector.

table below.

C030 (6) - D002 (1)
＜2Ω
C030 (5) - D002 (3)

6. INSPECT FRONT DOOR LOCK ACTUATOR LH
(a) Disconnect the D001&D002 front door lock actuator LH connector.
(b) While using key to lock the door, measure the resistance

D002 (1) - D002 (2) ＜2Ω
(c) While using key to unlock the door, measure the

resistance according to the value(s) in the table below.

D002 (3) - D001 (1) ＜2Ω

NO > Replace the front door lock actuator LH.
7. CHECK HARNESS AND CONNECTOR (FRONT DOOR LOCK ACTUATOR LH - GROUND)
(a) Disconnect the D001&D002 front door lock actuator LH connector.

04
table below.

D002 (2) - Ground ＜2Ω 04

table below.

D001 (1) - Ground ＜2Ω

8. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT - JUNCTION
CONNECTOR)

table below.

C030 (7) - C054 (3)
＜2Ω
C030 (8) - C054 (1)

(a) Remove front door inner guard board LH.

(b) Remove the front door water-proof film LH.

table below.
Tester
Condition Specified Condition
Connection
2-3 ＜2Ω
Use key to unlock
3-2 ≥ 1 MΩ
3-2 ＜2Ω
Use key to lock
2-3 ≥ 1 MΩ

10. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT DOOR LOCK
ACTUATOR LH)

(b) Disconnect the D001 front door lock actuator LH connector.

table below.

C054 (2) - D001 (2)
＜2Ω
C054 (4) - D001 (3)

ONE DOOR IS INOPERATIVE (USING THE KEY)

WIRING DIAGRAM
04
04
• This inspection procedure is an example of front door LH, other doors inspection procedure are similar


table below.
Tester
Condition Specified Condition
Connection
2-3 ＜2Ω
Use key to unlock
3-2 ≥ 1 MΩ
3-2 ＜2Ω
Use key to lock
2-3 ≥ 1 MΩ

2. CHECK HARNESS AND CONNECTOR (JUNCTION CONNECTOR - FRONT DOOR LOCK

ACTUATOR LH)

(b) Disconnect the D001 front door lock actuator LH connector.

table below.

C054 (2) - D001 (2)
＜2Ω
C054 (4) - D001 (3)

DOOR DOES NOT OPEN (USING THE REMOTE KEY)

WIRING DIAGRAM
04
04
1. INSPECT FUSE

(c) Inspect the dome light fuse (7.5 A) in body junction box
(C035).

2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - REMOTE KEYLESS ENTRY
RECEIVER)
(a) Disconnect the C038 remote keyless entry receiver connector.

table below.


3. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT FUSE- POWER
(a) Disconnect the C030 power door lock control unit connector. 04
table below.
Specified
Tester Connection
Condition 04


table below.

C030 (10)- Ground ＜2Ω


table below.

C030 (1)- Ground ≥ 1 MΩ


table below.

C030 (1) - C030 (5) ≥ 1 MΩ

NO > Replace the power door lock control unit.
7. CHECK HARNESS AND CONNECTOR (REMOTE KEYLESS ENTRY RECEIVER - POWER DOOR
LOCK CONTROL UNIT)
(a) Disconnect the C038 remote keyless entry receiver connector. 04


table below.
C038 (15) - C030 (5) ＜2Ω

8. INSPECT REMOTE KEYLESS ENTRY RECEIVER

table below.

C038 (1) - C038 (15) ≥ 1 MΩ

NO > Replace the remote keyless entry receiver.
9. CHECK HARNESS AND CONNECTOR (REMOTE KEYLESS ENTRY RECEIVER - JUNCTION

CONNECTOR)


table below.

C038 (1) - C055 (2) ＜2Ω


table below.

C055 (1) - C055 (2) ＜2Ω


04
table below.

C055 (1) - Ground ＜2Ω 04


table below.

C038 (8) - Ground ≥ 1 MΩ

CONNECTOR)

table below.

C030 (7) - C054 (3)
＜2Ω
C030 (8) - C054 (1)



table below.
Tester Specified
Condition
2-3 ＜2Ω
Use key to unlock
3-2 ≥ 1 MΩ

YES > Check the key battery. If the battery voltage is low, change the battery. If the problem is also exist,
replace the key.
DOORS DO NOT CLOSE (USING THE REMOTE KEY)

WIRING DIAGRAM
04
04
1. INSPECT FUSE

(c) Inspect the dome light fuse (7.5 A) in body junction box
(C035).

2. CHECK HARNESS AND CONNECTOR (DOME LIGHT FUSE - REMOTE KEYLESS ENTRY
RECEIVER)

table below.


3. CHECK HARNESS AND CONNECTOR (POWER DOOR LOCK CONTROL UNIT FUSE- POWER
(a) Disconnect the C030 power door lock control unit connector. 04
table below.
Specified
Tester Connection
Condition 04


table below.
C030 (10) - Ground ＜2Ω


table below.
C030 (1) - Ground ≥ 1 MΩ


table below.
C030 (1) - C030 (6) ＜2Ω

7. CHECK HARNESS AND CONNECTOR (REMOTE KEYLESS ENTRY RECEIVER- POWER DOOR
LOCK CONTROL UNIT)
(a) Disconnect the C038 remote keyless entry receiver connector. 04


table below.
C038 (7) - C030 (6) ＜2Ω


table below.

C038 (7) - C038 (14) ＜2Ω

9. CHECK HARNESS AND CONNECTOR (REMOTE KEYLESS ENTRY RECEIVER - INSTRUMENT

CLUSTER)


table below.

C038 (14) - C013 (C8) ＜2Ω

10. INSPECT INSTRUMENT CLUSTER


table below.

C013 (C8) - C014 (D5) ≥ 1 MΩ

NO > Replace the instrument cluster.
LH)
(a) Disconnect the C014 instrument cluster connector. 04

(b) Disconnect the A008 front door ajar switch LH.

table below.
C014 (D5) - A008 (1) ＜2Ω

12. INSPECT FRONT DOOR AJAR SWITCH LH GROUND
(a) Loosen the front door ajar switch LH retaining bolt. Check if the ground is rusting.
NO > Clean or replace the front door ajar switch LH.
CONNECTOR)

table below.

C030 (7) - C054 (3)
＜2Ω
C030 (8) - C054 (1)



table below.
Tester Specified
Condition
2-3 ＜2Ω
Use key to unlock
3-2 ≥ 1 MΩ

YES > Check the key battery. If the battery voltage is low, change the battery. If the problem is also exist,
replace the key.
11A
GASOLINE ENGINE CONTROL SYSTEM..................................... 11A-1
PRECAUTION............................................................................ 11A-1
SYSTEM OVERVIEW ................................................................ 11A-2
INTRODUCTION TO SYSTEM FUNCTION .............................. 11A-6 11A
BASIC PRINCIPLE .................................................................... 11A-8
MAIN COMPONENTS ............................................................. 11A-13
SYSTEM COMPONENTS DESCRIPTION .............................. 11A-14
ENGINE CONTROL MODULE (ECM) ........................................... 11A-15 11A
PRINCIPLE .............................................................................. 11A-15
REPLACEMENT ...................................................................... 11A-16
ENGINE COOLANT TEMPERATURE SENSOR........................... 11A-19
PRINCIPLE .............................................................................. 11A-19
OVERHAUL ............................................................................. 11A-20
THROTTLE BODY ......................................................................... 11A-24
THROTTLE BODY CLEANING................................................ 11A-24
THE FIXED SPEED ADJUSTING SCREW
(SAS) ADJUSTMENT ............................................................. 11A-25
BASIC IDLE SPEED ADJUSTMENT ....................................... 11A-26
OVERHAUL ............................................................................. 11A-27
IDLE AIR CONTROL MOTOR ....................................................... 11A-30
PRINCIPLE .............................................................................. 11A-30
ON-VEHICLE INSPECTION .................................................... 11A-31
OVERHAUL ............................................................................. 11A-32
THROTTLE POSITION SENSOR (TPS) ........................................ 11A-35
PRINCIPLE .............................................................................. 11A-35
OVERHAUL ............................................................................. 11A-37
MANIFOLD ABSOLUTE PRESSURE/INTAKE
TEMPERATURE SENSOR ............................................................ 11A-40
PRINCIPLE .............................................................................. 11A-40
OVERHAUL ............................................................................. 11A-42
CKP SENSOR ................................................................................ 11A-44
PRINCIPLE .............................................................................. 11A-44
OVERHAUL ............................................................................. 11A-45
UPSTREAM OXYGEN SENSOR ................................................... 11A-48
PRINCIPLE .............................................................................. 11A-48
OVERHAUL ............................................................................. 11A-50
DOWNSTREAM OXYGEN SENSOR............................................. 11A-52
PRINCIPLE .............................................................................. 11A-52
OVERHAUL ............................................................................. 11A-54
CANISTER SOLENOID VALVE..................................................... 11A-56
PRINCIPLE .............................................................................. 11A-56
OVERHAUL ............................................................................. 11A-58
VEHICLE SPEED SENSOR ........................................................... 11A-63
PRINCIPLE .............................................................................. 11A-63
OVERHAUL ............................................................................. 11A-65
IGNITION CONTROL MODULE.....................................................11A-67
PRINCIPLE .............................................................................. 11A-67
OVERHAUL ............................................................................. 11A-69
ENGINE CONTROL SYSTEM - GASOLINE ENGINE CONTROL SYSTEM 11A-1
GASOLINE ENGINE CONTROL SYSTEM

PRECAUTION
1. GASOLINE ENGINE CONTROL SYSTEM PRECAUTION. 11A
(a) Power off.
• The battery negative cable must be disconnected at first before removing or installing any electric 11A
appliance and when tools or facilities will touch the exposed terminals. It should be connected eventu-
ally. This will prevent injured person and vehicle damage. 11A
• The ignition switch must be off without any special descriptions.
11A
WARNING
The ignition and illumination switches must be shut off before removing or installing the battery 11A
negative cable (the semiconductor may be damaged without doing that).
(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this 11A
manual during maintenance.
(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 11A
sealing face is level and smooth and no greasy dirt on it before the installation. Don’t forget to remove
the sealant on the mounting hole, the threaded hole and the thread. 11A
(d) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts.
(e) The high impedance type digital multimeter should be used to the test except the especial description 11A
of the procedure in place of the traditional analogue types multimeter.
(f) The oxygen sensor can not contact with water or other liquids. 11A
(g) When installing or carrying the sensor, ensure it not damaged. Any shock or drop may cause great
damage to its performance. 11A
(h) Battery voltage is low or starter failure, not long time starting the engine, so as not to damage the
catalytic converter. 11A
(i) Do not use the needle puncture method to inspect system signal of wire harness.
11A
(j) Fuel pump can not operate for a long time without gasoline, also it can not run in the air.
(k) Because most electric sprayed parts are un-repairable, after confirming the part is damaged, replace it
11A
as necessary.
(l) The system should use anti-type spark plugs and high-voltage, non-resistant phenotype will not only
11A
release high-voltage spark plug and interference wave, but also effect the ignition coil driver module in
the ECM.
11A
(m) ECM can’t be disassembled for test and maintenance.
11A
11A
11A
11A
11A-2 ENGINE CONTROL SYSTEM - GASOLINE ENGINE CONTROL SYSTEM
SYSTEM OVERVIEW
1. INTRODUCTION.
The electrically controlled Multi-point Injection (MPI) engine control systems – BJ491EQ – take DELPHI
MT20U2 Engine Control Module (ECM) as the control center and measure various working parameters of the
engine through various sensors mounted on different components of the engine. Then the fuel injection
quantity is controlled precisely via the control injector according to the preset control program in the ECM,
which enables the engine to obtain the mixture with optimal concentration under various working conditions. In
addition, with the control program in the ECM, the electrically controlled fuel injection system can also enable
the functions of start-up enrichment, warm-up enrichment, acceleration enrichment, full-load enrichment,
deceleration dilution, forcible idle cutoff, automatic idle speed control etc, which meets the requirements for
mixture under special working conditions of the engine and enables the engine to obtain good fuel economy
and emission while enhancing the functional performance of the vehicle. In addition, ECM has some fault
diagnosis modes which can simplify the fault location.
2. ENGINE CONTROL SYSTEM FUNCTION.
Mileage memory
Over voltage pretection
Fuel pump control
Canister solenoid valve control
Idle air control motor control
Totally main power relay control

ECM control function
A/C, coolant water box fan control
Direct ignition
Closed-loop control multi-point squence fuel injection (MAP sensor pres-

sure judgement)
Intake pressure speed-density method air measurement
Trouble self-diagnosis function

3. ECM CONTROL STRUCTURE.
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
4. ENGINE CONTROL SYSTEM DIAGRAM.
1 Intake Manifold Absolute Pressure/Intake Air

10
Temperature (MAP/IAT) Sensor
2 Air Filter
11 From Fuel Pump
3 Idle Air Control Motor
12 Injector
4 Throttle Position Sensor (TPS)
13 Coolant Temperature Sensor
6 Canister
15 Upstream Oxygen Sensor
7 Fuel Pressure Regulation
16 Downstream Oxygen Sensor
8 To Fuel Box
17 Three-Way Catalyst (TWC)
Positive Crankshift Ventilation (PCV)
9
Valve
5. ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPHIC.
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
1 Engine Coolant Temperature Sensor 6 Fuel Pressure Regulator
Manifold Absolute Pressure/Intake Air Tem- 7 Upstream Oxygen Sensor 11A

2
perature Sensor
3 Throttle Body 11A
9 Exhaust Manifold
4 Idle Air Control Motor 11A
11A
11A
11A
11A
INTRODUCTION TO SYSTEM FUNCTION

1. IDLE SPEED CONTROL.
(a) Idle speed control function refers to system control of engine speed with the throttle valve closed. The
system makes the actual speed consistent with the target idle speed by controlling idle parameters.
(b) The system applies the idle air control motor and realizes high precision idle speed control.
2. AIR METERING OF SPEED-DENSITY METHOD (INTAKE MANIFOLD PRESSURE/ TEMPERATURE
SENSOR).
With intake temperature sensor and intake manifold pressure sensor, ECM calculates and defines the
air quantity entering the cylinder. Furthermore, ECM allows air/fuel ratio to meet the requirements of
various working conditions by controlling the fuel supply.
3. CYLINDER DETECTION SEQUENCE CONTROL.
In order to realize engine sequence control, the system applies intake pressure cylinder detection
technology. The intake pressure sensor is installed near the air inlet of the intake manifold for 4
cylinders. At the moment, when the inlet valve opens, there is an instantaneous pressure drop of which
the value is around 1 kPa at the sensor. ECM detects the instantaneous pressure drop. After receiving
the signal, ECM identifies compression Top Dead Centre (TDC) signal through the software analysis
and processing.
4. CLOSED LOOP CONTROL.
The system applies closed loop control for the engine fuel supply and idle speed. The advantage of
closed loop control is that the system effectively eliminates the difference between the system and
relevant mechanical parts due to the manufacture and usage wear, which enhances the integrated
coherence of the whole vehicle and reduces the emission.
5. GROUPING CONTROL.
The system divides the engine cylinders into two groups of 1-4 and 2-3 which control the ignition
respectively. The grouping control optimizes and simplifies the system structure. Ignition timing and fuel
injection control (crankshaft position sensor) systems determine crankshaft position and measure
engine speed according to 58X gear signal, which controls the engine ignition and fuel injection timing
precisely. The opening and closing of the power transistor control the continuity of the primary current in
the ignition coils. The ignition timing control is aimed to obtain the optimal ignition time so as to meet
the requirements of various working conditions of the engine. ECM determines the ignition time
according to the engine speed, intake vacuum degree, engine cooling water temperature and
atmospheric pressure.
6. SELF-DIAGNOSIS.
(a) The system fault self-diagnosis is an essential function for the engine control system. When one or
several parts in the system operate abnormally, the system will inform the vehicle owner to perform
necessary check and repair timely with fault indicator lamp ON. When the fault occurs, the system can 11A
also control the engine operation with temporary emergency mode, so as to ensure the owner can drive
the vehicle to repair. 11A
(b) When certain sensor and actuator is detected abnormal, the engine fault inspection lamp turns on to
remind the driver. 11A
(c) When certain sensor and actuator is detected abnormal, the fault code corresponding to the fault will be
exported. 11A
(d) RAM data related to the sensor and actuator in ECM can be read by fault diagnostic apparatus. In
addition, in certain situation, the actuator can be forcibly driven. 11A
7. OVERVOLTAGE PROTECTION.
When the voltage of the charging system is too high caused by the fault, the system will go to the
11A
protection status to restrict the engine speed to avoid the ECM damage.
11A
8. AIR CONDITIONING COMPRESSOR CONTROL.
When the A/C switch is on, the system will receive a A/C request signal and make preparations for 11A
operating the A/C system based on engine working condition. And then switch on the A/C compressor.
The system will switch on or switch off the A/C according to the protection demand for air-conditioner. 11A
To ensure the power output and protect the engine, the system will cut off the A/C system under
specified working condition.
11A
9. THREE-WAY CATALYTIC CONVERTER.
The function of three-way catalytic converter is to convert harmful exhaust gas from the engine to 11A
harmless gas to exhaust to the atmosphere. The internal structure of three-way catalytic converter
applies the cellular pipeline design. The cellular pipeline wall has precious metal coating on it, including 11A
palladium, rhodium, platinum etc, which acts as catalytic reaction media. The three-way catalytic
converter will cause 3% - 5% of the power consumption to the engine. 11A
10. OVERHEAT SYSTEM PROTECTION FUNCTION FOR THE THREE-WAY CATALYTIC CONVERTER.
The system predicts the rising trend of the engine exhaust temperature according to actual working 11A
condition of the engine and reduces the engine combustion temperature by timely controlling the air/
fuel ratio, so as to protect the three-way catalytic converter. 11A
11. CONTROL OF THE COOLING FAN.
(a) The vehicle is equipped with a silicon oil fan and an electronic fan. 11A
(b) Electrical fan control function: ECM determines to switch on various fans according to the engine
11A
coolant temperature. ECM also judges the temperature meets the condition for switching on the air-
conditioner or not, so as to reduce the engine internal power consumption accordingly..
11A
11A
11A
BASIC PRINCIPLE
1. PRINCIPLE OF START CONTROL.
(a) When turning the ignition switch on, the fuel pump will stop after running for 1.5 seconds.
(b) When the engine starts to rotate, the fuel pump will start to operate after ECM detected 2 valid 58X
signals.
(c) The fuel pump stops operating 0.8 seconds after the engine speed disappears (the analogue signal is
easy to be disturbed).
(d) Pre-injection: The pre-injection only injects once during the normal start process (if the fuel is absorbed
by the carbon deposition, the mixture dilutes, which makes it difficult to start).
(e) Preliminary stage for starting: The intake manifold internal pressure is displayed as ambient
atmospheric pressure. After the throttle valve closed, ECM specifies a fixed parameter according to the
start temperature.
(f) During the start process, the fuel injection quantity varies according to the change of the engine coolant
temperature. The ignition advance angle also adjusts continually and changes with the engine coolant
temperature, the intake air temperature and the engine speed.
(g) End of the start process: When the engine speed exceeds 600 RPM, the start working condition ends.
2. PRINCIPLE OF FUEL INJECTION CONTROL.
(a) ECM controls the injector driving time and the injection timing, which enables the engine to obtain the
mixture with optimal air/fuel ratio under various working conditions.
(b) Each cylinder is equipped with an injector at the air inlet. The fuel pump in the fuel tank pumps out the
fuel and delivers the fuel to the fuel high pressure rail. The fuel pressure regulator keeps the injection
pressure stable. The injector injects the fuel directly to the air passage of each cylinder. During each
working cycle (when the crankshaft rotates twice) of the cylinder, each cylinder injects the fuel once (the
injection sequence is 1 - 3 - 4 - 2). This injection type is called as sequential injection.
(c) When the engine operates under cold or high-load condition, ECM performs open loop control to supply
dense mixture, so as to keep good performance. When the engine operates under the normal working
condition (medium or small load), ECM performs closed loop control via the signal fedback by oxygen
sensor to obtain optimal air/fuel ratio, which enables the three-way catalytic converter to get the optimal
purifying effect.
(d) Inject pulse width control
Signal Input ECM Control Output

A/F modify
Closed loop feedback modify
Intake manifold absolute pressure
Air charging temperature
Air charging efficiency
Self-learning modify
Calculate fuel charge Inject pulse width
Power supply modify
Exhaust cycle
Accelerate deepen
Decelerate fuel reduction
Decelerate fuel cut
Injector parameter
3. CONTROL SIGNAL DESCRIPTION
Modified Item Content
• Start air/fuel ratio. 11A

• Air/fuel ratio while engine is running.
• Air/fuel ratio at low engine coolant temperature. 11A
Air/fuel ratio • Air/fuel ratio at normal engine coolant temperature.
• Theoretical air/fuel ratio. 11A
• Enriched air/fuel ratio.
• Overheat protection air/fuel ratio. 11A
Closed loop feedback • Control the actual air/fuel ratio around the theoretical air/fuel ratio via the
correction feedback signal from the oxygen sensor. 11A
Intake manifold pressure • Read directly via the MAP mounted on the intake manifold. 11A
Self-learning • Modify the engine internal slow change due to long time operation.
11A
Power voltage • When the battery voltage changes, the voltage modification can ensure the
correct fuel injection quantity. 11A
• When ECM detects the intake manifold pressure and the opening value of the
Acceleration enrichment throttle valve increases greatly, the fuel injection quantity is increased to avoid 11A
the engine mixture dilutes momentarily, so as to improve the power
performance. 11A
Deceleration dilution • When the system detects the vehicle is under deceleration status, it controls
the fuel cutoff to reduce the emission and fuel consumption. 11A
• When the system detects the vehicle is under deceleration status, it controls 11A
the fuel cutoff to reduce the emission and fuel consumption.
Deceleration cutoff
• When the engine speed is above the setting value, fuel cutoff starts.
11A
• When a fault occurs in the ignition system, the fuel cuts off.
Fuel injection parameter • It provides the relation between the engine and the fuel injection quantity. 11A
(a) Modification for the engine mixture: 11A

• Partial load control of the engine is closed loop fuel control at the normal working temperature. Then
the system modifies fuel injection quantity via ECM according to the feedback voltage signal from the 11A
oxygen sensor, so as to adjust the mixture concentration to around the theoretical air/fuel ratio, which
ensures the conversion efficiency of the harmful emission gas by the three-way catalytic converter 11A
reaches the optimal status while ensuring good fuel economy.
• When the engine operates with full-load within the normal working temperature range, it applies the 11A
open loop fuel control. At this time, in order to ensure the engine obtains the optimal power output, the
system will control the fuel injection quantity with a thick air/fuel ratio. Furthermore, with the premise 11A
that no engine knock occurs, the engine will increase the ignition advance angle moderately.
11A
• The system will also control the exhaust gas temperature using the exhaust gas temperature
mathematical model established during calibration, so as to protect the engine and the three-way
catalytic converter. The system determines the full-load condition of the engine according to the signal
supplied by the throttle valve position sensor. When the throttle valve opening is above 80% ~ 90%, the
system considers the engine goes to the full-load status. When the driver presses the accelerator pedal
to accelerate the vehicle, the system will increase the fuel injection quantity moderately to ensure the
power demand when the engine accelerates. The increased fuel injection quantity goes a direct
proportion with the changing rate of the throttle valve opening. When accelerating, ECM will retard the
ignition advance angle moderately, then recover step by step. The aim is to avoid impacting to the drive
train because the torque increases too rapid when the engine accelerates sharply.
• When the acceleration working condition is near the engine full-load, the system will automatically
switch off the A/C system temporarily, so as to ensure the engine power output well when accelerating.
Whatever the situation, when the engine speed exceeds the highest speed specified in the system, the
system will cut off the fuel supply to restrict the speed increasing, so as to protect the engine and avoid
the vehicle skidding. When the engine speed returns within specified in the system, the system will
restore the fuel supply immediately.
4. PRINCIPLE OF IGNITION CONTROL.
(a) Start: The engine applies a fixed ignition advance angle when starting, which allows the gas in the
cylinder to ignite and provide the positive torque. When the engine speed increases to certain speed,
ECM caculates the ignition advance angle according to the input signal.
(b) Ignition advance angle control.
Signal Modify ECM Output Control

ECT modify
IAT modify
Elevation modify
Idle modify
Main ignition angle Calculate ignition advance angle Ignition advance angle
Decelerate fuel reduction modify
Accelerate modify
Accelerate deepen modify
A/C modify
(c) Main ignition advance angle: When the engine temperature reaches the normal value, the main ignition
angle with the throttle valve opening is usually the minimum ignition angle at the optimal torque point.
When the throttle valve closes, the ignition angle should be reduced to obtain the idle speed stability.
(d) Correction of the ignition advance angle:
• Acceleration correction: When the vehicle accelerates, ECM detects the knock and corrects the ignition
advance angle until the knock disappears. Furthermore, it is also used to reduce the engine speed
fluctuation caused by the drive train torsion.
• Power enrichment correction: To obtain better power and torque near the exterior feature point, the air/
fuel ratio is enriched to the thinnest air/fuel ratio with the best torque.
• Deceleration cutoff correction: When the deceleration cutoff exits, correct the ignition advance angle to
get a stable transition.
• A/C correction: Switch off the A/C when the engine is idle. Correct the ignition advance angle, which
allows the speed to get a stable transition.
5. PRINCIPLE OF IDLE CONTROL.
(a) Idle control:
• Control the air flow in the bypass of the throttle valve according to the idle condition and the engine idle
load to maintain the idle speed at the optimal speed. According to the engine coolant temperature and
the A/C load, ECM drives the IAC motor to make the engine operate under the preset target idle speed.
In addition, when the engine operates at idle speed, turn on or turn off the A/C switch. The IAC motor
will regulate the air flow in the bypass according to the engine load to avoid idle speed unstable .
(b) Calculate the target idle speed.
Input ECM Output Control

Basic target idle speed 11A
Voltage compensation
11A
Vehicle speed compensation
11A
Fan compensation Calculate target idle speed Target idle speed
Headlamp compensation 11A

A/C compensation
11A
Deceleration adjustment
11A
• Voltage compensation: When the voltage is below 12V, the system will automatically increase the target
idle speed to increase the electrical energy production of the generator. 11A
• A/C compensation: Switch on the A/C when parking the vehicle at idle speed. To compensate the
power loss of the compressor, the target idle speed increases by 150 RPM. 11A
• Headlamp compensation: After switching on the low beam, the target idle speed increases by 50 RPM
to compensate the electricity loss. 11A
• Fan compensation: When the coolant temperature increases and the fan operates, the idle speed
11A
increases by 50 RPM to compensate the electricity loss for the fan operation.
(c) Idle speed control parameters: 11A
• Control of idle air flow.
• Control of fuel injection quantity. 11A
• Control of ignition timing.
(d) Idle speed design control timing: 11A
• Calibration of idle stability.
• Calibration of acceleration working condition.
11A
• Calibration of deceleration working condition.
11A
• Deceleration cutoff.
• Calibration for the fuel supply under engine transient transition working condition. 11A
• Calibration of constant speed driving.
• Calibration of increasing and reducing the mechanical and electricity load. 11A
(e) Decisive factors for the target idle speed:
11A
• When the coolant temperature is low, the system provides a high target idle speed to accelerate the
warm-up.
11A
• When the additional load (e.g. various electrical appliances such as the headlamp, A/C, cooling fan
etc.) opens, the system will raise the idle speed to compensate the increased load and keep the idle
11A
speed stable.
6. PRINCIPLE OF CARBON CANISTER SOLENOID VALVE CONTROL.

(a) Used for controlling the air flow of carbon canister cleaning. The carbon canister is controlled by ECM
sending the duration and frequency for the electrical impulse (duty cycle) through integrated
computation according to a series of signals including engine load, engine coolant temperature, and
engine speed etc. When too much gasoline vapor is accumulated in the activated carbon canister, it will
cause the gasoline leakage, which pollutes the environment. Therefore, the effect of carbon canister
solenoid valve is to open at the proper time to allow the excess gasoline vapor to enter the intake pipe
after mixing with the air sufficiently in the carbon canister to involve in the combustion.
(b) The carbon canister will not work in the following conditions:
• During a period after the cold start of the engine.
• When the cooling water temperature is low.
• During the engine idle operation period.
• During the engine big load period.
• When the important sensors of the system have fault.
MAIN COMPONENTS
11A
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SYSTEM COMPONENTS DESCRIPTION

Component Summary Quantity Function
ECM optimization control system
ECM 16 bit CPU 1
depends on the sensor signal.
Check oxygen concentration in

Upstream oxygen sensor With heated 1
exhaust.
ECM judges whether the TWC is

Downstream oxygen sensor With heated 1 good comparing the upstream with
downstream oxygen sensor signal.
Check the air inlet quantity and

MAP sensor Piezoelectric type 1
BTDC.
CKP sensor Magnetron induction coil type 1 Check CKP and engine RPM.
Inject fuel depends on the sensor

Injector 4 hole type 4
from ECM.
Idle air control motor Electromagnetic coil type 1 Control air inlet.
Control the exhaust depending on

Carbon solenoid valve Electromagnetic type 1
the digital pulse wave from ECM.
3- lines type carbon film

TPS 1 Check the open of throttle.
resistor sliding indicator
ECT sensor NTC thermal resistance type 1 Check ECT.
IAT sensor NTC thermal resistance type 1 Check IAT.
Vehicle speed sensor Hall effect type 1 Check vehicle speed.
Ignition coil Electromagnetic coil type 1 Ignite mixed gas.
Supply the enough pressure fuel

Fuel pump Electromagnetic type pump 1
for system.
ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11A-15
ENGINE CONTROL MODULE (ECM)

PRINCIPLE
11A
1. ECM DESCRIPTION.
(a) ECM is the electric engine control center with the micro 11A
processor as the core that having sensor signal input
interface and the executor drive circuit. The ECM 11A
receives and treats the engine status signal that inputted
from all sensors, sends control signal to the executor to
11A
drive the engine running in accordance with the preset
procedures so as to make the engine run under best
11A
status, ensure good power capability, fuel economy and
exhaust capability.
11A
(b) Normal operating voltage: 9 ～ 16V.
(c) Overvoltage protection: +24V/-12V ＜ 60 s. 11A
(d) Continuity power: terminal 17, 18.
(e) Controlled by ignition key: terminal 47. 11A
(f) Ground wire: terminal 73.
(g) Standard 5V power supply: terminal 20, 21. 11A
(h) Standard 5V ground supply: terminal 4, 5.
11A
(i) ECM has self-protection function. It may result the
ignition failure during repair and it will resume normal 11A
after replacement of ECM. In fact, the ECM doesn’t get
damaged, but just self-protection mode. ECM will 11A
resume normal after certain time period.
11A
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11A
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11A-16 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
REPLACEMENT
1. TURN IGNITION SWITCH OFF.
2. ROTATE DRIVER SEAT.

(a) Loosen the driver seat clamp.
(b) Rotate the driver seat.
3. OPEN THE BATTERY COVER.

(a) Loosen the battery cover lock knob.
(b) Open the battery cover.
4. DISCONNECT BATTERY NEGATIVE CABLE.

NOTE
When disconnecting or connecting the battery cables,
please first turn off the ignition switch and lighting switch
and completely loosen the cable nut. Do not pry up the
cable when peforming these operations.
5. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,
replacement”)
6. REMOVE BUCKLE ASSY.
7. REMOVE ENGINE SURFACING.

ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11A-17
8. REMOVE 7 ENGINE COVER RETAINING BOLTS.
11A
11A
11A
11A
9. REMOVE ECM.
(a) Disconnect ECM connector. 11A
NOTE 11A
After disconnecting the connector, do not have the
connectors contaminated by dirt, water and other matter. 11A
11A
11A
(b) Remove 4 bolts.
11A
11A
11A
11A
11A
(c) Remove ECM. 11A

NOTE
• After disconnecting ECM, pay attention to waterproof.
11A
• Protect the terminals.
11A
• Disconnect the battery negative cable more than 1
minute ahead of removing ECM. 11A
• Knock or impact is not allowed.
11A
10. INSTALL ECM. 11A

NOTE
Pay attention to electrostatic protection when installation.
(a) Tighten 4 bolts.
Torque: 5 N•m
11A-18 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
(b) Connect ECM connector.
11. CONNECT BATTERY NEGATIVE CABLE.

12. COVER AND TIGHTEN THE BATTERY COVER LOCK KNOB.
13. INSTALL 7 ENGINE COVER RETAINING BOLTS.

Torque: 21 ~ 25 N•m
14. INSTALL ENGINE SURFACING.
15. INSTALL BUCKLE ASSY.

16. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat,
replacement”)
17. PUT DOWN DRIVER SEAT AND LOCK IT.
ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR 11A-19
ENGINE COOLANT TEMPERATURE SENSOR

PRINCIPLE
11A
1. ENGINE COOLANT TEMPERATURE DESCRIPTION.
(a) The Engine Coolant Temperature (ECT) sensor uses a 11A
thermistor to control the signal voltage to the Engine
Control Module (ECM). 11A
(b) This ECT sensor is a 2-line type. Normally a 1-line type is
to provide coolant temperature signal to the instrument. 11A
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11A-20 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR
OVERHAUL



NOTE
replacement”)

11A
11A
11A
11A
9. DRAIN THE COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)
11A
10. REMOVE THE ENGINE COOLANT TEMPERATURE
(ECT) SENSOR. 11A
(a) Disconnect ECT sensor connector.
11A
11A
11A
11A
11A
11A
11A
(b) Remove ECT sensor.
NOTE 11A
• Clear the installation surface after removing.
• Clear the screw hollow after removing. 11A
• Clear the thread of sensor after removing.
11A
11A
. 11A
11. CHECK ECT SENSOR.
(a) Dip the sensing part of ECT sensor into hot water. Using 11A
the multimeter, measure resistance of the sensor.
(b) If the check result is not OK, replace it with a new one. 11A
Check Condition Specified Condition
0℃ 9098 ～ 9700 Ω
10 ℃ 5494 ～ 5822 Ω
20 ℃ 3420 ～ 3602 Ω
30 ℃ 2184 ～ 2296 Ω
11A-22 ENGINE CONTROL SYSTEM - ENGINE COOLANT TEMPERATURE SENSOR
CAUTION
Don’t let the water go into terminals. After checking, dry the
sensor.
12. INSTALL ECT SENSOR.

CAUTION
Apply sealant to thread. The specified sealant: 3M nut
LOCKING PART, type: NO.4171 or the equivalent.
(a) Install and tighten ECT sensor.
Torque: 29.4 N•m
(b) Connect ECT sensor connector.
13. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)

14. CHECK COOLANT LEAKAGE.


19. INSTALLE BUCKLE ASSY.

11A
11A
11A
11A
replacement”) 11A
21. PUT DOWN DRIVER SEAT AND LOCK IT. 11A
11A
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11A-24 ENGINE CONTROL SYSTEM - THROTTLE BODY
THROTTLE BODY
THROTTLE BODY CLEANING
1. CLEANING STEPS.
(a) Start the engine and warm it up until the coolant is heated to 80 ℃ or higher. then stop the engine.
(b) Remove the air intake hose from the throttle body.
(c) Plug the bypass passage inlet (arrow) of the throttle body.
CAUTION
Do not allow cleaning solvent to enter the bypass passage.
(d) Spray cleaning solvent into the valve through the throttle
body intake port and leave it for approximately five
minutes.
(e) Start the engine, accelerate it several times and then idle
it for about one minute. if the idle speed becomes
unstable (or if the engine stalls) due to the bypass
passage being plugged, slightly open the throttle valve to
keep the engine running.
(f) If the throttle valve deposits are not removed, repeat
steps d and e.
(g) Unplug the bypass passage inlet.
(h) Connect the air intake hose.
(i) Use the scan tool to erase any diagnostic trouble code.
(j) Adjust the basic idle speed.
NOTE
If the engine hunts while idling after adjustment of the basic
idle speed, keep the battery negative cable disconnected
for 10 seconds or more, and then reconnect it and run the
engine at idle for about 10 minutes after the engine is
warmed up.
ENGINE CONTROL SYSTEM - THROTTLE BODY 11A-25
THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUSTMENT

1. SINCE FIXED SAS IS ADJUSTED AT FACTORY, PLEASE DO NOT ADJUST “FIXED SAS” IN
NORMAL CASES UNLESS IT IS NECESSARY.
11A
2. IF “FIXED SAS” IS ROTATED RANDOMLY, PLEASE RE-ADJUST ACCORDING TO THE
FOLLOWING STEPS:
11A
(a) Loosen the tension of the acceleration cable.
11A
(b) Loosen the "fixed SAS” lock nut.
(c) Turn the idle switch counterclockwise until the throttle 11A
valve closes.
(d) Screw the “fixed SAS” clockwise until the point (i.e. the 11A
position when throttle is started to be opened) of throttle
rail is reached. 11A
(e) Keep the “fixed SAS” from moving when tightening the
lock nut. 11A
(f) Adjust the acceleration cable tension.
(g) Adjust the basic idle speed.
11A
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BASIC IDLE SPEED ADJUSTMENT

1. THE STANDARD IDLE SPEED HAS BEEN ADJUSTED WITH THE SPEED ADJUSTING SCREW
(SAS) BY THE MANUFACTURER, AND THERE SHOULD BE NO NEED FOR RE-ADJUSTMENT.
2. IF THE ADJUSTMENT HAS BEEN CHANGED BY MISTAKE, THE IDLE SPEED MAYBE COME TOO
HIGH OR TOO LOW WHEN LOADS A/C, DEFOGGER, ETC. ARE PLACED ON THE ENGINE. IF
THIS OCCURS, ADJUST BY THE FOLLOWING PROCEDURE.
NOTE
If make the adjustment, it should be made after confirming that the spark plugs, the injectors, the idle
air control motor, compression, etc., are all normal.
(a) Place the car in good condition before the inspection and
adjustment.
(DLC).
(d) Start the engine and run at idle speed.
(e) Check the idle speed.
Standard value: 750 ± 50 RPM
NOTE
• The engine speed may be 20 to 100 RPM lower than
indicated above for a new vehicle, but this is normal
and no adjustment is necessary.
• If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately
500 km (300 mile) or more, it is probable that
deposits are adhered to the throttle valve, clean it.
(f) If it is not within the standard value range, turn the Speed
Adjusting Screw (SAS) to make the necessary adjustment.
NOTE
If SAS gets to bottom completely, the idle speed is still more
than standard value, then check if “fixed SAS” was rotated.
If yes, re-adjust “fixed SAS”.
• Disconnect the scan tool.
• Start the engine again and let it idle for about 10 minutes.
Check that the idling condition is normal.
OVERHAUL
2. ROTATE DRIVER SEAT. 11A

(b) Rotate the driver seat. 11A
11A
11A
11A
3. OPEN THE BATTERY COVER. 11A

11A
11A
11A
11A
11A
NOTE 11A
please first turn off the ignition switch and lighting switch 11A
cable when peforming these operations. 11A
11A
11A
5. REMOVE ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver/assistant driver seat,
replacement”) 11A
6. REMOVE BUCKLE ASSY. 11A
11A
11A

9. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”)
10. REMOVE ACCELERATOR CABLE.

(a) Loosen accelerator cable adjustment nut on the throttle
body.
(b) Remove accelerator cable clip.
(c) Remove accelerator cable.
11. REMOVE AIR INTAKE HOSE. (Refer to “Chapter 14A intake air - intake air hose, replacement”)
12. INSTALL THROTTLE BODY. (Refer to “Chapter 14A

intake air - throttle body, replacement”)
13. INSTALL ACCELERATOR CABLE.


11A
Torque: 21 ~ 25 N•m 11A
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Torque: 41 ~ 51 N•m 11A
11A
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11A
21. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat, 11A
replacement”)
11A
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11A-30 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR
IDLE AIR CONTROL MOTOR

PRINCIPLE
1. IDLE AIR CONTROL MOTOR DESCRIPTION.
(a) The idle air control motor is essentially one micro motor.
since the motor will revolve in various directions when
the motor coil is supplied with current in various
directions. The motor revolution shaft will drive the
moving of the leading screw so as to control the open
extent of the valve indirectly. ECM will send the
digitalized square wave signal to control the positive
rotation and the reverse rotation of the motor so as to
control the stroke of the idle air control motor.
ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 11A-31
ON-VEHICLE INSPECTION
1. OPERATING SOUND INSPECTION.
(a) Check that coolant temperature of engine is below 20 ℃ .
11A
NOTE
If coolant temperature of engine is above 20 ℃ , remove the harness connector of engine coolant temperature 11A
sensor, and use the less than 20 ℃ sensor for connection.
(b) Check that when ignition switch is changed into the ON position (do not start engine), the operating 11A
sound of the IAC motor can be heard over the IAC motor.
(c) If an operating sound can be heard, check the IAC motor drive circuit. If the circuit is good, a defective 11A
IAC motor or ECM is suspected.
11A
2. CHECK ENGINE RPM.
(a) Start the engine and warm it to normal operating 11A
temperature.
(b) Turn the ignition switch OFF. 11A
(DLC) - use the most current software available. 11A
11A
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\
VIEW\ENGINE\491 GASOLINE ENGINE\MT20U2\ ACTIVE
11A
TEST”.
(f) Perform the idle air control motor test. 11A
(g) When the scan tool control the rotation of expansion of
the IAC motor, the engine RPM changes from high to low 11A
in synchronism (vibration can be felt when touching the
IAC motor). 11A
(h) If it is not OK, check IAC motor control harness or con-
nector. If harness or connector is OK, check IAC motor or 11A
ECM.
3. CHECK IDLE AIR CONTROL MOTOR STEPS. 11A
(b) Turn the ignition switch OFF. 11A
available.
11A
11A
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\ READ DATA STREAM.”
11A
Displayed Item Detection Condition Specified Condition
11A
• ECT: 80 ～ 95 ℃
• Accessories: OFF A/C switch: OFF → ON Add 10 ～ 70 steps
• Transmission: N
Idle air control motor
• Engine: idle
• A/C turns ON, A/C A/C switch: OFF 2 ～ 25 steps
should works
(f) If it is not OK, check idle air control motor, harness, connector or ECM.
OVERHAUL



NOTE
5. REMOVE IDLE AIR CONTROL MOTOR.

(a) Disconnect idle air control motor connector.
ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 11A-33
(b) Remove 2 idle air control motor retaining bolts.
11A
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(a) Clear surface after removing. 11A

(b) Clear the path of the idle.
11A
(c) If necessary, clean the IAC motor surface deposits.
11A
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11A
7. CHECK IDLE AIR CONTROL MOTOR COIL RESISTANCE.
(a) Connect special tool (for test).
(b) Check resistance between terminal A and B of idle air
control motor connector.
Standard resistance: 28 ~ 33 Ω (20 ℃ )
(c) Check resistance between terminal C and D of idle air
(d) If it is not OK, replace it with a new one.
8. INSTALL IDLE AIR CONTROL MOTOR.

(a) Install idle air control motor.
(b) Tighten 2 idle air control motor retaining bolts.
Torque: 3.4 N•m
NOTE
• Do not apply any axially type of force to press or pull
out the axle.
• The axle must be in the place of the retreating before
the idle air control motor being installed into the
throttle body.
• After removing battery or ECM, pay attention to the
idle air control motor self-learning.
• The IAC motor self-learning: Turn the ignition switch
OFF, do not start at once. After 5 seconds, start it
again.
(c) Connect idle air control motor connector.

ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 11A-35
THROTTLE POSITION SENSOR (TPS)

PRINCIPLE
11A
1. THROTTLE POSITION SENSOR DESCRIPTION.
(a) Throttle Position Sensor (TPS) is used to provide throttle 11A
angle, angle speed and engine idle position information
to the ECM. Based on this the ECM can obtain the 11A
engine load information, operating mode (such as start,
idle, reverse towing, partial load and full-load) and
11A
acceleration & deceleration information. This sensor is of
3-line type and the ECM will check the throttle open
11A
extent by monitoring the voltage variation.
(b) The throttle position sensor is comprised of carbon film 11A
resistance and slide indicator.
(c) The sensor slide indicator connects with the throttle and 11A
rotates following the shaft. When the throttle open extent
changes following the accelerator pedal, the position of 11A
the slide indicator will also change on the carbon film
resistance, at that moment the resistance output will also 11A
change, which reflects the open extent of the throttle
indirectly. 11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A-36 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)
1. START THE ENGINE AND WARM IT TO NORMAL
OPERATING TEMPERATURE.
2. TURN THE IGNITION SWITCH OFF.
3. CONNECT THE SCAN TOOL TO THE DATA LINK
CONNECTOR (DLC) - USE THE MOST CURRENT
SOFTWARE AVAILABLE.
4. TURN THE IGNITION SWITCH ON.
5. SELECT THE ITEM “AUTO DIAGNOSIS\FOTON\
LIGHT BUS\VIEW\ENGINE\491 GASOLINE ENGINE\
MT20U2\READ DATA STREAM”.

Idle position 0.3 ～ 1 V (0%)
• Ignition switch: ON Directly proportional with

TPS Open throttle slowly
• Engine stop the open degree
Open widely 4.5 ～ 5.5 V (100%)
6. IF IT IS NOT OK, CHECK TPS, HARNESS CONNECTORS AND ECM.

OVERHAUL

11A
11A
11A

11A
11A
11A
11A
11A
NOTE 11A
11A
11A
5. REMOVE TPS.
(a) Disconnect TPS connector. 11A
11A
11A
11A
11A-38 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)
(b) Remove 2 TPS retaining bolts.
6. REMOVE TPS.
NOTE
Clear the surface after removing.
7. CHECK TPS RESISTANCE.

table below.
Terminal A and B • Resistance: 3.5 ～ 6.5 Ω (20 ℃ )
• Open throttle from idle position to

Terminal A and C open wide.The output value is
proportional change to the open
degree.
(b) If the resistance is out of the range and the value

changes unsteadily, replace it.
8. POSITION TPS.
(a) Tighten 2 TPS retaining bolts.
Torque: 3.4 N•m
11A
11A
11A
11A
11A
11A
(b) Connect TPS connector. 11A
11A
11A
11A
11A
11A
11A
11A
9. CONNECT BATTERY NEGATIVE CABLE. 11A

11A
11A
11A
11A
MANIFOLD ABSOLUTE PRESSURE/
11A-40 ENGINE CONTROL SYSTEM -
INTAKE TEMPERATURE SENSOR
MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERA-

TURE SENSOR
PRINCIPLE
1. MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERATURE
SENSOR DESCRIPTION.
(a) MT20U2 adopted speed-density air measurement
method to check the air intake volume into the engine so
as to control the fuel injection pulse width for the precise
control of engine power output. Meanwhile, this system
adopted intake pressure cylinder determination
technology and the intake air sensor is installed near the
inlet opening of cylinder 4 intake manifold. At the
moment when the throttle is opened, there will be one
instantaneous pressure drop at the sensor, of which the
value is about 1 kPa. When the ECM detected and
received this instantaneous pressure drop. The ECM will
determine the compression upper dead center signal
after software diagnosis treatment.
(b) Intake air temperature sensor is a Negative Temperature
Coefficient (NTC) of resistance, with the intake air
temperature increases resistance decreases, the engine
ECM contrast through the internal circuitry to detect an
intake air temperature changes.
ENGINE CONTROL SYSTEM - 11A-41
OPERATING TEMPERATURE. 11A
3. CONNECT THE KT600 SCAN TOOL TO THE DATA 11A
LINK CONNECTOR (DLC) - USE THE MOST
CURRENT SOFTWARE AVAILABLE. 11A
5. SELECT THE ITEM “AUTO DIAGNOSIS\FOTON\ 11A
MT20U2\READ DATA STREAM”. 11A
11A
11A
11A
11A
IAT: -20 ℃ -20 ℃
11A
IAT: 0 ℃ 0℃
IAT sensor IAT: 20 ℃ 20 ℃ 11A
• Engine: running
IAT: 40 ℃ 40 ℃ 11A
IAT: 80 ℃ 80 ℃
11A
6. TURN DIGITAL MULTIMETER TO VOLTAGE RANGE. 11A

CHECK VOLTAGE OF MAP SENSOR BETWEEN
TERMINAL A OR D AND GROUND. 11A
(a) When engine runs at idle, terminal D is 5 V, terminal A is
1.3 V. 11A
(b) When engine runs unload, open throttle slowly, the signal
of terminal A is changed little. 11A
(c) Open throttle quickly, the signal of terminal A is to about
4 V, then drop to 1.5 V. 11A
(d) Turn multimeter to voltage range. Black pin to ground,
red pin to terminal C of the IAT sensor. Check IAT signal. 11A
11A
IAT: 0 ℃ 3.2 ～ 3.8V

IAT: 20 ℃ 2.3 ～ 2.9 V
IAT sensor Ignition switch: ON
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
(e) If it is not OK, check MAP/IAT sensor, harness or ECM.

AN
11A-42 ENGINE CONTROL SYSTEM -
OVERHAUL



NOTE
5. REMOVE MAP/IAT SENSOR CONNECTOR.

(a) Disconnect MAP/IAT sensor connector.
ENGINE CONTROL SYSTEM - 11A-43
6. REMOVE MAP/IAT SENSOR.
(a) Remove MAP/IAT sensor retaining bolt.
(b) Remove MAP/IAT sensor.
11A
NOTE
Clear surface after removing.
11A
11A
11A
7. CHECK IAT SENSOR RESISTANCE.
(a) Turn digital multimeter to Ohm range. Check resistance 11A
between terminal B and C of sensor. Using a hairdryer to
blow air to sensor (note: don’t close too near). Inspect 11A
the change of the value, the value should decline.
11A
(b) If it is not OK, replace it.
11A
11A
Displayed Item Detection Condition Specified Condition 11A
IAT: 0 ℃ 5.3 ～ 6.7 kΩ 11A

IAT: 10 ℃ 2.3 ～ 3.0 kΩ 11A
IAT: 20 ℃ 1.0 ～ 1.5 kΩ
11A
IAT: 30 ℃ 0.30 ～ 0.42 kΩ
11A
8. INSTALL MAP/IAT SENSOR. 11A

(a) Tighten MAP/IAT sensor retaining bolt.
Torque: Does not allow leakage for 1min under 200 11A
kPa pressure
(b) Connect MAP/IAT sensor connector. 11A
NOTE
11A
Do not use any impact tools (such as a hammer, etc.) to
knock sensor into mounting hole.
11A

11A-44 ENGINE CONTROL SYSTEM - CKP SENSOR
CKP SENSOR
PRINCIPLE
1. CRANKSHAFT POSITION SENSOR DESCRIPTION.
(a) The 58X reference signal is produced by the Crankshaft
Position (CKP) sensor. The Engine Control Module
(ECM) uses the 58X reference signal to caculate engine
RPM and CKP. The ECM constantly monitors the
number of pulses on the 58X reference circuit and
compares them with the number of MAP signal being
received.
ENGINE CONTROL SYSTEM - CKP SENSOR 11A-45
OVERHAUL

11A
11A
11A

11A
11A
11A
11A
11A
NOTE 11A
11A
11A
replacement”) 11A
11A
11A

11A-46 ENGINE CONTROL SYSTEM - CKP SENSOR
9. REMOVE CKP SENSOR.

(a) Disconnect CKP sensor connector.
(b) Remove harness from bracket.
(c) Remove the CKP sensor retaining bolt.

NOTE
10. CHECK CKP SENSOR.

(a) Turn digital multimeter to Ohm range, connect two
terminals to terminal A and B terminal of sensor. Check
resistance.
Standard resistance: 560 Ω ± 10% (20 ℃ )
(b) If the check result is not normal, replace it.
11. INSTALL CKP SENSOR.

CAUTION
Apply a layerof preventative oil on the O-ring of the CKP
sensor.
ENGINE CONTROL SYSTEM - CKP SENSOR 11A-47
(a) Tighten CKP sensor retaining bolt.

Torque: 7.5 ± 10% N•m
NOTE
Do not allow any impact tools (such as a hammer, etc.) to 11A
11A
11A
11A
(b) Connect the CKP sensor connector.
11A
11A
11A
11A
11A

11A
Torque: 21 ~ 25 N•m 11A
11A
11A
11A
11A
11A
Torque: 41 ~ 51 N•m 11A
11A
11A
17. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver/assistant driver seat,
replacement”)
11A-48 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
UPSTREAM OXYGEN SENSOR

PRINCIPLE
1. UPSTREAM OXYGEN SENSOR DESCRIPTION.
(a) This sensor is used to provide the excess oxygen
information after the injected fuel in the cylinder has
passed the full combustion in the sucked air. By means
of this information, the ECM can perform the closed loop
control upon the fuel quantity so that the 3 main toxic
substances in the exhaust, which named Hydrocarbon
(HC), Carbon Oxides (CO) and nitrogen oxides, can be
converted and purified in the three-way catalytic
converter.
ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11A-49
MT20U2\ READ DATA STREAM”. 11A
11A
11A
11A
Decelerate suddenly ≤ 0.2 V
1. A/F: to be rich when
11A
acceleration Accelerate suddenly 0.6 ～ 1 V
Upstream oxygen
Engine: idle
11A
0.1 ～ 0.9 V
2. A/F: to be lean when
deceleration Engine: 2500 RPM 0.6 ～ 1 V 11A
6. IF IT IS NOT OK, CHECK SENSOR, HARNESS AND ECM. 11A
11A
11A
11A
11A
11A
11A
11A
11A-50 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
OVERHAUL



NOTE
5. REMOVE UPSTREAM OXYGEN SENSOR.

CAUTION
Remove the exhaust pipe after cooling completely.
(a) Remove upstream oxygen sensor connector.
ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11A-51
(c) Remove upstream oxygen sensor.
11A
11A
11A
11A
6. CHECK UPSTREAM OXYGEN SENSOR.
(a) Turn digital multimeter to ohm range. Check resistance 11A
between terminal 3 and 4 of the sensor.
11A
Standard resistance: 9.6 ± 1.5 Ω (20 ℃ )
(b) If it is not OK, replace it. 11A
11A
11A
7. INSTALL UPSTREAM OXYGEN SENSOR.
11A
CAUTION
Paint a layer of rust-proof oil on the thread. 11A
(a) Install upstream oxygen sensor.
Torque: 40 ~ 60 N•m 11A
11A
11A
8. CONNECT UPSTREAM OXYGEN SENSOR CONNECTOR. 11A
11A
11A
11A
11A

11A
11A-52 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
DOWNSTREAM OXYGEN SENSOR

PRINCIPLE
1. DOWNSTREAM OXYGEN SENSOR DESCRIPTION.
(a) The purpose of the rear oxygen sensor is to check the
oxygen concentration in the exhaust that passed three-
way catalytic converter and the sensor will convert such
signal to dot signal and transmit to the ECM. After the
comparison of the signals of the upstream/downstream
oxygen sensors, the ECM will judge if the three-way
catalytic converter functions well.
(b) The structure of downstream oxygen sensor is same as
the upstream oxygen sensor.
ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11A-53
MT20U2\READ DATA STREAM”. 11A
11A
11A
11A
• Engine: warm
Downstream oxygen sensor • Check A/F with oxygen Engine: running About 0.1 V 11A
sensor
11A
6. IF IT IS NOT OK, CHECK SENSOR, HARNESS AND ECM.
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A-54 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
OVERHAUL



NOTE
5. RAISE VEHICLE.
6. REMOVE DOWNSTREAM OXYGEN SENSOR.

(a) Disconnect downstream oxygen sensor connector.
ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11A-55
(b) Remove downstream oxygen sensor.
11A
11A
11A
11A
7. CHECK DOWNSTREAM OXYGEN SENSOR.
(a) Turn digital multimeter to ohm range, check resistance 11A
11A
Standard resistance: 9.6 ± 1.5 Ω (20 ℃ )
(b) If it is not OK, replace it. 11A
11A
11A
8. INSTALL DOWNSTREAM OXYGEN SENSOR.
11A
CAUTION
Paint a layer of rust-proof oil on the thread. 11A
(a) Install downstream oxygen sensor.
Torque: 40 ~ 60 N•m 11A
(b) Connect downstream oxygen sensor connector.
11A
11A
9. LOWER VEHICLE. 11A

11A
11A
11A
11A
11A-56 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE
CANISTER SOLENOID VALVE

PRINCIPLE
1. CARBON CANISTER SOLENOID VALVE DESCRIPTION.
(a) The carbon canister solenoid valve is a kind of solenoid
valve mechanism internally and contrilled by ECM. ECM
will send digitalized square wave control pulse to control
the open extent of the solenoid valve. The open extent of
the carbon canister is different depending on the various
engine operating modes. In case of the great load of
engine or engine idle, the carbon canister solenoid valve
doesn’t operation in order to ensure the engine power
output well.
ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE 11A-57
MT20U2\ACTIVE TEST”. 11A
11A
11A
11A
6. CHECK THE ACTION OF CARBON CANISTER SOLENOID VALVE.
(a) Use the “action test” function of the diagnostic apparatus. 11A
• Touch the fuel Evaporative Emission Control (EVAP) system carbon canister solenoid valve with hand.
• Perform the action test of carbon canister solenoid valve with the “action test” function of the diagnostic 11A
apparatus.
• The carbon canister solenoid valve should vibrate slightly. If the carbon canister solenoid valve has no 11A
slight vibration, check solenoid valve, harness and ECM.
(b) Vacuum test method. 11A
• When the engine operates at the idle status, pull out the vacuum hose from the activated carbon
canister and check the vacuum hose for vacuum suction. If the carbon canister solenoid valve operates 11A
normally, the solenoid valve should be closed and there should be no vacuum suction in the vacuum
hose. If there is vacuum suction in the vacuum hose now, remove the socket connector from the 11A
solenoid valve. If there is voltage in the terminals of the harness socket connector in the carbon
canister solenoid valve, it indicates there is a fault in ECM. If there is no voltage, it indicates the carbon 11A
canister solenoid valve is stuck in the opening position.
• Press the accelerator pedal to allow the engine speed reach above 2000 RPM and check the vacuum
11A
hose for the vacuum suction. If the vacuum suction exists, it indicates the carbon canister solenoid
valve operates normally. If no vacuum suction exists in the vacuum hose and the voltage is normal on 11A
the terminal of harness socket connector in the carbon canister solenoid valve, it indicates there is a
fault in the carbon canister solenoid valve. If the voltage is abnormal, it indicates there is a fault in ECM 11A
or harness.
11A
11A
OVERHAUL



NOTE
5. DISCONNECT CANISTER SOLENOID VALVE CONNECTOR.

6. DISCONNECT CANISTER SOLENOID VALVE INLET

HOSE CLIPS AND TAKE AWAY HOSE (CONNECTING
TO CANISTER).
NOTE 11A
When disconnecting these hoses which used for a long time.
Twist hose to be loosed first, then operate disconnection. 11A
11A
11A
11A
11A
11A
7. DISCONNECT CANISTER SOLENOID VALVE OUTLET
HOSE CLIPS AND TAKE AWAY HOSE (CONNECT TO
11A
THROTTLE BODY LOWER INTAKE MANIFOLD).
11A
11A
11A
11A
11A
11A
11A
8. RELEASE CANISTER SOLENOID VALVE LOCKING
PLATES. 11A
11A
11A
11A
11A
9. REMOVE CANISTER SOLENOID VALVE.

10. CHECK CANISTER SOLENOID VALVE.

(a) Apply battery voltage to canister solenoid valve. Sound
should be heard. At this time, blow air into the inlet port:
• If air passes, then the canister solenoid valve is OK. If it is
not OK, replace it.
• If no power applied, the solenoid should be closed. No
air pass.
(b) Check carbon control solenoid valve resistance.

• Turn digital multimeter to Ohm range. Check resistance
between terminal A and B of canister solenoid valve.
• If it is not OK, replace it.
11. INSTALL CANISTER SOLENOID VALVE.

12. CONNECT CANISTER SOLENOID VALVE OUTLET

HOSE CLIPS (CONNECTING TO THROTTLE BODY
LOWER INTAKE MANIFOLD).
11A
11A
11A
11A
11A
11A
11A
13. CONNECT CANISTER SOLENOID VALVE INLET
HOSE CLIPS (CONNECTING TO CANISTER ).
11A
11A
11A
11A
11A
11A
11A
14. CONNECT CANISTER SOLENOID VALVE CONNECTOR. 11A
11A
11A
11A
11A
11A



replacement”)
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11A-63
VEHICLE SPEED SENSOR

PRINCIPLE
11A
1. VEHICLE SPEED SENSOR DESCRIPTION.
(a) ECM uses the sensor to receive the digital pulse signal. 11A
ECM can get the vehicle speed from the signal.
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A-64 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR
3. CONNECT THE KT600 SCAN TOOL TO THE DATA
CURRENT SOFTWARE AVAILABLE.
5. SELECT THE ITEM “AUTO DIAGNOSIS \ FOTON\
MT20U2\READ DATA STREAM”.
6. DRIVE THE VEHICLE, READ THE SCAN TOOL DATA
STREAM: VEHICLE SPEED.
7. VEHICLE SPEED: THE SAME VALUE AS THE
ACTUAL VEHICLE SPEED.
8. IF THE DISPLAYED VALUE IS NOT EQUAL TO THE
ACTUAL VALUE, CHECK SENSOR, HARNESS AND
ECM.
9. RAISE THE VEHICLE.

10. TURN THE IGNITION SWITCH ON AND NOT START ENGINE. CHECK AS FOLLOWING:
(a) Set digital multimeter to voltage range. Check voltage

between terminal 2 and 3 of the sensor. It should be 12V.
If it is not OK, replace it.
(b) Start engine, pull into gear. Using the oscilloscope, check
the wave output of terminal 3 of sensor. If it is not OK,
check harness and sensor.
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11A-65
OVERHAUL

11A
11A
11A

11A
11A
11A
11A
11A
NOTE 11A
11A
11A
5. RAISE VEHICLE.
11A
6. REMOVE VEHICLE SPEED SENSOR.
(a) Disconnect vehicle speed sensor connector. 11A
11A
11A
11A-66 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR
(b) Remove vehicle speed sensor retaining bolt.

NOTE
Clear surface after installation.
7. INSTALL VEHICLE SPEED SENSOR.

(a) Tighten vehicle speed sensor retaining bolt.
Torque: 7.5 N•m
NOTE
Do not allow any impact tools (such as a hammer, etc.) to
(b) Connect vehicle speed sensor connector.
8. LOWER VEHICLE.
ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE 11A-67
IGNITION CONTROL MODULE

PRINCIPLE
11A
1. IGNITION CONTROL MODULE DESCRIPTION.
(a) Adopting group ignition technology, taking advantage of the 11A
theory that the mutual induction of the electromagnetic coils
can generate high energy, controlling the switch-on/switch- 11A
off time of the primary coil, and taking advantage of the high
voltage power of the secondary coil to puncture the spark
11A
plug gap so as to generate strong spark to ignite the mixed
air. Since the air ionization is very great and the resistance
11A
is very low during the engine exhaust process, only low
voltage power is required to puncture the spark plug gap.
11A
Therefore, this system adopts group ignition technology so
as not to waste the energy.
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A
11A-68 ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE
1. INSPECTION STEPS.
(a) Start the engine and warm it to normal operating
temperature.
BUS\VIEW\ENGINE\491 GASOLINE ENGINE\ MT20U2\
READ DTC”.
(f) Dynamic detection of the ignition control module.
(g) Using the KT600 scan tool, confirm that there is no DTC.
If there is DTC, record it. Ensure that the DTC is resolved
even if nothing to do with the ignition system.
(h) Pull out fuel pump relay.
(i) Lightly pull out spark plug wire and remove the spark
plug.
(j) Install a new spark plug to the spark plug wire and con-
nect spark plug negative to the engine cylinder block.
(k) Start engine to check the flash over.
(l) If the flash over is weak or no flash over, replace with a
new ignition coil. After replacing, the flash over become
strong. We can ensure the ignition coil has damage. If
there is still no flash over, check the ignition circuit and
inspect the spark plug.
(m) Using KT600 scan tool, clear DTC.
OVERHAUL

11A
11A
11A

11A
11A
11A
11A
11A
NOTE 11A
11A
11A
replacement”) 11A
11A
11A

10. REMOVE IGNITION CONTROL MODULE.

(a) Disconnect ignition control module connector.
(b) Remove and inspect spark plug wire.

NOTE
Before disconnecting the spark plug wire on the ignition
coil, confirm the spark plug position on the ignition coil and
mark it.
• Check if the spark plug wire has been braken down
traces.
• Make sure the spark plug wire resistance ≤ 4 KΩ.
(c) Remove ignition control module retaining bolts.
11. REMOVE AND CHECK IGNITION CONTROL MODULE.

(a) Check whether carbon crack exists on the surface of the ignition control module.
(b) Primary resistance of ignition control module: 0.52 ± 0.05 Ω (23 ± 5 ℃ )
(c) Secondary resistance of ignition control module: 9840 ± 980 Ω (23 ± 5 ℃ )
12. INSPECT SPARK PLUG.

(a) Check spark plug insulator outer surface for the
existence of cracks.
(b) Check spark plug flash over for carbon deposition. 11A
(c) Check spark plugs for negative ablation.
11A
(d) Check spark plug gap.
Standard value: 1.0 ~ 1.2 mm
11A
11A
13. INSTALL SPARK PLUG.
11A
14. INSTALL THE IGNITION CONTROL MODULE RETAIN-
ING BOLTS. 11A
Torque: 5 ~ 8 N•m
11A
11A
11A
11A
15. CONNECT IGNITION CONTROL MODULE CONNEC-
TOR. 11A
11A
11A
11A
11A
16. INSTALL SPARK PLUG WIRE TO IGNITION CONTROL MODULE AS THE MARKS BEFORE 11A
REMOVING.
11A
17. INSTALL SPARK PLUG WIRE TO SPARK PLUG.
11A
11A
11A



replacement”)
FUEL
12A
FUEL SYSTEM................................................................................. 12A-1
PRECAUTION............................................................................ 12A-1
PROBLEM SYMPTOMS TABLE................................................ 12A-3
FUEL TANK ASSY........................................................................... 12A-4 12A
COMPONENTS ......................................................................... 12A-4
REPLACEMENT ........................................................................ 12A-5
FUEL FILTER ASSY ...................................................................... 12A-10
REPLACMENT......................................................................... 12A-10 12A
FUEL LEVEL SENSOR ASSY ....................................................... 12A-11
REPLACMENT......................................................................... 12A-11 12A
FUEL PUMP ASSY ........................................................................ 12A-12
OVERHAUL ............................................................................. 12A-12
FUEL INJECTOR ASSY................................................................. 12A-14
OVERHAUL ............................................................................. 12A-14
FUEL FILLING DOOR.................................................................... 12A-18
REPLACEMENT ...................................................................... 12A-18
FUEL - FUEL SYSTEM 12A-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12A
(a) Before working on fuel system, disconnect battery negative cable.
(b) When removing the fuel hose, use a suitable container to hold the fuel.
(c) Do not smoke, carry lighted tobacco or work near an open flame when working on fuel system.
Equipment with ventilator at woking area can avoid personal injury.
(d) Fuel in the fuel pump , railway and tubes remain under high pressure. In order to avoid personal injury,
do not loosen tube connector while engine is running.
(e) Keep gasoline away from rubber and leather parts.
(f) Before disconncting any of the fuel system lines or fuel system components, release the fuel system
pressure to prevent accidental spraying of fuel, even when the engine is not running. failure to follow
12A
this instruction may result in serious personal injury.
(g) Check if there is any dirt like mud around the fuel line connector before work. And clean it away,
otherwise it can damage fuel system or engine.
(h) Keep cleaner away from the O-ring of tube connector. Cleaner can corrode the seal of fuel system.
(i) Don’t bend or twist the fuel system tube and pipe by force.
(j) Before connceting fuel system tube, be sure there is no damage, otherwise, replace it with a new tube
assy.
12A-2 FUEL - FUEL SYSTEM
FUEL SYSTEM PRESSURE RELEASE PROCESS

(a) Disconnect the fuel pump connector.
(b) Start the engine untill it stops. Turn the ignition switch to OFF.
(c) Start the engine again for 5 seconds, ensure fuel rail pressure release is complete.
(d) Connect the fuel pump connector.
DRAIN FUEL TANK PROCESS

(a) Disconnect battery negative cable.
(b) Use the ignition key to open the fuel filling door.
(c) Open the fuel filling cap.
(d) Raise the vehicle.
(e) Remove the fuel tank drain bolt, then drain the fuel to the
suitable container.
FUEL TUBE CLEAN

(a) Use fuel treatment that Foton recommends to clean fuel system.
(b) Use fuel additives that Foton recommends to clean fuel system.
FUEL - FUEL SYSTEM 12A-3

cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts.
12A
1. Fuel pump (Damaged) Chapter 12A fuel - fuel pump, overhaul
2. Fuel tube (Choked) Chapter 12A fuel - fuel syste, precaution
3. Fuel pressure regulator (Fuel -

Engine does not start pressure too low)
4. Fuel tank (No fuel) -
5. Fuel pump relay(Damaged) -

12A
6. Fuel injector (Damaged) Chapter 12A fuel - fuel injector, overhaul
1. Fuel tube (Obstructed) Chapter 12A fuel - fuel syste, precaution

pressure too low)
3. Fuel injector (Leaking or Chapter 12A fuel - fuel injector, overhaul

obstructed)
Engine start hard
4. Fuel pump (Out of order) Chapter 12A fuel - fuel pump, overhaul
5. Fuel injector control system (Out Chapter 04 diagnostics - engine control

of order) system
6. Fuel pressure regulator or fuel -

pump (Return valve damaged)

pressure too low)
Engine idles rough 2. Fuel injector (Leaking or Chapter 12A fuel - fuel injector, overhaul
obstructed)
3. Fuel tube (Obstructed) Chapter 12A fuel - fuel syste, precaution

pressure too low)
2. Fuel injector (Leaking or Chapter 12A fuel - fuel injector, overhaul

obstructed)
Engine loss of power
3. Fuel pump (Out of order) Chapter 12A fuel - fuel pump, overhaul
4. Fuel tube (Obstructed) Chapter 12A fuel - fuel system, precaution
5. Fuel (Poor quality) -

12A-4 FUEL - FUEL TANK ASSY
FUEL TANK ASSY

COMPONENTS
1 Fuel Filter 5 Fuel Tank Breathe Hose
2 Fuel Return Tube 6 Fuel Filling Cap
3 Fuel Inlet Tube 7 Fuel Tank Cover
4 Fuel Tank 8 Fuel Filling Hose Board

FUEL - FUEL TANK ASSY 12A-5
REPLACEMENT
2. RELEASE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, precaution”)
12A
3. Remove spare wheel and spare wheel bracket.
(a) Loosen the spare wheel bracket holder bolt.
NOTE
Do not remove the holder bolt.
12A
(b) Loosen the holder, put down the bracket and remove the
spare wheel.
(c) Raise the vehicle.
(d) Remove the 3 bolts attaching spare wheel bracket to

vehicle body.
4. DRAIN FUEL TANK. (Refer to “Chapter 12A fuel - fuel system, precaution”)
5. SUPPORT FUEL TANK BY A JACK.
6. LOOSEN 3 BOLTS ATTACHING FUEL FILLING HOSE

BOARD TO VEHICLE BODY.
7. LOOSEN FUEL TANK BREATHE HOSE CLAMP AND

DISCONNECT IT.
8. LOOSEN FUEL FILLING HOSE CLAMP AND

DISCONNECT IT.
9. LOOSEN FUEL INLET / RETURN HOSE CLAMPS

AND DISCONNECT THEM.
10. REMOVE FUEL TANK ASSY.

(a) Loosen 8 bolts attaching fuel tank assy to vehicle body.
(b) Lower the fuel tank slowly, disconnect fuel pump and
fuel level sensor connectors.
NOTE
• Check if there is any dirt or mud and tube, harness around the fuel tank. Clean it if necessary.
• When removing fuel tank, as fuel tank is large and heavy, it is necessary to use sutiable tool or
have others help.
11. REMOVE FUEL LEVEL SENSOR ASSY.

(a) Loosen the 5 fuel level sensor sealing cover retaining
screws.
12A
(b) Take out the fuel level sensor.

NOTE
• Check if there is any dirt or other material around 12A
fuel level sensor before this work and clean the dirt if
necessary.
• There is a O-ring in sealing cover. Be careful not to
damage the O-ring when removing.
12. REMOVE FUEL PUMP ASSY.

(a) Loosen the 6 fuel pump sealing cover retaining screws.
(b) Take out the fuel pump.

NOTE
• Check if there is any dirty or other material around
fuel pump before this work and clean the dirt if
necessary.
13. INSTALL FUEL LEVEL SENSOR ASSY.

(a) Install fuel level sensor.
(b) Tighten 5 fuel level sensor sealing cover retaining
screws.
Torque: 6 ~ 8 N•m
14. INSTALL FUEL PUMP ASSY.

(a) Install fuel pump assy.
(b) Tighten 6 fuel pump sealing cover retaining screws.
Torque: 6 ~ 8 N•m
15. INSTALL FUEL TANK.

(a) Raise the fuel tank assy to suitiable position by jack.
Connect the fuel pump and fuel level sensor connectors.
(b) Tighten 8 bolts attaching fuel tank to vehicle body.

NOTE
The fuel tank should be fastened and without abnormal
viberation.
16. CONNECT FUEL FILLING HOSE AND TIGHTEN

CLAMP.
17. CONNECT FUEL TANK BREATHE HOSE AND

TIGHTEN CLAMP.
18. CONNECT FUEL TANK INLET/RETURN HOSE AND

TIGHTEN CLAMPS.
12A
19. TIGHTEN 3 FUEL FILLING HOSE BOARD RETAINING

BOLTS.
12A
20. INSTALL SPARE WHEEL BRACKET AND SPARE

WHEEL.
(a) Tighten 3 spare wheel bracket retaining bolts.
(b) Lower the vehicle.

(c) Position the spare wheel and install the apare wheel
bracket holder.
(d) Tighten the spare wheel bracket holder retaining bolts.

22. CHECK FUEL TUBE.
After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
Turn ignition switch on, inspect the fuel gauge display normal or not. Start engine, inspect if there is fuel
leakage from pipe connection.
12A-10 FUEL - FUEL FILTER ASSY
FUEL FILTER ASSY

REPLACMENT
1. RELEASE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, precaution”)
2. RAISE VEHICLE IN PLACE.
3. LOOSEN 2 FUEL FILTER CLIPS.
4. REMOVE THE FUEL FILTER.

(a) Loosen the fuel filter retaing belt bolt.
(b) Take off the fuel filter.
5. INSTALL NEW FUEL FILTER.

(a) Tighten the fuel filter and tighten the retaining belt bolt.
NOTE
Follow the arrow on the fuel filter when install the fuel filter.
6. CONNECT FUEL FILTER HOSE AND TIGHTEN CLIPS.
7. CHECK FUEL TUBE.

Turn ignition switch on, inspect the fuel gauge display normal or not. Start engine, inspect if there is
fuel leakage from pipe connection.
FUEL - FUEL LEVEL SENSOR ASSY 12A-11
FUEL LEVEL SENSOR ASSY

REPLACMENT
1. RELEASE THE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, precaution”) 12A
4. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

(a) Loosen 5 fuel level sensor sealing cover retaining
screws.
12A
(b) Take out fuel level sensor.

NOTE
• Check if there is any dirt or other material around
fuel level sensor before this work and clean the dirt
if necessary.

(a) Install fuel level sensor assy.
screws.
Torque: 6 ~ 8 N•m
7. INSTALL FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)
8. CHECK FUEL SYSTEM.
(a) After disconnecting fuel pump connector, connect fuel level sensor connector, turn ignition switch on.
Slide fuel level sensor position manually and then check the fuel gauge’s conditions in instrument
panel.
(b) In condition that all connectors are connected properly, turn the ignition switch on and check fuel
gauge’s conditions. Start the engine to check if there is any fuel leakage in fuel system.
12A-12 FUEL - FUEL PUMP ASSY
FUEL PUMP ASSY

OVERHAUL
1. RELEASE THE FUEL PRESSURE. (Refer to “Chapter 12A fuel - fuel system, precaution”)
4. REMOVE FUEL TANK. (Refer to “Chapter 12A fuel - fuel tank, replacment”)

(a) Loosen 6 fuel pump sealing cover retaining screws.
(b) Take out the fuel pump assy.

NOTE
necessary.
6. INSPECT FUEL PUMP RESISTANCE.

(a) Apply battery voltage to both terminals. Check the pump
injection flow.
Stardand: ≥ 16g/s
(b) Apply battery voltage to both terminals. Check that the
pump’s operation. If the fuel pump has abnormal noise,
replace it.
NOTE
• Keep fuel pump as far away from the battery as
possible.
• Always do the switching at the battery side.

Torque: 6 ~ 8 N•m
FUEL - FUEL PUMP ASSY 12A-13
8. INSTALL FUEL TANK. (Refer to“Chapter 12A fuel - fuel tank, replacment”)
9. CHECK FEUL SYSTEM.
In condition that all connectors are connected properly, turn the ignition switch on and check fuel 12A
12A
12A-14 FUEL - FUEL INJECTOR ASSY
FUEL INJECTOR ASSY

OVERHAUL
1. RELEASE THE FUEL PRESSURE. (Refer to “Chapter 12A fuel - precaution”)

(b) Turn over the driver seat.
4. LOOSEN FUEL RAIL INLET / RETURN HOSE

CLAMPS AND DISCONNECT THEM.
NOTE
After disconnecting the fuel hose， use the plastic bag to
seal up the fuel hose connector, prevent the dust from
entering the fuel hose.
5. REMOVE UPPER INTAKE MANIFOLD. (Refer to “Chapter 14A intake air- intake manifold,
replacement”)
6. DISCONNECT 4 FUEL INJECTORS CONNECTORS.

FUEL - FUEL INJECTOR ASSY 12A-15
7. REMOVE FUEL INJECTOR ASSY.

(a) Tighten 2 fuel rail retaining bolts.
(b) Take off the injector assy lightly.
12A
8. REMOVE 4 INJECTORS FROM FUEL RAIL.
12A
9. PULL CLIP AND REMOVE FUEL PRESSURE

REGULATOR.
10. USE AN OHMMETER TO MEASURE RESISTANCE BETWEEN TWO TERMINALS OF INJECTOR.

Resistance: 13 ~ 16 Ω
11. CHECK IF THERE IS ANY CARBON DEPOSITION OR DIRTY AROUD INJECTOR NOZZLE,CLEAR
IT AWAY IF BLOCKED.
12. IF NECESSARY, TAKE INJECTOR ON INJECTOR TEST

TABLE, CHECK INJECTOR LEAKAGE OR NOT.
13. INSPECT RETURN SPRING OF FUEL PRESSURE REGULATOR OPERATION.

12A-16 FUEL - FUEL INJECTOR ASSY
14. INSTALL NEW INSULATOR TO EACH FUEL

INJECTOR.
15. APPLY A LIGHT COAT OF SPINDLE OIL OR GASOLINE TO A NEW O-RING, AND INSTALL IT TO
EACH FUEL INJECTOR.
NOTE
Do not use engine oil or brake fluid.
16. INSTALL EACH FUEL INJECTOR TO FUEL RAIL.
17. INSTALL FUEL PRESSURE REGULATORS.
Note
Inspect it if fuel pressure regulator turns smoothly. If not, it means that O-ring is clamped. Reinstall it
with new O-ring.
18. INSTALL FUEL INJECTOR ASSY.

(a) Slightly push each injector to install injector into hole
properly.
(b) Install the 2 fuel injector assy retaining bolts.
19. CONNECT 4 INJECTORS CONNECTORS.
20. INSTALL UPPER INTAKE MANIFOLD. (Refer to “Chapter 14A intake air- intake manifold,
replacement”)
FUEL - FUEL INJECTOR ASSY 12A-17
21. CONNECT FUEL RAIL INLET/RETURN HOSE AND

TIGHTEN CLAMPS.
12A

In condition that all connectors are connected properly, turn the ignition switch on and check fuel
12A
23. PUT DRIVER SEAT DOWN AND LOCK CLAMP.
12A-18 FUEL - FUEL FILLING DOOR
FUEL FILLING DOOR

REPLACEMENT
1. USING IGNITION KEY, OPEN FUEL FILLING DOOR.
2. LOOSEN FUEL FILLING DOOR RETAINING BOLT.
3. TIGHTEN FUEL FILLING DOOR RETAINING BOLTS.

安装
EMISSION CONTROL
13A
FUEL TANK CAP .............................................................................13A-1
INSPECTION ............................................................................. 13A-1
CHARCOAL CANISTER .................................................................. 13A-2
OVERHAUL ............................................................................... 13A-2 13A
CHARCOAL CANISTER SOLENOID VALVE ................................. 13A-4
OVERHAUL ............................................................................... 13A-4
POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE).... 13A-5
OVERHAUL ............................................................................... 13A-5 13A
13A
EMISSION CONTROL - FUEL TANK CAP 13A-1
FUEL TANK CAP

EMISSION CONTROL
INSPECTION
13A
1. OPEN FUEL TANK FILLER CAP.
2. INSPECT FUEL TANK FILLER CAP ASSY.

(a) Visually inspect fuel tank cap and gasket. If deformed or 13A
damaged, replace with a new one.
(b) Termly lubricate the rotating part.
13A-2 EMISSION CONTROL - CHARCOAL CANISTER
CHARCOAL CANISTER
OVERHAUL
1. REMOVE BATTERY. (Refer to “Chapter 20A starting and charging - battery, replacement”)
2. REMOVE 3 BATTERY TRAY RETAINING BOLTS.
3. LOOSEN CHARCOAL CANISTER INLET/RETURN

HOSE CLAMP AND DISCONNECT THEM.
NOTE
When disconnecting these hoses which are used for a long
time, twist hose first and make them loosed, then perform
the disconnection.
4. REMOVE CHAROCAL CANISTER DIRECTLY.

5. VISUALLY CHECK CHARCOAL CANISTER FOR CRACK AND DAMAGE, REPLACE WITH A NEW
ONE IF NECESSARY.
6. BLOCK CHARCOAL CANISTER BREATHE PORT AND

BLOW COMPRESSED AIR INTO INTAKE OR VENT
PORT. CHECK IF AIR FLOWS FROM OTHER PORT.
NOTE
If no air flows from the other port, charcoal canister is
blocked, replace it if necessary.
7. INSTALL CHARCOAL CANISTER ON BRACKET.

EMISSION CONTROL - CHARCOAL CANISTER 13A-3
8. CONNECT CHARCOAL CANISTER INLET/RETURN

HOSE AND TIGHTEN CLAMPS.
13A
9. INSTALL 3 BATTERY TRAY RETAINING BOLTS.
13A
10. INSTALL BATTERY. (Refer to “Chapter 20A starting and charging - battery, replacement”)
11. INSTALL BATTERY COVER.
13A-4 EMISSION CONTROL - CHARCOAL CANISTER SOLENOID VALVE
CHARCOAL CANISTER SOLENOID VALVE

OVERHAUL

3. REMOVE CHARCOAL CANISTER SOLENIOD VALVE.

(a) Disconnect charcoal canister solenoid valve connector.
(b) Loosen charocal canister solenoid valve inlet/return hose
clamps and disconnect them.
4. CHECK CHARCOAL CANISTER SOLENIOD VALVE.

(a) Apply battery positive voltage to terminals. If air flows
from vent port (connect intake manifold), solenoid valve
work well. if not, replace with a new one.
5. INSTALL CHARCOAL CANISTER SOLENIOD VALVE.

(a) Connect charocal canister solenoid valve inlet/return
hoses and tighten the clamps.
(b) Connect charcoal canister solenoid valve connector.

EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE) 13A-5
POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)

OVERHAUL
13A
2. REMOVE PCV VALVE.

(a) Disconnect PCV hose from engine cylinder head. 13A
(b) Separate PCV valve and hose.
3. DISCONNECT PCV HOSE FROM ENGINE CYLINDER HEAD, START ENGINE AT IDLE SPEED.
PUT FINGER AT PCV PORT, CHECK IF VACUUM OF AIR INTAKE MANIFOLD EXITS. IF NOT,
CLEAN OR REPLACE WITH A NEW ONE.
4. INSPECT PCV VALVE.

(a) Blow air from port that connect cylinder. Air can flow out
from the other port.
(b) Blow air from port that connect air intake mainfold. Air
can’t flow out from the other port.
5. CHECK IF THE PCV VALVE SEALS AGING AND CRACKS EXIST, CRACKS, IF FOUND, REPLACE
WITH A NEW ONE.
13A-6 EMISSION CONTROL - POSITIVE CRANKCASE VENTILATION VALVE (PCV VALVE)
6. INSTALL PCV VALVE AND CONNECT HOSE.

NOTE
Install the PCV valve well to ensure there is no looseness.

INTAKE AIR
11A
INTAKE AIR SYSTEM...................................................................... 14A-1
PRECAUTION............................................................................ 14A-1
COMPONENTS ......................................................................... 14A-2
INTAKE AIR HOSE .......................................................................... 14A-3 11A
REPLACEMENT ........................................................................ 14A-3
AIR FILTER ASSY ........................................................................... 14A-6
REPLACEMENT ........................................................................ 14A-6
AIR STRAINING BOX ASSY ......................................................... 14A-10 11A
REPLACEMENT ...................................................................... 14A-10
INTAKE MANIFOLD....................................................................... 14A-13
COMPONENTS ....................................................................... 14A-13
REPLACEMENT ...................................................................... 14A-14
THROTTLE BODY ASSY............................................................... 14A-17
OVERHAUL ............................................................................. 14A-17
14A
INTAKE AIR - INTAKE AIR SYSTEM 14A-1
INTAKE AIR SYSTEM

INTAKE AIR
PRECAUTION
1. INTAKE AIR SYSTEM PRECATION. 14A
(a) To avoid impuriy entry, the intake air must be filtered before entering the engine. If the intake manifold
hose is broken or loosened, the unfiltered air will enter and abrade.
(b) The intake manifold hose connection must be reliable enough to avoid gaps and looseness, etc.
(c) Each cushion and bracket connection with intake manifold hose must be reliable. There are no cracks
on the apperance or gaps in the connection portion.
(d) The connection between cushion and intake manifold bracket must be reliable.
14A
14A-2 INTAKE AIR - INTAKE AIR SYSTEM
COMPONENTS
1 Intake Air Grille 4 Air Filter Assy
2 Air Straining Box Assy 5 Air Filter Bellow Hose
3 Intake Air Hose 6 Air Intake Pipe Assy

INTAKE AIR - INTAKE AIR HOSE 14A-3
INTAKE AIR HOSE

REPLACEMENT
14A
1. TURN OVER DRIVER SEAT.
replacement”)
6. REMOVE 3 AIR FILTER COVER RETAINING BOLTS.

14A-4 INTAKE AIR - INTAKE AIR HOSE
7. LOOSEN AIR FILTER BELLOW HOSE CLIPS.
8. REMOVE AIR FILTER BELLOW HOSE AND CHECK IT. IF FIND ANY ABNORMAL, REPLACE IT
WITH A NEW ONE.
9. REMOVE AIR INTAKE PIPE.

(a) Loosen the clamp attaching air intake pipe and throttle
body.
(b) Remove 2 air intake pipe retaining bolts.
(c) Disconnect air intake pipe and crankcase breather hose.
10. REMOVE AIR INTAKE PIPE AND CHECK IT. IF FIND ANY ABNORMAL, REPLACE IT WITH A NEW
ONE.
11. INSTALL AIR INTAKE PIPE.

(a) Connect air intake pipe and crankcase breather hose.
(b) Install 2 air intake pipe retaining bolts.
(c) Connect the clamp attaching air intake pipe and throttle
body, then tighten the clamp.
12. INSTALL AIR FILTER BELLOW HOSE.
13. CONNECT AIR FILTER BELLOW HOSE AND

TIGHTEN CLIPS.
14. AFTER INSTALLING AIR INTAKE HOSE, CHECK ALL PARTS AND PARTS CONNECTION AGAIN
TO MAKE SURE ENGINE OPERATES PROPERLY.
INTAKE AIR - INTAKE AIR HOSE 14A-5
15. INSTALL 3 AIR FILTER COVER RETAINING BOLTS.

14A

14A

replacement”)
14A-6 INTAKE AIR - AIR FILTER ASSY
AIR FILTER ASSY

REPLACEMENT
replacement”)

INTAKE AIR - AIR FILTER ASSY 14A-7
7. LOOSEN AIR INTAKE BELLOW HOSE AND AIR

FILTER ASSY CONNECTION CLAMP.
14A
8. LOOSEN AIR FILTER INTAKE AIR HOSE CLAMPS.
14A
9. REMOVE AIR FILTER INTAKE AIR HOSE.

10. RAISE VEHICLE.
11. REMOVE 2 RETAINING BOLTS FROM AIR FILTER

ASSY.
12. REMOVE AIR FILTER ASSY.
13. LOSSEN AIR FILTER LOWER COVER KNOB.

14A-8 INTAKE AIR - AIR FILTER ASSY
14. OPEN AIR FILTER LOWER COVER AND TAKE OUT

AIR FILTER.
(a) When cleaning the air filter, rotate the air filter by hand
and use compressed air to clean the dust from inside to
outside. The compressed air should be less than 0.07
MPa.
NOTE
• Air filter is made from paper. If necessary, clear the
air filter with high pressure air gun. Do not clean it
with water.
• Before using the compressed air, wear suitable
protective goggles and masks. Flying debris and dirt
can cause personal injury.
15. INSTALL AIR FILTER LOWER COVER AND TIGHTEN

KNOB.
16. TIGHTEN 2 AIR FILTER ASSY RETAINING BOLTS.

17. LOWER VEHICLE.
18. CONNECT AIR FILTER INTAKE AIR HOSE AND

TIGHTEN CLAMPS.
INTAKE AIR - AIR FILTER ASSY 14A-9
19. CONNECT AIR INTAKE BELLOW HOSE AND AIR

FILTER ASSY CLAMP.
14A
20. AFTER INSTALLING AIR FILTER, CHECK ALL PARTS AND PART CONNECTIONS AGAIN TO
ENSURE ENGINE OPERATES PROPERLY.

14A


replacement”)
14A-10 INTAKE AIR - AIR STRAINING BOX ASSY
AIR STRAINING BOX ASSY

REPLACEMENT
1. REMOVE 2 INTAKE AIR GRILLE RETAINING BOLTS.
2. REMOVE B-PILLAR INNER GUARD BOARD.

(a) Remove 6 B-pillar inner guard board retaining bolts.
(b) Set the B-pillar inner guard board aside.
3. REMOVE AIR FILTER ASSY. (Refer to “Chapter 14A intake air -air filter assy, replacement”)
4. REMOVE 4 AIR STRAINING BOX RETAINING BOLTS.

INTAKE AIR - AIR STRAINING BOX ASSY 14A-11
5. LOOSEN CLAMP ATTACHING AIR STRAINING BOX AND

OUTER AIR INLET HOSE.
14A
6. REMOVE AIR STRAINING BOX AND CHECK WHETHER THERE IS CRACK.

7. INSTALL AIR STRAINING BOX. 14A
8. INSTALL 4 AIR STRAINING BOX RETAINING BOLTS.
9. INSTALL AIR FILTER ASSY. (Refer to “Chapter 14A intake air -air filter assy, replacement”)
10. CONNECT CLAMP ATTACHING AIR STRAINING BOX

AND OUTER AIR INLET HOSE.
14A-12 INTAKE AIR - AIR STRAINING BOX ASSY
11. INSTALL 2 INTAKE AIR GRILLE RETAINING BOLTS.
12. POSITION B-PILLAR INNER GUARD BOARD AND

TIGHTEN 6 RETAINING BOLTS.
INTAKE AIR - INTAKE MANIFOLD 14A-13
INTAKE MANIFOLD
COMPONENTS
14A
14A
1 Throttle Body 4 Upper Intake Manifold Bracket
2 Throttle Body Gasket 5 Upper Intake Manifold Gasket
3 Upper Intake Manifold 6 Lower Intake Manifold

14A-14 INTAKE AIR - INTAKE MANIFOLD
REPLACEMENT


(a) Loosen accelerator cable adjustable nut on the throttle
body.
4. REMOVE INTAKE MANIFOLD ACCESSORIES:

(a) Remove charcoal canister solenoid valve.
(b) Loosen clamp attaching throttle body and intake air pipe.
(c) Disconnect idle air control motor connector.
(d) Disconnect TPS connector.
(e) Disconnect PCV valve hose and intake manifold.
5. LOOSEN UPPER INTAKE MANIFOLD BRACKET

RETAINING BOLT (AT THROTTLE BODY SIDE).
6. LOOSEN UPPER INTAKE MANIFOLD BRACKET

RETAINING BOLT (AT PCV VALVE SIDE).
INTAKE AIR - INTAKE MANIFOLD 14A-15
7. LOOSEN 5 UPPER INTAKE MANIFOLD RETAINING

NUTS.
14A
8. REMOVE UPPER INTAKE MANIFOLD.

9. REMOVE UPPER INTAKE MANIFOLD GASKET.
NOTE
After removing the intake manifold, replace the intake manifold gasket.
10. REMOVE FUEL INJECTOR ASSY. (Refer to “Chapter 12A fuel - fuel injector assy, overhaul”)
11. REMOVE 6 LOWER INTAKE MANIFOLD RETAINING 14A

NUTS.
12. REMOVE LOWER INTAKE MANIFOLD AND ENSURE TEHRE IS NO DOPANT ON CONTACT
SURFACE.
13. INSTALL LOWER INTAKE MANIFOLD.
14. TIGHTEN 6 LOWER INTAKE MANIFOLD RETAINING

NUTS.
15. INSTALL FUEL INJECTOR ASSY. (Refer to “Chapter 12A fuel - fuel injector assy, overhaul”)
16. INSTALL UPPER INTAKE MANIFOLD GASKET.
14A-16 INTAKE AIR - INTAKE MANIFOLD
17. POSITION UPPER INTAKE MANIFOLD AND TIGHTEN

5 RETAINING NUTS.
18. TIGHTEN UPPER INTAKE MANIFOLD BRACKET

RETAINING BOLT (AT THROTTLE BODY SIDE).
19. TIGHTEN UPPER INTAKE MANIFOLD BRACKET

RETAINING BOLT (AT PCV VALVE SIDE).
20. INSTALL INTAKE MANIFOLD ACCESSORIES:

(a) Install charcoal canister solenoid valve.
(b) Connect throttle body and intake air pipe, then tighten the clamp.
(d) Connect TPS connector.
(e) Connect PCV valve hose and intake manifold.

(a) Tighten accelerator cable adjustable nut on the throttle
body.
(b) Install accelerator cable clip.

INTAKE AIR - THROTTLE BODY ASSY 14A-17
THROTTLE BODY ASSY

OVERHAUL
1. DISCONNECT BATTERY NEGATIVE CABLE. 14A


body. 14A
4. REMOVE INTAKE AIR HOSE. (Refer to “chapter 14A intake air - intake air hose, replacement”)
5. DISCONNECT IDLE AIR CONTROL MOTOR CONNECTOR.

14A-18 INTAKE AIR - THROTTLE BODY ASSY
6. DISCONNECT TPS CONNECTOR.
7. REMOVE 4 THROTTLE BODY RETAINING BOLTS.
8. REMOVE THROTTLE BODY AND CHECK IT.

(a) Use cleaner to clean the carbon on throttle body.
(b) Check if the throttle body door can be opened or closed smoothly.
(c) Check if the throttle body bypass way has been blocked.
9. REPLACE A NEW THROTTLE BODY GASKET.
10. TIGHTEN 4 THROTTLE BODY RETAINING BOLTS.

Torque：10 N•m
INTAKE AIR - THROTTLE BODY ASSY 14A-19
11. CONNECT IDLE AIR CONTROL MOTOR CONNEC-

TOR.
14A
12. CONNECT TPS CONNECTOR.
14A
13. INSTALL INTAKE AIR HOSE. (Refer to “chapter 14A intake air - intake air hose, replacement”)

(a) Tighten accelerator cable adjustable nut on the throttle
body.
(b) Install accelerator cable clip.

NOTE
After cleaning the throttle body, the cleaner will exist in intake air tube. It will cause engine start hard.
Depress the accelerator pedal when starting.
MEMO
ENGINE MECHANICAL
15A
ENGINE MECHANICAL PART ........................................................ 15A-1
PRECAUTION............................................................................ 15A-1
ENGINE TECHNICAL PARAMETERS ...................................... 15A-3 15A
ENGINE ASSY ................................................................................. 15A-4
REPLACEMENT ........................................................................ 15A-4
ENGINE ACCESSORY BELT ........................................................ 15A-19
COMPONENTS ....................................................................... 15A-19 15A
OVERHAUL ............................................................................. 15A-22
ENGINE TIMING CHAIN COVER .................................................. 15A-27
REPLACENEMT ...................................................................... 15A-27
ENGINE TIMING CHAIN ................................................................ 15A-31
COMPONENTS ....................................................................... 15A-31
OVERHAUL ............................................................................. 15A-32
ROCKER ARM/ROCKER SHAFT.................................................. 15A-37
OVERHAUL ............................................................................. 15A-37 15A
HYDRAULIC ADJUSTER / VALVE PUSH ROD ........................... 15A-42
OVERHAUL ............................................................................. 15A-42
CAMSHAFT.................................................................................... 15A-47
OVERHAUL ............................................................................. 15A-47
CYLINDER HEAD .......................................................................... 15A-52
OVERHAUL ............................................................................. 15A-52
VALVE/VALVE SPRING ................................................................ 15A-60
OVERHAUL ............................................................................. 15A-60
PISTON AND CONNECTING RODS ............................................. 15A-64
COMPONENTS ....................................................................... 15A-64
OVERHAUL ............................................................................. 15A-65
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL.............................. 15A-75
COMPONENTS ....................................................................... 15A-75
OVERHAUL ............................................................................. 15A-77
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15A-1
ENGINE MECHANICAL PART

ENGINE MECHANICAL
PRECAUTION
1. EMGINE MECHNANICAL PART PRECAUTION. 15A
(a) Follow the instructions of maintenance methods and regulations to adjust or maintain.
(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. Check the
engine oil level, fill the engine oil if necessary.
(c) Do not adjust the position of throttle valve screw. It will cause the throttle valve closed angle change
and make the engine work abnormal.
(d) Do not pull up the spark plug wire when the engine is running.
(e) The clearance between ckp sensor and flywheel is 0.8 ～ 1.2 mm. Do not try to adjust it.
(f) The fuel should use ron ≥ 93 unleaded gasoline, otherwise the catalytic converter will be damaged.
(g) Use the oil as requirement, otherwise exacerbate engine wear.
(h) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.
(i) Do not use the high pressure water cannons to wash the ecm shell.
(j) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. Interval
time to next starting should not be less than 15 seconds.
(k) Keep the normal coolant temperature 85 ～ 105 ℃ .
(l) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running 15A
in low speed for 3~5 mins that the engine radiates eventually.
(m) Before opening the radiator cap, check the coolant level and must ensure the engine is cool.
(n) Use the sealant scraper to clear the sundries in seal surface. Confirm seal surface flat and smooth, no
oil stain there.
15A-2 ENGINE MECHANICAL - ENGINE MECHANICAL PART

1. Battery (Low voltage or loose Chapter 20A starting and charging - battery,
connect) precaution
2. Fuel pump (Damaged) Chapter 12A fuel - fuel pump, overhaul
Chapter 20A starting and charging - starter,

3. Starting (Damaged) overhaul
Chapter 19A ignition - ignition coil/spark plug

4. Ignition system (Damaged) wire/spark plug, overhaul
Engine does not start.
5. Spark plug (Over clearance) wire/spark plug, overhaul
6. Fuel system (Blocked) Chapter 12A fuel -fuel system precaution
Chapter 15A engine mechanical - timing belt,

7. Engine timing (Mistake) overhaul
8. Cylinder compressure -
1. Air-fuel mixing ratio Chapter 04 diagnostics - engine control system
2. Intake air hose (Leaking) Chapter 14A intake air - precaution

Engine idles rough. 3. Ignition coil (Damaged) wire/spark plug, overhaul
5. Idle control motor (Out of order) -
1. Spark plug (Carbon deposition Chapter 19A ignition - ignition coil/spark plug
over clearance) wire/spark plug, overhaul
Chapter 15A engine mechanical - timing belt,

3. Engine timing (Mistake) overhaul
4. Cylinder gasket (leaking) -
5. Cylinder compressure -
Engine loss of power.
6. Valve (Burned, warped, Chapter 15A engine mechanical - cylinder
excessive clearance, or pitted head/valve, overhaul
valves)
7. Exhaust system (blocked) Chapter 16A exhaust - precaution

9. Ignition system (Out of order) wire/spark plug, overhaul
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15A-3
ENGINE TECHNICAL PARAMETERS

Item Technical Parameters
Engine BJ491EQ1-40 15A
Engine Type 4 cylinder in-line, water cooling, 4 stroke, EFI
Chamber Type Deed type chamber
Cylinder Bore 91 mm
Stroke 86 mm
Compression Ratio 8.8:1
Firing Order 1-3-4-2
Rated Power 76/4600 Kw/ （r/min）
Maximum Torque 193　／ 2600 N•m/ （r/min）
Minimum Fuel Consumption ≤ 275 g/kW•h 15A

Idle Speed 800 ± 50 r/min
Crankshaft Direction Of Rotation Counterclockwise
Average Piston Velocity 13.19 m/s

15A-4 ENGINE MECHANICAL - ENGINE ASSY
ENGINE ASSY
REPLACEMENT
NOTE
• Before lifting the vehicle, ensure the support position on the vehicle.
• Turn ignition switch off and lock the steering column assy.
• Use the fender protection cover to avoid damaging paint surface.
• Avoid damaging, hold the head of the connector and carefully connect wire.
• Mark in all wires and hoses and confirm not touched with the other wires or hoses, or interfered
with other parts.
• Drain coolant. (Refer to “Chapter 17A cooling - coolant, replacement”)
1. OPEN BATTERY COVER.

2. LOOSEN BATTERY NEGATIVE AND POSITIVE CABLE

RETAINING BOLTS, THEN DISCONNECT THEM.
NOTE
Disconnect the negative first when removal.

replacement”)
ENGINE MECHANICAL - ENGINE ASSY 15A-5
15A
15A

body.

body.
10. DISCONNECT FUEL INLET / OUTLET HOSE FROM

FUEL RAIL.
NOTE
After disconnecting the fuel hose, use the plastic bag to
seal up the fuel hose connector, prevent the dust entering
the fuel hose.
11. REMOVE CLUTCH HYDRAULIC PIPELINE BRACKET

RETAINING BOLT.
12. DISCONNECT CLUTCH CYLINDER AND CLUTCH

HYDRAULIC PIPELINE CONNECTOR.
13. DISCONNECT TRANSMISSION WITH OTHER

COMPONENTS CONNECTION.
(a) Disconnect the gear selector short tie rod and transmission
connection. 15A
(b) Disconnect the gear shifting short tie rod and transmission
connection.
14. DRAIN STEERING FLUID, DISCONNECT POWER

STEERING PUMP OUTLET PIPE.
NOTE
Do not splash the steering fluid on the engine parts, clean
the fluid immediately if do.
15A
15. DISCONNECT POWER STEERING PUMP INLET HOSE
CLAMP.
16. REMOVE POWER STEERING FLUID RESERVOIR. (Refer to “Chapter 52 power steering- power
steering fluid reservoir, replacement”)
17. DISCONNECT HEATER INLET HOSES.

18. DISCONNECT HEATER OUTLET HOSES.
19. DISCONNECT UPPER RADIATOR COOLANT HOSE AND

COOLANT FILLING PIPE BYPASS HOSE CLAMPS.
20. DISCONNECT RADIATOR LOWER COOLANT HOSE.
21. DRAIN REFRIGERANT. (Refer to“Chapter 61 heater and air conditioning - refrigerant,
replacement”)
22. REMOVE 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Using clean cloth, block the A/C pipe and A/C compressor
hole to avoid dust entering.
23. INSTALL ENGINE LIFT CHAIN HANGERS.

24. RAISE THE VEHICLE TO TOP PLACE.
25. REMOVE THE FRONT WHEEL. (Refer to“Chapter 33 tire and wheel - front tire and wheel,
replacement”)
26. REMOVE STRUT ROD. (Refer to “Chapter 31 front suspension- strut rod, replacement”)
27. REMOVE 3 BOLTS ATTACHING FRONT EXHAUST PIPE

TO EXHAUST MANIFOLD.
15A
28. REMOVE LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
29. REMOVE STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
30. SEPARATE TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - propeller shaft, overhaul”)
31. DISCONNECT FOLLOWING ELECTRICAL CONNECTORS:
• MAP Sensor
• TP Sensor 15A
• Idle Control Motor
• Generator
• Generator Positive Cable
• Fuel Injector
• Ignition Coil
• KS Sensor
• Engine Oil Pressure Switch
• ECT Sensor
• ECM
• Charcoal Canister Solenoid Valve
• Front/rear Oxygen Sensor
• CKP Sensor
• Speed Sensor
• Reverse Gear Switch
• A/C Compressor
• Starter Positive Cable
• Engine Ground Cable
32. USING A JACK, SUPPORT VEHICLE.

33. REMOVE NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
34. REMOVE 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY AND TAKE AWAY SUB-FRAME.
NOTE
Before removing sub-frame, mark symbols both on the sub-
frame and sub-frame retaining bolts.
35. LOWER ENGINE SUPPORT JACK AND RELEASE ENGINE LIFT CHAIN HANGERS SLOWLY.
36. VERIFY ALL VACUUM HOSES, FUEL AND COOLANT HOSES, ELECTRICAL CONNECTORS
BETWEEN ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED.
37. LOWER ENGINE ABOUT 150 MM SLOWLY. VERIFY ALL COMPONENTS BETWEEN THE
ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED AGAIN.
38. REMOVE ENGINE AND TRANSMISSION FROM VEHICLE.
39. REMOVE BOLTS ATTACHING ENGINE TO SUB-

FRAME AND SEPARATE THEM.
40. REMOVE STARTER RETAINING BOLTS AND SEPARATE

STARTER FROM TRANSMISSION.
41. REMOVE 4 BRACKET BOLTS ATTACHING ENGINE TO

TRANSMISSION.
15A
42. REMOVE BOLTS ATTACHING ENGINE TO TRANSMISSION

AND SEPARATE TRANSMISSION FROM ENGINE.
15A
43. REMOVE CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
pressure plate, overhaul”)
44. REMOVE ENGINE ACCESSORY BELTS. (Refer to “Chapter 15A engine mechanical - engine
accessory belt, overhaul”)
45. REMOVE GENERATOR RETAINING BOLTS AND

SEPARATE GENERATOR FROM BRACKET.
46. REMOVE BOLTS ATTACHING A/C COMPRESSOR TO ENGINE AND TAKE AWAY A/C COMPRESSOR.
(Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
47. TIGHTEN GENERATOR RETAINING BOLTS.

48. INSTALL A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air
conditioning - compressor, overhaul”)
49. INSTALL CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
50. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine
51. TIGHTEN BOLTS ATTACHING ENGINE TO TRANSMISSION.

52. INSTALL 4 BRACKET BOLTS ATTACHING ENGINE TO

TRANSMISSION.
53. TIGHTEN STARTER RETAINING BOLTS.

15A
54. TIGHTEN BOLTS ATTACHING ENGINE TO SUB-

FRAME.
15A
55. INSTALL ENGINE AND TRANSMISSION FROM BOTTOM OF VEHICLE, INSTALL ENGINE LIFT
CHAIN HANGERS.
56. TIGHTEN 4 BOLTS ATTACHING SUB-FRAME TO

VEHICLE BODY.
Torque: 205 ~ 215 N•m
NOTE
According to the mark on the sub-frame retaining bolt,
position the sub-frame.
57. TIGHTEN NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
Torque: 110 ~ 130 N•m
58. TIGHTEN 3 BOLTS ATTACHING EXHAUST MANIFOLD

TO EXHAUST PIPE.
59. INSTALL LOWER CONTROL ARM. (Refer to “Chapter 31 front suspension - lower control arm,
replacement”)
60. INSTALL STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
61. CONNECT TRANSMISSION TO PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
62. INSTALL THE FRONT WHEEL. (Refer to“Chapter 33 tire and wheel - front tire and wheel,
replacement”)
63. LOWER VEHICLE AND LOSSEN ENGINE LIFT CHAIN HANGERS.
64. TIGHTEN 2 BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE
Install a new O-ring.
65. CONNECT HEATER INLET HOSES.
66. CONNECT HEATER OUTLET HOSES.

67. CONNECT UPPER RADIATOR COOLANT HOSE AND

COOLANT FILLING PIPE BYPASS HOSE THEN TIGHTEN
CLAMPS.
15A
68. CONNECT RADIATOR LOWER COOLANT HOSE.
15A
69. CONNECT POWER STEERING PUMP OUTLET PIPE.
70. CONNECT POWER STEERING PUMP INLET HOSE

CLAMP.
71. INSTALL POWER STEERING FLUID RESERVOIR. (Refer to “Chapter 52 power steering- power
steering fluid reservoir, replacement”)
72. CONNECT TRANSMISSION WITH OTHER COMPONENTS

CONNECTION.
(a) Connect the gear selector short tie rod and transmission
connection.
(b) Connect the gear shifting short tie rod and transmission
connection.
73. INSTALL CLUTCH HYDRAULIC PIPELINE BRACKET

RETAINING BOLT.
74. CONNECT CLUTCH CYLINDER AND CLUTCH HYDRAULIC

PIPELINE CONNECTOR.

(a) Connect the clamp attaching air intake pipe and throttle
body.
Torque: 21 ~25 N•m
(c) Connect air intake pipe and crankcase breather hose.

(a) Install accelerator cable clip.
(b) Install accelerator cable adjustable nut on the throttle
body. 15A
77. CONNECT FUEL RAIL INLET/OUTLET HOSE AND

TIGHTEN CLAMPS.
15A
78. ACCORDING TO THE MARK BEFORE REMOVAL, CONNECT FOLLOWING ELECTRICAL CONNECTORS:
• MAP Sensor
• TP Sensor
• Idle Control Motor
• Generator
• Generator Positive Cable
• Fuel Injector
• Ignition Coil
• Knock Sensor
• ECT Sensor
• ECM
• Charcoal Canister Solenoid Valve
• Front/rear Oxygen Sensor
• CKP Sensor
• A/C Compressor
• Starter Positive Cable

80. FILL STEERING FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
81. FILL CLUTCH PUMP RESERVOIR.
82. FILL BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid, replacement”)


replacement”)
ENGINE MECHANICAL - ENGINE ACCESSORY BELT 15A-19
ENGINE ACCESSORY BELT

COMPONENTS
15A
15A
1 A/C Compressor Pulley 4 Power Steering Pump Pulley
A/C Compressor Belt Tensioning Idle 5 Coolant Pump Pulley

2
Pulley
6 Generator Assy
Power Steering Pump Belt Tensioning Idle
3 7 Crankshaft Pulley
Pulley
15A-20 ENGINE MECHANICAL - ENGINE ACCESSORY BELT
replacement”)
6. COOL ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE ENVI-
RONMENT TEMPERATURE.
7. INSPECT TIMING BELT. INSPECT EACH PART OF

TIMING BELT CAREFULLY, IF FIND ANY DAMAGE AS
FOLLOWING, REPLACE WITH A NEW ONE.
(a) Inspect the timing belt back rubber for signs of aging and
glistening.
(b) Cracks in the back rubber.

(c) Cracks and stripping in the canvas.
(d) Cracks in the grooves.
(e) Cracks in the side of the belt. 15A
(f) Inspect the timing belt for abnormal abrasion in the side
of the belt.
15A
(g) Timing belt for abnormal abrasion.
(h) Teeth missing from the belt.
OVERHAUL
GENERATOR BELT
2. LOOSEN NUT ATTACHING GENERATOR TO GENER-

ATOR BRACKET.
3. LOOSEN TENSIONER LOCKED NUT.

4. ROTATE TENSIONER BOLT TO ADJUST TENSITY OF
GENERATOR BELT.
5. REPLACE IT WITH A NEW GENERATOR BELT IF NECESSARY.

6. ADJUST TENSIONER BOLT AND TIGHTEN LOCK NUT.

15A
7. TIGHTEN NUT ATTACHING GENERATOR TO GENER-

ATOR BRACKET.
15A
8. CHECK TENSITY OF GENERATOR BELT, ADJUST IT IF NECESSARY.
9. USING BELT TENSION DEVICE, INSPECT BELT TEN-

SITY.
Item Standard Tensity

New belt 490 ~ 686 N
Used belt 343 ~ 441 N

10. PRESS 100 N TO MIDDLE OF BELT AND CHECK

DEFLECTION.
Item Deflection
New belt 5.5 ~ 7.5 mm
Used belt 7.5 ~ 8.5 mm

POWER STEERING PUMP BELT

15A
2. LOOSEN POWER STEERING PUMP IDLE PULLEY
RETAINING BOLT AND POWER STEERING PUMP
IDLE PULLEY TENSIONER BOLT.
3. REMOVE GENERATOR BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.

4. INSTALL STEERING BELT.
5. ROTATE TENSIONER BOLT TO ADJUST BELT TEN-

SITY AND TIGHTEN POWER STEERING PUMP IDLE
PULLEY RETAINING BOLT. 15A

DEFLECTION.
Item Deflection

A/C COMPRESSOR BELT

2. LOOSEN A/C COMPRESSOR IDLE PULLEY RETAINING

BOLT AND A/C COMPRESSOR IDLE PULLEY TEN-
SIONER BOLT.
3. TAKE AWAY A/C COMPRESSOR BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.
4. INSTALL A/C COMPRESSOR BELT.
5. ROTATE A/C COMPRESSOR TENSIONER BOLT TO

ADJUST BELT TENSITY AND TIGHTEN A/C COMPRESSOR
BELT IDLE PULLEY RETAINING BOLT.

DEFLECTION.
Item Deflection
Used belt 8.0 ~9.0 mm

ENGINE MECHANICAL - ENGINE TIMING CHAIN COVER 15A-27
ENGINE TIMING CHAIN COVER

REPLACENEMT
15A
replacement”)
15A
6. REMOVE ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine
accessory belt, replacement”)
7. REMOVE IDLE PULLEY RETAINING BOLT.

15A-28 ENGINE MECHANICAL - ENGINE TIMING CHAIN COVER
8. REMOVE CRANKSHAFT POSITION SENSOR .
9. REMOVE COOLANT PUMP. (Refer to “Chapter 17A cooling-coolant punp, overhaul”)
10. REMOVE CRANKSHAFT PULLEY RETAINING BOLT.
11. REMOVE TIMING CHAIN COVER RETAINING BOLTS .

NOTE
After long time using, the gasket will stick to the connection
surface. Use scrape to clean the residue on the timing
chain cover.
12. EVENLY APPLY SEALANT TO TIMING CHAIN COVER.

ENGINE MECHANICAL - ENGINE TIMING CHAIN COVER 15A-29
13. INSTALL TIMING CHAIN COVER AND TIGHTEN RETAIN-

ING BOLTS.
Torque: 10 N•m
15A
14. INSTALL CRANKSHAFT PULLEY AND TIGHTEN

RETAINING BOLT.
Torque: 155 ~ 165 N•m
15A
15. INSTALL CKP SENSOR RETAINING BOLTS.
Torque: 7.5 ± 10% N•m
16. INSTALL COOLANT PUMP. (Refer to “Chapter 17A cooling - coolant pump, overhaul”)
17. INSTALL IDLE PULLEY AND TIGHTEN RETAINING

BOLT.
18. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine acces-
sory belt, replacement”)
15A-30 ENGINE MECHANICAL - ENGINE TIMING CHAIN COVER


replacement”)
23. PUT DRIVER SEAT DOWN AND LOCK IT.
ENGINE MECHANICAL - ENGINE TIMING CHAIN 15A-31
ENGINE TIMING CHAIN

COMPONENTS
15A
15A
1 Timing Chain Tensioner 4 Timing Chain Damper
2 Timing Chain 5 Crankshaft Chain Sprocket
3 Camshaft Chain Sprocket

15A-32 ENGINE MECHANICAL - ENGINE TIMING CHAIN
OVERHAUL
replacement”)
7. REMOVE ENGINE TIMING CHAIN COVER. (Refer to “Chapter 15A engine mechanical - engine
timing chain cover, replacement”)
8. REMEMBER TO ROTATE DIRECTION OF TIMING

CHAIN IN ORDER TO AVOID ANY ERROR WHEN
ASSEMBLING.
15A
9. INSTALL CRANKSHAFT CHAIN SPROCKET BOLT AND

ROTATE IT UNTIL ALIGN WITH TIMING MARKS.
15A
10. USING A SPRING SCALES, PULL TIMING CHAIN WITH
A FORCE OF 98 N. MEASURE THE CLEARANCE “ △ ”
BETWEEN CHAIN TENSIONER PLUG AND SUPPORT.
THE VALUE SHOULD NOT EXCEED STANDARD.
OTHERWISE REPLACE WITH NEW TIMING CHAIN AND
SPROCKET.
Stanard: ≤ 13.5 mm
11. REMOVE 2 CHAIN TENSIONER RETAINING BOLTS.
12. REMOVE CHAIN TENSIONER AND USE A CALIPER

CHECK THE THICKNESS OF RUBBER DAMPER ON
THE HEAD OF CHAIN TENSIONER PLUG.
Standard:15.0 mm
Limit:12.5 mm
13. REMOVE 2 TIMING CHAIN DAMPER RETAINING

BOLTS.
14. CHECK THICKNESS OF RUBBER DAMPER, IF LESS THAN LIMIT, REPLACE IT WITH NEW ONE.
Standard: 6.6 mm
Limit:5.0 mm
15. REMOVE CAMSHAFT CHAIN SPROCKET RETAINING
BOLT.
16. REMOVE TIMING CHAIN TOGETHER WITH CAMSHAFT CHAIN SPROCKET AND CRANKSHAFT
CHAIN SPROCKET.
17. SEPARATE TIMING CHAIN AND CHECK IT.
(a) Check length of timing chain. Using a spring scales,

force 49 N to pull the chain. Select 3~4 measurement
points at random to measure. If chain length exceeds the
limit value, replace it with a new one.
Limit: 291.4 mm
(b) Using a caliper, measure diameters of crankshaft timing

sprocket and camshaft timing sprocket (with chain). If
sprocket diameters are less than limit, replace timing
chain and two sprockets.
Item Limit
Crankshaft timing sprocket 59 mm
Camshaft timing sprocket 114 mm
18. ACCORDING TO THE TIMING MARKS BEFORE REMOVAL, INTALL TIMING CHAIN TOGETHER
WITH CAMSHAFT CHAIN SPROCKET AND CRANKSHAFT CHAIN SPROCKET.
19. ALIGN THE MARK OF KEYWAY ON THE CAMSHAFT AND CRANKSHAFT. INSTALL TIMING
CHAIN TOGETHER WITH THE CAMSHAFT SPROCKET AND CRANKSHAFT SPROCKET.
20. INSTALL CRANKSHAFT SPROCKET BOLT, ROTATE 10

15A
CIRCLES TO ALIGN TIMING MARKS AGAIN.
21. INSTALL 2 TIMING CHAIN DAMPER RETAINING

BOLTS. 15A
Torque: 24 N•m
22. INSTALL 2 CHAIN TENSIONER RETAINING BOLTS.

Torque: 5 N•m
23. INSTALL ENGINE TIMING BELT COVER. (Refer to “Chapter 15A engine mechanical - engine tim-
ing belt cover, replacement”)


replacement”)
ENGINE MECHANICAL - ROCKER ARM/ROCKER SHAFT 15A-37
ROCKER ARM/ROCKER SHAFT

OVERHAUL
15A
replacement”)
15A

body.
15A-38 ENGINE MECHANICAL - ROCKER ARM/ROCKER SHAFT
7. SEPARATE PCV VALVE FROM HOSE.
8. REMOVE CYLINDER HEAD COVER RETAINING BOLTS.
9. TAKE CYLINDER HEAD COVER AND CYLINDER HEAD COVER GASKET AWAY.
NOTE
Cylinder head cover gasket can not be recycled. Replace with a new one before installing.
10. REMOVE ROCKER SHAFT ASSY RETAINING BOLTS AS

SHOWN.
11. TAKE ROCKER SHAFT ASSY AWAY.

12. SEPARATE ROCKER SHAFT SPRING, ROCKER ARM AND ROCKER SHAFT, THEN HAVE A
INSPECTION.
(a) Check the rocker arm and the valve contact surface wear, if necessary, repair or replace the rocker
arm.
(b) Inspect the fitting clearance between rocker arm and

rocker shaft, if exceed the limit, replace rocker arm and
rocker shaft.
15A
Item Measured value
Rocker arm inner diameter 18.500 mm ~ 18.515 mm
Rocker shaft diameter 18.474 mm ~ 18.487 mm
Standard clearance 0.02 mm ~ 0.051 mm
Limit clearance 0.08 mm
13. ASSEMBLE ROCKER ARM, ROCKER SHAFT SPRING

AND ROCKER SHAFT ASSY.
NOTE
• When installing the rocker arm and rocker shaft assy,
position the oil hole forward.
15A
• ASSEMBLE WITH SPECIAL TOOL.
14. INSTALL ROCKER SHAFT ASSY RETAINING BOLTS

AS SHOWN.
Torque: 24 N•m
15A-40 ENGINE MECHANICAL - ROCKER ARM/ROCKER SHAFT
15. INSTALL CYLINDER HEAD COVER GASKET, POSI-

TION CYLINDER HEAD COVER AND TIGHTEN
RETAINING BOLTS.
Torque: 5 N•m
16. CONNECT PCV VALVE AND HOSE.

body.



15A
replacement”)
15A
15A-42 ENGINE MECHANICAL - HYDRAULIC ADJUSTER / VALVE PUSH ROD
HYDRAULIC ADJUSTER / VALVE PUSH ROD

OVERHAUL
1. REMOVE ROCKER ARM AND ROCKER SHAFT. (Refer to “Chapter 15A engine mechanical-
rocker arm/rocker shaft, overhaul”)
2. REMOVE VALVE PUSH ROD.
3. CHECK VALVE PUSH ROD.

(a) Check run-out at middle of push rod. If the value exceeds
the maximum, replace the push rod.
Limit: 0.30 mm
(b) Check oil passage hole of push rod for blocked. If found,
use compressed air to clear up.
4. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head, over-
haul”)
5. USING A PROPER TOOL, REMOVE HYDRAULIC

ADJUSTER FROM CYLINDER HEAD.
NOTE
• Hydraulic adjusters are a precision part. There should
not be any dust or foreign matter on its surface.
• Do not disassemble the hydraulic adjusters.
• It is required to use clean diesel oil to clean the hydraulic
adjusters.
6. CLEAN HYDRAULIC ADJUSTER.

(a) Prepare three containers and 5L diesel fuel. Pour enough
diesel fuel into each container until each upright adjuster
is completely submerged. Clean the hydraulic adjusters
as the following steps.
ENGINE MECHANICAL - HYDRAULIC ADJUSTER / VALVE PUSH ROD 15A-43
(b) Place the hydraulic adjuster in container A and wash its

surface.
NOTE
Use a nylon brush to remove deposits. 15A
(c) Using a metal wire, press the steel ball in the hydraulic
adjuster, move the plunger up and down 5-10 times until
it moves smoothly. This can eliminate the plunger sliding
resistance and expel contaminated oil.
NOTE
• The steel ball spring of the hydraulic adjuster is
extremely weak. The hydraulic adjuster's functionality
may be badly affected if the special tool is inserted
strongly.
15A
• Use the special tool to check whether the plunger can
be pressed. If it is hard to press, the hydraulic adjuster
is normal. If it is easy to press, repeat the previous
procedure and then check the hydraulic adjuster
again. If the plunger is still loose, the hydraulic
adjuster should be replaced.
(d) Take the hydraulic adjuster out of the container, then

move the plunger by pushing the steel ball gently to drain
the diesel fuel from the pressure chamber.
(e) Put the hydraulic adjuster into container B. Using a metal

wire, press the steel ball in the hydraulic adjuster and
move the plunger up and down 5-10 times until it moves
smoothly. This operation can wash the hydraulic
adjuster’s pressure chamber.
NOTE
The steel ball spring of the hydraulic adjuster is extremely
weak. The hydraulic adjuster's functionality may be badly
affected if the special tool is inserted strongly.
(f) Take the hydraulic adjuster out of the container B, then

move the plunger by pushing the steel ball gently to drain
the diesel fuel from the pressure chamber.
(g) Put the hydraulic adjuster into container C. Using a metal

wire, press the steel ball in the hydraulic adjuster.
NOTE
Do not use container C for cleaning. If cleaning is performed in
container C, foreign matter could enter the pressure chamber
when the chamber is filled with diesel fuel.
(h) Place the hydraulic adjuster upright with the plunger at

the top. Push the plunger firmly until it makes a full
stroke, then return the plunger slowly and release the
hold of the steel ball to allow the pressure chamber to be
filled with diesel fuel.
(i) Take the hydraulic adjuster out of the container C, place

it upright with the plunger at the top and push the plunger
firmly. The plunger can not be moved at all. Check the
height between the plunger and new hydraulic adjuster.
NOTE
If the hydraulic adjuster shrinks, perform the steps from (g)
to (i) again until pressure chamber has completely been
filled with diesel fuel (air has been exhausted). Replace the
hydraulic adjuster if it still shrinks even after the operation.
(j) Install hydraulic adjuster on checkout equipment. Apply

196 N pressure. After plunger has gone down about 2
mm, measure the time of going down 1 mm.
Standard: 7 ~ 50 seconds/mm (Diesel fuel at 15 ~ 20
℃)
NOTE
If the measured values do not conform to the standards,
replace the hydraulic adjuster.
ENGINE MECHANICAL - HYDRAULIC ADJUSTER / VALVE PUSH ROD 15A-45
(k) Put the hydraulic to adjuster into container C. Using a

metal wire, press the steel ball in the hydraulic adjuster.
Place the hydraulic adjuster upright with the plunger at
the top. Push the plunger firmly until it makes a full 15A
stroke, then return the plunger slowly and release the
hold of the steel ball to allow the pressure chamber to be
filled with diesel fuel.
(l) Take the hydraulic adjuster out of the container C, place

it upright with the plunger at the top and push the plunger
firmly. The plunger can not be moved at all. Check the
height between the plunger and new hydraulic adjuster.
NOTE
If the hydraulic adjuster shrinks, repeat steps (i) to (k) until
pressure chamber has been completely filled with diesel
fuel. Replace the hydraulic adjuster if it still shrinks even
after the operation.
15A
7. INSPECT HYDRAULIC ADJUSTER.
Item Standard Limit

Hydraulic adjuster external diameter 21.387 ~ 21.404 mm -
Hydraulic adjuster hole diameter 21.417 ~ 21.443 mm -
Fit clearance 0.017 ~ 0.056 mm 0.100 mm
8. INSTALL HYDRAULIC ADJUSTER.
9. INSTALL CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
10. INSTALL VALVE PUSH ROD.
11. REMOVE ROCKER ARM AND ROCKER SHAFT. (Refer to “Chapter 15A engine mechanical-
ENGINE MECHANICAL - CAMSHAFT 15A-47
CAMSHAFT
OVERHAUL
NOTE 15A
Remove the camshaft after remove the cylinder head.
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and
valve, overhaul”)
2. REMOVE TIMING CHAIN COVER. (Refer to “Chapter 15A engine mechanical - timimg chain
cover, replacement”)
3. REMOVE CAMSHAFT SPROCKET RETAINING BOLT.
15A
4. REMOVE TIMING CHAIN.
5. REMOVE OIL PUMP DRIVING SHAFT RETAINING

BOLT.
6. REMOVE CAMSHAFT THRUST PLATE RETAINING

BOLT.
15A-48 ENGINE MECHANICAL - CAMSHAFT
7. REMOVE CAMSHAFT THRUST PLATE.
8. PULL OUT CAMSHAFT.
9. INSPECT CAMSHAFT.
(a) Measure the camshaft cam lobe height.
Item Standard Limit

Intake 38.620 ~ 38.720 mm 38.26 mm
Exhaust 38.629 ~ 38.729 mm 38.27 mm
(b) If there is any wear or flaw, replace the camshaft.
(c) Check the camshaft journal diameter. (Start measuring

from the front.)
Item Standard
1st camshaft journal 46.459 ~ 46.475 mm
2nd camshaft journal 46.209 ~ 46.225 mm
3rd camshaft journal 45.959 ~ 45.975 mm
4th camshaft journal 45.709 ~ 45.725 mm
5th camshaft journal 45.459 ~ 45.475 mm

(d) Check the camshaft bearing bore diameter. (The bearing

had been installed.)
Item Standard
15A
1st camshaft bearing bore 46.500 ~ 46.570 mm
2nd camshaft bearing bore 46.250 ~ 46.320 mm
3rd camshaft bearing bore 46.000 ~ 46.070 mm
4th camshaft bearing bore 45.750 ~ 45.820 mm
5th camshaft bearing bore 45.500 ~ 45.570 mm
(e) Measure the clearance between camshaft bearing bore

and camshaft journal. If exceed the limit, replace the
camshaft.
Standard: 0.025 ~ 0.111 mm
Limit: 0.140 mm
(f) Install the thrust plate and camshaft sprocket onto

camshaft, tighten the fixing bolts of camshaft sprocket 15A
with a 90N.m tightening torque, and then measure axial
clearance between thrust plate and 1st journal thrust
surface with a feeler.
Limit: 0.30 mm
(g) Measure journal run-out at middle of camshaft.

Limit: 0.06 mm
10. REMOVE CAMSHAFT OIL SEAL.

NOTE
Replace with a new oil seal after moving the camshaft oil seal.
11. LIGHTLY COATED WITH ENGINE OIL ON CAMSHAFT OIL SEAL LIP AREA AND INSTALL
CAMSHAFT OIL SEAL.
15A-50 ENGINE MECHANICAL - CAMSHAFT
12. INSTALL CAMSHAFT.
13. INSTALL CAMSHAFT THRUST PLATE.
14. INSTALL CAMSHAFT THRUST PLATE RETAINING

BOLT.
Torque: 24 N•m
NOTE
• When installing the thrust plate, position the 2 pits
face front.
• Rotate camshaft, position the keyway upwards and
align the pit on the thrust plate.
15. INSTALL OIL PUMP DRIVING SHAFT RETAINING

BOLT.
Torque：24 N•m
15A
16. INSTALL CAMSHAFT SPROCKET RETAINING BOLT.

Torque：90 ~ 100 N•m
15A
17. INSTALL TIMING CHAIN. (Refer to “Chapter 15A engine mechanical - timing chain , overhaul”)
18. INSTALL TIMING CHAIN COVER. (Refer to “Chapter 15A engine mechanical - timing chain cover,
overhaul”)
19. INSTALL CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and valve,
overhaul”)
15A-52 ENGINE MECHANICAL - CYLINDER HEAD
CYLINDER HEAD
0
去
OVERHAUL

replacement”)

ENGINE MECHANICAL - CYLINDER HEAD 15A-53

body.
(b) Remove 2 air intake pipe retaining bolts. 15A

10. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15A engine mechanical - engine timing belt,
overhaul”)
11. REMOVE CLUTCH HYDRAULIC PIPELINE BRACKET

RETAINING BOLT.
15A
12. DISCONNECT HEATER HOSES.


14. LIGHTLY ROTATE SPARK PLUG WIRE AND PUT IT

OUT.
15. REMOVE OIL DIPSTICK RETAINING BOLTS.
16. LOOSEN FUEL RAIL INLET/OUTLET HOSE CLAMP

17. REMOVE INTAKE MANIFOLD. (Refer to “chapter 14A intake - intake manifold, replacement”)
18. REMOVE FUEL RAIL. (Refer to “ Chapter 12A fuel - fuel injector assy, overhaul”)
19. REMOVE CYLINDER HEAD COVER RETAINING

BOLTS.
15A
20. REMOVE CYLINDER HEAD COVER AND CYLINDER HEAD COVER GASKET.
NOTE
Before installing, replace the cylinder head cover gasket with a new one.
15A
21. REMOVE ROCKER SHAFT ASSY RETAINING BOLTS
AS SHOWN.
22. TAKE DOWN ROCKER ARM AND ROCKER SHAFT ASSY.
23. REMOVE 14 CYLINDER HEAD BOLTS.
24. REMOVE CYLINDER HEAD ASSY.

25. REMOVE CYLINDER HEAD GASKET.
26. CHECK CYLINDER HEAD GASKET.

(a) There should be no damage, oil leakage, water leakage and indication.
(b) After removing the cylinder head, use a scraper to clean the gasket material on the connect surface.
27. CHECK CYLINDER HEAD GASKET SURFACE FOR

FLATNESS BY USING A RULER AND THICKNESS
GAUGE.
Limit: 0.15 mm
NOTE
Check whether there is corrode on the face of cylinder
head. Replace it with a new cylinder head if found.
28. INSTALL A NEW CYLINDER HEAD GASKET.

CAUTION
Please position the cylinder head gasket according to the
mark on the gasket, align the water and oil way. Otherwise,
it will damage the engine.
29. POSITION CYLINDER HEAD GASKET TO LOCATE PIN.
NOTE
The cylinder head bolt only can be uesd for twice.
30. INSTALL AND TIGHTEN CYLINDER HEAD BOLTS

AND TORQUED IN THE SEQUENCE AS SHOWN.
M12: 93 ~ 105 N•m
M8: 20 ~ 25 N•m 15A
31. INSTALL ROCKER ARM AND ROCKER SHAFT. (Refer to “Chapter 15A engine mechanical -
32. INSTALL AND TIGHTEN CYLINDER HEAD COVER

RETAINING BOLTS.
Torque: 5 N•m
15A
33. INSTALL FUEL RAIL. (Refer to “Chapter 12A fuel - fuel injector assy, replacement”)
34. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14A intake - intake manifold, replacement”)
35. INSTALL OIL DIPSTICK RETAINING BOLT.

Torque：10 N•m
36. CONNECT FUEL RAIL INLET/OUTLET HOSES.

37. INSTALL CLUTCH HYDRAULIC PIPELINE BRACKET

RETAINING BOLT.
38. CONNECT HEATER HOSES.

COOLANT FILLING PIPE BYPASS HOSE.
40. INSTALL SPARK PLUG WIRE .


body.
(b) Install 2 air intake pipe retaining bolts. 15A

15A

replacement”)
48. CONNECT BATTERY NEGATIVE CABLE, THEN INSTALL BATTERY COVER.
15A-60 ENGINE MECHANICAL - VALVE/VALVE SPRING
VALVE/VALVE SPRING
OVERHAUL
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
2. USING PROPER TOOL, COMPRESS VALVE SPRING.

THEN TAKE VALVE SPRING LOCK AWAY.
3. REMOVE UPPER VALVE SPRING RETAINER AND VALVE SPRING.

NOTE
Store removed valves, spring and other parts. Tag to indicate their cylinder numbers and location for
assembly.
4. INSPECT VALVE SPRING.

(a) Check the valve spring free length/height， discard the
springs that do not meet specifications.
(b) Check the valve spring center line, discard the springs
that do not meet specifications.
Standard: ≤ 2 mm
(c) Using a spring tester measure the spring elastic when

the valve spring is in standard length 40.6 mm. If the
spring elastic does not conform to the standard, replace
it with a new one.
Standard: 292 ~ 336 N
ENGINE MECHANICAL - VALVE/VALVE SPRING 15A-61
5. REMOVE VALVE OIL SEAL.

NOTE
Do not reuse valve oil seal.
15A
6. REMOVE LOWER VALVE SPRING RETAINER.

7. TAKE VALVE AWAY AND CHECK IT.
(a) Check valve work surface, such as carbon deposition existence, clear it if find.
(b) Check valve work surface, such as burn or wear, replace with a new one if necessary.
(c) When the valves and valve seat worn lightly, it can be fixed by polishing. The method is as follows: first,
remove valve, the valve seat catheter and coke, then in the valve cone are coated with a thin layer of
valve sand. Use the eraser bowl with wooden valve flap to absorb, combined with the method of
rotating and grinding. Each rotation is not more than 90°, until the valve cone appears a well-balanced
without burnish band width for 1.5 ~ 2 mm. Too wide band is harm for seal. Too narrow, against heat 15A
dissipation, the valve will burned for high temperature. Sand has the different in thick and thin.
According to the wear and ablation of choice.
(d) Check the valve tightness.

• Using pencil, draw 8 ~ 12 marks on the valve work
surface, tap the valve with the valve seat (do not rotate
the valve), if the mark is broken in middle part of the
mark, the valve tightness is OK.
(e) Measure the valve diameter.
Item Standard
Intake Valve 7.970 ~ 7.985 mm
Exhaust Valve 7.965 ~ 7.980 mm
Valve Guide Inner Bore 8.010 ~ 8.030 mm

15A-62 ENGINE MECHANICAL - VALVE/VALVE SPRING
(f) Measure valve stem diameter and valve guide inner

diameter. Check that clearance is within specification. If it
exceeds the limit, replace valve or valve guide.
Clearance Standard Limit

Intake Valve 0.025 ~ 0.060 mm 0.10 mm
Exhaust Valve 0.030 ~ 0.065 mm 0.12 mm
(g) Check the valve face for correct contection.

Standard: 44.5 °
(h) If the edge thickness exceeds the service limit, replace
the valve.
Edge Thinkness Standard Limit

(i) Measure the valve height. If the measurement is less

than specification, replace the valve.
Valve Height Standard Limit

Intake Valve 108.2 mm 107.7 mm
Exhaust Valve 108.5 mm 108.0 mm
8. HEAT CYLINDER HEAD AND TAKE AWAY VALVE SEAT.

9. USING A PRESSOR, PUSH VALVE GUIDE OUT TOWARDING THE CYLINDER BLOCK SIDE.
10. REBORE VALVE GUIDE HOLE IN CYLINDER HEAD.
Valve Guide Hole Diameter

0.05 oversize 11.05~11.068 mm
0.25 oversize 11.25~11.268 mm
0.50 oversize 11.50~11.518 mm

ENGINE MECHANICAL - VALVE/VALVE SPRING 15A-63
11. RECONDITIONING VALVE SEAT.

(a) Before correcting the valve seat, check for clearance
between the valve guide and valve, if necessary, replace
the valve guide. 15A
(b) Using the special tool or seat grinder, correct the seat
width and angle.
(c) After correction, valve and valve seat should be lapped
with a lapping compound. Then, check the valve stem
projection.
12. FOLLOW MARK TO INSTALL VALVE.

13. INSTALL LOWER VALVE SPRING RETAINER.
14. USING SUITABLE TOOL, INSTALL NEW VALVE OIL SEAL.

IMPROPER INSTALLATION COULD RESULT IN OIL
LEAKAGE.
15A
15. INSTALL VALVE SPRING.

NOTE
Position the valve spring end with color toward the upper valve spring retainer.
16. INSTALL UPPER VALVE SPRING RETAINER.
17. USING SUITABLE TOOL, COMPRESS VALVE SPRING.

THEN TAKE VALVE SPRING LOCK AWAY.
18. INSTALL CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head and valve,
overhaul”)
15A-64 ENGINE MECHANICAL - PISTON AND CONNECTING RODS
PISTON AND CONNECTING RODS

COMPONENTS
1 No. 1 Compression Ring 7 Piston
2 No. 2 Compression Ring 8 Piston And Connecting Rod Assy
3 Oil Control Ring 9 Upper Connecting Rod Bearing
4 Piston Pin 10 Lower Connecting Rod Bearing
5 Connecting Rod 11 Connecting Rod Cap
6 Connecting Rod Bolts 12 Connecting Rod Nut

ENGINE MECHANICAL - PISTON AND CONNECTING RODS 15A-65
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replace-
ment”)
15A
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
3. REMOVE TIMING CHAIN. (Refer to “Chapter 15A engine mechanical - timing chain, overhaul”)
4. FIX ENGINE BLOCK ASSY TO FLIP FRAME FOR DISASSEMBLY.
5. REMOVE OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
6. REMOVE OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
7. REMOVE TIMING CHAIN REAR COVER.
15A
8. REMOVE CLUTCH PRESSURE PLATE.

(a) Make a mark on clutch pressure plate and flywheel.
(b) Loosen 6 bolts diagonally until the clutch pressure plate
is loosened completely.
9. LOOSEN 6 FLYWHEEL RETAINING BOLTS DIAGONALLY.
10. REMOVE REAR ENGINE BLOCK COVER RETAINING

BOLTS.
11. USING A SUITABLE TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
12. MARK CYLINDER NUMBER ON SIDE OF THE

CONNECTING ROD BIG END FOR CORRECT
ASSEMBLY.
NOTE
Keep the removed connecting rods, caps, and bearings in
order according to the cylinder number.
13. REMOVE CONNECTING ROD CAP NUTS IN SEQUENCE

AS SHOWN.
14. USING A STICK OR SIMILAR TOOL, PUSH PISTON

AND CONNECTING ROD ASSY OUT THROUGH THE
CYLINDER HEAD SIDE OF ENGINE BLOCK.
15A
15. REMOVE CONNECTING ROD BEARINGS.
16. USING SPECIAL TOOL, REMOVE PISTON PIN.

NOTE
Keep the disassembled pistons, piston pins and connecting
rods in order according to the cylinder number.
1 Push Rod
2 Guide Block B
15A
3 Guide Block C
4 Guide A
5 Guide A
6 Guide A
7 Guide A
8 Base
(a) Insert the push rod (special tool) into the piston from the
side on which the front mark is stamped in the piston
head, and attach the guide C to the push rod end.
(b) Place the piston and connecting rod assy on the piston
pin setting base (special tool) with the mark face upward.
(c) Press the piston pin.

NOTE
Keep the disassembled pistons, piston pins and connecting
rods in order according to the cylinder number.
17. REMOVE NO.1 COMPRESSION RING, NO.2 COMPRESSION RING AND OIL CONTROL RING BY
HAND.
18. INSPECT PISTON RING.
(a) If the piston needs to be reused, clean the carbon deposition on piston, compression ring and the
greasy dirt on oil ring with clean diesel.
NOTE
Do not damage the piston surface.
(b) Check the piston ring for damage, excessive wear, and breakage. Replace it if happened. If the piston
has been replaced with a new one, the piston rings must also be replaced.
(c) Check piston ring to groove side clearance. If the limit is

exceeded, replace the ring or piston, even both.
Limit: 0.1 mm
19. INSERT PISTON RING INTO CYLINDER BLOCK.

FORCE IT DOWN WITH A PISTON TO CORRECTLY
POSITION IT. THEN MEASURE END GAP WITH A
FEELER GAUGE. IF RING GAP IS EXCESSIVE,
REPLACE PISTON RING.
Item First Ring Second Ring Oil Ring

Standard 0.27 ~ 0.39 mm 0.40 ~ 0.55 mm 0.20 ~ 0.70 mm
Limit 1.11 mm 1.07 mm 1.10 mm

Standard 3.3 ± 0.1 mm 4.0 ± 0.1 mm 3.25 mm
21. CHECK DIAMETER OF PISTON PIN BORE, THEN

CHECK OUTER DIAMETER OF PISTON PIN.
Piston Pin Bore Diameter: 22.013 ~ 22.018 mm
Piston Pin Outer Diameter: 22.003 ~ 22.006 mm 15A
Piston Pin Bore And Piston Pin Clearance: 0.007 ~
0.015 mm
Wear Limit: 0.03 mm
22. CHECK THE INNER DIAMETER OF CONNECTING

ROD (SMALL END).
Connecting Rod And Piston Pin Clearance: 0.021 ~
0.037 mm 15A
23. INSTALL PISTON PIN.
(a) Measure the following dimensions of each piston, piston

pin and connecting rod.
• A: Length of piston pin in hole
• B: Width of pin socket
• C: Length of piston pin
• D: Width of small end of connecting rod
(b) Put measured values above into following formula to

calculate L.
L ＝ ((A - C) - (B - D)) / 2
(c) After inserting the push rod of the special tool into piston
pin, install pipe A in the top of the push rod.
(d) Install forward marks of piston and connecting rod in the

same direction.
(e) Lubricate the external diameter of piston pin with engine

oil.
(f) Through pipe A, insert the push rod, piston pin and pipe
component into piston pin hole from the side with the
forward mark.
(g) Screw on guide block B into guide pipe A to gain

clearance between guide block A and guide block B
equal to the value L (L=((A-C)-(B-D)) / 2) plus 3 mm.
(h) Keep the forward mark of piston upward. Install piston

and connecting rod in tool base of piston pin installer.
(i) Press the piston pin into the piston. When the pressure is
less than standard value, replace piston pin and piston
component or replace connecting rod.
Standard: 7350 ～ 17200 N
24. MAKE SURE PISTON ROTATE FREELY AFTER INSTALLING.

NOTE
When installing the connecting rod, the mark on the top of
piston, bulge at connect rod center should toward engine
front end. 15A
25. INSTALL OIL CONTROL RING.

(a) Install oil control ring spacer into the piston ring groove.
NOTE
There is no difference between the upper and lower oil control rings.
(b) Install the top oil control ring. When installing the ring,
force one side of the piston ring into the piston oil ring
groove. Then force the ring into oil ring groove with the
thumb as shown.
15A
NOTE
Do not use a piston ring expander when installing oil
control ring. It will break the oil control ring.
(c) Install the bottom oil control ring as step (b).

(d) Ensure the ring can turn from the left to the right freely
after installation.
26. INSTALL No. 1 COMPRESSION RING AND No. 2

COMPRESSION RING.
(a) Using a piston ring expander, install the No.2 compression
ring, then install the No.1 compression ring.
(b) The compression rings have an identification mark on

the top of the ring.
• No. 1 compression ring: A
• No. 2 compression ring: A
• When installing piston ring, keep the mark upward
and toward the top of piston.
27. INSTALL PISTON AND CONNECTING ROD.

(a) Oil the piston ring and the side of the piston.
(b) Position the piston ring as shown:
1 Top Oil Control Ring
2 Piston Pin
3 Bottom Oil Control Ring
No. 2 Compression Ring And Oil Control

4
Ring Spacer
5 No. 1 Compression Ring
6 Crankshaft Pulley Side
(c) Using a suitable piston ring compressor, insert the piston

and connecting rod assembly into cylinder.
NOTE
• Make sure the forward mark on the top of the piston
faces the front of the engine.
• Using a suitable tool, tap the piston and connecting
rod assembly into cylinder.
28. VERIFY MARK MADE DURING DISASSEMBLY,

INSTALL BEARING CAP TO THE CONNECTING ROD.
IF CONNECTING ROD IS NEW WITH NO INDEX
MARK, MAKE SURE THAT BEARING LOCK
NOTCHES COME ON THE SAME SIDE AS SHOWN.
29. INTSALL CONNECTING ROD CAP.

NOTE
The pulge mark on the connecting rod cap towards the
engine timing belt side.
30. APPLY ENGINE OIL TO EACH CONNECTING ROD BOLT.

31. TIGHTEN CONNECTING ROD CAP NUTS IN SEQUENCE

AS SHOWN.
15A
32. CHECK AXIAL CLEARANCE OF CONNECTING RODS.

Standard: 0.160 ~ 0.312 mm
Limit: 0.35 mm
15A
33. USING SPECIAL TOOL, INSTALL REAR CRANKSHAFT
OIL SEAL.
34. INSTALL REAR CRANKSHAFT OIL SEAL SEAT.

Torque: 10 N•m
35. INSTALL REAR ENGINE BLOCK COVER RETAINING

BOLTS.


NOTE
According to the mark made before removal, install the
clutch pressure plate retaining bolts diagonally.
Torque: 35 N•m
38. INSTALL TIMING CHAIN REAR COVER.

Torque: 25 N•m
39. INSTALL OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
40. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
41. REMOVE ENGINE BLOCK ASSY FROM FLIP FRAME.
42. INSTALL TIMING CHAIN. (Refer to “15A engine mechanical - timing chain, overhaul”)
43. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
44. INSTALL ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replacement”)
ENGINE MECHANICAL - CRANKSHAFT/ENGINE BLOCK/FLYWHEEL 15A-75
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL
COMPONENTS
15A
15A
15A-76 ENGINE MECHANICAL - CRANKSHAFT/ENGINE BLOCK/FLYWHEEL
1 Camshaft Journal Bushing 11 Crankshaft
2 Main Bearing Cap 12 Crankshaft Keyway
3 Main Bearing Cap Bolt 13 Crankshaft Sprocket
4 Lower Canshaft Bearing 14 Crankshaft Belt Pulley Bush
5 Upper Canshaft Bearing 15 Crankshaft Belt Pulley
6 Cylinder Sleeve 16 Crankshaft Belt Pulley Bolt
7 Cylinder Head Gasket 17 Flywheel Location Pin
8 Engine Block 18 Flywheel Bolt
9 Rear Engine Block Cover 19 Rear Crankshaft Oil Seal
10 Location Pin
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replace-
ment”)
15A
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
3. REMOVE OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
4. REMOVE OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
5. REMOVE OIL PUMP FRONT COVER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
6. FIX ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLE IT.
7. REMOVE TIMING CHAIN REAR COVER.
15A

is loosened completely.

BOLTS.
11. USING A PROPER TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
12. ROTATE ENGINE BLOCK, MAKE OIL PAN PART UP.
13. REMOVE MAIN BEARING CAP BOLTS IN SEQUENCE

AS SHOWN.
NOTE
The crankshaft main bearing caps is precision-machined
with the engine block, do not exchange with each other.
Avoid error of installation, there are mark number such as 15A
"1","2" on the connecting rod cap. The arrow on the
crankshaft main bearing cap directs to the crankshaft
pulley.
14. REMOVE MAIN BEARING CAP AND DISASSEMBLE THE LOWER CRANKSHAFT BEARING.
15. DISASSEMBLE UPPER CRANKSHAFT BEARING

AND THRUST BEARING ON THIRD CRANKSHAFT
JOURNAL.
15A
16. INSPECT THRUST BEARING

(a) Inspect thrust bearing, there should be no serious wear,
galling, pitting.
(b) Check the thickness of thrust bearing.
Standard：2.450 ~ 2.490 mm
17. MARK CYLINDER NUMBER AT SIDE OF CONNECTING

ROD BIG END FOR CORRECT ASSEMBLY.
NOTE

AS SHOWN.

AND CONNECTING ROD ASSY OUT.
20. TAKE CRANKSHAFT AWAY AND INSPECT IT.

(a) Check crankshaft main journal.
Crankshaft main journal: 57.985 ~ 58.000 mm
(b) Check crankshaft main journal for excessive wear, roundness

and scoring. If found, check the oil hole pluged or not.
(c) Check crankshaft circular runout.
Limit: 0.06 mm
(d) Measure the clearance between crankshaft main journal
and main bearing. If exceed the limit, replace the main
bearing. If necessary, replace the crankshaft.
Standard: 0.020 ~ 0.051 mm
Limit: 0.1 mm
(e) Inspect the crankshaft.

• Using a plastigauge, check the oil clearance of the
crankshaft as following.
• Clean all engine oil off from the crankshaft journals.

• Install the crankshaft.
• Cut the plastigauge into length as wide as the crankshaft
journal. Lay the plastigauge across the crankshaft 15A
journal.
• Carefully install the main bearing cap. Tighten the main
bearing cap to the specified torque.
• Carefully disassemble the main bearing cap.
• Use the measuring ruler imprinted on the plastigauge

package to measure the width of the widest part of the
plastigauge.
Standard: 0.020 ~ 0.051 mm
Limit: 0.1 mm
15A
21. REMOVE UPPER CRANKSHAFT BEARING AND CRANKSHAFT THRUST BEARING.
22. TAKE ENGINE BLOCK FROM FLIP FRAME AND

INSPECT IT.
(a) Check for scratches, rust, and corrosion visually or with
flaw detecting agent. If defects are evident, repair or
replace it.
(b) Use a straightedge and feeler gauge to check the block
top surface for warpage. Make sure that the surface is
free from gasket chips and other foreign matters.
Standard: ≤ 0.05 mm
Limit: 0.02 mm
(c) The cylinder walls should be checked for out-of-round

and taper with cylinder indicator or equivalent. If the
cylinder walls are badly scuffed or scored, the cylinder
block should be replaced, and new pistons and rings
should be fitted.
(d) Measure the cylinder bore at three levels in directions A

and B. Top measurement should be within 12 mm and
bottom measurement should be out of 12 mm from
bottom of bore.
Standard: 91.00 ~ 92.03 mm
Limit: 91.23 mm
Cylinder Cylindrically: ≤ 0.01 mm
(e) Piston size identification.

NOTE
Size mark is stamped on piston top.
Group 1 91.00mm ≤ D ＜ 91.01 mm
Group 2 91.01mm ≤ D ＜ 91.02 mm
Group 3 91.02mm ≤ D ＜ 91.03 mm
(f) Measure piston outer diameter is in thrust direction as

shown.
Group 1 90.938mm ≤ D ＜ 90.948 mm
Group 2 90.948mm ≤ D ＜ 90.958 mm
Group 3 90.958mm ≤ D ＜ 90.968 mm
(g) Follow the piston outer diameter to calculate cylinder

bore dimension.
Cylinder bore dimension = W + F - 0.02 mm
NOTE
• “W” means “piston outer diameter”. “F” means
“clearance between piston outer diameter and
cylinder bore”.
• To prevent distortion that may result from temperature
rising during honing. Follow the sequence of No.2,
No.4, No.1 then No.3 to hone the cylinder.
(h) Bore all cylinders to same honing dimension.(Honing
dimension=piston E.D. + clearance between piston E.D.
and cylinder)
(i) Check clearance between piston and cylinder bore.
NOTE
When boring cylinders, make all of 4 cylinders be same
oversize. Do not bore only one cylinder.
23. ROTATE ENGINE BLOCK, MAKE OIL PAN PART UP.

24. INSTALL CRANKSHAFT BEARING AND THRUST.
(a) Main bearing bore size divided into 3 groups, first to the
fifth main bearing hole to be shown in the cylinder group
15A
number back right side of the plane on the bottom plane.
(b) The main bearing can be divided into 3 groups. When

assembling, choose the main bearing bore with the same
number of main bearing block mounted on the
corresponding main bearing bore.
15A
(c) Install main bearing and thrust bearing.

• Install the main bearings with oil grooves on the cylinder
block side.
• Install the main bearings without oil grooves on the
bearing cap.
• Install the 2 thrust bearings on crankshaft journal No.3.
Apply clean oil to the surface of thrust bearing.
25. INSTALL MAIN BEARING CAPS.

(a) Install the main bearing caps with the arrow on the main
caps facing the front of the engine.
(b) Install the main bearing cap bolts.

(c) Apply engine oil to the threaded portion bearing surface
of the bolt.
(d) Tighten the bearing cap bolts in the sequence as shown.

Torque:78 ~ 88 N•m
26. AFTER INSTALLING MAIN BEARING CAPS, ENSURE

THAT CRANKSHAFT ROTATES SMOOTHLY AND
INSPECT CRANKSHAFT AXIAL CLEARANCE. IF THE
CRANKSHAFT AXIAL CLEARANCE EXCEEDS THE
MAXIMUM LIMIT, REPLACE THE No.3 CRANKSHAFT
THRUST BEARING.
Limit: 0.35 mm
27. INSTALL CONNECTING ROD CAP.

NOTE
The bulge mark on the connecting rod towards the engine
timing belt side.
28. APPLY ENGINE OIL TO EACH CONNECTING ROD BOLT..

AS SHOWN.
30. USING PROPER TOOL, INSTALL REAR CRANKSHAFT

OIL SEAL.
15A
31. INSTALL REAR CRANKSHAFT OIL SEAL SEAT.

Torque: 10 N•m
15A
32. INSTALL REAR ENGINE BLOCK COVER RETAINING
BOLTS.


NOTE
Torque: 35 N•m
35. INSTALL TIMING CHAIN REAR COVER.

Torque: 25 N•m
36. INSTALL OIL STRAINER. (Refer to “Chapter 18A lubrication - oil pump, overhaul”)
37. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication - oil pan, replacement”)
38. REMOVE ENGINE BLOCK ASSY FROM FLIP FRAME.
39. INSTALL TIMING CHAIN. (Refer to “15A engine mechanical - timing chain, overhaul”)
40. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15A engine mechanical - cylinder head,
overhaul”)
41. INSTALL ENGINE ASSY. (Refer to “Chapter 15A engine mechanical - engine assy, replacement”)
EXHAUST
16A
EXHAUST PIPE ............................................................................... 16A-1
COMPONENTS ......................................................................... 16A-1
REPLACEMENT ........................................................................ 16A-2
EXHAUST MANIFOLD..................................................................... 16A-7 16A
REPLACEMENT ........................................................................ 16A-7
16A
16A
EXHAUST - EXHAUST PIPE 16A-1
EXHAUST PIPE
EXHAUST
COMPONENTS
16A
16A
1 Front Exhaust Pipe 5 First Rubber Support
2 Middle Exhaust Pipe 6 Rear Exhaust Pipe With Muffler Assy
3 Third Rubber Support 7 Second Rubber Support
4 Heat Shield 8 Catalytic Converter

16A-2 EXHAUST - EXHAUST PIPE
REPLACEMENT
WARNING
Exhaust pipe is a high temperature part. Never work around or attempt to service any parts of the
exhaust system until it cools down.
NOTE
• When the exhaust pipe is in high temperature, trying to remove the manifold will cause defor-
mation. High temperature can cause metal expansion and make the bolts remove more difficult,
the bolt can be easily broken.
• Exhaust pipe is the a cast production, it can not be repaired. When found the deformation, cor-
rosion, rust and leakage are found, replace the exhaust pipe assy.
2. RAISE AND SUPPORT VEHICLE.
3. REMOVE REAR EXHAUST PIPE WITH MUFFLER ASSY.

(a) Remove 2 bolts attaching rear exhaust pipe with muffler
assy to middle exhaust pipe.
(b) Disconnect the first rubber support.
(c) Disconnect the second rubber support.
(d) Remove the exhaust pipe gasket from the rear exhaust
pipe with muffler assy.
4. REMOVE MIDDLE EXHAUST PIPE ASSY.

(a) Remove 4 middle exhaust pipe assy retaining bolts.
16A
(b) Disconnect the third rubber support.
(c) Remove the exhaust pipe gasket from the both ends of
16A
middle exhaust pipe assy.
5. DISCONNECT REAR OXYGEN SENSOR CONNECTOR.
6. REMOVE CATALYTIC CONVERTER.

(a) Remove 3 nuts attaching catalytic converter to middle
exhaust pipe.
(b) Remove 3 nuts attaching catalytic converter to front
exhaust pipe.
(c) Remove catalytic converter assy carefully.

7. Inspect catalytic converter.
(a) Tap the catalytic converter, if any noise is heared, replace with a new one.
(b) Using a scan tool, check the oxygen sensor signal fluctuation range. If the catalytic converter is
damaged, oxygen sensor signal fluctuation range will become larger.
(c) Remove the gasket from both ends of catalytic converter.
8. REMOVE FRONT EXHAUST PIPE ASSY.

(a) Remove 3 nuts attaching front exhaust pipe to catalytic
converter.
(b) Remove 3 bolts attaching front exhaust pipe to exhaust

manifold.
(c) Remove the gasket from both ends of front exhaust pipe.
9. INSTALL FRONT EXHAUST PIPE ASSY

(a) Install the both ends of front exhaust pipe gaskets.
NOTE
• Replace it with a new gasket after removing gasket.
• After a long-time use, the exhaust pipe gasket will be adhered to exhaust pipe. After removing
the muffler, use the scraper to clean the surface of exhaust pipe and replace it with a new gasket
to avoid exhaust leakage.
(b) Install 3 nuts attaching front exhaust pipe to catalytic

converter.
(c) Install 3 bolts attaching front exhaust pipe to exhaust

manifold.
10. INSTALL CATALYTIC CONVERTER.

(a) Install the both ends of catalytic converter gasket.
(b) Install 3 nuts attaching catalytic converter to middle exhaust
pipe.
(c) Install 3 nuts attaching catalytic converter to front exhaust
pipe.
11. CONNECT REAR OXYGEN SENSOR CONNECTOR .
12. INSTALL MIDDLE EXHAUST PIPE ASSY.

(a) Connect the third rubber support. 16A
(b) Install the both ends of middle exhaust pipe assygaskets.
(c) Install 5 middle exhaust pipe assy retaining bolts.

Torque: Front side 22 ~ 25 N•m
Rear side 41 ~ 51 N•m
16A
13. INSTALL REAR EXHAUST PIPE WITH MUFFLER ASSY.

(a) Install the rear exhaust pipe with muffler assy gasket.
(b) Connect the first rubber support.
(c) Connect the second rubber support.

(d) Install 2 bolts attaching rear exhaust pipe with muffler assy
to middle exhaust pipe.
14. LOWER THE VEHICLE.

15. START ENGINE AND CHECK EXHAUST GAS LEAKAGE.
(a) If gas leakage is found, tighten the connect bolt to prevent leakage. If necessary, replace the damaged
part.
EXHAUST - EXHAUST MANIFOLD 16A-7
EXHAUST MANIFOLD
REPLACEMENT
16A
2. REMOVE INTAKE MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replacement”)
3. REMOVE EXHAUST MANIFOLD HEAT SHIELD.

(a) Remove 5 exhaust manifold heat shield retaining bolts.
(b) Take off the heat shield.
16A
4. DISCONNECT FRONT OXYGEN SENSOR CONNEC-

TOR.
5. REMOVE EXHAUST MANIFOLD ASSY.

(a) Remove 3 bolts attaching exhaust manifold to front exhaust
pipe.
16A-8 EXHAUST - EXHAUST MANIFOLD
(b) Remove 4 exhaust manifold retaining bolts.

NOTE
The exhaust manifold retaining nuts will be rusted after a
long-time drive. Use derusting spray when loosen the bolts.
6. REMOVE EXHAUST MANIFOLD AND GASKET.

7. CHECK EXHAUST MANIFOLD.
(a) Check if parts have any damage or crack.
(b) Check exhaust manifold and cylinder head surface for flatness using a ruler and thickness gauge.
Standard: 0.15 mm or less
Limit value: 0.20 mm
(c) Clean the dirt on exhaust manifold and cylinder head connect surface.
8. INSTALL EXHAUST MANIFOLD ASSY.

(a) Install a new exhaust manifold gasket.
(b) Install 4 exhaust manifold retaining bolts.

NOTE
• Daub rust-inhibiting lubricant on nuts for next
removing conveniently.
• Install the exhaust manifold retaining bolts diagonally.
(c) Install 3 bolts attaching exhaust manifold to front exhaust

pipe.
EXHAUST - EXHAUST MANIFOLD 16A-9
9. INSTALL EXHAUST MANIFOLD HEAT SHIELD.

(a) Install 5 exhaust manifold heat shield retaining bolts.
16A
10. CONNECT FRONT OXYGEN SENSOR CONNECTOR.
11. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14A intake air - intake manifold, replacement”) 16A
part.
MEMO
COOLING
17A
COOLING SYSTEM ......................................................................... 17A-1
PRECAUTION............................................................................ 17A-1
ON-VEHICLE INSPECT............................................................. 17A-3 17A
COOLANT ........................................................................................ 17A-5
REPLACEMENT ........................................................................ 17A-5
ON-VEHICLE INSPECT............................................................. 17A-9
RADIATOR ..................................................................................... 17A-10 17A
COMPONENTS ....................................................................... 17A-10
REPLACEMENT ...................................................................... 17A-11
SILICONE OIL FAN AND FAN COWL .......................................... 17A-16
OVERHAUL ............................................................................. 17A-16
THERMOSTAT ............................................................................... 17A-20
OVERHAUL ............................................................................. 17A-20
COOLANT PUMP...........................................................................17A-22
OVERHAUL ............................................................................. 17A-22
17A
COOLING - COOLING SYSTEM 17A-1
COOLING SYSTEM
COOLING
PRECAUTION
1. COOLING SYSTEM PRECAUTION. 17A
(a) When disconnecting the cooling hose, use a suitable container to recycle the retains of coolant. If it is
not to be used, dispose of them according to the regulations.
(b) When disconnecting the pipes of cooling system, do not let debris go into the pipes of cooling system. It
may damage the cooling system and engine.
(c) When disconnecting the cooling system pipes connectors, a special plug must be used to cover the
nozzle to prevent dirt and impurities.
(d) Coolant is poisonous, always keep it away from children and pets. If it is not to be used, disposal them
according to the regulations..
(e) Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃
(120 ℉ ) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause
personal injury.
(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine
because of corrosion.
(g) Clean radiator outside regularly, which can prevent mud and dust deposition from damaging radiator.
17A
17A-2 COOLING - COOLING SYSTEM

1. Coolant (Lack or leaking) Chapter 17A cooling - coolant, replacement
2. Coolant (Non-standard) Chapter 17A cooling - coolant, replacement
3. Thermostat (Damaged) Chapter 17A cooling - thermostat, overhaul
Engine overheated 4. Engine (Rough work) -
5. Radiator (Poor cooling) Chapter 17A cooling - cooling system, precaution
6. Silicone oil fan (Damaged) Chapter 17A cooling - cooling fan, overhaul
7. Cooling system (Blocked) -
1. Radiator(Damaged) Chapter 17A cooling - radiator, replacement
2. Cooling system hose -

(Broken)
Coolant leaking
3. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, replacement
Chapter 17A cooling - coolant reservoir,

4. Coolant reservoir(Damaged) replacement
1. Silicone oil fan(Damaged) Chapter 17A cooling - cooling fan, overhaul

Engine room noise
2. Coolant pump(Damaged) Chapter 17A cooling - coolant pump, replacement
COOLING - COOLING SYSTEM 17A-3
ON-VEHICLE INSPECT
1. CHECK WHETHER COOLANT LEVEL IS NORMAL.
2. IF COOLANT LACKS ABNORMALLY, CHECK COOLING SYSTEM FOR LEAKAGE.
17A
WARNING
Never remove the radiator cap while the engine and radiator are still hot, as fluid and steam can be
blown out under pressure.
(a) Fill the radiator with coolant and attach a radiator cap
tester.
(b) Warm up the engine.
(c) Pump it to 110 kPa, and check that the pressure does not
drop.
NOTE
If the pressure drops, check the hoses, radiator or water
pump for leakage. If no external leakage is found, check the
heater core, cylinder block and head.
3. CHECK ENGINE COOLANT LEVEL IN COOLANT 17A

RESERVOIR.
(a) When the engine is cool, the engine coolant level should
be between the ”LOW” and ”FULL” line.
(b) If the coolant level too low, check for leakage and add
”FOTON Long-effective coolant” or equivalent up to the
”FULL” line.
NOTE
Do not use water instead of coolant.
17A-4 COOLING - COOLING SYSTEM
4. CHECK ENGINE COOLANT QUALITY.

WARNING
(a) Remove the radiator cap.
(b) Place a container under the radiator to bloom the coolant from the coolant drain hole.
(c) Loosen the coolant drain plug to drain the coolant and check if there is any excessive deposits of rust or
scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively
dirty, replace the coolant.
(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary.
5. INSPECT FINS BLOCKAGE.
(a) If fins are clogged, wash them with water or a steam cleaner and dry them with compressed air.
NOTE
If the distance between the steam cleaner and core is too close, there is a possibility of damaging the
fins. So keep the following injection distance.
(b) Be careful not to spary water directly onto electronic components.
6. INSPECT COOLING FAN.
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Temperature: 20°C
Current: 8.0 ~ 12.0 A
(d) Connect the cooling fan connector.
(e) No abnormal noise except fan itself when the fan is rotating at a high speed.
COOLING - COOLANT 17A-5
COOLANT
REPLACEMENT
WARNING 17A
Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ° C
(120 ° F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may
cause personal injury.
1. COOL ENGINE TO NORMAL INDOOR TEMPERATURE.

3. REMOVE RADIATOR CAP.

NOTE
Press the radiator cap and counterclockwise rotate to open radiator cap.
17A
4. DISCONNECT CLAMP ATTACHING COOLANT RESERVOIR
HOSE TO COOLANT FILLING PIPE.
5. REMOVE COOLANT RESERVOIR RETAINING BOLT.

17A-6 COOLING - COOLANT
6. DISCONNECT COOLANT LEVEL SENSOR CONNECTOR.
7. REMOVE COOLANT RESERVOIR AND DRAIN COOLANT.

9. INSTALL CONDUIT BETWEEN RADIATOR DRAIN PLUG

AND CONTAINER.
NOTE
Using a suitable container, hold the coolant. If not to be
used, dispose of them according to the regulations .
10. LOOSEN COOLANT DRAIN PLUG AT RADIATOR BOTTOM

AND DRAIN COOLANT.
11. TIGHTEN COOLANT DRAIN PLUG AT RADIATOR BOTTOM.

17A
12. LOWER VEHICLE.
13. CONNECT CLAMP ATTACHING COOLANT RESERVOIR

17A
14. INSTALL COOLANT RESERVOIR AND TIGHTEN BOLT.

15. CONNECT COOLANT LEVEL SENSOR CONNECTOR.

17A-8 COOLING - COOLANT
16. ADD COOLANT.

(a) Slowly fill the radiator with ”FOTON Long-effective coolant”.
Standard volume: 10 L
(b) Push the radiator inlet/outlet hose several times, check the coolant level. If coolant is at the low level ,
fill the coolant.
(c) Install the radiator cap and coolant reservoir cap.
(d) Start and warm the engine until the cooling fan at high speed.
(e) Stop the engine and check the coolant level.
(f) Check the coolant level in reservoir. If necessary, add the coolant to specified position.
NOTE
The air in cooling system can be bled automatically.
ON-VEHICLE INSPECT
1. CHECK RADIATOR CAP SUB-ASSEMBLY.
(a) Measure the valve opening pressure.
17A
• If there are water stains or other matter on rubber packing
1, 2 or 3, clean the part(s) with water and finger scouring.
• Check that rubber packings 1, 2 and 3 are not deformed,
cracked or swollen.
• Check that rubber packings 3 and 4 are not stuck together.
• Apply engine coolant to rubber packings 2 and 3 before
using the radiator cap tester.
• Using the cap tester, tilt it to 30° or more above the horizontal.
• Pump the cap tester several times, and check the maximum
pressure.
Pumping speed: 1 pump every second
Item Specified Condition

Standard value
(for brand-new cap)
90 ± 15 kPa
Minimum standard value

(after using cap)
75 kPa
17A
(b) If the maximum pressure is less than the specified pressure
for the minimum standard value, replace the radiator cap
sub-assembly.
17A-10 COOLING - RADIATOR
RADIATOR
COMPONENTS
1 Radiator Assy 5 Coolant Reservoir
2 Coolant Filling Pipe 6 Lower Radiator Coolant Hose
3 Upper Radiator Coolant Hose 7 Radiator
4 Fan Cowl 8 Cooling Fan

COOLING - RADIATOR 17A-11
REPLACEMENT
WARNING
17A
1. COOL THE ENGINE TO NORMAL INDOOR TEMPERATURE.


4. DRAIN COOLANT. (Refer to “Chapter 17A cooling- coolant, replacement”)
replacement”)


10. REMOVE RADIATOR UPPER RETAINING NUTS.
11. REMOVE COOLANT FILLING PIPE RETAINING NUTS.
12. REMOVE SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17A cooling-silicone oil fan
and fan cowl, overhaul”)
14. DISCONNECT COOLING FAN CONNECTOR.
15. DISCONNECT LOWER RADIATOR COOLANT HOSE

CLAMP.
16. LOOSEN 2 RADIATOR LOWER SUPPORT RETAINING

NUTS.
17A
17. LOWER VEHICLE.

18. REMOVE RADIATOR ASSY, IF NECESSARY, USE COMPRESSED AIR CLEAN RADIATOR.
19. REMOVE 4 COOLING FAN RETAINING BOLTS.
17A
20. POSITION COOLING FAN TO RADIATOR AND TIGHTEN
4 RETAINING BOLTS.
21. INSTALL RADIATOR AND COOLING FAN ASSY TO RADIATOR FRAME.

NOTE
Before installing radiator, position the rubber cushion.
22. LIFT VEHICLE.
23. POSITION LOWER RADIATOR SUPPORT AND TIGHTEN

2 RETAINING NUTS.
24. CONNECT LOWER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
25. CONNECT COOLING FAN CONNECTOR

26. LOWER VEHICLE.
27. TIGHTEN UPPER RADIATOR SUPPORT RETAINING

NUTS.
28. INSTALL SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17A cooling-silicone oil fan
29. INSTALL COOLANT FILLING PIPE RETAINING NUTS.

COOLANT FILLING PIPE BYPASS HOSE THEN TIGHTEN
CLAMPS.

33. AFTER INSTALLING RADIATOR, LET ENGINE BE RUNNING UNTIL COOLING FAN RUNS AT
HIGH SPEED. CHECK COOLANT FOR LEAKAGE.

17A

17A
replacement”)
17A-16 COOLING - SILICONE OIL FAN AND FAN COWL
SILICONE OIL FAN AND FAN COWL

OVERHAUL
replacement”)

COOLING - SILICONE OIL FAN AND FAN COWL 17A-17
6. REMOVE 4 SILICONE OIL FAN RETAINING NUTS.
17A
7. TAKE DOWN SILICONE OIL FAN.

8. CHECK SILICONE OIL FAN.
(a) Visual inspection silicone oil clutch leakage, wire ablation, replace a new one when find.
(b) On vehicle inspection: Start the engine in low temperature for 1~ 2 min and stop the engine, turn the sil-
icone oil fan by hand, if the silicone oil fan can run smoothly, the silicone oil fan is O.K. Srart the engine,
when the temperature reach 88 ℃ , stop the engine,turn the silicone oil fan by hand, if the silicone oil fan
can not be run, it’s OK. If the silicone oil fan can run smoothly, replace it with a new one.
17A
10. REMOVE 4 FAN COWL RETAINING BOLTS.
11. REMOVE FAN COWL.

17A-18 COOLING - SILICONE OIL FAN AND FAN COWL
12. TIGHTEN 4 FAN COWL RETAINING BOLTS.

13. INSTALL 4 SILICONE OIL FAN RETAINING NUTS.

Torque: 10 N•m


COOLING - SILICONE OIL FAN AND FAN COWL 17A-19

17A
replacement”)
17A
17A-20 COOLING - THERMOSTAT
THERMOSTAT
OVERHAUL
WARNING
1. COOL ENGINE TO NORMAL ROOM TEMPERATURE.

4. REMOVE THERMOSTAT HOUSING RETAINING BOLTS.
5. REMOVE THERMOSTAT.
6. INSPECT THERMOSTAT.
(a) The thermostat is numbered with the valve opening
temperature.
COOLING - THERMOSTAT 17A-21
(b) Immerse the thermostat in water and gradually heat the

water.
(c) Check the valve opening temperature.
Valve opening temperature: 17A
80 - 84 ℃
NOTE
If the valve opening temperature is out of the specification,
replace the thermostat.
(d) Check the valve lift.

Valve lift: 8 mm or more, at 95 ℃ .
NOTE
• Check that the valve is fully closed when the thermostat
is at low temperature (below 77 ℃ ).
• If it is not closed, replace it with a new one.
7. CLEAN THERMOSTAT HOUSE CONNECT SURFACE, INSTALL A NEW THERMOSTAT GASKET.
8. INSTALL THERMOSTAT.
17A
9. TIGHTEN THERMOSTAT HOUSING RETAINING BOLTS.

10. FILL COOLANT. (Refer to “Chapter 17A cooling - coolant， replacement”)

11. AFTER INSTALLING THERMOSTAT, START ENGINE UNTIL COOLING FAN RUNS AT HIGH
SPEED. CHECK COOLANT FOR LEAKAGE.
17A-22 COOLING - COOLANT PUMP
COOLANT PUMP
OVERHAUL
WARNING
2. REMOVE SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17A cooling- silicone oil fan
5. LOOSEN GENERATOR BRACKET.

(a) Loosen the generator adjust bolt.
(b) Loosen the generator bracket bolt.
6. REMOVE COOLANT PUMP PULLEY RETAINING BOLTS.

COOLING - COOLANT PUMP 17A-23
7. REMOVE COOLANT PUMP RETAINING BOLTS.
17A
8. REMOVE COOLANT PUMP GASKET.

9. USING A SCRAPER, CLEAN DIRT ON COOLANT PUMP AND ENGINE BLOCK CONNECT SURFACE.
NOTE
Clean the dirt, do not damage coolant pump and engine block connect surface.
10. INSPECT COOLANT PUMP.

(a) Rotate coolant pump and it should turn smoothly.
17A
(b) There should be no clearance between coolant pump

shaft and coolant punp bearing, and no abnormal noise
when it turns.
(c) No coolant leakage around coolant pump.

17A-24 COOLING - COOLANT PUMP
11. INSTALL COOLANT PUMP GASKET. TO AVOID COOLANT

LEAKING, USE COOLANT PUMP SEALANT IF NECESSARY.
NOTE
After using the coolant pump sealant, wait for 15 minutes
then fill the coolant.
12. INSTALL COOLANT PUMP RETAINING BOLTS.

13. INSTALL COOLANT PUMP PULLEY RETAINING BOLTS.

Torque: 25 N•m
COOLING - COOLANT PUMP 17A-25
14. INSTALL GENERATOR BRACKET.

(a) Install the generator adjust bolt.
(b) Install the generator bracket bolt.
17A
16. INSTALL SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17A cooling- silicone oil fan
18. AFTER REPLACING COOLANT PUMP, LET ENGINE BE RUNNING UNTIL COOLING FAN RUNS
AT HIGH SPEED. CHECK COOLANT FOR LEAKAGE.
17A
MEMO
LUBRICATION
18A
LUBRICATION SYSTEM ................................................................. 18A-1
PRECAUTION............................................................................ 18A-1
ENGINE OIL ..................................................................................... 18A-2
REPLACEMENT ........................................................................ 18A-2 18A
OIL FILTER ...................................................................................... 18A-4
REPLACEMENT ........................................................................ 18A-4
OIL PAN ...........................................................................................18A-7
REPLACEMENT ........................................................................ 18A-7 18A
OIL PUMP ........................................................................................ 18A-9
OVERHAUL ............................................................................... 18A-9
18A
LUBRICATION - LUBRICATION SYSTEM 18A-1
LUBRICATION SYSTEM
LUBRICATION
PRECAUTION
WARNING 18A
Prolonged and repeated contact with engine oil will cause the skin fat to be removed, resulting in dry
skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants which
may cause skin cancer. Therefore, the skin must be protected in appropriate methods and with
cleaning equipment.
1. LUBRICATION SYSTEM PRECAUTION.
(a) Avoid contacting with oil for a long time, especially the used engine oil.
(b) Wear protective clothing including waterproof work gloves.
(c) Avoid contaminated clothing, especially underwear containing the oil.
(d) Never put rags contaminated with oil in pockets.
(e) Avoid eyes contacting with oil, must wear goggles, In addition, equipment must be prepared to clean
the eye. And wrapping the wound must be dealt with immediately.
(f) Frequent use of soap and water can clean, especially before meals, and make sure all the oil has been
removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is
recommended to replace the natural skin oils cotton suet.
(g) Do not use gasoline, kerosene, diesel, thinner or solvent to clean skin.
(h) Before each work, apply cream to help skin cleaning after work.
(i) If your skin is abnormal, consult a doctor immediately.
18A
18A-2 LUBRICATION - ENGINE OIL
ENGINE OIL
REPLACEMENT
1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL,
OIL LEVEL MUST BE LOCATED WITHIN THE OIL DIPSTICK MARK.
2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE MUST
HAVE ENOUGH CONCENTRATIONS AND LUBRICATION DEGREE.
3. START ENGINE AND ENSURE ENGINE COOLANT TEMPERATURE WITHIN 80 ~ 90 ℃ .

5. OPEN OIL FILLER CAP.
6. LIFT THE VEHICLE.
7. REMOVE OIL DRAIN PLUG.

WARNING
The engine oil maybe hot, be careful, avoid personal injury.
8. USING A SPECIAL CONTAINER, COLLECT OR DISPOSE USED OIL AS REQUIRED.

LUBRICATION - ENGINE OIL 18A-3
9. REPLACE WITH NEW DRAIN PLUG GASKET AND

TIGHTEN PLUG.
Torque: 34 ~ 45 N.m
18A
10. LOWER VEHICLE.

11. FILL ENGINE OIL.
Engine oil: 4 L
Oil filter oil: 0.3 L
NOTE
Engine oil with ACEA A3/B3 and API SL (or higher) specifications of SAE 0W-30, 5W-30, 5W-40 are
allowed.
12. INSTALL OIL FILLER CAP.
13. START ENGINE AND RUN FOR 5 MINUTES WITH THE VEHICLE PARKING ON LEVEL GROUND.
14. CHECK AND ENSURE THERE IS NO OIL LEAKAGE.
16. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK TO

ENSURE OIL LEVEL IS BETWEEN “MAX” MARK
AND THE “MIN” MARK. 18A

18A-4 LUBRICATION - OIL FILTER
OIL FILTER
REPLACEMENT
NOTE
Without special circumstances, the oil filter should be replaced with engine oil, avoid oil pollution and
keep engine operation.

(b) Turn the driver seat.
4. LIFE THE VEHICLE.

WARNING
Be careful, the engine oil may be hot.

LUBRICATION - OIL FILTER 18A-5
7. USING PROPER TOOL TO REMOVE OIL FILTER.
18A
8. CLEAN THE CONNECT SURFACE OF OIL FILTER AND OIL FILTER BRACKET.
9. APPLY OIL TO O-RING OF NEW OIL FILTER.
18A
10. TIGHTEN OIL FILTER BY HAND UNTIL O-RING TOUCHES

OIL FILTER BRACKET. USE A SUITABLE TOOL TO
TIGHTEN OIL FILTER.
18A-6 LUBRICATION - OIL FILTER
11. TIGHTEN DRAIN PLUG.

12. LOWER VEHICLE.

13. FILL ENGINE OIL TO SPECIFIED LEVEL, INSTALL OIL FILLER CAP.
17. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK TO

ENSURE OIL LEVEL IS BETWEEN “MAX” MARK
AND THE “MIN” MARK.

LUBRICATION - OIL PAN 18A-7
OIL PAN
REPLACEMENT
18A

18A
WARNING

6. REMOVE OIL PAN RETAINING BOLTS.
7. INSERT PROPER TOOL BETWEEN CYLINDER BLOCK

AND OIL PAN, THEN SEPARATE THEM BY HAMMER.
NOTE
Never use screwdriver or chisel to remove the oil pan. It will
damage the oil pan flange and cause oil leakage.
8. CLEAN CONNECT SURFACE OF OIL PAN AND ENGINE BLOCK.

18A-8 LUBRICATION - OIL PAN
9. APPLY A 4MM WIDE SEALANT TO THE ENTIRE

CIRCUMFERENCE OF OIL PAN FLANGE.
NOTE
Circle the bolt hole with sealant strips around.
10. INSTALL OIL PAN.

NOTE
Be sure to install the oil pan quickly while the sealant is wet (within 15 minutes).
11. TIGHTEN OIL PAN RETAINING BOLTS DIAGONALLY.
Torque: 6 ~ 7 N•m
NOTE
After installation, keep the sealant area away from the oil for about one hour.
12. INSTALL DRAIN PLUG.

13. LOWER VEHICLE, FILL ENGINE OIL TO SPECIFIED LEVEL.

LUBRICATION - OIL PUMP 18A-9
OIL PUMP
OVERHAUL
18A
replacement”)
18A
6. REMOVE OIL PUMP DRIVING SHAFT RETAINING BOLT.
7. TAKE OUT OIL PUMP DRIVING SHAFT.

8. LIFT VEHICLE.
18A-10 LUBRICATION - OIL PUMP
9. REMOVE OIL PAN. (Refer to “Chapter 18A lubrication- oil pump, replacement”)
10. REMOVE OIL STRAINER RETAINING BOLTS.
11. REMOVE OIL PUMP RETAINING BOLTS.
12. INSPECT OIL PUMP.

(a) Oil pump gear and camshaft gear tooth surface should not exist ablation, wear, missing teeth. If found,
replace the oil pump assy.
(b) Ensure the oil pump can be rotated smoothly.
13. INSTALL OIL STRAINER RETAINING BOLTS.

14. INSTALL OIL STRAINER RETAINING BOLTS.

15. INSTALL OIL PAN. (Refer to “Chapter 18A lubrication- oil pump, replacement”)
16. LOWER VEHICLE.
LUBRICATION - OIL PUMP 18A-11
17. INSTALL OIL PUMP DRIVING SHAFT RETAINING BOLT.
18A


18A
replacement”)
MEMO
IGNITION
19
IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG....................... 19-1
OVERHAUL ................................................................................. 19-1
19
19
19
IGNITION - IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG 19-1
IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG

IGNITION
OVERHAUL
19
replacement”)
4. REMOVE ENGINE SURFACING. 19
5. LOOSEN 7 ENGINE COVER RETAINING BOLTS.

7. REMOVE INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”)
8. PULL OUT SPARK PLUG WIRE BY SLIGHTLY TURNING.

19-2 IGNITION - IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG
9. REMOVE AND INSPECT SPARK PLUG WIRE.

NOTE
Before disconnecting the spark plug wire on the ignition coil, confirm the spark plug position on the
ignition coil and mark it.
(a) Check if the spark plug wire has been broken down.
(b) Make sure the spark plug wire resistance is less than 4 KΩ.
10. DISCONNECT IGNITION COIL CONNECTOR.
11. REMOVE IGNITION COIL RETAINING BOLTS AND

COIL RETAINING.
12. CHECK IGNITION COIL.

(a) Check ignition coil condition.
• Install ignition coil connector and spark plug wire, then connect battery negative cable.
• Using KT600, ensure there exists no DTC. If there exists DTC, record it. Ensure that the DTC fault is
resolved even the DTC is unrelated with ignition system.
• Pull out fuel pump relay.
• Lightly pull out spark plug wire and remove the spark plug.
• Install a new spark plug to the spark plug wire, touch spark plug negative to the engine cylinder block.
• Start engine, check the flash over.
• If the flash over is weak or no flash over, replace with a new ignition coil. After replacing the new ignition
coil, if the flash over become strong, we can ensure the ignition coil has been damaged. If there is still
no flash over, check the ignition circuit and inspect the spark plug.
• Using KT600, ensure there appears no DTC, except for the DTC record in step (b). Clear all DTCs.
(b) Check if crack exists on the ignition module.
IGNITION - IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG 19-3

• Check spark plug insulator outer surface for cracks.
• Check spark plug flash over for carbon deposition.
• Check spark plugs for burned off or melted positive and 19
negative electrode.
• Check spark plug gap.
15. TIGHTEN IGNITION COIL RETAINING BOLTS.

Torque: 5 ~ 8 N•m
19
17. INSTALL SPARK PLUG WIRE TO IGNITION COIL AS THE MARKS BEFORE REMOVING.
18. CONNECT IGNITION COIL CONNECTOR.
19. INSTALL INTAKE HOSE. (Refer to “Chapter 14A intake air- intake air hose, replacement”)
21. START ENGINE AND INSPECT ENGINE OPERATION CONDITION.
19-4 IGNITION - IGNITION COIL/SPARK PLUG WIRE/SPARK PLUG
22. TIGHTEN 7 ENGINE COVER RETAINING BOLTS.


replacement”)
20A
STARTING AND CHARGING SYSTEM .......................................... 20A-1
PRECAUTION............................................................................ 20A-1
GENERATOR ................................................................................... 20A-4 20A
COMPONENTS ......................................................................... 20A-4
OVERHAUL ............................................................................... 20A-5
STARTER ....................................................................................... 20A-12
COMPONENTS ....................................................................... 20A-12 20A
OVERHAUL ............................................................................. 20A-13
BATTERY ....................................................................................... 20A-22
COMPONENTS ....................................................................... 20A-22
USE AND MAINTENANCE ...................................................... 20A-23
INSPECTION ........................................................................... 20A-25
BATTERY COMMON PROBLEMS, THE CAUSES ANALYSIS
AND TROUBLESHOOTING ................................................... 20A-26
REPLACEMENT ...................................................................... 20A-27
20A
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20A-1
STARTING AND CHARGING SYSTEM

PRECAUTION
1. STARTING AND CHARGING SYSTEM PRECAUTION. 20A
(a) Battery may have escaping explosive gas. in order to avoid personal injury, keep ventilated in engine
room before maintaining battery. To avoid electric arc, disconnect battery negative cable first and
connect the negative cable last.
(b) Battery electrolyte is very dangerous. It can damage the machine and cause serious burns. When
maintaining battery, prepare neutralizers concentration soda water, wear safety eyepiece and wear
protective clothing, which can avoid personal injury.
(c) When using compressed air, wear appropriate goggles and protective mask. Dust particles and dirt can
cause injury.
(d) Don't tighten the electrical connectors excessively, which may damage the starter.
(e) Never short two cables of the battery, it will cause a rapid battery fever even an explosion occur. The
escaping gas from battery is easily be burned by the spark, so do not use fire near battery.
(f) After the generator operation, do not try to use spark check whether the generator works. Use bulb or
multimeter to perform the test. Otherwise it will damage the generator diode.
(g) Check the generator silicon rectifier devices, it is strictly forbidden to use multimeter or apply 220V
directly for generator insulation check, otherwise it will make diode breakdown and damaged.
20A
20A-2 STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

Use the table below to help you find the cause of the problem. The numbers indicate the priority of
the likely cause of the problem. Check each part in order. If necessary, replace these parts.
1. Starter switch control circuit (Open) -
2. Brush and rectifier (Poor Chapter 20A starting and charging - starter,
Starter out of operation connection) overhaul

3. Starter inside circuit (Open or short) overhaul
Chapter 20A starting and charging - battery,

1. Battery (Low voltage) use and maintenance
2. Starter wire (Poor connection) -
3. Rectifier (Surface damaged or -Chapter 20A starting and charging - starter,

stains) overhaul
Starter lacks power,
can not srart engine 4. Brush (Wear) or Brush spring (Loss Chapter 20A starting and charging - starter,
elastic force) overhaul

5. Solenoid switch (Contacts ablation) overhaul
6. Bearing (Wear)，commutator (Wipe Chapter 20A starting and charging - starter,

shell) overhaul

1. Starter relay (Copper contacts bond) overhaul
Starter keep working Chapter 20A starting and charging - starter,

2. Starter commutator (Bend or break) overhaul
after engine start
3. Starter gear tooth surface contact Chapter 20A starting and charging - starter,
(Roughening or stuck) overhaul
1. Generator connect wire (damaged) -
Chapter 20A starting and charging - genera-

2. Rotor winding (Open) tor, overhaul
Generator out of opera- Chapter 20A starting and charging - genera-

3. Rectifier diode (Damaged) tor, overhaul
tion
4. Brush (Poor connection) tor, overhaul

5. Regulator (Damaged) tor, overhaul
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20A-3

Chapter 15A engine mechanical - engine
1. Belt losing tensity accessory belt, overhaul
20A
2. Brush (Poor connection) or collector Chapter 20A starting and charging - genera-
ring (Burn) tor, overhaul
Generator lacks Chapter 20A starting and charging - genera-

enough electricity 3. Regulator (Damaged) tor, overhaul

4. Battery lose electrolyte use and maintenance

5. Battery plate (Damaged) use and maintenance


Generator over charg- 2. Rectifier diode (Damaged) tor, overhaul
ing
3. Rotor winding (Short) tor, overhaul
20A
20A-4 STARTING AND CHARGING - GENERATOR
GENERATOR
COMPONENTS
1 Generator Belt Pulley 8 Anchor Plate
2 Rotator Component 9 Regulator And Brush Carriage
3 Rear Bearing 10 Brush
4 Bearing Carrier 11 Brush Ring
5 Front Bearing 12 Rectifier Component
6 Front Cover 13 Back Cover
7 Stator Component
STARTING AND CHARGING - GENERATOR 20A-5
OVERHAUL
(a) Loosen the driver seat clamp. 20A


NOTE
Disconnect the negative cable at first when removal.
20A
4. COOL ENGINE AND MAKE BELT TEMPERATURE AS CLOSE AS POSSIBLE TO NORMAL TEMPERATURE.
5. ROTATE GENERATOR BELT AND CHECK FOR CRACK.
6. LOOSEN GENERATOR BRACKET NUT.

7. LOOSEN BELT TENSIONER LOCKED NUT.
8. REMOVE GENERATOR BELT.

9. LOOSEN GENERATOR POSITIVE CABLE CONNECT NUT.
10. DISCONNECT GENERATOR CONNECTOR.
11. LOOSEN GENERATOR RETAINING BOLTS.
12. REMOVE GENERATOR.
13. DISASSEMBLE GENERATOR.

(a) Using pneumatic tools, loosen generator belt pulley retaining
nut.
(b) Loosen retaining bolts attaching generator front cover to

stator component.
20A
(c) Insert a screwdriver between front cover and stator then

separate them.
NOTE
• If it is difficult to be separated, slap the front cover
slightly with rubber hammer and pry it with screwdriver.
• Do not insert screwdriver too deep to prevent stator
component being damaged.
(d) Using a electric iron (180 ~ 250 w), remove stator. This
operation should be within 4 seconds to prevent diode
from heat.
(e) Loosen 4 retaining bolts from rectifier. 20A
(f) Using a electric iron, remove rectifier from regulator

NOTE
• Ensure that the heat is not transmitted from electric
iron to diode for long time.
• Do not let diode pin bear too much force.
(g) Remove and inspect rotor.

• Check the rotor coil is conductive, and confirm that the
collector rings are conductive. Measure the resistance of
rotor. If the resistance is less than specified value, it
means the rotor is short circuit. If it is not conductive or it
is short circuit, replace the rotor assy.
Specified value: 3 ~ 5 Ω
• Check that rotor coil ground. Confirm that it is insulative

between collector ring and core. If not, replace the rotor
assy.
• Using a vernier caliper, measure the slip ring diameter.

Limit: 12.8 mm
(h) Remove and inspect stator.

• Check the stator for continuity. Confirm that the coil lead
is conductive. If not, replace the stator assy.
• Check the coil ground. Confirm that it is not conductive

between coil and stator core. Replace the stator assy if
conductive.
(i) Inspect stator rectifier.

• Diode group (three diodes) check: Using an ammeter to
connect two ends of each diode, check if three diodes
are conductive. If it is not conductive in both directions, it 20A
means the diodes are broken, and it is required to
replace the rectifier assy.
(j) Get rid of welding point of brush lead, then take out the
brush.
(k) If brush is so worn to reach wear limit line, replace brush.
20A
14. ASSEMBLE GENERATOR.

(a) When installing new brush, weld brush lead in the
condition when brush is pressed down to brush bracket
as shown.
(b) Tighten 4 retaining bolts of rectifier.

Torque: 6 ~ 8 N•m
(c) Weld rectifiers and stator.
(d) Before mounting rotor on rear cover, insert a steel wire

into small hole on rear cap, then erect mounted rotor by
brush, pull out steel wire.
(e) Install rotor.

(f) Tighten the retaining bolts attaching generator front
cover to stator component.
15. POSITION GENERATOR BELT PULLY. USING PNEUMATIC TOOLS, INSTALL GENERATOR BELT
PULLEY RETAINING NUT.
16. POSITION GENERATOR AND INSTALL GENERATOR

RETAINING BOLTS.
NOTE
Just install, do not tighten.
17. CONNECT GENERATOR CONNECTOR.

18. TIGHTEN GENERATOR POSITIVE CABLE RETAINING NUT.

19. INSTALL GENERATOR BELT.

20A
20. ADJUST TENSIONER BOLT AND TIGHTEN LOCK NUT.
21. ADJUST GENERATOR BELT TO REGULATION TENSITY. (Refer to “Chapter 15A engine mechan-
ical - engine accessory belt, overhaul”)
22. TIGHTEN GENERATOR BRACKET NUT.

20A
23. CONNECT BATTERY AND TIGHTEN RETAINING

BOLTS.
NOTE
Connect the negative cable first when install.
24. POSITION BATTERY COVER.

20A-12 STARTING AND CHARGING - STARTER
STARTER
COMPONENTS
1 Front Bracket 11 Overdrive Clutch
2 Spring 12 Locating Snap Ring
3 Starter Drive Lever 13 Magnet Yoke Assy
4 Rubber Washer 14 Commutator
5 Planetary Gear Bracket 15 Brush
6 Solenoid Component 16 Brush Bracket
7 Rubber Washer 17 Starter Shell Bolt
8 Steel Ball 18 Rear Bearing
9 Planetary Gear 19 Rear Bracket
10 Internal Gear
STARTING AND CHARGING - STARTER 20A-13
OVERHAUL
(a) Loosen the driver seat clamp. 20A


NOTE
Disconnect the negative cable first when removal.
20A
4. LIFT VEHICLE.
5. REMOVE STARTER ELECTRICAL WIRE CONNECTING

NUT.
6. DISCONNECT STARTER CONTROL WIRE CONNEC-

TOR.
7. REMOVE 2 STARTER RETAINING BOLTS.
8. REMOVE STARTER AND INSPECT IT.

(a) Pinion gap adjustment.
• Disconnect the field coil wire from the M-terminal of the
magnetic switch.
• Connect a 12-volt battery between the S-terminal and M-
terminal.
NOTE
This test must be performed quickly (less than 10 seconds)
to prevent the coil from being burned.
• When the 12-volt battery is connected between the S-
terminal and M-terminal, the pinion will move out.
• Check the pinion-to-stopper clearance (pinion gap) with

a feeler gauge.
• If the pinion gap is out of specification, adjust by adding

or removing gasket(s) between the magnetic switch and
front bracket.
20A
(b) Magnetic switch pull-in test.

magnetic switch.
terminal.
NOTE
• When turn ignition switch on, the pinion will move out. If
the pinion moves out, the pull-in coil is good. If it doesn't,
replace the magnetic switch.
(c) Magnetic switch hold-in test.

magnetic switch.
• Connect a 12-volt battery between the S-terminal and
body.
NOTE
This test must be performed quickly (less than 10 seconds) 20A
• Manually pull out the pinion as far as the pinion stopper
position.
• If the pinion remains out, everything is operating prop-
erly. If the pinion moves in, the hold-in circuit is open.
Replace the magnetic switch.
(d) Magnetic switch return test.

magnetic switch.
• Connect a 12-volt battery between the M-terminal and
body.
NOTE
to prevent the coil from burning.
• Pull the pinion out and release. If the pinion quickly
returns to its original position, everything is operating
properly. If it doesn't, replace the magnetic switch.
WARNING
Be careful not to get your fingers caught when pulling out
the pinion.
9. DISASSEMBLE STARTER.
(a) Disconnect magnetic coil lead nut from magnetic switch.
(b) Remove magnetic switch retaining bolts.
(c) Remove starter shell retaining bolts.
(d) Disassemble starter as components art shown.

NOTE
• When removing armature, do not lose the steel ball
mounted in the bearing ends.
• Using a proper control sleeve, push and press the
locating snap ring to the overdrive clutch side, and
make it be away from the clip spring.
• Remove the snap spring with snap ring pliers, then

remove the locating snap ring and overdrive clutch.
20A
10. CLEAN STARTER PARTS.

(a) Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is
immerged in detergent, their insulating ability will be damaged.
(b) Clean starter parts with cloth.
(c) Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the
overdrive clutch is greased. If clean it by detergent, its grease might be removed.
(d) Using a brush and dipping with detergent, clean drive parts then dry them with a cloth.
11. INSPECT COMMUTATOR.

(a) Support the commutator with a pair of V block and turn it
to measure the runout of the surface using a dial gauge.
Limit: 0.1 mm
(b) Measure the diameter of the commutator. 20A

Standard: 29.4 mm
Limit: 28.4 mm
(c) Measure the depth of the undercut between segments.

Standard: 0.5 mm
Limit: 0.2 mm
12. INSPECT BRUSH AND BRUSH BRACKET.

(a) Check that it is conductive between brush plate and brush bracket, if not, it is normal.
(b) Check the commutator contact surface of each brush for abnormal roughness. Also check the height of
the brush. Replace the brush holder if the height is lower than the limit.
Limit: 7.0 mm
(c) When the contact surface of the brush is rectified or the brush holder is replaced, recondition the
contact surface with sandpaper wrapping around the commutator.
13. INSPECT OVERDRIVE CLUTCH.

(a) Make sure that the pinion can not be turned counterclockwise
and can be turned clockwise freely.
(b) Check the pinion for abnormal waring and damage.
14. INSPECT ARMATURE COIL.

(a) Set the armature in a growler.
(b) While holding a thin strip of iron against the armature in
parallel with its axis, turn the armature slowly. The
armature is normal if the iron strip is not attracted to the
armature or it does not vibrate.
NOTE
Clean the surface of the armature thoroughly before performing
the test.
(c) Check the insulation between commutator segments and

armature coils. It is normal if there is not continuity.
(d) Check continuity between a segment and another. It is

normal if there is continuity.
15. INSPECT MAGNETIC SWITCH.

(a) Coil open circuit test.
• Check that there is continuity between the M terminal
and body A. 20A
• If there is no continuity, replace the magnetic switch.
(b) Contact fusion check.

• Check that there is no continuity between the B terminal
and M terminal.
• If there is continuity, replace the magnetic switch.
(c) Switch contact check.

• Push the indicated end of the magnetic switch with a
strong force to close the internal contacts. Without
releasing the switch end, check that there is continuity
between the B terminal and M terminal.
20A
16. ASSEMBLE STARTER.

(a) Using a suitable puller, pull stop ring until it gets over
snap ring.
(b) Install locating snap ring and overdrive clutch.

(c) Assemble starter as components art shown.
(d) Tighten the starter shell retaining bolts.

(e) Tighten the magnetic switch retaining bolts.

(f) Connect the magnetic coil lead nut from magnetic switch.
(g) Connect the starter electrical wire connecting nut.

(h) Connect starter control wire harness connector.
20A
17. TIGHTEN 2 STARTER RETAINING BOLTS.

Torque: 68~ 72 N•m
18. LOWER VEHICLE.


BOLTS.
NOTE
Connect the negative cable first when installing.
20A

20A-22 STARTING AND CHARGING - BATTERY
BATTERY
COMPONENTS
1 Negative Terminal 5 Overall Groove
2 Battery Cover 6 Negative Plate
3 Cross Wall Connect 7 Partition
4 Bus Bars 8 Positive Plate

STARTING AND CHARGING - BATTERY 20A-23
USE AND MAINTENANCE

1. CHARGING DEVICE.
NOTE 20A
DC power supply must be used for battery charging, howerever, what is supplied by power plant is AC
that it must be transformed into DC, After transform, the charging can be performed.
(a) Rectifier.
(b) Controllable silicone voltage regulation charger.
2. CHARGE PRECAUTIONS
(a) Charging should choose in ventilated dry room, indoor temperature in 5 ℃ ~ 40 ℃ is advisable.
(b) Battery can not be overlap shelved, also do not put them on the ground directly. It should be put on the
wooden support, and cannot be set with alkaline battery or other chemicals.
(c) Charging in field should be far away from fire and heat.
(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken (by
reducing filling current or stopping sharge or being cooled down in water tank).
3. CHARGE CONNECTION.
(a) The positive pole of charger is to be connected with the positive pole of battery, while the negative pole
of charger should be connected with the negative pole of battery. Never connect them reversely.
(b) Charge of most batteries may be determined based on the size of motor power. Connection for charge
must be firm.
4. CHARGING MODES.
(a) Constant current charge.
(b) Constant voltage charge.
(c) Quick charge.
5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS
RESTORED TO STANDARD. 20A
(a) Voltage method
Voltage Determination Treatment

above 12.5 v normal go on using
11.5 ～ 12.5 v undercharge additional charge
below 11.5 v over-discharge or internal failure to be further checked after charging
(b) Capacity method
Capacity Tester Display Determination Treatment

white zone fully charged go on using
green zone normal go on using
yellow zone undercharge additional charge
red zone over-discharge to be further checked after charging

6. USING AND MAINTENANCE OF BATTERY IN WINTER

(a) Keep the battery is to be maintained under full charge status, avoid the electrolyte from being frozen
arising from drop in density, which may give rise to breakage of container, curve of pole plats, as well as
smash and dropout of active substances, and other failures.
(b) Because the battery capacity reduced in winter, when start the engine in cold status, preheated the
engine and each time start the engine should not more than 15 seconds, two starting interval 2 ~ 3
minutes, if can not start the engine in three times, troubleshooting, then restarting.
INSPECTION
1. APPEARANCE INSPECTION.
(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are
connected firmly. 20A
(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and
center partitions respectively, listen to the sound without breaking, especially the central baffle and shell
side of shell wall at the junction of four, prone to crack, should be carefully examined.
(c) Through mirrors, green for fully charged, red and white says lack of electricity and no electricity. Need
of the following capacity, voltage detection.
2. CAPACITY TEST.
(a) The excel tester is also known as the discharging tongs.
It consists of a DC voltmeter of three volts and one load
resistance.
(b) The tips of the two tongs shall be pressed on the anode
and the cathode tightly and maintain for five seconds in
the measurement. Observe the terminal voltage in the
state of the big load discharging and the discharging
content and the starting ability can be judged correctly.
(c) For the excel tester of different brands, the readings of
the current and the voltage shall be read according to the
regulations of the factory manual. Generally, the single
voltage of the battery in good state shall be above 1.5 V
and keep steady within five seconds. If the voltage drops
rapidly within five minutes or the voltage of one single
cell is 0.1 V lower than that of others, it indicates there
are troubles in the battery and it shall be repaired.Below
is the use of excel tester of discharge plan detection
income cross-references.
20A
Display Zone Determination Treatment
3. VOLTAGE TEST.
The following table is derived using the digital multimeter test table.

11.5 ~ 12.5 v undercharge additional charge
under 112.5 v over-discharge or internal fault to be further checked after charging

BATTERY COMMON PROBLEMS, THE CAUSES ANALYSIS AND

TROUBLESHOOTING
1. ELECTRICAL QUALITY OF ONE FULL-CHARGED BATTERY REDUCE WITHOUT USE FOR A
LONG PERIOD.
• Causes analysis:
The full-charged battery without use will lose its electrical quality gradually and this phenomenon is
known as “self-discharge”. The important cause of self-discharge is the impure materials. If there are
impurities in the material of the polar plate or in the electrolyte, there will be a potential difference
between the impurity and the polar plate and between the impurities. A closed “local current” is formed
and would make the discharge of the battery.
• Troubleshooting:
For the battery which has discharged seriously, it can be discharged completely or excessively. This will
enable the impurities on the polar plate into the electrolyte. Then, pour the electrolyte out and clean the
battery with distilled water. Finally, inject the new electrolyte and re-charge the battery.
2. BATTERY EXPLODE.
The water in the electrolyte hydrolyzes into hydrogen or oxygen and a lot of bubbles are generated;
there are short circuit and vulcanization troubles in the battery; the temperature increases while
charging and large amount of water are evaporated. Then if the vent holes of the injection hole cover
are plugged or there are a lot of gases which are unable to escape, the battery will explode when the
inner pressure comes to a limit (or there are sparks).
(a) The vent holes of the injection hole cover shall be cleared.
(b) In order to avoid sparks, the wirings on the polar stud shall be fastened.
(c) The injection hole cover shall be opened first when check with the excel tester.
(d) Control the charging amount and do not over-charge in order to reduce the releasing amount of the
gases. Open flames are prohibited and the ventilation shall be ensured in the charging room.
3. RAPID DECREASE OF THE LIQUID LEVEL DURING THE USE PROCESS OF THE BATTERY.
(a) Excessive charging current lead to evaporation of water.
(b) Battery shell broken.
(a) Add distilled water.
(b) Repair shell, add the electrolyte.
4. A YELLOW OR WHITE PASTE APPEARS ON BATTERY COVER.

The yellow or white paste surrounding the battery cover and the polar stud is caused by the corrosion of
the polar studs, wiring clip and the fixed frame by the sulfuric acid sprayed.
In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a
cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth.
The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If
there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to
smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened.
REPLACEMENT
2. OPEN BATTERY COVER. 20A

(a) Loosen battery cover lock knob.
(b) Open battery cover.

NOTE
4. LOOSEN BATTERY HOLD DOWN RETAINING BOLTS.
20A
5. REMOVE BATTERY.
NOTE
Battery should be put up, placing upside down the battery
is avoided.
(a) Unscrew the bolt, add distilled water or electrolyte through
the hole above battery.
6. LOOSEN 3 BATTERY TRAY RETAINING BOLTS.
7. TIGHTEN 3 BATTERY TRAY RETAINING BOLTS.

8. POSITION BATTERY.
9. TIGHTEN BATTERY HOLD DOWN RETAINING BOLTS.

10. CONNECT BATTERY NEGATIVE/POSITIVE CABLE AND

TIGHTEN BATTERY CABLE RETAINING BOLTS.
NOTE
• If terminals has sediments, remove the impurities
then apply thin layer of grease to terminal.
• Connect positive battery cable first when installing.

11B
DIESEL ENGINE CONTROL SYSTEM............................................ 11B-1
PRECAUTION............................................................................ 11B-1
SYSTEM OVERVIEW ................................................................ 11B-2
SYSTEM FUNCTION INTRODUCTION .................................... 11B-8 11B
VE PUMP BASIC STRUCTURE .............................................. 11B-10
EGR VALVE CONTROL UNIT ....................................................... 11B-16
PRINCIPLE .............................................................................. 11B-16
REPLACEMENT ...................................................................... 11B-17 11B
EGR COOLANT TEMPERATURE SENSOR.................................11B-20
PRINCIPLE .............................................................................. 11B-20
OVERHAUL ............................................................................. 11B-21
COOLANT TEMPERATURE SENSOR FOR FAN......................... 11B-25
PRINCIPLE .............................................................................. 11B-25
OVERHAUL ............................................................................. 11B-26
PREHEAT TEMPERATURE SENSOR .......................................... 11B-29
PRINCIPLE .............................................................................. 11B-29
OVERHAUL ............................................................................. 11B-30
EGR VALVE LIFT SENSOR .......................................................... 11B-34
PRINCIPLE .............................................................................. 11B-34
OVERHAUL ............................................................................. 11B-35
EGR VACUUM REGULATOR........................................................ 11B-39
PRINCIPLE .............................................................................. 11B-39
OVERHAUL ............................................................................. 11B-40
VEHICLE SPEED SENSOR ........................................................... 11B-44
PRINCIPLE .............................................................................. 11B-44
ON-VEHICLE INSPECTION .................................................... 11B-45
OVERHAUL ............................................................................. 11B-46
THROTTLE POSITION SENSOR .................................................. 11B-48
PRINCIPLE .............................................................................. 11B-48
11B
REPLACEMENT ...................................................................... 11B-49
PREHEAT CONTROL UNIT........................................................... 11B-52
PRINCIPLE .............................................................................. 11B-52
REPLACEMENT ...................................................................... 11B-53
ENGINE RELAY BOX .................................................................... 11B-56
PRINCIPLE .............................................................................. 11B-56
REPLACEMENT ...................................................................... 11B-57
ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM 11B-1
DIESEL ENGINE CONTROL SYSTEM

PRECAUTION
1. DIESEL ENGINE CONTROL SYSTEM PRECAUTION. 11B
(a) Power off.
• The battery negative cable must be disconnected at first before removing or installing any electric 11B
ally. This will prevent injuring person and vehicle damage. 11B
• The ignition switch must be OFF without any special descriptions.
11B
WARNING
The ignition and illumination switches must be shut off before removing or installing the battery nega- 11B
tive cable (the semiconductor maybe damage without doing that).
(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this 11B
(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 11B
sealing face is level and smooth and no greasy dirt on it before installation. Don’t forget to remove the
sealant on the mounting hole, the threaded hole and the thread. 11B
(d) Paint some sealant evenly on the prescribed diameters to surround the mounting hole. The sealant not
hardened yet can be scraped away. Install it in place when the sealant is wet (within 15 minutes). Take 11B
care not to stick the sealant to the place where it's not desired during installation. Wait the sealant to be
very hardened (1 hour or so) after installation. Don’t apply oil on the painted parts or wet or start the 11B
engine during this time.
(e) Tighten the straining bolts with prescribed torque during installing the sensors, actuators or other parts. 11B
Ensure the diesel engine is always in clean and complete state. Clean or wipe up the parts to ensure
the clean parts and the assembly quality before removing and assembling the parts. The complicated 11B
adjustment and maintenance should be taken indoors to avoid the diesel engine being polluted by the
environment. 11B
(f) When installing and handling sensors, handle them gently to avoid damage, any impact or falling may
cause severe damage. 11B
(g) Don’t test the system electrical signal by use of a fine needle to pierce the harness.
(h) Take a visual inspection to check if the sensing element at the head of sensor is damaged or color 11B
changed; Replace it if it's damaged or the color is severe changed.
11B
11B
11B
11B
11B
11B-2 ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM
SYSTEM OVERVIEW
1. BJ493ZQ DIESEL ENGINE FUEL INJECTION SYSTEM .
(a) BJ493ZQ diesel engine fuel injection system uses a single plunger VE pump. Its role is to put the fuel
pressure from low to high, then according to the supply order, the fuel time, quantity and evenly through
the fuel injector. VE pump spray the mist into the combustion chamber of diesel combustion for power.
(b) VE pump, compact structure, small number of parts, small size and light weight. Governor and the
injection timing advance device are automatically installed in the pump body.
(c) Good high speed. Distribution pump cam lift is small, is conducive to adapt to the requirements of high
speed diesel engine.
(d) Supply good uniformity
(e) Complete in attachments. Through the deformation, VE pump can be fitted with various additional
equipment, diesel engines to meet the needs of different uses, such as the pressurized compensation
device, atmospheric pressure compensation device, torque calibration device, load and speed of the
automatic timing device and so on.
(f) Easy maintenance. VE pump diesel lubricating moving parts, so ease of maintenance and
maintenance.
2. ENGINE CONTROL SYSTEM DIRGRAM.
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
1 Fuel Tank 8 Speed Handle
11B
2 Fuel Water Separator 9 Pump
3 Primary Pump 10 Injector 11B

4 Secondary Pump 11 Return Pipe
11B
5 Fuel Filter 12 VE Pump
11B
6 Regulator 13 Injection Advance Device
7 Fuel Pump Drive Shaft 14 Governor Drive Gear 11B
11B
11B
11B
11B
11B
3. DIESEL ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.(1)
1 Coolant Temperature Sensor For Fan 6 Delivery Valve Seat
2 Throttle Position Sensor 7 VE Pump
3 Inlet Pipe 8 Return Pipe
4 Intake Manifold 9 EGR Coolant Temperature Sensor
5 Oil Dipstick
4. DIESEL ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.(2)
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
1 Coolant Temperature Sensor For Fan 4 VE Pump
2 EGR Coolant Temperature Sensor 5 Diesel Engine Mount 11B

3 Intake Manifold 6 Turbocharger
11B
11B
11B
11B
11B
11B
5. DIESEL ENGINE CONTROLSYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.(3)
1 Flywheel 4 Vacuum Pump
2 EGR Valve Assembly 5 Generator
3 Turbocharger
6. DIESEL ENGINE CONTROLSYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.(4)
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
1 Coolant Temperature Sensor For Fan 6 Glow Plug
2 Generator 7 VE Pump 11B

3 Vacuum Pump 8 Intake Manifold
11B
4 Turbocharger 9 Injector
11B
5 EGR Valve Assembly
11B
11B
11B
11B
SYSTEM FUNCTION INTRODUCTION

1. VE PUMP.
(a) BJ493ZQ3 diesel engine is equiped with VE pump. Its structure is characterized by a set of institutions
through the allocation of fuel components to the fixed quantity of fuel supply for diesel engine cylinder.
VE pump assembly fuel pump, governor and supply pump etc. in advance in one sector. It is a closed
whole. VE pump is compact, small size and light weight. It has high-speed performance, reliable, func-
tional, and easy installation layout.
(a) When the A/C switch is on, the system will receive a A/C request signal and make preparations for
The system will switch on or switch off the A/C according to the protection demand for air-conditioner.
3. FAN CONTROL.
(a) This vehicle is equipped with a silicon oil fan. The silicon oil fan clutch is installed between the shaft
and fan, based on the needs of the engine cooling system to control the fan speed, and the cooling
intensity adjustment. Compared to the fan with traditional rigid fixation, the cooling system is installed
with silicon oil fan clutch, the main advantages for the silion oil fan clutch is installed on the cooling sys-
tem are energy saving, noise reduction, low emissions and wear and so on.
4. PREHEAT CONTROL.
(a) The preheating process of BJ493ZQ3 diesel engine is controlled by preheat control unit. The preheat-
ing actuator executes the orders of preheat control unit to power up the heating plug and only plays a
role of relay.
(b) At the beginning of preheating, the coil first becomes red hot to complete the function of rapid
preheating. If the rapid preheating state continues and the temperature rises over the desired, the coil
can be shut off power automatically, but for the braking coil with large temperature resistance
coefficient, the resistance value will increase with increasing temperature to reduce the power supply
current, so as to inhibit the temperature increasing and make the saturation temperature in given value.
Meanwhile the protective sleeve becomes red hot from the front end then to the rear, as reaching the
saturation temperature, the whole protective becomes red hot completely to achieve good preheating
performance.
(c) The post-heating after successful starting can promote to form a kind of unbroken and less smoke
speed up and idling running during warming up process. It can reduce the combustion noise and white
smoke during cold starting.
(d) Preheating system ensures the cold weather start-ability of diesel engine. The preheating system
enhances the engine start-ability through heating the pressed air by the glow plug before the engine
cold start. When the ignition switch is on, the preheating process begins and meanwhile the preheating
indicator is lighted. When the preheating indicator is off, the glow plug has reached sufficiently high
temperature. This moment, turn the ignition switch to START quickly within 2 seconds and the engine is
started.
NOTE
If the ignition switch isn’t switched to START within 2 seconds as the preheating indicator is off, please
turn the ignition switch OFF for preheating again.
5. EGR CONTROL PRINCIPLE.
(a) BJ493ZQ3 diesel engine is equipped with the electrically controlled Exhaust Gas Recirculation (EGR)
system. EGR system consists of EGR valve control unit, EGR valve lift sensor, EGR valve, EGR
vacuum regulator, EGR coolant temperature sensor, pressure maintaining valve and associated piping
components.
(b) Based on the calibration data in different conditions, EGR valve control unit calculates required quantity
of exhaust gas recirculation, controls the EGR valve opening by controlling the EGR vacuum regulator
returns part of exhaust gas in the exhaust pipe through recirculation to the intake manifold, makes it
mixed with flesh air and into the combustion chamber to reduce the combustion temperature, so as to 11B
reduce the generation of oxynitride, thus to reduce the air pollution.
6. TURBO-CHARGING PRINCIPLE. 11B
(a) BJ493ZQ3 diesel engine adopts the exhaust gas turbocharger unit. The air intake and exhaust and
supercharger system consists of the intake manifold, exhaust manifold, intake pipe, air filter and 11B
supercharger. The turbo machine and compressor of the supercharger are installed on the same axis.
The turbo is driven by the exhaust gas exhausted by the engine and drives the compressor to 11B
compress the air inhaled by the air cleaner, so as to increase the air density in the cylinder and increase
the air input, which can accordingly increase the fuel delivery of fuel injection pump, thus to improve the 11B
engine output.
7. EGR COOLANT TEMPERATURE SENSOR. 11B
(a) EGR coolant temperature sensor for detecting engine operating temperature. Depending on the tem-
perature, EGR valve control unit provide the best control scheme. 11B
8. CONTROL OF THE COOLING FAN.
11B
(a) Electrical fan control function: Fan control unit determines whether to switch on various fans according
to the engine coolant temperature and whether the temperature meets the condition for switching on 11B
the air-conditioner, so as to reduce the engine internal power consumption.
9. GLOW PLUG. 11B
(a) Heating part of the glow plug stretching from pre-combustion chamber heat the air. Ensure diesel
engine to start at a lower temperature smoothly. 11B
10. EGR VALVE LIFT SENSOR.
(a) Based on the different conditions, EGR valve control unit calculates required quantity of exhaust gas
11B
recirculation, controls the EGR valve opening by controlling the EGR vacuum regulator returns part of
exhaust gas in the exhaust pipe through recirculation to the intake manifold, makes it mixed with flesh 11B
air and into the combustion chamber to reduce the combustion temperature, so as to reduce the
generation of oxynitride, thus to reduce the air pollution. 11B
11. EGR VACUUM REGULATOR.
11B
(a) Based on the different conditions, EGR valve control unit calculates required quantity of exhaust gas
recirculation, controls the EGR valve opening by controlling the EGR vacuum regulator returns part of 11B
exhaust gas in the exhaust pipe through recirculation to the intake manifold, makes it mixed with flesh
air and into the combustion chamber to reduce the combustion temperature, so as to reduce the 11B
generation of oxynitride, thus to reduce the air pollution.
12. VEHICLE SPEED SENSOR. 11B
(a) Vehicle speed sensor is the type of hall effect sensor. It works together with signal wheel on
transmission output shaft. Unified meter measure digital voltage signal through it, and determine the 11B
current speed of the vehicle.
13. THROTTLE POSITION SENSOR. 11B
(a) Throttle position sensor is used to provide EGR valve electronic control unit throttle angle, engine idling
rotation rate and location information. The sensor is three-wire type. EGR valve electronic control unit
detect changes by monitoring the voltage of the throttle opening.
14. PREHEATING CONTROL UNIT.
(a) Preheating system includes the four glow plugs, a conductive plate, a connecting harness and a pre-
heat control unit. Heating part of the glow plug stretching from pre-combustion chamber heat the air.
Ensure diesel engine to start at a lower temperature smoothly.
VE PUMP BASIC STRUCTURE

(a) VE pump. As shown, from left to right is drive shaft, feed pump, governor drive gear, cam, piston, piston
kits, solenoid valve stops fuel installations. The upper part of the pump for the governor, the bottom part
is the advancer.
1 Secondary Pump 12 Orifice
2 Governor Drive Gear 13 Parking Handle
3 Injection Advance Device 14 Governor Spring
4 Flat CAM Plate 15 Governor Handle
5 Fuel Adjustment Sleeve 16 Governor Sleeve
6 Plunger Spring 17 Flyweight
7 Distributive Plunger 18 Regulator
8 Delivery Valve 19 Drive Shaft
9 Plunger Set 20 Fuel Inlet
10 Cut-off Valve 21 Flow To Fuel Tank
11 Governor Tension Lever 22 To Injector

(b) Transmission system

• The distributeive plunger, governor and feed pump are
linked by the drive mechanism of the pump. And pass
the driving torque of the diesel engine. 11B
No. Component 11B

1 Drive Shaft
11B
2 Drive Gear
3 Double-slider Coupling 11B
4 Roller Support Bracket 11B

5 End Cam
11B
(c) Feed pump
11B
• Diesel output increased pressure with the increase of
speed. Output of diesel to lubricate and cool the parts. 11B
Advance device also controls the action.
11B
No. Component
1 Rotor 11B
2 Sliding Blade
11B
3 Eccentric Ring
11B
4 Feed Pump Cover
11B
(d) Pressure regulating valve
• Pressure regulating valve controls the pump pressure of 11B
pump chamber.
11B
No. Component
1 Pressure Regulating Valve Body 11B
2 Regulator Piston
11B
3 Regulator Spring
11B
4 Gasket Ring
5 Block 11B
11B
(e) Fuel advancer

• VE pump uses hydraulic fuel advancer. It is in the bottom
of pump.
No. Component
1 Pump Body
2 Roller Support Bracket
3 Inside And Outside Roller
4 Roller Support Bracket Pin
5 Damper Hole
6 Advancer Cover
7 Advancer Plunger
8 Pendulum Shaft
9 Advancer Spring
(f) Allocation and distribution of fuel

• VE pump pumps fuel from a supply component to a
number of cylinders.
No. Component
1 Plunger
2 Distribution Of Fuel
3 Fuel Inlet Passage
4 Fuel Feed Groove
5 Discharge Orifice
6 Overflow Orifice
(g) Regulator
• Regulator is in the upper of VE pump. It is mainly com-
posed of flying blocks patrs, flying blocks, regulating
11B
sleeve, regulating shaft, regulating frame parts and other
components.
11B
No. Component
11B
1 Flying Blocks Patrs
2 Regulating Spring 11B
3 Flying Blocks 11B

4 Regulating sleeve
11B
5 Regulating Cradle
11B
6 Regulating Support Bracket
7 Fuel Adjustment Screw 11B

8 Regulator Activation Lever
11B
9 Starting Spring
11B
10 Sleeve
11 Regulating Shaft 11B
(h) Cut-off sector 11B

• VE pump use the fuel cut solenoid valve to control fuel
11B
supply. The solenoid valve is mounted on the upper end
of the inlet of the plunger distribution cover.
11B
No. Component
11B
1 Magnetic Coil
2 Spring 11B
3 Valve Plug 11B

4 Inlet
11B
5 The Fuel Channels Is Open
6 The Fuel Channels Is Closed 11B
11B
(i) Load advancer

• Advance the role of the load device is based on the
engine load change, to automatically change supply
starting point.
No. Component
1 Regulator Shaft
2 Control Hole
3 Regulator Cover
4 Control Slot
5 Fly Block
6 Oil Circuit
7 Supply Pump
8 Full Load
9 Part Load
10 Pump Speed
11 Advance Angle
(j) Throttle position sensor

• To get the EGR condition suitable to the running to vehi-
cle (exhaust gas recirculation), a variety of sensors
needed to detect its running condition. EGR valve control
unit process these signal.
No. Component
2 Throttle Position Sensor Bracket
3 Connection Block
4 Connection Block Jacket
5 Handle Shaft
6 Handle
(k) Cold start device

• Through advancing injection starting point, cold starting
device improve cold start performance of the engine.
11B
No. Component
11B
1 Pressure Regulating Valve Parts
2 Cold Start Parts 11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-16 ENGINE CONTROL SYSTEM - EGR VALVE CONTROL UNIT
EGR VALVE CONTROL UNIT

PRINCIPLE
1. EGR VALVE CONTROL UNIT DESCRIPTION.
(a) Based on the calibration data in different conditions,
EGR valve control unit calculates required quantity of
exhaust gas recirculation, controls the EGR valve
opening by controlling the EGR vacuum regulator returns
part of exhaust gas in the exhaust pipe through
recirculation to the intake manifold, makes it mixed with
flesh air and into the combustion chamber to reduce the
combustion temperature, so as to reduce the generation
of oxynitride, thus to reduce the air pollution.
ENGINE CONTROL SYSTEM - EGR VALVE CONTROL UNIT 11B-17
REPLACEMENT
2. ROTATE DRIVER SEAT. 11B

(b) Rotate the driver seat. 11B
11B
11B
11B
3. OPEN THE BATTERY COVER. 11B

11B
11B
11B
11B
11B
NOTE 11B
please first turn off the ignition switch and lighting switch 11B
cable when peforming these operations. 11B
11B
11B
replacement”) 11B
6. REMOVE BUCKLE ASSY. 11B
11B
11B

11B-18 ENGINE CONTROL SYSTEM - EGR VALVE CONTROL UNIT
10. REMOVE EGR VALVE CONTROL UNIT.

(a) Disconnect EGR valve control unit connector.
(b) Remove 2 EGR valve control unit retaining bolts.

NOTE
• After disconnecting EGR valve control unit, pay
attention to waterproof.
• Not allow to impact.
(c) Install 2 EGR valve control unit retaining bolts.

NOTE
ENGINE CONTROL SYSTEM - EGR VALVE CONTROL UNIT 11B-19
11. INSTALL EGR VALVE CONTROL UNIT.

(a) Connect EGR valve control unit connector.
11B
11B
11B
11B
Torque: 9 ~ 11 N•m 11B
11B
11B
11B
11B
I
11B
11B
11B
11B
11B
14. INSTALL ENGINE SURFACING. 11B
15. INSTALL BUCKLE ASSY. 11B

11B
11B
11B
11B
replacement”)
11B-20 ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR
EGR COOLANT TEMPERATURE SENSOR

PRINCIPLE
1. EGR COOLANT TEMPERATURE SENSOR DESCRIP-
TION.
(a) EGR coolant temperature sensor is used to detect the
engine temperature. Depending on the temperature of
the engine to provide the best control scheme.
(b) This sensor is the 2-line type.
ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR 11B-21
OVERHAUL

11B
11B
11B

11B
11B
11B
11B
11B
NOTE 11B
11B
11B
replacement”) 11B
11B
11B

9. DRAIN THE COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)
10. REMOVE EGR COOLANT TEMPERATURE SENSOR.

(a) Disconnect EGR coolant temperature sensor connector.
(b) Remove EGR coolant temperature sensor.
NOTE
• Clear the screw hollow after removing.
• In the course of removal and installation, be careful
not to allow tools to touch the connector (resin
parts).
.
11. CHECK EGR COOLANT TEMPERATURE SENSOR.
(a) Dip the sensing part of EGR coolant temperature sensor
into hot water. Using the multimeter, measure resistance
of the sensor.
(b) If the check result is not OK, replace it.
Check condition Specified Condition (KΩ)
-20 ℃ 20.2 ± 1.95
20 ℃ 3.27 ± 0.16
40 ℃ 1.55 ± 0.09
60 ℃ 0.78 ± 0.045
80 ℃ 0.42 ± 0.02
100 ℃ 0.244 ± 0.01
CAUTION
Don’t let the water into terminals. After checking, dry the
sensor.
ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR 11B-23
12. INSTALL EGR COOLANT TEMPERATURE SENSOR.

CAUTION
Apply sealant on thread. The specified sealant: 3M nut
locking part, type: NO.4171 or the equivalent. 11B
11B
11B
11B
(a) Install EGR coolant temperature sensor. Tighten it to
specified torque. 11B
(b) Connect EGR coolant temperature sensor connector.
11B
11B
11B
11B
11B
11B
11B
13. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)
14. CHECK COOLANT LEAKAGE. 11B
15. INSTALL 7 ENGINE COVER RETAINING BOLTS. 11B

11B
11B
11B
11B
11B

replacement”)
ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR FOR FAN 11B-25
COOLANT TEMPERATURE SENSOR FOR FAN

PRINCIPLE
11B
1. COOLANT FAN CONTROL DESCRIPTION.
(a) Fan control unit determines whether to switch on various 11B
fans according to the engine coolant temperature and
whether the temperature meets the condition for 11B
switching on the air-conditioner, so as to reduce the
engine internal power consumption.
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-26 ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR FOR FAN
OVERHAUL



NOTE
replacement”)

ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR FOR FAN 11B-27
11B
11B
11B
11B
11B
10. REMOVE COOLANT TEMPERATURE SENSOR FOR
FAN. 11B
(a) Disconnect coolant temperature sensor for fan connec-
tor. 11B
(b) Remove coolant temperature sensor for fan.
11B
NOTE
• Clear the installation surface after removing. 11B
• Clear the thread of sensor after removing. 11B
not to allow tools to touch the connector (resin 11B
parts).
11B
. 11B
11. CHECK COOLANT TEMPERATURE SENSOR FOR
FAN. 11B
(a) Dip the sensing part of coolant temperature sensor for
fan into hot water. Using the multimeter, measure 11B
resistance of the sensor.
(b) If the check result is not OK, replace it with a new one. 11B
Check Condition Specified Condition (Ω) 11B
-20 ℃ 15.462
11B
0℃ 5.986
11B
20 ℃ 2.500
80 ℃ 0.323 11B
CAUTION
sensor.
11B-28 ENGINE CONTROL SYSTEM - COOLANT TEMPERATURE SENSOR FOR FAN
12. INSTALL COOLANT TEMPERATURE SENSOR FOR FAN.

CAUTION
Apply sealant on thread . The specified sealant: 3M nut locking part, type: NO.4171 or the equivalent.
(a) Install coolant temperature sensor for fan. Tighten it to

specified torque.
Torque: 25 N•m
(b) Connect coolant temperature sensor for fan connector.



replacement”)
ENGINE CONTROL SYSTEM - PREHEAT TEMPERATURE SENSOR 11B-29
PREHEAT TEMPERATURE SENSOR

PRINCIPLE
11B
1. PREHEAT TEMPERATURE SENSOR DESCRIPTION.
(a) Heating part of the glow plug stretching from pre- 11B
combustion chamber heat the air. Ensure diesel engine
to start at a lower temperature smoothly. 11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-30 ENGINE CONTROL SYSTEM - PREHEAT TEMPERATURE SENSOR
OVERHAUL



NOTE
replacement”)

11B
11B
11B
11B
11B
10. REMOVE PREHEAT TEMPERATURE SENSOR.
(a) Disconnect preheat temperature sensor connector. 11B
11B
11B
11B
11B
11B
11B
11B
(b) Remove preheat temperature sensor.
NOTE 11B
• Clear the screw hollow after removing. 11B
11B
not to allow tools to touch the connector (resin 11B
parts).
11B
11B
11B
11B-32 ENGINE CONTROL SYSTEM - PREHEAT TEMPERATURE SENSOR
11. CHECK PREHEAT TEMPERATURE SENSOR.

(a) Dip the sensing part of preheat temperature sensor into
hot water. Using the multimeter, measure resistance of
the sensor.
(b) If the check result is not OK, replace it.
Check Condition Specified Condition (KΩ)
25 ℃ 10 ± 1
CAUTION
sensor.
12. INSTALL PREHEAT TEMPERATURE SENSOR.

CAUTION
Apply sealant on thread. The specified sealant: 3Mnut
locking part, type: NO.4171 or the equivalent.
13. CONNECT PREHEAT TEMPERATURE SENSOR CONNECTOR.


11B
11B
11B
11B
11B
Torque: 41 ~ 51 N•m 11B
11B
11B
11B
11B
11B
replacement”)
20. CONNECT BATTERY NEGATIVE CABLE. 11B
22. PUT DOWN DRIVER SEAT AND LOCK IT. 11B
11B
11B
11B
11B
11B
11B
11B
11B-34 ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR
EGR VALVE LIFT SENSOR

PRINCIPLE
1. EGR VALVE LIFT SENSOR DESCRIPTION.
(a) Based on the different conditions, EGR valve electronic
control unit calculates required quantity of exhaust gas
recirculation, controls the EGR valve opening by controlling
the EGR vacuum regulator returns part of exhaust gas in the
exhaust pipe through recirculation to the intake manifold,
makes it mixed with flesh air and into the combustion
chamber to reduce the combustion temperature, so as to
reduce the generation of oxynitride, thus to reduce the air
pollution.
ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR 11B-35
OVERHAUL

11B
11B
11B

11B
11B
11B
11B
11B
NOTE 11B
11B
11B
replacement”) 11B
11B
11B

9. REMOVE EGR VALVE LIFT SENSOR.

(a) Disconnect EGR valve lift sensor connector.
10. REMOVE EGR VALVE.

(a) Remove EGR valve vacuum tube.
(b) Remove 2 bolts retaining EGR valve to intake manifold.
(c) Remove 2 bolts retaining EGR valve to EGR cooling

tube.

NOTE
Check the EGR valve opening and closing is smooth, If the valve is stuck, replace it.
ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR 11B-37
12. CHECK EGR VALVE LIFT SENSOR RESISTANCE.

(a) Using the multimeter, measure resistance of the sensor
between terminal 1 and 2.
(b) Measure the resistance according to the value in the 11B
table below.
Standard resistance 11B
Tester Connection Specified Condition 11B

C079 (1) - C079 (2) Hall type
11B
13. INSTALL EGR VALVE LIFT SENSOR. 11B
14. INSTALL EGR VALVE. 11B

(a) Install 2 bolts retaining EGR valve to EGR cooling tube.
Torque: 15 ～ 18 N•m 11B
11B
11B
11B
(b) Install 2 bolts retaining EGR valve to EGR recirculation 11B

tube.
Torque: 15 ～ 18 N•m
11B
(c) Connect EGR valve vacuum tube and connector.
11B
11B
11B
11B
Torque: 21 ~ 25 N•m 11B
11B
11B
11B


replacement”)
ENGINE CONTROL SYSTEM - EGR VACUUM REGULATOR 11B-39
EGR VACUUM REGULATOR

PRINCIPLE
11B
1. EGR VACUUM REGULATOR DESCRIPTION.
(a) Based on the different conditions, EGR valve electronic 11B
control unit calculates required quantity of exhaust gas
recirculation, controls the EGR valve opening by controlling 11B
the EGR vacuum regulator returns part of exhaust gas in the
exhaust pipe through recirculation to the intake manifold,
11B
makes it mixed with flesh air and into the combustion
chamber to reduce the combustion temperature, so as to
11B
pollution.
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-40 ENGINE CONTROL SYSTEM - EGR VACUUM REGULATOR
OVERHAUL



NOTE
5. REMOVE EGR VACUUM REGULATOR.

(a) Disconnect EGR vacuum regulator connector.
(b) Remove the harness from the mounting bracket.
(c) Remove EGR vacuum regulator inlet vacuum hose and

exhaust vacuum hose.
NOTE
After removal, clean the mounting surface to ensure that no 11B
oil.
11B
11B
11B
11B
11B
11B
6. REMOVE EGR VACUUM REGULATOR.
(a) Remove 2 EGR vacuum regulator retaining bolts. 11B
11B
11B
11B
11B
11B
11B
7. CHECK EGR VACUUM REGULATOR. 11B

between terminal 1 and 2. 11B
Standard resistance: 14 ± 10%Ω (20 ℃ )
11B
11B
11B
11B
11B-42 ENGINE CONTROL SYSTEM - EGR VACUUM REGULATOR
8. INSTALL EGR VACUUM REGULATOR.

(a) Install 2 EGR vacuum regulator retaining bolts.
(b) Connect EGR vacuum regulator connector.
(c) Install EGR vacuum regulator inlet vacuum hose and

exhaust vacuum hose.

11B
11B
11B
11B
11B
Torque: 41 ~ 51 N•m 11B
11B
11B
11B
11B
11B
replacement”)
13. CONNECT BATTERY NEGATIVE CABLE. 11B
15. PUT DOWN DRIVER SEAT AND LOCK IT. 11B
11B
11B
11B
11B
11B
11B
11B
11B-44 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR

PRINCIPLE
(a) Vehicle speed sensor is the type of hall effect sensor. It
works together with signal wheel on transmission output
shaft. Unified meter measure digital voltage signal through
it, and determine the current speed of the vehicle.
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11B-45
11B
(c) Connect the oscilloscope to the vehicle speed sensor. 11B
(d) Driving the vehicle, read the scan tool data stream: vehicle speed.
(e) Vehicle speed: Same value as the actual vehicle speed. 11B
(f) If the displayed value is not equal to the actual value, then check sensor, harness and EGR valve
electronic control unit . 11B
(g) Raise vehicle.
11B
(h) Turn the ignition switch ON and engine stop. Check as
following:
11B
• Set digital multimeter to voltage range. Check voltage
between terminal 2 and 3 of the sensor. It should be 12 11B
V. If it is not OK, replace it.
11B
11B
11B
(i) Start engine. push the shift lever to gear. Using the oscilloscope, check the wave output of terminal 1 of
sensor. If it’s not OK, check harness and sensor. 11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-46 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR
OVERHAUL



NOTE
5. RAISE VEHICLE.

(a) Disconnect vehicle speed sensor connector.
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11B-47

NOTE
11B
11B
11B
11B
(a) Tighten vehicle speed sensor retaining bolt. 11B
Torque: 7.5 N•m
11B
NOTE
Do not allow any impact tools (such as a hammer, etc.) to 11B
11B
11B
11B
11B
11B
11B
11B
8. CONNECT VEHICLE SPEED SENSOR CONNECTOR. 11B

9. LOWER VEHICLE.
11B
11. COVER AND TIGHTEN THE BATTERY COVER LOCK KNOB. 11B
11B
11B
11B
11B-48 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR
THROTTLE POSITION SENSOR

PRINCIPLE
(a) Throttle position sensor is used to provide EGR valve
electronic control unit throttle angle, engine idling rotation
rate and location information. The sensor is three-wire type.
EGR valve electronic control unit detect changes by
monitoring the voltage of the throttle opening.
ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR 11B-49
REPLACEMENT

11B
11B
11B

11B
11B
11B
11B
11B
NOTE 11B
11B
11B
5. REMOVE WATER PIPE BRACKET.
(a) Loosen water pipe bracker retaining bolt. 11B
(b) Remove it aside.
11B
11B
11B
11B-50 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR
6. REMOVE THROTTLE POSITION SENSOR.

(a) Disconnect throttle position sensor connector.
(b) Remove 2 throttle position sensor retaining bolts.
7. CHECK THROTTLE POSITION SENSOR.

between terminal 1 and 3.
Standard resistance: Hall type (20 ℃ )
(b) If it is not OK, replace it with a new one.
8. INSTALL THROTTLE POSITION SENSOR.

(a) Install 2 throttle position sensor retaining bolts.
(b) Connect throttle position sensor connector.
9. ADJUST THROTTLE POSITION SENSOR.

ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR 11B-51
10. INSTALL WATER PIPE BRACKET.

(a) Install water pipe bracket retaining bolts.
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B-52 ENGINE CONTROL SYSTEM - PREHEAT CONTROL UNIT
PREHEAT CONTROL UNIT

PRINCIPLE
1. PREHEATING SYSTEM DESCRIPTION.
(a) Preheating system includes the four glow plugs, a
conductive plate, a connecting harness and a preheat
control unit. Heating part of the glow plug stretching from
pre-combustion chamber heat the air. Ensure diesel engine
to start at a lower temperature smoothly.
ENGINE CONTROL SYSTEM - PREHEAT CONTROL UNIT 11B-53
REPLACEMENT

11B
11B
11B

11B
11B
11B
11B
11B
NOTE 11B
11B
11B
replacement”) 11B
11B
11B

11B-54 ENGINE CONTROL SYSTEM - PREHEAT CONTROL UNIT
9. REMOVE PREHEAT CONTROL UNIT.

(a) Disconnect preheat control unit connector.
(b) Remove 2 preheat control unit retaining bolts.

(c) Remove preheat control unit.
10. INSTALL PREHEAT CONTROL UNIT.

(a) Install 2 preheat control unit retaining bolts.
ENGINE CONTROL SYSTEM - PREHEAT CONTROL UNIT 11B-55
(b) Connect preheat control unit connector.
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
11B
14. INSTALL ENGINE SURFACING. 11B

11B
11B
11B
11B
16. INSTALL ASSISTANT DRIVER SEAT. (Refer to “Chapter 84 seat - driver / assistant driver seat, 11B
replacement”)
11B-56 ENGINE CONTROL SYSTEM - ENGINE RELAY BOX
ENGINE RELAY BOX

PRINCIPLE
1. ENGINE RELAY BOX DESCRIPTION.
(a) Preheat control unit controls the glow plug through the
engine relay box.
ENGINE CONTROL SYSTEM - ENGINE RELAY BOX 11B-57
REPLACEMENT

11B
11B
11B

11B
11B
11B
11B
11B
NOTE 11B
11B
11B
5. REMOVE ENGINE RELAY BOX.
(a) Disconnect engine relay box connector. 11B
11B
11B
11B
11B-58 ENGINE CONTROL SYSTEM - ENGINE RELAY BOX
(b) Remove 2 engine relay box retaining bolts.
6. INSTALL ENGINE RELAY BOX.

(a) Install 2 engine relay box retaining bolts.
(b) Connect engine relay box connector.

FUEL
12B
FUEL SYSTEM................................................................................. 12B-1
PRECAUTION............................................................................ 12B-1
PROBLEM SYMPTOMS TABLE................................................ 12B-3
FUEL TANK ASSY........................................................................... 12B-5 12B
COMPONENTS ......................................................................... 12B-5
REPLACEMENT ........................................................................ 12B-6
FUEL PRECIPITATOR ASSY ........................................................ 12B-11
REPLACEMENT ...................................................................... 12B-11 12B
FUEL LEVEL SENSOR ASSY ....................................................... 12B-15
REPLACEMENT ...................................................................... 12B-15
FUEL STRAINER ASSY ................................................................ 12B-16
REPLACEMENT ...................................................................... 12B-16
VE DISPENSING PUMP ASSY...................................................... 12B-17
COMPONENTS ....................................................................... 12B-17
REPLACEMENT ...................................................................... 12B-18
FUEL INJECTOR ASSY................................................................. 12B-23
OVERHAUL ............................................................................. 12B-23
FUEL FILLING DOOR.................................................................... 12B-25
REPLACEMENT ...................................................................... 12B-25
11B
12B
FUEL - FUEL SYSTEM 12B-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12B
(a) Before working on fuel system, disconnect battery negative cable if necessary.
(b) When removing the fuel hose, use a suitable container to hold the diesel.
(d) Fuel in the VE dispensing pump and tubes remain under high pressure. In order to avoid personal
injury, do not loosen tube connector while engine is runing.
(e) Keep diesel away from rubber and leather parts.
(f) Diesel injection equipment is designed to very precise tolerances and fine clearances. To prevent fuel
system damage, it is essential that absolute cleanliness is oberved when working with these
components. Always install fuel system caps to any open orifices or tubes.
(g) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system
pressure to prevent accidental spraying of fuel, even when the engine is not running. Failure to follow
(h) Check if there is any dirt like mud around the fuel tube connector before this work. And clean dirt away,
(i) Keep cleaner away from the O-ring of tube connecter. Cleaner can harm seal of fuel system.
(j) Don’t bend or twist the fuel system tube and pipe by force.
(k) Before connceting fuel system tube, be sure there is no damage to tube connector. If there is damage,
crack or dirt on surface. replace it with a new tube assy.
(l) Wearing eyeshield equipment is needed when working on fuel system compoments. Failure to follow
this instruction may result in personal injury.
(m) The metal parts like zn, cu, mn are easily dissolved in diesel. coking may appears in fuel injector which
reduces the injected diesel to cylinder. So the matal parts above should not be used in high-pressure
common rail fuel system.
(n) It is essential to keep fuel system clean. especially it can not contain any impurity, such as corrosion,
welding spatter. Otherwise, these impurity can block fuel tube, engine shut down suddenly. The
common rail parts are even damaged.
12B
12B-2 FUEL - FUEL SYSTEM
FUEL SYSTEM PRESSURE RELIEF PROCESS

(a) Disconnect VE dispensing pump fuel cut solenoid valve harness connector.
(b) Start and idle the engine till it stops on its own. turn the ignition switch to lock.
(c) Start the engine again for 5 seconds, ensure fuel manifold branch relief pressure is complete.
(d) Connect VE dispensing pump fuel cut solenoid valve harness connector.

(b) Using the ignition key, open the fuel filling door.
(c) Open the fuel filling door.
(d) Raise the vehicle in place.
(e) Remove the fuel tank drain bolt and drain the fuel to the
suitable container.
FUEL TUBE CLEAN

FUEL - FUEL SYSTEM 12B-3

12B
1. Main relay (Damaged) -
2. Fuel (No fuel or poor fuel quality ) -
Chapter 12B fuel - fuel precipitator, replace-

3. Fuel system (Air inside) ment
Engine does not start 4. Lower-pressure fuel circuit Chapter 12B fuel - fuel system, precaution
(Blocked or leaking)
Chapter 12B fuel - VE dispensing pump, over-

5. VE dispensing pump (Damaged) haul
6. Heater plug (Damaged) -
7. Fuel injector (Damaged) Chapter 12B fuel - fuel injector, overhaul
1. Lower-pressure fuel circuit Chapter 12B fuel - precaution

(Blocked or low pressure)

Engine starts hard 4. Heater plug (Faulty) -
5. High-pressure fuel circuit (Low Chapter 12B fuel - VE dispensing pump, over-
pressure) hau

6. VE dispensing pump (Faulty) haul
7. Fuel injector (Faulty) Chapter 12B fuel - fuel injector, overhaul
1. Fuel (Poor quality) - 12B

Engine idles rough 3. Lower-pressure fuel circuit Chapter 12B fuel - fuel system, precaution
4. Fuel injector (Out of order) Chapter 12B fuel - fuel injector, overhaul


Engine emits white or
2. Lower-pressure fuel circuit Chapter 12B fuel - fuel system, precaution
blue smoke
(Blocked)
3. Heater plug (Faulty) -
Engine emit black

1. Fuel injector (Faulty) Chapter 12B fuel - fuel injector, overhaul
smoke
12B-4 FUEL - FUEL SYSTEM
1. Poor fuel quality -
2. Lower-pressure fuel circuit Chapter 12B fuel - fuel system, precaution

Engine loss of power
3. Fuel injector (Work badness) Chapter 12B fuel - fuel injector, overhaul

FUEL - FUEL TANK ASSY 12B-5
FUEL TANK ASSY

COMPONENTS
12B
1 Diesel Fuel Precipitator Assy 6 Fuel Filling Cap
2 Diesel Fuel Precipitator Assy Bracket 7 Fuel Tank Cover
3 Fuel Return Hose 8 Fuel Filling Hose Board

12B
4 Fuel Tank 9 Fuel Inlet Hose
5 Fuel Tank Breathe Hose

12B-6 FUEL - FUEL TANK ASSY
REPLACEMENT
2. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, precaution”)
3. Remove spare tire and spare tire bracket.

(a) Loosen the spare tire bracket holder bolt.
NOTE
Do not remove the spare sheel bracket holder bolt.
(b) Loosen the holder, put down the bracket and take off the
spare tire.
(d) Loosen 3 bolts attaching spare tire bracket to vehicle

body.
4. DRAIN FUEL IN THE TANK. (Refer to “Chapter 12B fuel - fuel system, precaution”)


DISCONNECT IT.

DISCONNECT IT.
12B
9. LOOSEN FUEL INLET/RETURN HOSE CLAMPS AND

DISCONNECT THEM.

(b) Lower the fuel tank slowly, disconnect the fuel level
sensor connectors.
12B
NOTE
• Check if there is any dirt like mud and tube, harness around the fuel tank. Clean the dirt if
necessary.
• When removing fuel tank, as fuel tank is large and heavy, it is necessary to use sutiable tool or
have others help.

screws.

NOTE
necessary.
12. REMOVE FUEL STRAINER ASSY.

(a) Loosen 6 fuel strainer sealing cover retaining screws.
(b) Take out the fuel strainer.

NOTE
fuel strainer before this work and clean the dirty
away.

(b) Tighten the 5 fuel level sensor sealing cover retaining
screws.
Torque: 6 ~ 8 N•m
14. INSTALL FUEL STRAINER ASSY.

(a) Install fuel strainer assy.
(b) Tighten 6 fuel strainer sealing cover retaining screws.

(a) Raise the fuel tank assy to satiable position by jack.

NOTE
viberation.

CLAMP.
12B

TIGHTEN CLAMP.
18. CONNECT FUEL TANK INLET / RETURN HOSE AND

TIGHTEN CLAMPS.

BOLTS.
20. INSTALL SPARE TIRE BRACKET AND SPARE TIRE.

(a) Tighten 3 spare tire bracket retaining bolts.

(c) Position the spare tire and install the apare tire bracket
holder.
(d) Tighten the spare tire bracket holder retaining bolt.

With ignition switch ON, inspect the fuel gauge display normal or not. Start engine, inspect if there is
fuel leaking from pipe connection.
FUEL - FUEL PRECIPITATOR ASSY 12B-11
FUEL PRECIPITATOR ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, precaution”) 12B

3. LOOSEN FUEL PRECIPITATOR INLET / RETURN

HOSE CLIPS AND DISCONNECT THEM.
4. LOOSEN FUEL PRECIPITATOR HAND PUMP

RETAINING BOLTS.
12B
5. REMOVE FUEL PRECIPITATOR ASSY.

6. REPLACE FUEL PRECIPITATOR ASSY.
(a) Clean fuel precipitator suface completly and clamp diesel inlet hose.
12B-12 FUEL - FUEL PRECIPITATOR ASSY
(b) Remove the fuel precipitator assy by wrench or suitable

tool.
(c) Clean precipitator bottom base, be sure to tighten the
screw connector of precipitator.
(d) Apply clean diesel to the new precipitator seal surface
and fill clean diesel to new precipitator.
(e) Lightly screw the fuel precipitator into bottom base, and
tighten it until feeling resistance.
(f) Using wrench or special tool, tighten fuel precipitator.
Inspect fuel leakage.
(g) Bleed the air from fuel precipitator.
7. TIGHTEN FUEL PRECIPITATOR HAND PUMP

RETAINING BOLTS.
8. CONNECT FUEL PRECIPITATOR INLET / RETURN

HOSE AND TIGHTEN CLIPS .

With ignition switch ON, inspect the fuel gauge conditions. Start engine and inspect if there is fuel
leakage from pipe.
FUEL - FUEL PRECIPITATOR ASSY 12B-13
FUEL PRECIPITATOR BLEEDING

1. LOWER FUEL CIRCUIT.
(a) Push hand pump knob at 40 times/min till feel unable to 12B
press so far.
(b) Hold the push knob and loosen the air bleeding bolt on
the fuel precipitator. Bleeding the air, then tighten the
bleeding bolt.
NOTE
Release the push knob after tighten the air bleeding bolt.
12B
(c) Push the hand pump knob and bleeding air for several
times until there is no air exhaust from the air bleeding
bolt.
2. HIGH-PRESSURE FUEL CIRCUIT.

(a) Loosen the nut attaching high-pressure tube to injector.
Starting the engine, bleed the air in the high-pressure cir-
cuit.
(b) Ensure there is no air exhaust from the high-ressure
tube. Tighten the nut quickly. Use the same way bleeding
the air from the high-pressure in proper order until the
engine can be started.
(c) Ensure the hand pump had been locked.
12B-14 FUEL - FUEL PRECIPITATOR ASSY
BLEEDING WATER FROM WATER/FUEL SEPARATOR

NOTE
During engine running, water/fuel separator indicator keeps light, it means that water in water/fuel
separator needs to be bleeded.
1. STOP THE VEHICLE AT FLAT AND SAFE PLACE.
2. BLEEDING WATER FROM WATER SEPARATOR.

(a) open the driver seat, put the suitable container (0.2l)
under the fuel/water seperator.
(b) Loosen drain plug (about five circles). Push and pull
knob 10 times to drain water until fuel/water seperator is
full of diesel.
(c) Tighten drain plug after bleeding the water. Pull and push
knob serval times.
(d) Start the engine to make sure that no fuel leaks from
drain plug. Check water/fuel indictor off.
NOTE
• If draining water from water/fuel sperator is frequent, it means that fuel is not qualified or there
is water in fuel tank. Please drive the vehicle to service station for repair.
• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel
precipitator sechudle maintenance. Replacement cycle: 15000 km.
FUEL - FUEL LEVEL SENSOR ASSY 12B-15

REPLACEMENT
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, precaution”) 12B
4. REMOVE FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacment”)

screws.

NOTE
fuel level sensor before this work and clean the dirty
away.

screws.
7. INSTALL FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacement”)
(a) After disconnecting fuel pump connector, connect fuel level sensor connector, turn ignition switch on.
Slide fuel level sensor position manually. Ensure fuel gauge is in good condition from instrument
cluster.
(b) After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
With the ignition switch ON, inspect the fuel gauge conditions. Start engine and inspect if if there is fuel
leakage from pipe.
12B-16 FUEL - FUEL STRAINER ASSY
FUEL STRAINER ASSY

REPLACEMENT
4. REMOVE FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacment”)

(b) Take out the fuel fuel strainer.

NOTE
away.
6. IF NECESSARY, USE THE CLEANER CLEANING THE SEDIMENTS ON THE FUEL STRAINER TO
KEEP THE FUEL SUPPLY WAY UNBLOCKED.

Torque: 6 ~ 8 N•m
8. INSTALL FUEL TANK. (Refer to “Chapter 12B fuel - fuel tank, replacement”)
leakage from pipe.
FUEL - VE DISPENSING PUMP ASSY 12B-17
VE DISPENSING PUMP ASSY

COMPONENTS
12B
1 Hose Protector Assy 4 VE Dispensing Pump Bracket
2 Fuel Injector 5 Idle Ascension Valve Assy
3 High-pressure Tube 6 VE Dispensing Pump Assy

12B
12B-18 FUEL - VE DISPENSING PUMP ASSY
REPLACEMENT

4. LOOSEN VE DISPENSING PUMP INLET/RETURN

HOSE CLAMP AND DISCONNECT THEM.
5. DISCONNECT ACCELERATOR CABLE.
6. REMOVE VE DISPENSING PUMP ACCESSORY.

(a) Loosen VE dispensing pump vacuum hose bolt.
(b) Loosen coolant pipe bracket retaining bolt.
7. DISCONNECT 4 FUEL HIGH-PRESSURE TUBE.
12B
8. LOOSEN FUEL HIGH-PRESSURE TUBE CLAMP.
9. REMOVE ENGINE TIMING GEARS. (Refer to “Chapter 15B engine mechanical - timing gear,
overhaul”)
10. REMOVE VE DISPENSING PUMP TIMING GEAR

RETAINING BOLT.
12B
11. SEPERATE VE DISPENSING PUMP TIMING GEAR.
12. DISCONNECT VE DISPENSING PUMP CONNECTORS AS FOLLOWING:
• Accelerator position sensor
• Fuel cut solenoid valve
• Speed sensor
13. LOOSEN 3 BOLTS ATTACHING VE DISPENSING

PUMP TO VE DISPENSING PUMP FLANGE.
14. REMOVE VE DISPENSING PUMP.

NOTE
• Every bolt of VE dispensing pump has alreay been tightened before leaving factory. Do not
remove or adjust when using. If VE dispensing pump has malfunction, it need authroized
engineer inspection and testing if necessary.
• Do not knock pump shaft when installing.
• The new VE dispensing pump must be lubricated with special equipment and correct process at
the first time. Pump fuel from inlet till no bubble appear at fuel return flow. Noraml lubrication is
needed for friction pieces and sealing area.
15. TIGHTEN 3 BOLTS ATTACHING VE DISPENSING

PUMP TO VE DISPENSING PUMP FLANGE.
NOTE
• Before installing VEdispensing pump, clean dirt from
drive shaft by gaslion and alcohol.
• Make sure the correct installing position is followed
when install the VEdispensing pump.
16. TIGHTEN VE DISPENSING PUMP TIMING GEAR

TAINING BOLT.
12B
17. INSTALL ENGINE TIMING GEAR. (Refer to “Chapter 15B engine mechanical - timing gear,
overhaul”)
18. TIGHTEN 4 FUEL HIGH-PRESSURE TUB NUTS.

19. INSTALL FUEL HIGH-PRESSURE TUBE CLAMP.
12B
20. CONNECT VE DISPENSING PUMP INLET / RETURN
HOSE AND TIGHTEN CLAMP.
21. CONNECT ACCELERATOR CABLE.
22. INSTALL VE DISPENSING PUMP ACCESSORY.

(a) Tighten VE dispensing pump vacuum hose bolt.
(b) Tighten coolant pipe bracket retaining bolt.
23. Connect VE dispensing pump connectors as following:

• Speed sensor
FUEL - FUEL INJECTOR ASSY 12B-23
FUEL INJECTOR ASSY

OVERHAUL
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12B fuel - fuel system, precaution”) 12B

4. LOOSEN NUTS ATTACHING HIGH PRESSURE TUBE

TO FUEL INJECTOR.
NOTE
To avoid injector bolt seat looseness, fixing related bolt
seat by other tool is needed when removing injector nut.
5. LOOSEN INJECTOR PRESSING PLATE NUTS.
12B
6. DISCONNECT FUEL INJECT RETURN TUBE CLIP.

12B-24 FUEL - FUEL INJECTOR ASSY

NOTE
• Inspect the inject with carbon deposition blocked . Clean carbon deposition by ultrasonic clean-
ing.
• Replace with a new copper gasket after removing the injector.
NOTE
• Position injector gasket on atomizer element seal surface . slightly push injector into cylinder
injector hole.
• Apply clean oil to lubricate all seal (O type ) when installation.
9. TIGHTEN INJECTOR PLATE RETAINING BOLTS.

Torque:
First step: 7.5 ~ 9 N•m
Second step: turn 40 ~ 45°
10. CONNECT INJECTOR FUEL RETURN TUBE

ASSEMBLY CLIP.
NOTE
Fixing Bracket of injector fuel return tube assembly must
be relaced if bended.
11. TIGHTEN NUTS ATTACHING FUEL HIGH PRESSURE

TUBE TO FUEL INJECTOR.

After connecting all connectors, check if the fuel tube connector and pipe are securely connected by
pulling them. With the ignition switch ON, inspect the fuel gauge conditions. Start engine , Inspect if
there is fuel leakage from fuel filter pipe.
FUEL - FUEL FILLING DOOR 12B-25
FUEL FILLING DOOR

REPLACEMENT
12B
1. REMOVE FILLING DOOR.
(a) Using ignition key, open fuel filling door.
(b) Loosen the fuel filling door retaining bolt.
2. INSTALL FUEL FILLING DOOR.

(a) Tighten the fuel filling door retaining bolts.
12B
MEMO
EMISSION CONTROL
13B
FUEL TANK CAP .............................................................................13B-1
INSPECTION ............................................................................. 13B-1
ELECTRONIC CONTROL EGR VALVE .......................................... 13B-2
COMPONENTS ......................................................................... 13B-2 13B
REPLACEMENT ........................................................................ 13B-3
VACUUM REGULATOR .................................................................. 13B-6
OVERHAUL ............................................................................... 13B-6
13B
11B
12B
13B
EMISSION CONTROL - FUEL TANK CAP 13B-1
FUEL TANK CAP

EMISSION CONTROL
INSPECTION
13B

(a) Visually inspect fuel tank cap and gasket. If deformed or
13B
13B-2 EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE
ELECTRONIC CONTROL EGR VALVE

COMPONENTS
1 ECT Sensor 5 EGR Control Moudle
2 Pressure Maintaining Valve 6 EGR Gasket
3 Vacuum Regulator 7 EGR Circulating Pipe
4 Electronic Control EGR Valve

EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE 13B-3
REPLACEMENT
(a) Loosen the driver seat clamp. 13B
replacement”)
13B
6. REMOVE ELECTRONIC CONTROL EGR VALVE.

(a) Disconnect electronic control EGR valve connector and
vacuum hose.
(b) Remove 2 bolts attaching EGR valve and EGR exhaust
pipe.
13B-4 EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE
(c) Remove 2 bolts attaching EGR valve and EGR cooling

pipe.
7. REPLACE EGR VALVE.

NOTE
Inspect if EGR valve opens/closes smoothly or not. Replace with a new one if blocked .
8. REPLACE EGR GASKET.
9. INSTALL EGR VALVE.

(a) Install 2 bolts attaching EGR valve and EGR cooling
pipe.
(b) Install 2 bolts attaching EGR valve and EGR exhaust

pipe.
(c) Connect electronic control EGR valve connector and vacuum
hose.


EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE 13B-5

13B
13. CHECK EGR LIFT SENSOR. (Refer to “Chapter 04 diagnostics-diesel engine control system,
DTC code”)
replacement”)
13B
13B-6 EMISSION CONTROL - VACUUM REGULATOR
VACUUM REGULATOR
OVERHAUL
replacement”)
6. DISCONNECT VACUUM REGULATOR CONNECTOR

AND VACUUM HOSE.
NOTE
Mark the vacuum hose position, to avoid incorrect installation.
EMISSION CONTROL - VACUUM REGULATOR 13B-7
7. REMOVE VACUUM REGULATOR RETAINING BOLTS.
13B
8. TAKE OFF VACUUM REGULATOR.

NOTE
• Visully inspect vacuum regulator for deform and damage. Replace with a new one if abnormal.
• Turn the ignition switch off. Remove vacuum regulator connector, measure the resistance
between two terminals. The resistance is around 41 ohm. If not, replce with a new one. Vacuum
regulator working voltages is 12 volt, opening time is less than 1s, closing time is less than
0.2s.
• When EGR valve opens difficultly or vacuum degree absence, please check if air leakage exists.
• It can cause engine exhaust be heavy black smoke with failed vacuum regulator.
9. POSITION VACUUM REGULATOR.
10. INSTALL VACUUM REGULATOR RETAINING BOLTS.

11. CONNECT VACUUM REGULATOR CONNECTOR AND

VACUUM HOSE.
13B
NOTE
Install the vacuum hose following the mark before remove.
13B-8 EMISSION CONTROL - VACUUM REGULATOR


replacement”)
INTAKE AIR
14B
INTAKE AIR SYSTEM...................................................................... 14B-1
PRECAUTION............................................................................ 14B-1
COMPONENTS ......................................................................... 14B-2
INTAKE AIR HOSE .......................................................................... 14B-3 14B
REPLACEMENT ........................................................................ 14B-3
AIR FILTER ASSY ........................................................................... 14B-6
REPLACEMENT ........................................................................ 14B-6
AIR STRAINING BOX ASSY ......................................................... 14B-11 14B
REPLACEMENT ...................................................................... 14B-11
TURBOCHARGER ASSY .............................................................. 14B-14
COMPONENTS ....................................................................... 14B-14
MAINTENANCE OF TURBOCHARGER ................................. 14B-15
REPLACEMENT ...................................................................... 14B-16
INTAKE AIR CONNECT PIPE ....................................................... 14B-22
REPLACEMENT ...................................................................... 14B-22
INTAKE MANIFOLD....................................................................... 14B-26
REPLACEMENT ...................................................................... 14B-26
11B
12B
14B
14B
INTAKE AIR - INTAKE AIR SYSTEM 14B-1
INTAKE AIR SYSTEM

INTAKE AIR
PRECAUTION
1. INTAKE AIR SYSTEM PRECAUTION. 14B
(d) When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice to
wear protective clothing and goggles to avoid personal injury.
(e) When dealing with corrosive work, use skin and eye protection device to reduce the possibility of
personal injury.
(f) When using compressed air, wear appropriate goggles and protective mask. Both dust particles and
dirt will cause injury.
14B
14B-2 INTAKE AIR - INTAKE AIR SYSTEM
COMPONENTS
1 Intake Air Grille 4 Turbocharger Intake Hose
2 Air Straining Box Assy 5 Crankcase Breather Hose
3 Intake Air Hose 6 Air Filter Assy

INTAKE AIR - INTAKE AIR HOSE 14B-3
INTAKE AIR HOSE

REPLACEMENT
14B
replacement”)
14B
6. LOOSEN 3 AIR FILTER COVER RETAINING BOLTS.

14B-4 INTAKE AIR - INTAKE AIR HOSE

NOTE
The clamp can be used only once, replace it after removing.
8. REMOVE AIR FILTER BELLOW HOSE.

(a) Loosen turbocharger intake air hose and air filter bellow
hose clip.
(b) Disconnect crankcase breather hose clip.

10. CHECK AIR FILTER BELLOW HOSE. IF FIND SOMETHING DAMAGE LIKE BROKEN, PLEASE
REPLACE WITH A NEW ONE.

(a) Connect turbocharger intake air hose and air filter bellow
hose, then tighten the clip.
(b) Connect crankcase breather hose and tighten the clip.

TIGHTEN CLIPS.
13. AFTER INSTALLING AIR INTAKE HOSE, CHECK ALL PARTS AND PARTS CONNECTION AGAIN
INTAKE AIR - INTAKE AIR HOSE 14B-5
14. TIGHTEN 3 AIR FILTER COVER RETAINING BOLTS.

14B

I

replacement”)
14B
14B-6 INTAKE AIR - AIR FILTER ASSY
AIR FILTER ASSY

REPLACEMENT
replacement”)

INTAKE AIR - AIR FILTER ASSY 14B-7

NOTE
14B
8. LOOSEN AIR FILTER ASSY INTAKE HOSE CLAMP.
9. RAISE VEHICLE.
10. LOOSEN 2 RETAINING BOLTS FROM AIR FILTER

ASSY.
12. LOOSEN AIR FILTER LOWER COVER KNOB.
14B
13. OPEN AIR FILTER LOWER COVER AND TAKE OUT

AIR FILTER.
(a) When cleaning the air filter, rotate the air filter by hand
MPa.
NOTE
with water.
• Before using the compressed air, wear suitable
14. CLEAN OR REPLACE AIR FILTER.
15. INSTALL AIR FILTER LOWER COVER AND TIGHTEN

KNOB.
16. POSITION AIR FILTER ASSY.
17. TIGHTEN 2 AIR FILTER ASSY RETAINING BOLTS.

18. LOWER VEHICLE.

TIGHTEN CLIPS.
INTAKE AIR - AIR FILTER ASSY 14B-9
20. CONNECT AIR FILTER ASSY INTAKE HOSE AND

TIGHTEN CLAMP.
14B
21. AFTER INSTALLING AIR FILTER, CHECK ALL PARTS AND PARTS CONNECTION AGAIN TO
MAKE SURE ENGINE OPERATES PROPERLY.



Torque: 41 ~ 51 N•m 14B
replacement”)
NOTE
• The clean intake air has a great effect on diesel engine. Do not operate the engine without
installing the air filter.
• Air filter blocking will cause oil leakage from turbocharger. Therefore, the maintenance or
replacement of air filter must be performed periodically.
INTAKE AIR - AIR STRAINING BOX ASSY 14B-11

REPLACEMENT
14B
1. REMOVE 2 INTAKE AIR GRILLE RETAINING BOLTS.

(a) Loosen 6 B-pillar inner guard board retaining bolts.
3. REMOVE AIR FILTER ASSY. (Refer to “Chapter 14B intake air -air filter assy, replacement”)
4. LOOSEN 4 AIR STRAINING BOX RETAINING BOLTS.
14B
14B-12 INTAKE AIR - AIR STRAINING BOX ASSY
5. LOOSEN CLAMP ATTACHING AIR STRAINING BOX

6. REMOVE AIR STRAINING BOX AND CHECK WHETHER THERE IS CRACK.

7. INSTALL AIR STRAINING BOX.
8. TIGHTEN 4 AIR STRAINING BOX RETAINING BOLTS.

9. INSTALL AIR FILTER ASSY. (Refer to “Chapter 14B intake air -air filter assy, replacement”)
10. CONNECT CLAMP ATTACHING AIR STRAINING BOX

INTAKE AIR - AIR STRAINING BOX ASSY 14B-13
11. TIGHTEN 2 INTAKE AIR GRILLE RETAINING BOLTS.
14B
12. POSITION B-PILLAR INNER GUARD BOARD AND

TIGHTEN 6 RETAINING BOLTS.
14B
14B-14 INTAKE AIR - TURBOCHARGER ASSY
TURBOCHARGER ASSY
COMPONENTS
1 Adjustable Nut 10 Compressor Machine
2 Exhaust Valve 11 Intake Hose
3 Rocker Arm 12 Fresh Air
4 Pin 13 Vacuum Hose
5 Exhaust Pipe 14 Compressing Room
6 Turbo Machine 15 Mebrane
7 Turbine Blade 16 Spring
8 Middle Body 17 Push Rod
9 Compressor Blade 18 Exhaust Gas Intake

INTAKE AIR - TURBOCHARGER ASSY 14B-15
MAINTENANCE OF TURBOCHARGER
To ensure work efficiency and reliability of turbo-charged diesel, the turbocharger must be given a
regular maintenance besides the proper operation of the diesel. Turbocharger is a kind of precise
machine with high rotating speed, its maximum speed can reach 180000 r/min and even normal speed 14B
can reach from tens of thousands per minute to hundreds of thousands per minute. Therefore
disassembly is not permitted. If the rotor is hard to rotate or the diesel engine has poor performance
due to excessive dirt or carbon deposits, replace turbocharger parts.
NOTE
Don’t have the impeller collided when replacing the turbocharger. If deformed, the blade can not be
used any more, replace it with a new one. Kerosene, gasoline or diesel oil with high quality can be
used as cleaning agent.
14B
REPLACEMENT
replacement”)
6. LOOSEN 4 EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.
7. LOOSEN TURBOCHARGER AIR INTAKE BELLOW

CLAMP.
14B
8. LOOSEN TURBOCHARGER AND INTAKE CONNECT

PIPE CLAMP.
9. LOOSEN TURBOCHARGER OIL INLET PIPE

RETAINING BOLT.
10. LOOSEN 2 TURBOCHARGER OIL OUTLET PIPE

RETAINING BOLTS.
14B
11. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust -
exhaust manifold, replacement”)
12. LOOSEN 4 BOLTS ATTACHING TURBOCHARGER TO

EXHAUST PIPE.
13. REMOVE GASKET AND REPLACE IT WITH A NEW ONE.
14. LOOSEN 4 BOLTS ATTACHING TURBOCHARGER TO

EXHAUST MANIFOLD.
15. REMOVE GASKET AND REPLACE IT WITH A NEW ONE.

16. REMOVE TURBOCHARGER ASSY.
NOTE
• The valve of open pressure is set by the manufacturer. It is forbidden for user to make any
adjustments for the nut on the push rod. Otherwise, it will seriously damage the engine
performance, oil economy and reliability.
• During the engine operation, if find leakage from lead tracheal or push rod not flexible enough,
please stop the engine and resolve the malfunction at once.
• Neither exhaust valve nor compressing room can be serviced. If damaged, replace the
turbocharger assy.
• Please do not replace the turbocharger unless you find out the malfunction.
17. INSPECT TURBOCHARGER.
(a) Check of rotor’s radial clearance: Press the compressor blades with a hand in radial direction and
measure the minimum clearance between the compressor blade and compressor case with gauge. The
measured value should not be less than 0.10mm, if not, replace the turbocharger assy.
(b) Check of rotor’s axial clearance: Fix a magnetic base on outlet flange facing of turbocharger. Let the
dial indicator touch the rotor spindle, and then push or pull the turbocharger rotor in axial direction to get
a clearance value. The measured value is the clearance value. The rotor’s axial clearance value of new
turbocharger should not be more than 0.1mm and operating limit value should not be more than
0.25mm. If the axial clearance value of turbocharger rotor exceeds the operating limit value, replace the
turbocharger.
(c) Check whether the impeller blades of compressor are damaged. If there is a damage, replace the
turbocharger. If the impeller of compressor is damaged, check whether the inlet pipe and core of filter
are damaged. Repair all damaged parts before running the engine.
(d) Check whether the turbine blades are damaged. If there is a damage, replace the turbocharger.
(e) Check whether there is an abnormal status in linked push rod. If the push rod is bent or excessive
abrasion, replace the turbocharger.
(f) Check whether there is any oil in compressor inlet and outlet of the turbocharger. If there is oil in
compressor inlet and outlet, check the upper parts of turbocharger to find out the source of oil leakage.
NOTE
A little oil and/or mist on the engine of closed crankcase ventilation system is permitted. It will be 14B
discharged into the intake pipe through the crankcase.
18. INSTALL TURBOCHARGER ASSY.
19. TIGHTEN 4 BOLTS ATTACHING EXHAUST

MANIFOLD TO TURBOCHARGER AFTER
INSTALLING A NEW GASKET.
20. TIGHTEN 4 BOLTS ATTACHING EXHAUST PIPE TO

TURBOCHARGER AFTER INSTALLING A NEW GAS-
KET.
21. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust -
22. TIGHTEN 2 TURBOCHARGER OIL OUTLET PIPE

RETAINING BOLTS.
Torque: 7.5 ~ 8.5 N•m
14B
23. TIGHTEN TURBOCHARGER OIL INLET PIPE

RETAINING BOLT.
24. CONNECT THE TURBOCHARGER AIR INTAKE

BELLOW AND TIGHTEN CLAMP.
25. CONNECT THE TURBOCHARGER AND INTAKE

CONNECT PIPE, THEN TIGHTEN CLAMP.
26. TIGHTEN 4 EXHAUST MANIFOLD HEAT SHIELD

RETAINING BOLTS.



14B
replacement”)
14B
14B-22 INTAKE AIR - INTAKE AIR CONNECT PIPE
INTAKE AIR CONNECT PIPE

REPLACEMENT
replacement”)
6. LOOSEN TURBOCHARGER AND INTAKE CONNECT

PIPE CLAMP.
INTAKE AIR - INTAKE AIR CONNECT PIPE 14B-23
7. LOOSEN THE BOLT ATTACHING INTAKE CONNECT

PIPE TO CYLINDER HEAD.
14B
8. LOOSEN 2 BOLTS ATTACHING INTAKE CONNECT

PIPE TO EGR VALVE EXHAUST CONNECT PIPE.
9. REMOVE 2 BOLTS ATTACHING INTAKE CONNECT PIPE

TO INTAKE MANIFOLD.
10. REMOVE INTAKE CONNECT PIPE.

11. REPLACE INTAKE CONNECT PIPE GASKET.
12. TIGHTEN 2 BOLTS ATTACHING INTAKE CONNECT PIPE

TO INTAKE MANIFOLD.
14B
14B-24 INTAKE AIR - INTAKE AIR CONNECT PIPE
13. TIGHTEN 2 BOLTS ATTACHING INTAKE CONNECT PIPE

TO EGR VALVE EXHAUST CONNECT PIPE.
14. TIGHTEN THE BOLT ATTACHING INTAKE CONNECT

PIPE TO CYLINDER HEAD.
15. CONNECT THE TURBOCHARGER AND INTAKE

CONNECT PIPE, THEN TIGHTEN CLAMP.
16. AFTER INSTALLING INTAKE CONNECT PIPE, CHECK ALL PARTS AND PARTS CONNECTION
AGAIN TO MAKE SURE ENGINE OPERATES PROPERLY.


INTAKE AIR - INTAKE AIR CONNECT PIPE 14B-25

14B
replacement”)
14B
14B-26 INTAKE AIR - INTAKE MANIFOLD
INTAKE MANIFOLD
REPLACEMENT
replacement”)
6. LOOSEN 2 BOLTS ATTACHING INTAKE CONNECT PIPE

TO INTAKE MANIFOLD.
INTAKE AIR - INTAKE MANIFOLD 14B-27
7. REMOVE INTAKE MANIFOLD ACCESSORY BOLTS.

(a) Loosen VE dispensing pump vaccum pipe retaining bolt.
(b) Loosen coolant hose bracket retaining bolts.
14B
8. REMOVE 4 FUEL HIGH-PRESSURE PIPES. (Refer to “Chapter 12B fuel- VE dispensing pump,
overhaul”)
9. LOOSEN 8 INTAKE MANIFOLD RETAINING BOLTS.
10. TAKE OFF INTAKE MANIFOLD.

NOTE
Check the intake manifold carefully. If there is groove,
scratch, craze or crank on it, please replace it with a new
one.
11. REMOVE INTAKE MANIFOLD GASKET.

NOTE
Any debris on seal surface will lead to leakage. Use scraper to clean intake manifold gaskete. Be
careful, do not scratch the connection portion of metal surface. 14B
12. INSTALL INTAKE MANIFOLD WITH A NEW GASKET.

14B-28 INTAKE AIR - INTAKE MANIFOLD
13. TIGHTEN 8 RETAINING BOLTS BY HAND FIRST,

THEN TIGHTEN BOLTS FROM MIDDLE TO SIDE
REGULARLY.
14. INSTALL 4 FUEL HIGH-PRESSURE PIPES. (Refer to “Chapter 12B fuel- VE dispensing pump,
overhaul”)
15. INSTALL INTAKE MANIFOLD ACCESSORY BOLTS.

(a) Tighten VE dispensing pump vaccum pipe retaining bolt.
(b) Tighten coolant hose bracket retaining bolts.
16. TIGHTEN 2 BOLTS ATTACHING INTAKE CONNECT

PIPE TO INTAKE MANIFOLD.
17. AFTER INSTALLING INTAKE MANIFOLD, CHECK ALL PARTS AND PARTS CONNECTION AGAIN


INTAKE AIR - INTAKE MANIFOLD 14B-29

14B
replacement”)
14B
MEMO
ENGINE MECHANICAL
15B
ENGINE MECHANICAL PART ........................................................ 15B-1
PRECAUTION............................................................................ 15B-1
ENGINE TECHNICAL PARAMETERS ...................................... 15B-4 15B
ENGINE ASSY ................................................................................. 15B-5
REPLACEMENT ........................................................................ 15B-5
ENGINE ACCESSORY BELT ........................................................ 15B-18
COMPONENTS ....................................................................... 15B-18 15B
ON-VEHICLE INSPECTION .................................................... 15B-19
OVERHAUL ............................................................................. 15B-21
ENGINE TIMING GEAR COVER ................................................... 15B-25
REPLACEMENT ...................................................................... 15B-25
ENGINE TIMING GEAR ................................................................. 15B-30
COMPONENTS ....................................................................... 15B-30
OVERHAUL ............................................................................. 15B-31
CYLINDER HEAD ASSY................................................................ 15B-35
COMPONENTS ....................................................................... 15B-35
OVERHAUL ............................................................................. 15B-36
VALVE / VALVE SPRING .............................................................. 15B-45
OVERHAUL ............................................................................. 15B-45
CAMSHAFT.................................................................................... 15B-51
OVERHAUL ............................................................................. 15B-51
ENGINE BLOCK ............................................................................ 15B-54
COMPONENTS ....................................................................... 15B-54
OVERHAUL ............................................................................. 15B-56
PISTON AND CONNECTING ROD ASSY..................................... 15B-63
COMPONENTS ....................................................................... 15B-63
OVERHAUL ............................................................................. 15B-65
11B
12B
14B
14B
15B
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15B-1

ENGINE MECHANICAL
PRECAUTION
1. EMGINE MECHNANICAL PART PRECAUTION. 15B
(a) Follow the instructions of maintenance methods and regulations to adjust or maintain.
(b) Before starting the engine, check the coolant level, fill or drain the coolant if necessary. check the
engine oil level, fill the engine oil if necessary.
(c) The clearance between ckp sensor and flywheel is 0.5 ~ 1.5 mm. Do not try to adjust it.
(d) Use the oil as requirement. otherwise exacerbate engine wear.
(e) Use the original fittings, otherwise it will damage the engine or affect the engine working condition.
(f) Do not use the high pressure water cannons wash the ecm shell.
(g) The engine starting time should be less than 5s. Not more than 5 consecutive starting times. The
interval time to next starting should not be less than 15 seconds.
(h) Keep the normal coolant temperature 85 ～ 105 ℃ .
(i) When the engine in high speed or high load, do not turn the ignition switch off. Keep the engine running
in low speed for 3~5 mins, so that the engine radiates eventually.
(j) Before opening the radiator cap, ensure the engine is cool.
(k) Use the sealant scraper to clear the sundrise in seal surface. Confirm seal surface flat and smooth, no
pollution and foreign bodies.
(l) Disassembly sequence should be generally from inner to outer, assembly to parts. In order to improve
the efficiency and ensure the assembly and disassembly correct, pay attention to checking and making
mark. Removed parts should be cleaned and inspected. The parts can be reused according to the
classification. Precision parts should be separated with general parts. Put them in clean containers.
(m) Assembly sequence should be from inside to outside, parts to components, components to assembly.
Pay attention to the size, location, clearance, torque, etc. When assembling, avoid the missing,
mistaking, scratching and foreign parts into machine. Assemble bolts, nuts with suitable wrench,
uniform properly. Use anti-losseness device correctly. According to regulations, appropriately use split
cotters, spring washer, thrust washers, etc. In addition, in the assembly process, must pay attention to
the marks to ensure the good position.
(n) Ensure the diesel engine always in the state of complete cleaness. Before removing or assembling,
parts should be cleaned to ensure clean and high quality assembly. More complicated adjustment and
maintenance should be done indoor to prevent diesel engine internal parts from environmental
pollution.
(o) Pay attention to the security when repairing or dismantling. Improper tool or engine starting suddenly
will result in injury.
15B
15B-2 ENGINE MECHANICAL - ENGINE MECHANICAL PART

1. Battery (Low voltage or loose Chapter 20B starting and charging - battery,
connect) precaution
Chapter 12B fuel - VE dispensing pump,

2. VE dispensing pump (Damaged) overhaul
Chapter 20B starting and charging - starter,

3. Starting (Damaged) overhaul
4. Fuel system (Blocked) Chapter 12B fuel - precaution
Engine does not start 6. Fuel supply system (Air inside) Chapter 12B fuel - fuel filter, replacement
7. Fuel injector (Damaged) Chapter 12B fuel - fuel injector, overhaul
Chapter 15B engine mechanical - piston and

8. Piston ring (Worn) connecting rod, overhaul
Chapter 15B engine mechanical - cylinder

9. Valve (Air leaking) head, overhaul
Chapter 15B engine mechanical - timing

10.Engine timing (Incorrect) gear, overhaul
11. Engine Cylinder compressure -

(Lower)
1. Fuel system (Blocked) Chapter 12B fuel - precaution
Chapter 15B engine mechanical - timing gear,

2. Engine timing (Incorrect) overhaul
3. Cylinder head gasket (Air leak- Chapter 15B engine mechanical - cylinder
ing) head, overhaul
Engine loss of power 4. Engine cylinder compressure -

(Lower)
5. Valve (Burned, warped, Chapter 15B engine mechanical - cylinder

excessive clearance) head, overhaul
6. Exhaust system (Blocked) Chapter 16B exhaust - precaution

ENGINE MECHANICAL - ENGINE MECHANICAL PART 15B-3
1. Piston pin and small head bushing Chapter 15B engine mechanical - piston and
hole clearance (Excessive bearing connecting rod, overhaul 15B
clearance)
2. Piston and cylinder sleeve clear- Chapter 15B engine mechanical - piston and
ance (Excessive bearing connecting rod, overhaul
clearance)
Engine noise 3. Connecting rod bearing, main Chapter 15B engine mechanical - piston and
bearing (Excessive bearing connecting rod, overhaul
clearance)
4. Valve and piston (Valve touch Chapter 15B engine mechanical - cylinder
the piston) head and valve, overhaul
5. Intake and exhaust valve Chapter 15B engine mechanical - cylinder

(Excessive clearance) head and valve, overhaul
1. Piston ring (Lock, excessive Chapter 15B engine mechanical - piston and
wear, wrong position) connecting rod, overhaul
Engine exhausts blue 2. Piston and cylinder sleeve clear- Chapter 15B engine mechanical - piston and
vapor ance (Excessive bearing connecting rod, overhaul
clearance)
3. Engine oil (Too much) -
1. Individual cylinder does not -

Engine exhausts white operate
vapor
2. Diesel (Water inside) Chapter 12B fuel - fuel filter, replacement
1. Diesel engine overload Chapter 15B engine mechanical - precaution
Chapter 15B engine mechanical - cylinder

2. Valve (Excessive clearance) head and valve, overhaul
Engine exhausts black Chapter 14B intake air - intake air filter,
vapor 3. Intake air filter (Blocked) replacement
Chapter 13B emission control - EGR valve,

4. EGR valve (Damaged) replacement
5. Injector solenoid valve (Damaged) Chapter 12B fuel - fuel injector, overhaul
15B
15B-4 ENGINE MECHANICAL - ENGINE MECHANICAL PART

Engine BJ493ZQ-13Ke
4 cylinder in-line, water cooling, 4 stroke, turbocharging, electronic

Engine Type
control EGR
Chamber Type Direct injection ω type
Cylinder Bore 93 mm
Stroke 102 mm
Compression Ratio 17.4:1
Rated Power 70/3600 Kw/r/min
Maximum Torque 225 ≤ 2300 N•m/r/min
Minimum Fuel Consumption ≤ 222 g/kW•h
Crankshaft Direction Of Rotation Counterclockwise

ENGINE MECHANICAL - ENGINE ASSY 15B-5
ENGINE ASSY
REPLACEMENT
NOTE 15B
• Before lifting the vehicle, ensure the support position on the vehicle correctly.
• Turn the ignition switch off and lock the steering column assy.
• Use the fender protect cover to avoid damaging paint surface.
• Avoid damaging, hold the head of the connector and carefully connect wire.
• Mark in all wires and hoses, and confirm not touch with the other wires or hoses, or interfered
with other parts.
• Drain coolant. (Refer to “Chapter 17B cooling - coolant, replacement”)


NOTE
Disconnect the negative cable firstly when removal.

15B
replacement”)
15B-6 ENGINE MECHANICAL - ENGINE ASSY
8. REMOVE AIR INTAKE BELLOW HOSE.

(a) Loosen turbocharger intake air hose and air filter bellow
hose clip.
(b) Disconnect crankcase breather hose clip.
(c) Remove air intake bellow hose.
9. DISCONNECT VE DISPENSING PUMP FUEL INLET/

OUTLET HOSE.
NOTE
the fuel hose. 15B


connection.
connection.
12. DRAIN STEERING FLUID, DISCONNECT STEERING

FLUID RESERVOIR INLET/OUTLET HOSE.
NOTE
15B
Do not splash the steering fluid on the engine parts, clean
the fluid immediately.
13. DISCONNECT POWER STEERING PUMP HIGH-PRES-

SURE PIPE.
14. DISCONNECT VACCUM REGULATOR CONNECTOR

AND VACCUM HOSES.
NOTE
Mark the hose connect position, avoid mistake when install-
ing.
15. DISCONNECT RADIATOR UPPER COOLANT HOSE.
16. DISCONNECT HEATER INLET/OUTLET HOSES ON

THE VEHICLE.

18. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
19. REMOVE BOLTS ATTACHING A/C PIPE TO A/C

15B
COMPRESSOR.
NOTE

21. RAISE VEHICLE TO TOP PLACE.
22. REMOVE THE FRONT WHEEL. (Refer to “ Chapter 33 tire and wheel - front tire and wheel,
replacement”)
23. REMOVE STRUT ROD. (Refer to “Chapter 31 front suspension- strut rod, replacement”)
24. REMOVE 2 BOLTS ATTACHING TURBOCHARGER

TAIL PIPE TO EXHAUST PIPE.
replacement”)
26. REMOVE STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy, replacement”)
28. DISCONNECT FOLLOWING ELECTRICAL CONNECTORS.
• Accelerator Position Sensor
• Fuel Cut Solenoid Valve
• Speed Sensor 15B
• Generator
• Electronic Control EGR Valve
• EGR Vaccum Regulator
• Generator
• Generator Positive Terminal
• Glow Plug
• Fuel/Water Seperator
• ECT Sensor
• Instrument Temperature Sensor
• ECM
• Vehicle Speed Sensor
• A/C Compressor Solenoid Switch
• Starter Positive Terminal
• Cooling Fan
• Cooling Fan Temperature Sensor
30. REMOVE NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
31. REMOVE BOLTS ATTACHING SUB-FRAME TO VEHICLE

BODY AND TAKE AWAY SUB-FRAME.
NOTE
Before removing front sub-frame, mark the sub- frame and
sub-frame retaining bolts.
34. LOWER ENGINE ABOUT 150 MM SLOWLY. VERIFY ALL COMPONENTS BETWEEN THE ENGINE/
TRANSMISSION AND VEHICLE ARE DISCONNECTED AGAIN.
35. REMOVE ENGINE WITH TRANSMISSION ABOVE VEHICLE.
36. REMOVE BOLTS ATTACHING ENGINE TO SUB-

FRAME AND SEPARATE THEM.
37. REMOVE STARTER RETAINING BOLTS AND SEPARATE

15B
38. REMOVE BOLTS ATTACHING ENGINE TO TRANSMISSION

40. REMOVE ENGINE ACCESSORY BELT. (Refer to “Chapter 15B engine mechanical - engine
41. REMOVE GENERATOR RETAINING BOLTS AND

SEPARATE GENERATOR FROM BRACKET.
15B
42. REMOVE BOLTS ATTACHING A/C COMPRESSOR TO ENGINE AND TAKE AWAY A/C COMPRESSOR.
(Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)

44. TIGHTEN A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air conditioning
- compressor, overhaul”)
45. TIGHTEN CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
46. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15B engine mechanical - engine



FRAME.
15B
50. INSTALL ENGINE WITH TRANSMISSION FROM BOTTOM OF VEHICLE, INSTALL ENGINE LIFT
CHAIN HANGERS.

VEHICLE BODY.
Torque: 205 ~ 215 N•m
NOTE
52. TIGHTEN NUTS ATTACHING TRANSMISSION MOUNT

TO VEHICLE BODY.
Torque: 110 ~ 130 N•m
53. TIGHTEN 2 BOLTS ATTACHING TURBOCHARGER

TAIL PIPE TO EXHAUST PIPE.
15B
replacement”)
55. INSTALL STRUT ROD. (Refer to “Chapter 31 front suspension- strut rod, replacement”)
56. INSTALL STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
replacement”)

COMPRESSOR.
NOTE

HOSES.
62. CONNECT HEATER INLET/OUTLET HOSES.
63. CONNECT RADIATOR UPPER COOLANT HOSE AND

TIGHTEN CLAMP.
64. CONNECT RADIATOR LOWER COOLANT HOSE AND

TIGHTEN CLAMP.
15B
65. CONNECT STEERING FLUID RESERVOIR INLET/OUTLET

HOSE.
66. INSTALL POWER STEERING PUMP HIGH-PRESSURE

PIPE.

PIPELINE CONNECTOR.
15B

CONNECTION.
connection.
connection.
70. LOWER VEHICLE.
71. CONNECT VE DISPENSING PUMP FUEL INLET/OUT-

LET HOSE.
72. CONNECT FOLLOWING ELECTRICAL CONNECTORS:

• Speed Sensor
• Generator
• Generator
• Glow Plug
• ECT Sensor
• ECM
• Cooling Fan
• Cooling Fan Temperature Sensor
75. FILL CLUTCH/BRAKE FLUID.

(a) Connect turbocharger intake air hose and air filter bellow
hose then tighten the clip.
(b) Connect crankcase breather hose and tighten the clip. 15B


replacement”)
15B
15B-18 ENGINE MECHANICAL - ENGINE ACCESSORY BELT

COMPONENTS
1 Generator Assy Power Steering Pump Belt Tensioning Idle

5
Pulley
2 A/C Compressor Assyy
6 Power Steering Pump Pulley
3 Coolant Pump Pulley
7 Crankshaft Pulley
A/C Compressor Belt Tensioning Idle
4
Pulley
ENGINE MECHANICAL - ENGINE ACCESSORY BELT 15B-19
replacement”)
15B
7. INSPECT ENGINE ACCESSORIES. INSPECT EACH PART
OF ENGINE ACCESSORIES CAREFULLY, IF FIND ANY
DAMAGE AS FOLLOWING, REPLACE WITH A NEW ONE.
(a) Inspect the belt back rubber for signs of aging and
glistening.

(e) Cracks in the side of the belt.
(f) Inspect the belt for abnormal abrasion in the side of the
belt.
(g) Timing belt for abnormal abrasion.

OVERHAUL
A/C COMPRESSOR BELT
1. COOL ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE 15B
NORMAL TEMPERATURE.
2. REMOVE POWER STEERING PUMP BELT. (Refer to “Chapter 15B engine mechanical - engine
3. LOOSEN A/C COMPRESSOR IDLE PULLEY TEN-

SIONER BOLT.
NOTE
Loosen, do not remove.
4. REMOVE A/C COMPRESSOR BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.

5. INSTALL A/C COMPRESSOR BELT.
6. TIGHTEN AND ADJUST A/C COMPRESSOR IDLE

PULLEY TENSIONER BOLT.

MOVE SPACE.
Item Deflection

15B
8. INSTALL POWER STEERING PUMP BELT. (Refer to “Chapter 15B engine mechanical - engine
POWER STEERING PUMP BELT

1. COOL ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE
NORMAL TEMPERATURE.
2. LOOSEN POWER STEERING PUMP IDLE PULLEY

TENSIONER BOLT.
NOTE
Just loosen, do not remove.
3. REMOVE POWER STEERING PUMP BELT AND CHECK CRACK, REPLACE IT IF NECESSARY.
4. INSTALL POWER STEERING PUMP BELT.
5. TIGHTEN AND ADJUST POWER STEERING PUMP

IDLE PULLEY TENSIONER BOLT.
6. PRESS 98 N TO MIDDLE OF BELT AND CHECK MOVE

SPACE.
Item Deflection

GENERATOR BELT
1. COOL ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO NORMAL
TEMPERATURE.
2. REMOVE POWER STEERING PUMP BELT. (Refer to “Chapter 15B engine mechanical - engine 15B
3. REMOVE A/C COMPRESSOR BELT. (Refer to “Chapter 15B engine mechanical - engine
4. LOOSEN BOLT ATTACHING GENERATOR TO GENERATOR

BRACKET.
NOTE
5. LOOSEN GENERATOR TENSIONER LOCK NUT.

NOTE
6. INSPECT EACH PART OF GENERATOR BELT CAREFULLY, IF FIND ANY DAMAGE, REPLACE
WITH A NEW ONE.
7. POSITION GENERATOR BELT.
8. USING PRY BAR，MOVE GENERATOR AND TIGHTEN

GENERATOR LOCK UNT.
15B
9. TIGHTEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.

DEFLECTION.
Item Deflection
New belt 6 ~ 7 mm
Used belt 7 ~ 8 mm
12. INSTALL POWER STEERING PUMP BELT. (Refer to “Chapter 15B engine mechanical - engine
13. INSTALL A/C COMPRESSOR BELT. (Refer to “Chapter 15B engine mechanical - engine
ENGINE MECHANICAL - ENGINE TIMING GEAR COVER 15B-25
ENGINE TIMING GEAR COVER

REPLACEMENT
15B
replacement”)
6. DISCONNECT UPPER RADIATOR COOLANT HOSE. 15B
15B-26 ENGINE MECHANICAL - ENGINE TIMING GEAR COVER
8. REMOVE IDLE PULLEY TENSIONER RETAINING BOLT.
9. REMOVE 4 COOLANT PUMP PULLEY RETAINING

BOLTS.
11. REMOVE ENGINE TIMING GEAR OUTSIDE COVER

RETAINING BOLTS.
12. REMOVE ENGINE TIMING GEAR OUTSIDE COVER.
13. REMOVE TIMING GEAR OUTSIDE COVER GASKET.

14. REMOVE TIMING GEAR COVER RETAINING BOLTS.
15B
15. USING A SCREWDRIVER, PRY OUT TIMING GEAR

COVER LIGHTLY.
NOTE
The timing gear cover is seal by sealant, position on loca-
tion pin. Do not remove the timing gear cover forcibly.
16. USING SCRAPER, CLEAR SEALANT ON TIMING GEAR COVER CONNECT SURFACE.
17. APPLY NEW SEALANT TO TIMING GEAR COVER EQUALITY.
18. INSTALL TIMING GEAR COVER RETAINING BOLTS.

15B
19. INSTALL TIMING GEAR OUTSIDE COVER GASKET.

15B-28 ENGINE MECHANICAL - ENGINE TIMING GEAR COVER
20. INSTALL TIMING GEAR OUTSIDE COVER RETAIN-

ING BOLTS.
21. TIGHTEN 4 COOLANT PUMP PULLEY RETAINING

BOLTS.
22. TIGHTEN CRANKSHAFT PULLEY RETAINING BOLTS.

Torque: 260 ~ 300 N•m
24. INSTALL IDLE PULLEY TENSIONER RETAINING BOLT.
25. CONNECT UPPER RADIATOR COOLANT HOSE.


15B

replacement”)
15B
15B-30 ENGINE MECHANICAL - ENGINE TIMING GEAR
ENGINE TIMING GEAR

COMPONENTS
1 Camshaft Timing Gear 4 Upper Idle Gear
2 Lower Idle Gear 5 VE Dispensing Pump Timing Gear
3 Lubricate Rail 6 Crankshaft Timing Gear

ENGINE MECHANICAL - ENGINE TIMING GEAR 15B-31
OVERHAUL
1. REMOVE ENGINE TIMING GEAR COVER. (Refer to “Chapter 15B engine mechanical - engine
timing gear cover, replacement”)
15B
2. INSTALL CRANKSHAFT PULLEY BOLT, ROTATE BOLT
AND ALIGNED TIMING MARKS.
3. REMOVE LUBRICATE RAIL RETAINING BOLTS.
4. REMOVE TIMING GEAR TRAIN.

(a) Remove camshaft timing gear retaining bolt.
(b) Remove lower idle gear retaining bolt.
15B
(c) Remove upper idle gear retaining bolt.
(d) Remove VE dispensing pump timing gear retaining bolt.
(e) Remove the crankshaft timing gear directly.
5. CHECK TIMING GEAR.

NOTE
• Can not exist missing teeth, interface galling, pitting corrosion.
• The upper and lower idle pulley should turn smoothly.
6. INSTALL TIMING GEAR TRAIN.

(a) According to the keyway on the camshaft, install the
camshaft timing gear.
ENGINE MECHANICAL - ENGINE TIMING GEAR 15B-33
(b) According to the keyway on the crankshaft, install the

crankshaft timing gear.
15B
(c) Install the lower idle gear according to the timing marks
on camshaft timing gear and crankshaft timing gear.
(d) According to the timing mark on lower idle gear, install

the upper idle gear.
(e) According to the timing mark on upper idle gear, install

VE dispensing pump timing gear.
15B
7. MAKE SURE ALL TIMING MARKS ALIGNMENT.

(a) Please confirm the following timing marks:
• The “Y-Y”mark on camshaft timing gear align with the
“Y”mark on lower idle gear.
• The “X-X”mark on crankshaft timing gear align with the
“X”mark on the lower idle gear.
• The “Z-Z”mark on lower idle gear align with the “Z”mark
on the upper idle gear.
• The “V-V”mark on upper idle gear align with the “V”mark
on the VE dispensing pump.
8. INSTALL ENGINE TIMING GEAR COVER. (Refer to “Chapter 15B engine mechanical - engine
ENGINE MECHANICAL - CYLINDER HEAD ASSY 15B-35
CYLINDER HEAD ASSY

COMPONENTS
15B
1 Valve Spring Lock 11 Cylinder Head Cover Gasket
2 Upper Valve Spring Retainer 12 Oil Filling Cap
3 Valve Spring 13 Cylinder Head Cover
4 Valve Oil Seal 14 Rocker Arm And Rocker Shaft Assy
5 Lower Valve Spring Retainer 15 Cylinder Head Bolt
6 Exhaust Valve 16 Cylinder Head Bolt (With Groove)
7 Intake Valve 17 Fuel Injector Pressure Plate Bolt

15B
8 Rear Engine Lifting Hook 18 Fuel Injector Pressure Plate
9 Front Engine Lifting Hook 19 Fuel Injector Pressure Plate Block
10 Cylinder Head Cover Bolt

15B-36 ENGINE MECHANICAL - CYLINDER HEAD ASSY
OVERHAUL
replacement”)
6. REMOVE INTAKE AIR CONNECT PIPE. (Refer to “Chapter 14B intake air - intake air connect
pipe, replacement”)

HEATER HOSES.
15B
9. REMOVE 3 CYLINDER HEAD COVER RETAINING

BOLTS.
10. DISCONNECT CRANKCASE BREATHER HOSE.
15B
11. REMOVE INTAKE MANIFOLD. (Refer to “Chapter 14B intake air - intake manifold, replacement”)
12. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGE ASSY. (Refer to “Chapter 16B exhaust -
13. REMOVE FUEL INJECTORS. (Refer to “Chapter 12B fuel - fuel injector, overhaul”)
14. REMOVE A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor,
replacement”)
15. REMOVE 4 ROCKER ARM AND ROCKER SHAFT

ASSY RETAINING BOLTS.
16. REMOVE ROCKER ARM AND ROCKER SHAFT ASSY.
17. REMOVE 8 VALVE PUSH RODS.
18. REMOVE HEATER PLUG.
19. REMOVE CYLINDER HEAD BOLTS IN SEQUENCE AS

SHOWN.
NOTE
The 4 cylinder head retaining bolts at intake manifold side
are with groove.
20. REMOVE CYLINDER HEAD ASSY.
15B
21. REMOVE CYLINDER HEAD GASKET.


GAUGE.
Standard: 0.05 mm
Limit: 0.2 mm
NOTE
• If the service limit is exceeded, grind to meet specification.
• Grind limit: 0.2 mm (0.2 mm includes combination with
cylinder block grinding)
• Cylinder head height (new specification): 91.95 ~ 92.05
mm
• Check the cylinder head whether corroded underside，
replace with a new cylinder head if find.
24. CHOOSE A SUITABLE CYLINDER HEAD GASKET.

15B
(a) Carefully clear the carbon deposition and residue on the top of piston and surface of cylinder head.
(b) Position a micrometer caliper on the top of piston.

(c) Measure the piston protruding length. Measure it on

point (1) (3) on piston top and point (2) (4) on engine
block. Each piston need be measured.
(d) Record the highest measured values. This value will

determine the thickness of the cylinder head gasket. The
piston protruding length is 0.700 ~ 1.000 mm, divided
into three groups of the four piston protruding length of
the engine in one group. If the length is out of specifica-
tion, replace the piston connecting rod according to the
chart below.
Cylinder Head Gasket Mark Piston Protruding Length Cylinder Head Gasket Thinkness
One Gap 0.700 ~ 0.800 mm 1.60 mm
Two Gaps 0.801 ~ 0.900 mm 1.65 mm
Three Gaps 0.901 ~ 1.000 mm 1.70 mm

CAUTION
mark on the gasket, align the water and oil way. Otherwise it
will damage the engine.
27. POSITION CYLINDER HEAD ASSY.

NOTE
The cylinder head bolt only can be uesd for twice, replace a
new one after using twice.
15B
28. CYLINDER HEAD BOLTS SHOULD BE INSTALLED AND

TIGHTENED IN ORDER AS SHOWN.
NOTE
The 4 cylinder head retaining bolts at intake manifold side
are with groove.
Tighten steps:
(a) Tighten the bolts to 35 N·m.
(b) Completely loosen the bolts.
(c) Retighten the bolts to 30 ~ 35 N·m.
(d) Tighten the bolts an additional 60° ~ 180°.
29. INSTALL 8 VALVE PUSH RODS.
30. INSTALL HEATER PLUG.
15B
31. INSTALL ROCKER ARM AND ROCKER SHAFT ASSY.
NOTE
When installing the rocker arm and rocker shaft assy,
32. TIGHTEN ROCKER ARM AND ROCKER SHAFT ASSY

RETAINING BOLTS.
NOTE
Rocker arm and rocker shaft assy retaining bolts should be
installed and tightened in order as shown. Before tightening
the bolts, loosen the valve adjustment bolt to avoid damaging
the valve, push rod, camshaft and rocker arm.
33. INSTALL 3 CYLINDER HEAD COVER RETAINING

BOLTS.
15B

HEATER HOSES.
35. CONNECT CRANKCASE BREATHER HOSE.
15B
36. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14B intake air - intake manifold, replacement”)
37. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGE ASSY. (Refer to “Chapter 16B exhaust -
38. INSTALL FUEL INJECTORS. (Refer to “Chapter 12B fuel - fuel injector, overhaul”)
39. INSTALL A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor,
replacement”)
40. INSTALL INTAKE AIR CONNECT PIPE. (Refer to “Chapter 14B intake air - intake air connect


replacement”)
ENGINE MECHANICAL - VALVE / VALVE SPRING 15B-45
VALVE / VALVE SPRING

OVERHAUL
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15A engine mechanical - cylinder head, 15B
overhaul”)
2. USING PROPER TOOL, COMPRESS VALVE SPRING

AND REMOVE VALVE SPRING LOCK.

NOTE
Store removed valves, spring and other parts, tag to indicate their cylinder number and location for
assembly.

(a) Check the valve spring free length/height， discard the
Standard: ≤ 2°
15B

NOTE
15B-46 ENGINE MECHANICAL - VALVE / VALVE SPRING

7. REMOVE VALVE AND CHECK IT.
(b) Check valve work surface, such as burn or wear, replace with a new one if necessary.
When the valves and valve seat wear lighting, use manual polishing method to recover. The method is
as follows: firstly, remove valve, the valve seat catheter and coke, then in the valve cone are coated
with a thin layer of valve sand. Use the eraser bowl with wooden valve flap to absorb, combined with
the method of rotating and grinding. Each rotation is not more than 90°, until the valve cone appears a
well-balanced without burnish band width for 1.5 ~ 2 mm. Too wide band is harm for seal. Too narrow,
against heat dissipation, the valve will burned for high temperature. Sand has the different in thick and
thin. According to the wear and ablation of choice.
(c) Chenck the valve tightness.

• Using pencil, draw 8 ~ 12 marks on the valve work
surface, tap the valve with the valve seat (do not rotate
(d) Measure the valve diameter.
Item Standard
Intake Valve 7.946 ~ 7.961 mm
Exhaust Valve 7.921 ~ 7.936 mm
(e) Measure valve stem diameter and valve guide inner


Intake Valve 0.039~0.071 mm 0.20 mm
Exhaust Valve 0.064~0.096 mm 0.25 mm
8. HEAT CYLINDER HEAD AND REMOVE VALVE SEAT.

9. USING A PRESSOR, PUSH VALVE GUIDE OUT TOWARD THE CYLINDER BLOCK SIDE.
10. REBORE THE VALVE GUIDE HOLE IN THE CYLINDER HEAD TO MATCH THE OVERSIZE VALVE
GUIDE THAT IS TO BE FITTED.
Valve Guide Hole Diameter

15B
0.05 oversize 11.05~11.068 mm
0.25 oversize 11.25~11.268 mm
0.50 oversize 11.50~11.518 mm
NOTE
Do not install a valve guide of the same size again.
11. THE VALVE GUIDE MUST BE INSTALLED FROM UPPER SIDE OF CYLINDER HEAD.
12. AFTER INSTALLING VALVE GUIDE, CHECK VALVE SEAT INNER DIAMETER.
Standard: 8.000 ~ 8.017 mm
13. AFTER INSTALLING VALVE GUIDE, INSERT A NEW VALVE AND CHECK IT SLIDES SMOOTHLY.
14. FOLLOW THE MARK BEFORE REMOVAL TO INSTALL VALVE.
16. USING A PROPER TOOL, INSTALL NEW VALVE OIL SEAL.

NOTE
IMPROPER INSTALLATION WILL CAUSE OIL LEAKAGE.

NOTE
19. USING PROPER TOOL, INSTALL VALVE SPRING

LOCKER.
15B
20. INSTALL CYLINDER HEAD. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
21. ADJUST VALVE CLEARANCE.

(a) When the engine is cool, the intake valve clearance and the exhaust valve clearance is 0.35 ~ 0.45
mm. If excessive clearance, it will close lax. If the clearance is less than standard, it will damage the
valve.
(b) Rotate the crankshaft to NO.1 cylinder in compression
stroke BTDC. The crankshaft pulley first mark align to the
mark on engine timing cover, and the NO.1 cylinder
intake and exhuast valve are closed.
(c) Adjust the valve clearance as shown.
(d) Set the valve clearance feeler gauge into rocker arm and
valve top which need adjusting. Loosen the rocker arm
retaining bolt and rotate the adjustment screw until the
feeler guage moves out of nimbleness, then tighten the
rocker arm retaining bolt.
(e) After adjusting the valve clearance above, rotate the

crankshaft 360°. NO.4 cylinder is in compression stroke
BTDC. Adjust the valve clearance as shown in the same
way.
22. INSTALLE 3 CYLINDER HEAD COVER RETAINING

BOLTS.
15B
23. CONNECT CRANKCASE BREATHER HOSE.

15B


replacement”)
ENGINE MECHANICAL - CAMSHAFT 15B-51
CAMSHAFT
OVERHAUL
NOTE 15B
BJ493ZQ diesel engine is adopted camshaft in the middle block.
1. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
2. ROTATE CRANKSHAFT, MAKE TIMING MARK “Y”

ON LOWER IDLE GEAR ALIGN WITH “Y-Y” ON
CAMSHAFT TIMING GEAR.
3. REMOVE CAMSHAFT TIMING GEAR RETAINING BOLT.
4. REMOVE CAMSHAFT TIMING PULLEY.
5. REMOVE CAMSHAFT THRUST PLATE RETAINING

BOLT.
15B

15B-52 ENGINE MECHANICAL - CAMSHAFT
(a) Measure the camshaft base diameter.
Base diameter: 35.5 mm
(b) Measure the camshaft follower lift.
Maximum: 6.511 mm
9. USING A BUSHING PULLER, REMOVE CAMSHAFT JOURNAL BUSHING.

(a) If there any wear or flaw on the camshaft journal bushing, replace the camshaft bushing.
10. USING A PROPER TOOL, INSTALL NEW BUSHING.
NOTE
• When installing the bushing, align the oil hole on camshafe journal bushing with the oil hole on
engine block.
• The diameter after installing the bushing is 50.010 ~ 50.035 mm.
• Check the clearance between camshaft journal bushing and camshaft journal.
Standard: 0.025 ~ 0.085 mm
Limit: 0.12 mm
• If excessive limit clearance, relpace the camshaft.
12. USING A PROPER TOOL, INSTALL CAMSHAFT OIL

SEAL.
ENGINE MECHANICAL - CAMSHAFT 15B-53
13. INSATLL CAMSHAFT THRUST PLATE AND RIGHTEN

RETAINING BOLTS.
15B
14. TIGHTEN CAMSHAFT TIMING GEAR RETAINING BOLTS.

15. ACCORDING TO TIMING MARK BEFORE REMOVAL,

ENSURE CAMSHAFT KEYWAY POSITION, INSTALL
CAMSHAFT TIMING GEAR CORRECTLY.
16. ENSURE TIMING MARK ON CANSHAFT ALIGN WITH LOWER IDLE GEAR TIMING MARK.
17. INSTALL ENGINE TIMING GEAR COVER. (Refer to “Chapter 15B engine mechanical - engine
15B
15B-54 ENGINE MECHANICAL - ENGINE BLOCK
ENGINE BLOCK
COMPONENTS
ENGINE MECHANICAL - ENGINE BLOCK 15B-55
1 Engine Block Vacuum Pump Fuel Supply Line

14
Connector
2 Round Pin
15 Coolant Drain Plug
3 Upper Crankshaft Bearing 15B
16 Oil Return Pipe
4 Lower Crankshaft Bearing
17 Location Pin
5 Fifth Main Bearing Cap
18 Cylinder Head Gasket
6 Third Main Bearing Cap
19 Cylinder Sleeve
7 First ,Second, Fourth Main Bearing Cap
20 Rear Engine Block Cover
8 Main Bearing Cap Bolt
21 Rear Crankshaft Oil Seal
9 Crankshaft Thrust Bearing
22 Plug
10 Front Camshaft Journal Bushing
23 Left Bracket
11 Middle Camshaft Journal Bushing
24 Engine Oil Pressure Switch Seat
12 Oil Plug
25 Engine Oil Pressure Switch
13 Right Bracket
15B
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replace-
ment”)
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
3. REMOVE ENGINE TIMING GEAR. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
4. REMOVE OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
5. REMOVE OIL STRAINER AND OIL PUMP. (Refer to “Chapter 18 B lubrication - oil pump, over-
haul”)

relieve completely.

BOLTS.
10. USING PROPER TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
15B
11. ROTATE ENGINE BLOCK AND MAKE OIL PAN PART UP.
12. REMOVE MAIN BEARING CAP BOLTS IN ORDER AS

SHOWN.
NOTE
Avoid installing error, there are mark number such as "1","2"
on the connecting rod cap. The arrow on the crankshaft main
bearing cap forward crankshaft pulley.
15B
14. DISASSEMBLE UPPER CRANKSHAFT BEARING
AND THRUST BEARING ON THIRD CRANKSHAFT
JOURNAL.
15. INSPECT THRUST BEARING, THERE SHOULD BE

NO SERIOUS WEAR, GALLING, PITTING.
16. TAKE ENGINE BLOCK OFF FROM FLIP FRAME AND

INSPECT IT.
(a) Visually check for scratches, rust, and corrosion. Use a
flaw detecting agent for the check as well. If defects are
found, correct or replace it.
(b) Use a straightedge and feeler gauge, check the block top
surface for warpage. Make sure that the surface is free
from gasket chips and other foreign matters.
(c) If the warpage is excessive, correct it within the allowable
limit or replace.
Grinding limit: 0.2 mm
(d) The cylinder walls should be checked for out-of-round
cylinder walls are badly scuffed or scored, the cylinder
block should be replaced and install new pistons and
rings.

ROD BIG END FOR CORRECT ASSEMBLING.
NOTE
18. REMOVE CONNECTING ROD CAP NUTS IN ORDER

AS SHOWN.

AND CONNECTING ROD ASSY OUT THROUGH
CYLINDER HEAD SIDE OF ENGINE BLOCK.
15B
20. REMOVE CRANKSHAFT.
21. PRESS CYLINDER SLEEVE TOWARD CYLINDER

HEAD DIRECTION.
22. MEASURE CYLINDER BORE AT THREE LEVELS IN

DIRECTIONS A AND B. TOP MEASUREMENT SHOULD
BE 12 MM DOWN AND BOTTOM MEASUREMENT
SHOULD BE 12 MM UP FROM BOTTOM OF BORE.
Standard:
Cylinder size: 95.001 ~ 95.030 mm
Cylinder cylindrically: ≤ 0.01 mm
23. CHOOSE CYLINDER SLEEVE ACCORDING TO CYLINDER SIZE.

15B
Item Group 0 Group 1 Group 2 Group 3 Group 4
94.991~ 95.001~ 95.011~ 95.021~ 95.031~
Cylinder Size
95.000 mm 95.010 mm 95.020 mm 95.030 mm 95.040 mm
Cylinder Sleeve 95.001~ 95.011~ 95.021~ 95.031~ 95.041~

Outer Diameter 95.010 mm 95.020 mm 95.030 mm 95.040 mm 95.050 mm
24. MESURE MAIN BEARING INNER DIAMETER, CHOOSE SUITABLE BEARING BUSHING.
Group Number Bearing Inner Diameter Suitable Bearing Thickness

1 73.991~74.000 mm 2.002~2.006 mm
2 73.983~73.990 mm 2.006~2.010 mm
3 73.975~73.982 mm 2.010~2.014 mm
25. USING PROPER TOOL, PRESS CORRECT CYLINDER SLEEVE TO ENGINE BLOCK.
26. INSTALL PISTON AND CONNECTING ROD ASSY. (Refer to “Chapter 15B engine mechanical -
piston and connecting rod, overhaul”)
27. INSTALL MAIN BEARING AND THRUST BEARING.

(a) Install the main bearings with oil grooves on the cylinder
block side.
(b) Install the main bearings without oil grooves on the
bearing cap.
(c) Install the 2 thrust bearings on crankshaft journal No.3.

NOTE
Install the main bearing caps with the arrow on the main
29. INSTALL THE MAIN BEARING CAP BOLTS.

(a) Apply clean engine oil to the threaded portion bearing surface of the bolt.
(b) Tighten the bearing cap bolts in sequence as shown.
Torque:
First tighten the bolts: 40 ~ 50 N•m
Second tighten the bolts: 90 ~ 100 N•m
Third tighten the bolts: 160 ~ 180 N•m
30. USING PROPER TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.
15B
31. TIGHTEN REAR ENGINE BLOCK COVER RETAINING

BOLTS.
32. TIGHTEN 8 FLYWHEEL RETAINING BOLTS DIAGONALLY.

Torque: 113 ~ 133 N•m
33. INSTALL CLUTCH PRESSURE PLATE AND TIGHTEN

BOLTS.
Torque: 35 N•m
NOTE
15B
34. INSTALL OIL STRAINER AND OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump, overhaul”)
35. INSTALL OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”)
36. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
37. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
38. INSTALL ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replacement”)
ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY 15B-63
PISTON AND CONNECTING ROD ASSY

COMPONENTS
15B
1 Crankshaft Pulley Bolt 5 Crankshaft
2 Crankshaft Pulley 6 Piston And Connecting Rod Assy
3 Crankshaft Timing Pulley 7 Flywheel
4 Crankshaft Flat Key 8 Flywheel Bolt
15B
15B-64 ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY
1 No.1 Compression Ring 6 Connecting Rod
2 No.2 Compression Ring 7 Piston Pin
3 Oil Control Ring 8 Piston Pin Snap Spring
4 Piston 9 Connecting Rod Nut
5 Connecting Rod Bolt 10 Connecting Rod Bearing

OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replace-
ment”)
15B
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
3. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
5. REMOVE OIL PUMP AND OIL STRAINER. (Refer to “Chapter 18B lubrication - oil pump,
replacement”)
6. FIXING ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLE IT.

relieve completely.
9. REMOVE REAR ENGINE BLOCK COVER RETAINING 15B

BOLTS.
10. USING PROPER TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
11. ROTATE ENGINE BLOCK AND MAKE OIL PAN UP.
12. REMOVE CRANKSHAFT MAIN BEARING CAP BOLTS

IN ORDER AS SHOWN.

ASSEMBLING.
NOTE
14. REMOVE CONNECTING ROD CAP NUTS IN ORDER

AS SHOWN.
15. USING A HAMMER HANDLE OR SIMILAR TOOL, PUSH

PISTON AND CONNECTING ROD ASSY OUT THROUGH
THE CYLINDER HEAD SIDE OF ENGINE BLOCK.
15B
16. REMOVE CRANKSHAFT AND INSPECT CRANKSHAFT

MAIN JOURNALS.
(a) Check for excessive wear, roundness and scoring. If
found, check the oil hole pluged or not.
(b) Limits of out of round on any crankshaft journals should
be held to less than 30 g•cm.
Crankshaft main journals: 69.932 ~ 69.917 mm
HAND.
NOTE
Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder
number.

NOTE
(b) Check the piston ring for damage, excessive wear, and breakage. Replace it if defects are found. If the
piston has been replaced with a new one, the piston rings must also be replaced with a new one.
(c) Check piston ring to groove side clearance.If the limit is

15B

Standard 0.078 ~ 0.137 mm 0.045 ~ 0.090 mm 0.030 ~ 0.070 mm
Limit 0.20 mm 0.15 mm 0.15 mm



Standard 0.20 ~ 0.40 mm 0.60 ~ 0.85 mm 0.35 ~ 0.65 mm
Limit 0.8 mm 1.5 mm 1.2 mm

Standard 3.70 ~ 4.00 mm 3.75 ~ 4.05 mm 3.25 ~ 3.50 mm
21. USING SNAP RING PLIERS, REMOVE PISTON PIN

SNAP RING.
22. CHECK SNAP RING, THERE SHOULD BE NO CRACK, WOUND. WHEN INSTALLING, SNAP RING
OPENING SHOULD STAGGER WITH NOTCH ON PISTON TOP.
23. USING A PRESSURE MACHINE, PUSH PISTON PIN

OUT.
15B
24. CHECK DIAMETER OF PISTON PIN BORE, AND

Item Specification
Piston Pin Bore Diameter 34.002 ~ 34.010 mm
Piston Pin Outer Diameter 33.994 ~ 34.000 mm
Piston Pin Bore And Piston Pin Clearance 0.002 ~ 0.015 mm
Wear Limit 0.03 mm
25. CHECK THE INNER DIAMETER OF CONNECTING

ROD (SMALL END)
15B
Item Specification
Connecting Rod And Piston Pin Clearance 0.008 ~ 0.020 mm
Wear Limit 0.05 mm

26. MEASURE PISTON OUTER DIAMETER.
27. ACCORDING TO CYLINDER SLEEVE INNER DIAMETER (AFTER INSTALLING INTO CYLINDER
BLOCK) CHOOSE SUITABLE PISTON SIZE.
Size
Item
Piston Cylinder Sleeve
S 92.960 ~ 92.931 mm 93.011 ~ 93.020 mm
A 92.970 ~ 92.979 mm 93.021 ~ 93.030 mm
B 92.980 ~ 92.989 mm 93.031 ~ 93.040 mm
C 92.990 ~ 92.999 mm 93.041 ~ 93.050 mm
D 93.000 ~ 93.009 mm 93.051 ~ 93.060 mm
E 93.010 ~ 93.019 mm 93.061 ~ 93.070 mm
(a) The clearance between piston and cylinder sleeve is 0.042 ~ 0.060 mm， wear limit is 0.20 mm. Mea-
sure the clearance, if the clearance exceed the wear limit, replace the piston and cylinder sleeve.
NOTE
If replace the piston, replace the piston ring also.

(a) The piston pin center should outline with the piston
center 0.7 mm for reduce the noise.
(b) When installing the connecting rod, the mark on piston

top, bulge at connect rod center should toward engine
front end.
29. INSTALL PISTON PIN SNAP RING.
15B
30. INSTALL SPIRAL SPRING BY HAND, THEN INSTALL

OIL CONTROL RING.
NOTE
• Do not use a piston ring expander when installing oil
control ring. Use of ring expander to expand the oil
control ring end gap can break the oil control ring,
unlike other piston rings.
• Ensure the ring can turn from the left to the right
freely after installation.
31. INSTALL NO.1 COMPRESSION RING, NO.2

COMPRESSION RING.
(a) Using a piston ring expander, install the NO.2
compression ring, then install the NO.1 compression
ring.
NOTE
• The NO.1 compression ring is the keystone ring.
15B
• The NO.2 compression ring is the cone distortion

ring.
• The compression rings have an identification mark

on the top of the ring.
(b) Oil the piston rings and piston side.
(c) Position the piston rings in the proper alignment with the
piston pin as shown:
1 No.2 Compression Ring Open Mouth
2 Piston Pin Position
4 Spiral Spring Open Mouth
5 Oil Control Ring Open Mouth
6 Timing Gear Direction
32. USING PROPER PISTON RING COMPRESSOR,

INSERT PISTON AND CONNECTING ROD ASSEMBLY
INTO CYLINDER ACCORDING TO MARK BEFORE
REMOVAL.
33. INSTALL CRANKSHAFT.
34. VERIFY MARK MADE DURING DISASSEMBLY,

INSTALL BEARING CAP TO THE CONNECTING ROD.
IF CONNECTING ROD IS NEW WITH NO MARK,
MAKE SURE THAT BEARING LOCK NOTCHES IS ON
THE SAME SIDE AS SHOWN.

NOTE
The pulge mark on the connecting rod cap is toward the
engine timing belt side. 15B
37. TIGHTEN CONNECTING ROD CAP NUTS IN ORDER

AS SHOWN.
Torque:
First step: 40 ~ 50 N•m
Second step: 80 ~ 90 N•m

Limit: 0.4 mm
39. ROTATE CRANKSHAFT, AVOID CRANKSHAFT BALANCE BLOCK CRASHING WITH CONNECT-
ING ROD BIG END.
Item Specification
Crankshaft Connecting Rod Journal Standard 52.015 ~ 52.030 mm
Radial Chance Between Connecting Rod Standard 0.029 ~ 0.075 mm 15B

Bearing And Journal Wear Limit 0.10 mm
Clearance Between Connecting Rod And Standard 0.175 ~ 0.29 mm

Crankshaft Journal Wear Limit 0.35 mm
40. INSTALL CRANKSHAFT MAIN BEARING CAP BOLTS

IN ORDER AS SHOWN.
Torque:
Third step: 160 ~ 180 N•m
41. USING PREPER TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.

BOLTS.

Torque: 113 ~ 133 N•m

BOLTS.
Torque: 35 N•m
NOTE 15B
45. INSTALL OIL STRAINER AND OIL PUMP. (Refer to “Chapter 18B lubrication - oil pump,
overhaul”)
47. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15B engine mechanical - engine timing belt,
overhaul”)
48. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15B engine mechanical - cylinder head,
overhaul”)
49. INSTALL ENGINE ASSY. (Refer to “Chapter 15B engine mechanical - engine assy, replacement”)
15B
MEMO
EXHAUST
16B
EXHAUST PIPE ............................................................................... 16B-1
COMPONENTS ......................................................................... 16B-1
REPLACEMENT ........................................................................ 16B-2
EXHAUST MANIFOLD..................................................................... 16B-6 16B
COMPONENTS ......................................................................... 16B-6
REPLACEMENT ........................................................................ 16B-7
16B
11B
12B
14B
16B
EXHAUST - EXHAUST PIPE 16B-1
EXHAUST PIPE
EXHAUST
COMPONENTS
16B
1 Second Rubber Support 4 Third Rubber Support
2 Rear Exhaust Pipe With Muffler Ass 5 Middle Exhaust Piper
3 First Rubber Support 6 Front Exhaust Pipe
16B
16B-2 EXHAUST - EXHAUST PIPE
REPLACEMENT
WARNING
NOTE
• When the exhaust pipe is in high temperature, trying to remove the manifold will cause defor-
mation. High temperature can cause metal expansion and make the bolts remove more difficult,
the bolt can be easily broken.
rosion, rust and leakage are found, replace the exhaust pipe assy.

3. LIFT VEHICLE.

assy to middle exhaust pipe.
(b) Disconnect the first rubber support.

(c) Disconnect the second rubber support.

(d) Remove the exhaust pipe gasket from the rear exhaust
pipe with muffler assy.
16B

(a) Remove 4 middle exhaust pipe assy retaining bolts.
(b) Remove the exhaust pipe gasket from the both ends of
middle exhaust pipe assy.

(a) Remove 2 bolts attaching front exhaust pipe to middle
exhaust pipe.
(b) Remove 2 bolts attaching front exhaust pipe to turbo-

charger tail pipe.
(c) Disconnect third rubber support. 16B

16B-4 EXHAUST - EXHAUST PIPE
(d) Remove front exhaust pipe retaining belt bolt.

(e) Remove the gasket from both ends of front exhaust pipe.
NOTE
• replace it with a new gasket after removing gasket.
• After a long-time used, the exhaust pipe gasket will
be adhered to exhaust pipe. After removing the
muffler, use the scraper to clean the surface of
exhaust pipe and replace with a new gasket to avoid
exhaust leakage.
7. INSTALL FRONT EXHAUST PIPE ASSY.

(a) Install front exhaust pipe gasket.
(b) Install 2 bolts attaching front exhaust pipe to middle exhaust
pipe.
(c) Install 2 bolts attaching front exhaust pipe to turbocharger

tail pipe.
(d) Install front exhaust pipe retaining belt bolt.

(e) Connect the third rubber support.


(a) Install middle exhaust pipe gasket.
(b) Install 4 middle exhaust pipe assy retaining bolts. 16B

(a) Install rear exhaust pipe with muffler assy gasket.
(b) Connect the first rubber support.
(c) Connect the second rubber support.
(d) Install 2 bolts attaching rear exhaust pipe with muffler assy
to middle exhaust pipe.
16B
10. LOWER VEHICLE.
part.
16B-6 EXHAUST - EXHAUST MANIFOLD
EXHAUST MANIFOLD
COMPONENTS
1 Exhaust Manifold Heat Shield 3 Exhaust Manifold Gasket
2 Exhaust Manifold 4 Exhaust Gas Connect Pipe

EXHAUST - EXHAUST MANIFOLD 16B-7
REPLACEMENT
replacement”)

(b) Take off the exhaust manifold heat shield.
16B
7. REMOVE INTAKE CONNECT PIPE. (Refer to “Chapter 14B intake air- intake connect pipe,
replacement”)
8. REMOVE 2 BOLTS ATTACHING FRONT EXHAUST

PIPE TO TURBOCHARGER TAIL PIPE.
9. REMOVE 2 BOLTS ATTACHING EGR EXHAUST PIPE

TO EGR VALVE.
10. REMOVE TURBOCHARGER ACCESSORIES. (Refer to “Chapter 14B intake air-turbocharger,

replacement”)
11. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

ASSY.
(a) Remove exhaust manifold retaining nuts.
(b) Take off exhaust manifold with turbocharger assy.
NOTE
The exhaust manifold retaining nuts will be rusted after a
long-time running. Use derusting spray when loosen the
nuts.
12. REMOVE EXHAUST MANIFOLD GASKET.

13. SEPARATE TURBOCHARGER. (Refer to “Chapter 14B intake air - turbo charger, replacement”）
(a) Check if parts have any damage or crack.
(b) Using a ruler and thickness gauge, check exhaust manifold and cylinder head surface for flatness.
Limit: 0.20 mm
(c) Clean the dirt on exhaust manifold and cylinder head surface.
15. INSTALL TURBOCHARGER. (Refer to “Chapter 14B intake air - turbo charger, replacement”）
EXHAUST - EXHAUST MANIFOLD 16B-9
16. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

ASSY.
(a) Install a new exhaust manifold gasket.
(b) Remove exhaust manifold retaining nuts. 16B
NOTE
• If a new gasket is not used, use exhaust sealant to
avoid exhaust leakage.
17. INSTALL TURBOCHARGER ACCESSORIES. (Refer to “Chapter 14B intake air-turbocharger, replace-
ment”)
18. INSTALL INTAKE CONNECT PIPE. (Refer to “Chapter 14B intake air- intake connect pipe, replace-
ment”)
19. INSTALL 2 BOLTS ATTACHING FRONT EXHAUST PIPE

TO TURBOCHARGER TAIL PIPE.
20. INSTALL 2 BOLTS ATTACHING EGR EXHAUST PIPE

TO EGR VALVE.

16B

part.


replacement”)
COOLING
17B
COOLING SYSTEM ......................................................................... 17B-1
PRECAUTION............................................................................ 17B-1
ON-VEHICLE INSPECT............................................................. 17B-3 17B
COOLANT ........................................................................................ 17B-5
REPLACEMENT ........................................................................ 17B-5
ON-VEHICLE INSPECT............................................................. 17B-8
RADIATOR ....................................................................................... 17B-9 17B
COMPONENTS ......................................................................... 17B-9
REPLACEMENT ...................................................................... 17B-10
COOLING FAN............................................................................... 17B-15
OVERHAUL ............................................................................. 17B-15
THERMOSTAT ............................................................................... 17B-20
OVERHAUL ............................................................................. 17B-20
COOLANT PUMP...........................................................................17B-23
OVERHAUL ............................................................................. 17B-23
11B
12B
14B
14B
17B
COOLING - COOLING SYSTEM 17B-1
COOLING SYSTEM
COOLING
PRECAUTION
1. COOLING SYSTEM PRECAUTION. 17B
(a) When disconnecting the cooling hose, use a suitable container to recycle the retains of coolant. If it is
not to be used, dispose of them according to the regulations.
(b) When disconnecting the pipes of cooling system, do not let debris go into the pipes of cooling system. It
nozzle to prevent dirt and impurities.
(d) Coolant is poisonous, always keep it away from children and pets. If it is not to be used, disposal them
according to the regulations..
(e) Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃
personal injury.
(f) Use foton specified coolant, do not use water instead of coolant. Water will damage the engine because
of corrosion.
(g) Clean radiator outside regularly, which can prevent mud and dust deposition from damaging radiator.
17B
17B-2 COOLING - COOLING SYSTEM

1. Coolant (Lack or leaking) Chapter 17B cooling - coolant, replacement
2. Coolant (Non-standard) Chapter 17B cooling - coolant, replacement
3. Thermostat (Damaged) Chapter 17B cooling - thermostat, overhaul
Engine overheated 4. Engine (Rough work) -
5. Radiator (Poor cooling) Chapter 17B cooling - cooling system, precaution
6. Cooling fan (Damaged) Chapter 17B cooling - cooling fan, overhaul
7. Cooling system (Blocked) -
1. Radiator(Damaged) Chapter 17B cooling - radiator, replacement
2. Cooling system hose(Blocked) -

Coolant leaking
3. Coolant pump(Damaged) Chapter 17B cooling - coolant pump, replacement
4. Coolant reservoir(Damaged) Chapter 17B cooling - coolant, replacement
1. Cooling fan(Damaged) Chapter 17B cooling - cooling fan, overhaul

Engine room noise
2. Coolant pump(Damaged) Chapter 17B cooling - coolant pump, replacement
COOLING - COOLING SYSTEM 17B-3
ON-VEHICLE INSPECT
1. CHECK WHETHER COOLANT LEVEL IS NORMAL.
2. IF COOLANT LACKS ABNORMALLY, CHECK COOLING SYSTEM FOR LEAKAGE.
17B
WARNING
tester.
drop.
NOTE
If the pressure drops, check the hoses, radiator or water pump
for leaks. If no external leaks are found, check the heater core,
cylinder block and head.
3. CHECK ENGINE COOLANT LEVEL IN COOLANT

RESERVOIR.
”FULL” line.
NOTE
Do not use water instead of coolant.
17B
17B-4 COOLING - COOLING SYSTEM

WARNING
To avoid the danger of being burned, do not remove the radiator cap while the engine and radiator are
still hot, as fluid and steam can be blown out under pressure.
scale around the radiator cap and radiator filler hole, the coolant should be free from oil. If excessively
(d) Tighten the drain plug, check the coolant level in the coolant reservoir. Fill the coolant, if necessary.
NOTE
fins, so keep the following injection distance.
(b) Be careful not spary water directly onto electronic components.
(a) Disconnect the cooling fan connector.
(b) Connect battery and ammeter to the connector.
(c) Check that the cooling fan rotates smoothly, and check the reading on the ammeter.
Temperature:20°C
Current: 8.0 ~ 12.0 A
(d) Connect the cooling fan connector.
(e) No abnormal noise except fan itself when the fan is running at a high speed.
COOLING - COOLANT 17B-5
COOLANT
REPLACEMENT
WARNING 17B
Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 °C
(120 °F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause
personal injury.


NOTE
4. DISCONNECT CLAMP ATTACHING COOLANT RESERVOIR

5. REMOVE COOLANT RESERVOIR.

(a) Remove coolant reservoir retaining bolt.
(b) Disconnect coolant level sensor connector.
17B
6. REMOVE COOLANT RESERVOIR AND DRAIN COOLANT.

17B-6 COOLING - COOLANT
8. INSTALL CONDUIT BETWEEN RADIATOR DRAIN PLUG

AND CONTAINER.
NOTE
Using a suitable container, hold the coolant. If not to be
used, dispose of them according to the regulations .
9. LOOSEN COOLANT DRAIN PLUG AT RADIATOR BOTTOM

AND DRAIN COOLANT.
10. TIGHTEN COOLANT DRAIN PLUG AT RADIATOR BOTTOM.

11. LOWER VEHICLE.

COOLING - COOLANT 17B-7
12. INSTALL COOLANT RESERVOIR.

(a) Install coolant reservoir retaining bolt.
(b) Connect coolant level sensor connector. 17B
13. CONNECT COOLANT RESERVOIR HOSE TO COOL-

ANT FILLING PIPE AND TIGHTEN THE CLAMP.
14. ADD COOLANT.

(a) Slowly fill the radiator with ”FOTON Long-effective coolant” .
(b) Push the radiator inlet/outlet hose several times, check the coolant level. If coolant is at the low level, fill
the coolant.
NOTE
The air in cooling system can be bled automatically.
17B
17B-8 COOLING - COOLANT
ON-VEHICLE INSPECT
• If there are water stains or other matter on rubber packing
cracked or swollen.
• When using the cap tester, tilt it to 30° or more above the
horizontal.
pressure.

Standard value
90 ± 15 kPa
(for brand-new cap)
Minimum standard value

75 kPa
(after using cap)

sub-assembly.
COOLING - RADIATOR 17B-9
RADIATOR
COMPONENTS
17B
1 Lower Cover 4 Lower Radiator Coolant Hose
2 Radiator Assy 5 Upper Radiator Coolant Hose
3 Cooling Fan 6 Coolant Reservoir
17B
17B-10 COOLING - RADIATOR
REPLACEMENT
WARNING
Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50°C
(120°F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause
personal injury.


4. DRAIN COOLANT. (Refer to “ Chapter 17B cooling - coolant, replacement”)
replacement”)

9. DISCONNECT COOLANT FILLING PIPE BYPASS HOSE

CLAMPS.
17B
10. DISCONNECT UPPER RADIATOR COOLANT HOSE

CLAMP.
11. REMOVE RADIATOR UPPER RETAINING NUTS.
17B

14. REMOVE COOLING FAN. (Refer to “ Chapter 17B cooling-cooling fan, overhaul”)
15. REMOVE A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air condi-
tioner - A/C compressor, replacement”)
16. DISCONNECT LOWER RADIATOR COOLANT HOSE

CLAMP.
17. LOOSEN 2 RADIATOR LOWER SUPPORT RETAINING

NUTS.
18. LOWER VEHICLE.

19. REMOVE RADIATOR ASSY, IF NECESSARY, USE COMPRESSED AIR CLEAN RADIATOR.
NOTE
20. POSITION LOWER RADIATOR SUPPORT AND TIGHTEN

2 RETAINING NUTS.
21. CONNECT LOWER RADIATOR COOLANT HOSE AND

TIGHTEN CLAMP.
22. TIGHTEN UPPER RADIATOR SUPPORT RETAINING

NUTS.
17B
23. INSTALL COOLING FAN. (Refer to “ Chapter 17B cooling-cooling fan, overhaul”)

TIGHTEN CLAMP.
25. CONNECT COOLANT FILLING PIPE BYPASS HOSE

CLAMPS.
26. CONNECT COOLING FAN CONNECTOR.
17B
28. INSTALL A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air condi-
tioner - A/C compressor, replacement”)
29. FILL COOLANT. (Refer to “Chapter 17B cooling - coolant， replacement”)
31. AFTER INSTALLING RADIATOR, LET ENGINE BE RUNNING UNTIL COOLING FAN RUNS AT
HIGH SPEED. CHECK COOLANT FOR LEAKAGE.


replacement”)
COOLING - COOLING FAN 17B-15
COOLING FAN
OVERHAUL
17B
replacement”)
6. DISCONNECT UPPER RADIATOR COOLANT HOSE 17B

CLAMP.
17B-16 COOLING - COOLING FAN
7. DISCONNECT COOLANT FILLING PIPE BYPASS HOSE

CLAMPS.
8. REMOVE COOLANT RESERVOIR.

(a) Remove coolant reservoir retaining bolt.
(b) Disconnect coolant level sensor connector.
9. TAKE DOWN COOLANT RESERVOIR.


12. REMOVE 2 UPPER COOLING FAN RETAINING BOLTS.
17B
13. LIFT VEHICLE.
14. REMOVE 2 LOWER COOLING FAN RETAINING BOLTS.
15. LOWER VEHICLE, REMOVE COOLING FAN FROM AT UPPER PLACE.

(a) Using an ohmmeter, measure the resistance between the terminals
Temperature: 20 ℃
Resistance: 1.17 - 1.43 Ω
(b) Rotate cooling fan by hand, the fan blades should be rotated smoothly.
17. POSITION COOLING FAN.
18. INSTALL 2 UPPER COOLING FAN RETAINING BOLTS.

17B
19. LIFT VEHICLE.

17B-18 COOLING - COOLING FAN
20. INSTALL 2 LOWER COOLING FAN RETAINING BOLTS.
21. LOWER VEHICLE.
23. CONNECT COOLING FAN CONNECTOR.
24. CONNECT COOLANT FILLING PIPE BYPASS HOSE

CLAMPS.
25. INSTALL COOLANT RESERVOIR.

(a) Install coolant reservoir retaining bolt.
(b) Connect coolant level sensor connector. 17B

TIGHTEN CLAMP.


17B
replacement”)
31. PUT DRIVER SEAT DOWN AND LOCK IT
17B-20 COOLING - THERMOSTAT
THERMOSTAT
OVERHAUL
WARNING
Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃
personal injury.

4. LOOSEN UPPER RADIATOR COOLANT HOSE CLAMP.
5. DISCONNECT ECT SENSOR CONNECTOR.
6. REMOVE THERMOSTAT HOUSING RETAINING BOLTS.

COOLING - THERMOSTAT 17B-21
7. REMOVE THERMOSTAT.
17B
temperature.

water.
Valve opening temperature: 80 ~ 84 ℃
NOTE

NOTE 17B
• If the valve opening temperature is out of the
specification, replace the thermostat.
• Check that the valve is fully closed when the
thermostat is at low temperature (below 77 ℃ ).
• If it is not closed, replace it with a new one.
9. CLEAN THERMOSTAT HOUSE CONNECT SURFACE, REPLACE A NEW THERMOSTAT GASKET.

17B-22 COOLING - THERMOSTAT
10. INSTALL THERMOSTAT.
11. INSTALL THERMOSTAT HOUSING RETAINING BOLTS.

12. CONNECT ECT SENSOR CONNECTOR

TIGHTEN CLAMP.

15. AFTER INSTALLING THERMOSTAT, LET ENGINE BE RUNNING UNTIL COOLING FAN RUNS AT
HIGH SPEED, CHECK COOLANT FOR LEAKAGE.
COOLING - COOLANT PUMP 17B-23
COOLANT PUMP
OVERHAUL
WARNING 17B
Do not open the radiator cap when the engine is hot. Coolant temperature should be reduced to 50 ℃
(120 ℉) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat may cause
personal injury.
2. DRAIN COOLANT. (Refer to “Chapter 17B cooling - coolant, replacement”)
3. REMOVE GENERATOR BELT. (Refer to “Chapter 15B engine mechanical - engine accessory
belt, overhaul”)
4. REMOVE COOLANT PUMP PULLEY RETAINING BOLTS.
5. REMOVE COOLANT PUMP RETAINING BOLTS.
6. REMOVE COOLANT PUMP GASKET. 17B

7. USING A SCRAPER, CLEAN DIRT ON COOLANT PUMP AND ENGINE BLOCK CONNECT SURFACE.
NOTE
17B-24 COOLING - COOLANT PUMP

(a) Rotate coolant pump and it should turn smoothly.
(b) There should be no clearance between coolant pump shaft

and coolant punp bearing and no abnormal noise when it
turns.
(c) No coolant leakage around water pump.
9. INSTALL COOLANT PUMP GASKET. TO AVOID COOLANT

LEAKING, USE COOLANT PUMP SEALANT IF NECESSARY.
NOTE
After using the coolant pump sealant, wait for 15 minutes
then fill the coolant.
COOLING - COOLANT PUMP 17B-25
10. INSTALL COOLANT PUMP RETAINING BOLTS.

17B
11. INSTALL COOLANT PUMP PULLEY RETAINING BOLTS.

12. INSTALL GENERATOR BELT. (Refer to “Chapter 15B engine mechanical - engine accessory belt,
overhaul”)
14. AFTER REPLACING COOLANT PUMP, LET ENGINE RUNNING UNTIL COOLING FAN RUNS AT
HIGH SPEED. CHECK COOLANT FOR LEAKAGE
17B
MEMO
LUBRICATION
14B
LUBRICATION SYSTEM ................................................................. 18B-1
PRECAUTION............................................................................ 18B-1
COMPONENTS ......................................................................... 18B-2
ENGINE OIL ..................................................................................... 18B-3 14B
REPLACEMENT ........................................................................ 18B-3
OIL FILTER ...................................................................................... 18B-5
REPLACEMENT ........................................................................ 18B-5
OIL PAN ...........................................................................................18B-8 14B
COMPONENTS ......................................................................... 18B-8
REPLACEMENT ........................................................................ 18B-9
OIL PUMP ...................................................................................... 18B-12
OVERHAUL ............................................................................. 18B-12
OIL FILTER BRACKET.................................................................. 18B-14
REPLACEMENT ...................................................................... 18B-14
11B
12B
14B
18B
LUBRICATION - LUBRICATION SYSTEM 18B-1
LUBRICATION SYSTEM
LUBRICATION
PRECAUTION
BJ493ZQ Diesel Engine has two ways of lubrication: pressure and splash type. The gear type oil pump is fixed 18B
on the cylinder block. The pump inner rotor is driven by the camshaft. Oil pump strainer tube is in the sump of
the oil pan.
WARNING
skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants may
cause skin cancer. Therefore, the skin must be protected in appropriate methods and with cleaning
equipment.
(b) Wear protective clothing, including waterproof work gloves.
(e) Avoid eyes contact with oil, must wear goggles, In addition, equipment must be prepared to clean the
eyes and wrapping the wound must be dealt with immediately.
(f) Frequent use of soap and water can clean, especially before meals, and make sure all the oil have
been removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is
18B
18B-2 LUBRICATION - LUBRICATION SYSTEM
COMPONENTS
1 Oil Pan 6 Camshaft
2 Oil Strainer 7 Crankshaft
3 Oil Filter 8 Piston
4 Oil Filter Bracket 9 Valve Push Rod
5 Oil Cooler 10 Valve Rocker Arm

LUBRICATION - ENGINE OIL 18B-3
ENGINE OIL
REPLACEMENT
1. PARK VEHICLE IN LEVEL ROAD, SLOWLY PULL OUT OIL DIPSTICK, AND CHECK OIL LEVEL, 18B
2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE MUST
HAVE ENOUGH CONCENTRATIONS AND LUBRICATION DEGREE.


WARNING
18B

18B-4 LUBRICATION - ENGINE OIL
9. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN

DRAIN PLUG.
Torque: 35 ~ 45 N.m
10. LOWER VEHICLE.

Engine oil: 4.5 ~ 5 L
Oil filter oil: 0.3 L
NOTE
The specifications of CF- 4 engine oil is: 15W-40 and 15W-30.
12. INSTALL OIL FILL CAP.
16. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK TO ENSURE

OIL LEVEL IS BETWEEN “MAX” MARK AND THE “MIN”
MARK.

LUBRICATION - OIL FILTER 18B-5
OIL FILTER
REPLACEMENT
NOTE 18B
Without special circumstances, the oil filter should be replaced with engine oil to avoid oil pollution
and keep engine normal operation.

3. OPEN OIL FILL CAP.


WARNING
Be careful, the engine oil maybe hot.
7. USING SUITABLE TOOL, REMOVE OIL FILTER.
18B
8. CLEAN THE SURFACE BETWEEN OIL FILTER AND OIL FILTER BRACKET.
18B-6 LUBRICATION - OIL FILTER
9. APPLY OIL TO O-RING OF NEW OIL FILTER.
10. FILL CLEAN OIL INTO OIL FILTER.
11. TIGHTEN OIL FILTER BY HAND UNTIL O-RING TOUCHES

OIL FILTER BRACKET. USING SUITABLE TOOL,
TIGHTEN OIL FILTER.
Torqure: 25 ~ 30 N•m

Torque: 35 ~ 45 N.m
13. LOWER VEHICLE.

14. FILL ENGINE OIL TO SPECIFIED LEVEL AND THEN INSTALL OIL FILLER CAP.
LUBRICATION - OIL FILTER 18B-7
18. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK TO ENSURE

MARK.
18B
18B
18B-8 LUBRICATION - OIL PAN
OIL PAN
COMPONENTS
1 Oil Pan Retaining Bolt 5 Ladder Frame
2 Oil Pan 6 Oil Pan Arc Gasket
3 Oil Pan Gasket 7 Oil Dipstick
4 Ladder Frame Retaining Bolt

LUBRICATION - OIL PAN 18B-9
REPLACEMENT

WARNING

18B
7. USING A SCREWDRIVER SEPARATE LADDER FRAME AND OIL PAN.

8. REMOVE OIL PAN GASKET.
18B-10 LUBRICATION - OIL PAN
9. REMOVE LADDER FRAME RETAINING BOLTS.
10. CLEAN SURFACE BETWEEN LADDER FRAME AND ENGINE BLOCK.
11. REPLACE LADDER FRAME ARC GASKET AT FRONT

SIDE OF CRANKSHAFT (CRANKSHAFT PULLEY SIDE).
12. REPLACE LADDER FRAME ARC GASKET AT REAR

SIDE OF CRANKSHAFT (FLYWHEEL SIDE).
13. INSTALL LADDER FRAME ARC GASKET, APPLYING

SEALANT ON ROOTS OF BOTH ENDS OF CRANKSHAFT
BEARING CAP.
NOTE
Be sure to install the oil pan quickly while the sealant is wet
(within 15 minutes).
LUBRICATION - OIL PAN 18B-11
14. INSTALL LADDER FRAME AND OIL PAN BOLTS

DIAGONALLY.
NOTE 18B
After installation, keep the sealant area away from the oil
for about one hour.

Torque: 35 ~ 45 N.m
16. LOWER VEHICLE.

17. FILL ENGINE OIL TO SPECIFIED LEVEL.
18B
18B-12 LUBRICATION - OIL PUMP
OIL PUMP
OVERHAUL

WARNING

6. REMOVE LADDER FRAME. (Refer to “Chapter 15B， lubrication - oil pan, replacement”)

LUBRICATION - OIL PUMP 18B-13
8. TAKE OIL PUMP AWAY.
18B

(a) Oil pump gear and camshaft gear tooth surface should not have erosion, wear, or missing teeth. If
found, replace the oil pump assembly.
10. LOOSEN OIL PIPE CONNECTOR AND REPLACE A NEW O-RING.
11. TIGHTEN OIL PUMP RETAINING BOLTS.

12. INSTALL OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”）
13. TIGHTEN OIL DRAIN PLUG.

18B
14. LOWER VEHICLE.

16. PUT DOWN DRIVER SAET AND LOCK IT.
18B-14 LUBRICATION - OIL FILTER BRACKET
OIL FILTER BRACKET

REPLACEMENT
1. REMOVE OIL FILTER. (Refer to “Chapter 18B lubrication
- oil filter, replacement”)
2. DISCONNECT OIL COOLER INLET/OUTLET HOSE

CLAMP AND THEN DRAIN COOLANT TO A SUIT-
ABLE CONTAINER.
3. REMOVE 4 OIL FILTER RETAINING BOLTS.

LUBRICATION - OIL FILTER BRACKET 18B-15
4. REMOVE OIL COOLER RETAINING BOLT.
18B
5. SEPARATE OIL COOLER AND TAKE OIL FILTER BRACKET AWAY.

6. REPLACE A NEW O-RING.
7. POSITION OIL COOLER TO OIL FILTER BRACKET

AND TIGHTEN RETAINING BOLT.
8. TIGHTEN OIL FILTER BRACKET RETAINING BOLTS.

18B
18B-16 LUBRICATION - OIL FILTER BRACKET
9. CONNECT OIL COOLER INLET/OUTLET HOSE AND

TIGHTEN CLAMP.
10. INSTALL OIL FILTER. (Refer to “Chapter 18B lubrication - oil filter, replacement”)
12. FILL COOLANT TO SPECIFIED LEVEL. (Refer to “Chapter 17B cooling - coolant, replacement”)
20B
STARTING AND CHARGING SYSTEM .......................................... 20B-1
PRECAUTION............................................................................ 20B-1
GENERATOR ................................................................................... 20B-4 20B
OVERHAUL ............................................................................... 20B-4
Generator and Regulator Maintenance.................................... 20B-12
STARTER ....................................................................................... 20B-13
COMPONENTS ....................................................................... 20B-13 20B
OVERHAUL ............................................................................. 20B-14
BATTERY ....................................................................................... 20B-23
COMPONENTS ....................................................................... 20B-23
USE AND MAINTENANCE ...................................................... 20B-24
INSPECTION ........................................................................... 20B-26
TROUBLESHOOTING ............................................................. 20B-27
REPLACEMENT ...................................................................... 20B-28
11B
12B
20B
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20B-1

PRECAUTION
1. STARTING AND CHARGING SYSTEM PRECAUTION. 20B
cause injury.
20B
20B-2 STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

1. Starter switch control circuit (Open) -
2. Brush and rectifier (Poor Chapter 20B starting and charging - starter,
Starter out of operation connection) overhaul

3. Starter inside circuit (Open or short) overhaul
Chapter 20B starting and charging - battery,

3. Rectifier (Surface damaged or -

stains)
Starter lacks power,
can not srart engine 4. Brush (Wear) or Brush spring Chapter 20B starting and charging - starter,
(Loss elastic force) overhaul

5. Solenoid switch (Contacts ablation) overhaul

6. Bearing (Wear) overhaul
1. Starter relay （Copper contacts Chapter 20B starting and charging - starter,
bond） overhaul
Starter keep working Chapter 20B starting and charging - starter,

after engine start. 2. Starter commutator (Bend or break) overhaul
3. Starter gear tooth surface contact Chapter 20B starting and charging - starter,
1. Generator connect wire -
Chapter 20B starting and charging - genera-

Generator out of opera- Chapter 20B starting and charging - genera-

tion

STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20B-3

Chapter 15B engine mechanical - engine
20B
2. Brush (Poor connection) or Collec- Chapter 20B starting and charging - genera-
tor ring (Smery) tor, overhaul
Generator lacks Chapter 20B starting and charging - genera-

enough electricity 3. Regulator (Damaged) tor, overhaul

4. Battery lose electrolyte use and maintenance



Generator over 2. Rectifier diode (Damaged) tor, overhaul
charging
20B
20B-4 STARTING AND CHARGING - GENERATOR
GENERATOR
OVERHAUL


NOTE
4. COOL ENGINE AND MAKE BELT TEMPERATURE AS CLOSE AS POSSIBLE TO NORMAL

TEMPERATURE.
6. DISCONNECT GENERATOR CONNECTOR.
7. LOOSEN GENERATOR POSITIVE CABLE CONNECT NUT.
8. LOOSEN GENERATOR BRACKET BOLT.

STARTING AND CHARGING - GENERATOR 20B-5
9. LOOSEN GENERATOR TENSIONER LOCK NUT.
20B
10. REMOVE GENERATOR BELT.
11. DISCONNECT VACUUM PUMP CONNECTOR.

(a) Remove vacuum pump inlet oil pipe.
(b) Disconnect vacuum pump outlet oil hose clip.
(c) Disconnect vacuum outlet hose clip.
20B
12. LOOSEN GENERATOR RETAINING BOLTS.
13. REMOVE GENERATOR ASSY.

14. CHECK VACUUM PUMP WORKING CONDITION.
(a) Rotate generator belt pully, the vacuum pump should run smoothly, no block feel and abnormal noise.
(b) On vehicle inspection: When the engine is running, pull out the vacuum outlet hose carefully, there
should be have attraction on the hose end. If the attraction is not obvious, the vacuum pump interior
blade had wear. replace the generator assy.
15. USING PNEUMATIC TOOLS, REMOVE GENERATOR

BELT PULLEY RETAINING NUT.
16. REMOVE GENERATOR FAN.
17. LOOSEN RETAINING BOLTS ATTACHING GENERATOR

FRONT COVER TO STATOR COMPONENT.
18. INSERT SCREWDRIVER BETWEEN FRONT COVER AND STATOR THEN SEPARATE THEM.
NOTE
• If it is difficult to be separated, slap the front cover slightly with rubber hammer and pry it with
screwdriver.
• Do not insert screwdriver too deep to prevent stator component being damaged.

(a) Using a electric iron (180 ~ 250 w), remove stator. This
from heat. 20B
(b) Loosen 4 retaining bolts from rectifier.
(c) Using a electric iron, remove rectifier from regulator

NOTE
iron to diode for a long time.
(d) Remove and inspect rotor.

means the rotor is short circuit. If it is not conductive or it 20B

assy.

Limit: 12.8 mm
(e) Remove and inspect stator.


conductive.
(f) Inspect stator rectifier.

are conductive. If it is not conductive in both directions, it
(g) Get rid of welding point of brush lead, then take out the
brush.
(h) If brush is so worn to reach wear limit line, replace brush.
20B

as shown.

Torque: 6 ~ 8 N•m
20B
21. POSITION ROTOR.

22. TIGHTEN RETAINING BOLTS ATTACHING GENERATOR

FRONT COVER TO STATOR COMPONENT.
23. POSITION GENERATOR FAN.

24. POSITION GENERATOR BELT PULLEY AND USING PNEUMATIC TOOLS, INSTALL GENERATOR
BELT PULLEY RETAINING NUT.
26. INSTALL VACUUN PUMP ACCESSORIES.

(a) Install vacuum pump inlet oil pipe.
(b) Connect vacuum pump outlet oil hose clip.

(c) Connect vacuum outlet hose clip.
20B
27. INSTALL GENERATOR BELT.
28. TIGHTEN GENERATOR BRACKET BOLT.

29. USING CROWBAR, PRY THE GENERATOR AND TIGHTEN

THE LOCK NUT.
30. ADJUST GENERATOR BELT TO REGULATED TENSITY. (Refer to “Chapter 15B engine mechani-
cal - engine accessory belt, overhaul”)
31. CONNECT GENERATOR CONNECTOR. 20B
32. TIGHTEN GENERATOR POSITIVE CABLE RETAINING NUT.

BOLTS.
NOTE
Connect the negative first when install.

Generator and Regulator Maintenance

1. GENERATOR AND REGULATOR MAINTENANCE.
(a) After disassemble the generator, blow dust inside by compressed air. Clean greasy dirt inside by
gasoline. Grind slip ring of rotor by No.00 sandpaper.
(b) Clean bearing and check looseness. Replace with new one and fill grease if loosen.
(c) Check rotor if field coil and slip ring welding is firm or not (the field coil resistance is about 5 ~ 6 Ω).
Check stator lead line and diode lead line welding is firm or not.
STARTING AND CHARGING - STARTER 20B-13
STARTER
COMPONENTS
20B
1 Front Bracket 11 Overdrive Clutch 20B

10 Internal Gear
20B-14 STARTING AND CHARGING - STARTER
OVERHAUL


NOTE
4. LIFT VEHICLE.
5. LOOSEN 2 STARTER RETAINING BOLTS.

6. DISCONNECT STARTER ELECTRICAL WIRE CONNECTING

NUT.
20B
7. DISCONNECT STARTER CONTROL WIRE CONNEC-

TOR.

magnetic switch.
terminal.
NOTE

a feeler gauge.
Standard: 0.5 ~ 2.0 mm 20B

front bracket.

magnetic switch.
terminal.
NOTE

magnetic switch.
body.
NOTE
position.

magnetic switch.
body.
NOTE
WARNING
the pinion.
20B

NOTE
• When removing armature, do not lose the steel ball
mounted in the bearing ends. 20B


• Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is
• Clean starter parts with cloth.
• Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the
• Using a brush and dipping with detergent, clean drive parts then dry them with a cloth.

Limit: 0.1 mm
(b) Measure the diameter of the commutator.

Standard: 29.4 mm
Limit: 28.4 mm

Standard: 0.5 mm
Limit: 0.2 mm

the brush. Replace the brush holder if the height is lower than the limit. 20B
Limit: 7.0 mm

(b) Check the pinion for abnormal waring and damage.

NOTE
the test.

20B


and body A.

and M terminal.


snap ring.


20B


20B
17. TIGHTEN 2 STARTER RETAINING BOLTS.

18. LOWER VEHICLE.
19. CONNECT BATTERY AND TIGHTEN RETAINING BOLTS.

NOTE

STARTING AND CHARGING - BATTERY 20B-23
BATTERY
COMPONENTS
Lead-acid battery consists of plus and minus plate, partition, sulfuric acid electrolyte, battery shell. 20B
20B
20B-24 STARTING AND CHARGING - BATTERY
USE AND MAINTENANCE

1. CHARGING DEVICE.
NOTE
(a) Rectifier.
2. CHARGE PRECAUTIONS
(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures shouldl be taken (by
reducing filling current or stopping sharge or being cooled down in water tank).
must be firm.
4. CHARGING MODES.
(c) Quick charge.
5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS RESTORED
TO STANDARD.
(a) Voltage method

(b) Capacity method



smash and dropout of active substances, and other failures. 20B
minutes, if can not start the engine in three times, troubleshoot, then restart.
20B
INSPECTION
(a) Observe whether the battery appearance in good condition. Check if fixed terminal and wires are
connected firmly.
(b) The electrolyte densitometer was arranged inside the battery and it can display the storage state and
the liquid level of the electrolyte. In the case the indication window of the densitometer appears blue, it
means that there is sufficient storage and the battery can be used normally. And in the case of white, it
indicates the electric storage is insufficient and the charging is needed. If it were red, it means that the
battery is to be discarded.
2. CAPACITY TEST.
resistance.
are troubles in the battery and it shall be repaired.
Below is the use of excel tester of discharge plan detection income cross-references.

3. VOLTAGE TEST



TROUBLESHOOTING
20B
LONG PERIOD.
2. BATTERY EXPLODE.
20B
4. A YELLOW OR WHITE PASTE APPEARS ON BATTERY COVER.

In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a cloth
soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth. The paste on
the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If there are oxides of poor
conductivity, scrape them with a little knife and clean them. It would be best to smear a coat of Vaseline or
butter on the cover after the polar studs and wiring clips are fastened.
REPLACEMENT


NOTE
4. LOOSEN BATTERY HOLD DOWN RETAINING BOLTS.
5. REMOVE BATTERY.
NOTE
• Battery should be put up, placing upside down the
battery is avoided.
(a) Unscrew the bolt, add distilled water or electrolyte
through the hole above battery.
20B

8. POSITION BATTERY.
9. TIGHTEN BATTERY HOLD DOWN RETAINING BOLTS.

10. CONNECT BATTERY NEGATIVE/POSITIVE CABLE AND

TIGHTEN BATTERY CABLE RETAINING BOLTS.
NOTE
then apply a thin layer of grease to terminal.

(a) Tighten battery cover lock button
11C
DIESEL ENGINE CONTROL SYSTEM............................................ 11C-1
PRECAUTION............................................................................ 11C-1
SYSTEM OVERVIEW ................................................................ 11C-2
SYSTEM FUNCTION INTRODUCTION .................................... 11C-5 11C
BASIC PRINCIPLE .................................................................... 11C-6
EGR VALVE ELECTRONIC CONTROL MODULE ......................... 11C-9
PRINCIPLE ................................................................................ 11C-9
REPLACEMENT ...................................................................... 11C-10 11C
EGR COOLANT TEMPERATURE SENSOR.................................11C-13
PRINCIPLE .............................................................................. 11C-13
OVERHAUL ............................................................................. 11C-14
THROTTLE POSITION SENSOR .................................................. 11C-17
PRINCIPLE .............................................................................. 11C-17
INSPECTION ON VEHICLE .................................................... 11C-18
REPLACEMENT ...................................................................... 11C-19
EGR VALVE LIFT SENSOR .......................................................... 11C-22
PRINCIPLE .............................................................................. 11C-22
OVERHAUL ............................................................................. 11C-23
FUEL INLET SOLENOID VALVE .................................................. 11C-27
PRINCIPLE .............................................................................. 11C-27
OVERHAUL ............................................................................. 11C-28
GLOW PLUG.................................................................................. 11C-32
OVERHAUL ............................................................................. 11C-32
EGR VACUUM SOLENOID VALVE...............................................11C-35
OVERHAUL ............................................................................. 11C-35
VEHICLE SPEED SENSOR ........................................................... 11C-38
PRINCIPLE .............................................................................. 11C-38
ON-VEHICLE INSPECTION .................................................... 11C-39
OVERHAUL ............................................................................. 11C-40
11B
11C
ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM 11C-1
DIESEL ENGINE CONTROL SYSTEM

PRECAUTION
1. DIESEL ENGINE CONTROL SYSTEM PRECAUTION. 11C
(a) Power off.
• The battery negative cable must be disconnected at first before removing or installing any electric 11C
ally. This will prevent person injured and vehicle damaged. 11C
• The ignition switch must be OFF without any special descriptions.
11C
WARNING
The ignition and illumination switches must be shut off before removing or installing the battery nega- 11C
tive cable (the semiconductor maybe damaged without doing that).
(b) Please do disassembly and assembly and testing in accordance with the provisions introduced in this 11C
(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 11C
the sealant on the mounting hole, the threaded hole and the thread. 11C
(d) Paint some sealant evenly on the prescribed diameters to surround the mounting hole. The sealant not
hardened yet can be scraped away. Install it in place when the sealant is wet (within 15 minutes). Take 11C
care not to stick the sealant to the place where it's not desired during installation. Wait the sealant to be
very hardened (1 hour or so) after installation. Don’t apply oil on the painted parts or wet or start the 11C
engine during this time.
(e) Tighten the straining bolts with prescribed torque during installing the sensors, actuators or other parts. 11C
Ensure the diesel engine always in clean and complete state. Clean or wipe up the parts to ensure the
clean parts and the assembly quality before removing and assembling the parts. The complicated 11C
adjustment and maintenance should be taken indoors to avoid the diesel engine polluted by the
environment. 11C
(f) Don’t test the EGR valve electronic control module or the sensor with an analogue multimeter but using
a digital multimeter with high impedance except for specified instructions during the testing. 11C
(g) When installing and handling sensors, handle them gently to avoid damage, any impact or falling may
cause severe damage. 11C
(h) Don’t test the system electrical signal by use of a fine needle to pierce the harness.
(i) Take a visual inspection to check if the sensing element at the head of sensor is damaged or color 11C
changed. Replace it if it's damaged or the color is severe changed.
(j) Because most electric sprayed parts are un-serviceable, replace it generally after confirming the part is 11C
damaged.
(k) Prevent EGR valve electronic control module from being damaged by static electricity. The static 11C
electricity can damage or even destroy EGR valve electronic control module and other electronic
elements, which makes the device damaged completely and unable to work or hard to determine the 11C
cause of failure. EGR valve electronic control module installed on vehicle has a function of preventing
static electricity. However, if removed from the vehicle, it doesn't have the function of preventing static 11C
electricity. So, make sure it grounds when removing EGR valve electronic control module from the
whole vehicle.
(l) The connector on EGR valve electronic control module can be unplugged for only 90 seconds after the
ignition switch off.
(m) EGR valve electronic control module should be firmly installed and the installation position should be
waterproof and dustproof. It is not allowed to be soaked in water or other liquid.
(n) EGR valve electronic control module can’t be disassembled for testing and maintenance. However,
basic testing can be performed.
11C-2 ENGINE CONTROL SYSTEM - DIESEL ENGINE CONTROL SYSTEM
SYSTEM OVERVIEW
1. 4D20 DIESEL ENGINE ELECTRONIC CONTROL VE PUMP TECHNOLOGY.
(a) 4D20 diesel engine adopts electronic control VE pump technology which is improved on the
performance on engine power, economy and fuel emissions. 4D20 diesel engine electronic control VE
pump is very different from traditional diesel engines. Engine timing is controlled by the EGR valve
electronic control module and the timing can be revised based on the water temperature. It has good
acceleration, fuel consumption and low noise advantages. The features are as following:
(b) VE pump electronic control system using a number of sensors detecting engine operating states and
environmental conditions, EGR valve electronic control module controls the fuel delivery per cycle. The
control system uses the position control system of fuel supply and electrical control loop timing
adjustment control. When it needs to expand the control functions, just change the storage software of
EGR valve electronic control module, no additional devices added.
(c) The quantity of fuel supply will be difference because of setting error, wear and other reasons in
mechanical VE pump system. But the re-check process will always be performed based on the speed
signal in the VE pump electronic control system. Therefore, it is accurate for the advance angle of fuel
supply.
(d) Control device can change the program or data via changing the control characteristics. Therefore, an
electric control device can be applied to a variety of diesel engines.
(e) Conventional fuel supply system is still the high-pressure pump to high pressure fuel pipe and then to
fuel injector systems.
(f) VE pump electronic pump based on the mechanical VE pump, fuel injection quantity is still controlled
by mechanical governor.
2. DIESEL ENGINE CONTROL SYSTEM DIRGRAM.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
1 EGR Vacuum Solenoid Valve 9 EGR Valve Electronic Control Module
2 Diagnostic Connector 10 Timming Stroke Sensor 11C

3 Engine Speed Sensor 11 Timming Solenoid Valve
11C
4 Wiring Harness 12 Fuel Inlet Solenoid Valve
11C
5 Fuel Tank 13 Throttle Position Sensor
6 Fuel Strainer 14 EGR Coolant Temperature Sensor 11C

7 Fuel Water Separator 15 Return Fuel Solenoid Valve
11C
8 Engine
11C
11C
3. DIESEL ENGINE CONTROLSYSTEM MAIN COMPONENTS DISTRIBUTION GRAPH.
1 EGR Solenoid Valve Assy 7 Speed Handle
2 Oil Dipstick 8 Fuel Inlet Pipe
3 Oil Pan 9 Return Fuel Solenoid Valve
4 Fuel Delivery Valve Seat 10 Fuel Inlet Solenoid Valve
5 Electronic Control VE Pump 11 Fuel Injector
6 Fuel Return Pipe 12 Warm Water Pipe

SYSTEM FUNCTION INTRODUCTION

1. ELECTRONIC CONTROL SYSTEM.
(a) 4D20 diesel electric EGR valve system consists of electronic control modules, sensors and actuators
of three parts. 11C
(b) The role of the sensor is detecting the engine running in real time, driver's operating intentions and
11C
others, which are transfered into EGR valve electronic control module.
(c) EGR valve electronic control module is responsible for the information collection, processing,
11C
calculation and implementation procedures. Also it outputs the operating results as a control command
to the actuator.
11C
(d) The role of the actuator is in accordance with the control instructions from EGR valve electronic control
module, regulate fuel supply and fuel supply timing, in order to achieve the purpose of adjust the
11C
engine running.
(e) The most important control function is to fuel supply and fuel supply timing control. Other extensions 11C
generally need to fuel supply and fuel supply timing control to achieve.
2. AIR CONDITIONING COMPRESSOR CONTROL. 11C
When the A/C switch is on, the system will receive a A/C request signal and make preparations for
operating the A/C system based on engine working condition. And then switch on the A/C compressor. 11C
The system will switch on or switch off the A/C according to the protection demand for air-conditioner.
To ensure the power output and protect the engine, the system will cut off the A/C system under 11C
3. FAN CONTROL. 11C
This vehicle is equipped with a silicon oil fan. The silicon oil fan clutch is installed between the shaft
and fan, based on the needs of the engine cooling system to control the fan speed, and the cooling 11C
intensity adjustment. Compared to the fan with traditional rigid fixation, the cooling system is installed
with silicon oil fan clutch. The main advantages for the silion oil fan clutch installed on the cooling sys- 11C
tem are energy saving, noise reduction, low emissions and worn and so on.
11C
11C
11C
11C
11C
11C
11C
11C
BASIC PRINCIPLE
ELECTRONIC CONTROL VE PUMP
1. FUEL SUPPLY.
(a) System calculates the basic fuel supply with input signal from the accelerator pedal position and engine
speed then adjusts the fuel supply based on the temperature signal from EGR coolant temperature
sensor and other signals. Endly system determine the optimum fuel supply after the feedback
amendment with the trip sensor signal.
1 Throttle Position Sensor 8 Complement
2 Engine Speed Sensor 9 Correction
3 EGR Coolant Temperature Sensor 10 Feedback Control
4 Engine Start Signal 11 Amplifier
5 Fuel Solenoid Valve 12 EGR Valve Electronic Control Module
6 Movable Core 13 Electronic Control VE Pump
7 Basic Fuel Supply
2. IDLE SPEED.
(a) Based on the signals from throttle position sensor, speed sensor and the start signal, EGR valve
electronic control module decide when to start idle speed control. And in accordance with the coolant
temperature sensor, air conditioning and neutral switch signal, it calculates the set idle speed and the
corresponding fuel supply. Based on the engine speed feedback signal, and continuously corrected for
fuel supply. This will make the idle speed stability.
3. REGULAR SUPPLY.
(a) Firstly, according to engine speed and throttle position sensor input signals, EGR valve electronic
control module identify a supply point initially, then correct it according to coolant temperature sensor
signal.
4. ADVANCE ANGLE.
(a) According to the collection information (accelerator pedal position), and the current engine/vehicle
conditions, EGR valve electronic control module calculate the required advance angle. High-pressure
pump outputs the advance angle. 11C
(b) Timing control function: Engine timing control is closed loop control. EGR valve electronic control
module request and advance angle control to set the value. The stroke sensor on the high-pressure 11C
pump will feedback current location information to the EGR valve electronic control module, which
forms a closed loop. 11C
(c) Correction function: EGR valve electronic control module can also correct the engine timing and
preheating time to adapt to specified conditions based on the engine coolant temperature. For 11C
example, it can get better cold start performance at low temperature, etc.
(d) Preheating function: System control strategy is completed by the EGR valve electronic control module. 11C
Temperature setting is according to different needs of the warm-up time.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
1 Inlet Fuel 8 Inlet Air
2 Fuel Solenoid Valve 9 Engine Speed Sensor 11C

3 Electronic Control VE Pump 10 Engine Speed Control
4 Injector 11 Fuel Quantity Control
5 EGR Valve Electronic Control Module 12 EGR Control
6 Acceleration Pedal 13 EGR Vacuum Solenoid Valve
7 Unified Meter 14 Diesel Engine And Vehicle

PREHEATING CONTROL PRINCIPLE

1. PREHEATING SYSTEM.
(a) Preheating system ensurestarting performance of diesel engine at low-temperature. Before starting
engine, preheating system heats compressed air through glow plug. This improves the starting
performance of the engine. When turn the ignition switch on, the preheating process begins. At this
moment, preheating indicator lights up. When the preheating indicator flash, glow plug has reached the
adequate temperature. At this moment, turning the ignition switch START within 5 seconds, start the
engine.
2. STARTING AT ROOM TEMPERATURE.
(a) If the preheating indicator lights on, it means that the coolant temperature is below 10 ℃ , the
preheating system is warming up the engine. The operator can skip the warm-up process (When the
starting is trouble, it can also warm-start as normal operation) and operate as following.
• Depress clutch pedal with the accelerator pedal placed in the medium of speed position.
• Start diesel engine.
(b) After starting, turn the ignition switch ON immediately, which avoids damage to the starter.
3. THE ENGINE WHEN THE AMBIENT TEMPERATURE IS BELOW 0 ℃ .
(a) Turn the ignition switch ON. check whethe the preheating indicator on the unified meter indicates
normal.
• If the coolant temperature is higher than 10 ℃ , and the engine is warm, preheating indicator does not
shine. At this moment, when the ambient temperature is above 0 ℃ , directly start the engine.
• If the coolant temperature is below 10 ℃ , and when the preheating indicator on the unified meter is
normlly on, it means preheating system begins to work. When starting after completion of glow plug
preheating, preheating indicator light to 1/s frequency of flashes, prompts the operator starting engine.
If the operator does not start diesel engine in 30 seconds, preheating indicator is off, preheating system
automatically stop working. To start now, need to turn off the power. re-operate the process as above.
If the cold start preheating indicator does not light or turn the ignition switch OFF, it means that the
preheating system is failure. Eliminate faults in engine control system before starting.
EGR CONTROL PRINCIPLE

(a) 4D20 diesel engine is equipped with the electrical controlled Exhaust Gas Recirculation (EGR) system.
EGR system consists of EGR valve electronic control module, EGR valve lift sensor, EGR valve, EGR
vacuum regulator, EGR coolant temperature sensor, pressure maintaining valve and associated piping
components.
(b) Based on the calibration data in different conditions, EGR valve electronic control module calculates
required quantity of exhaust gas recirculation, controls the EGR valve opening by controlling the EGR
vacuum regulator returns part of exhaust gas in the exhaust pipe through recirculation to the intake
manifold and makes it mixed with flesh air and into the combustion chamber to reduce the combustion
temperature, so as to reduce the generation of oxynitride, thus to reduce the air pollution.
TURBO-CHARGING PRINCIPLE
(a) 4D20 diesel engine adopts the exhaust gas turbocharger unit. The air intake/exhaust and supercharger
system consists of the intake manifold, exhaust manifold, intake pipe, air filter and supercharger. The
turbo machine and compressor of the supercharger are installed on the same axis. The turbo is driven
by the exhaust gas exhausted by the engine and drives the compressor to compress the air inhaled by
the air cleaner, so as to increase the air density in the cylinder and increase the air input, which can
accordingly increase the fuel delivery of fuel injection pump, thus to improve the engine output.
ENGINE CONTROL SYSTEM - EGR VALVE ELECTRONIC CONTROL MODULE 11C-9
EGR VALVE ELECTRONIC CONTROL MODULE

PRINCIPLE
11C
1. EGR VALVE ELECTRONIC CONTROL MODULE
DESCRIPTION.
11C
(a) EGR valve electronic control module is a sensor signal input
interface, the actuator driven by electronic control module. It 11C
receives and processes the sensor input signal of the
engine condition, and send control signals to the actuator to
11C
ensure good fuel economy and emissions.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-10 ENGINE CONTROL SYSTEM - EGR VALVE ELECTRONIC CONTROL MODULE
REPLACEMENT



NOTE
replacement”)

ENGINE CONTROL SYSTEM - EGR VALVE ELECTRONIC CONTROL MODULE 11C-11
11C
11C
11C
11C
9. REMOVE EGR VALVE ELECTRONIC CONTROL
MODULE. 11C
(a) Disconnect EGR valve electronic control module
connector. 11C
(b) Remove 4 bolts.
11C
WARNING
Using the special diagnostic tool and soft-ware to operate. 11C
If not, the EGR valve electronic control module will be
damaged. 11C
NOTE
When check the EGR valve electronic control module, 11C
generally note the following:
• Turn the ignition switch OFF, and wait 90 seconds, then 11C
check it.
11C
• Do not damage the wires, plugs and sockets, so as not to
touch the ground short circuit or high voltage.
11C
• Carefully use the electronic testing equipment and
instruments. If the test equipment is greater than 5V
11C
power supply, the chip circuitry in EGR valve electronic
control module will be damaged by over-voltage. When
11C
check EGR valve electronic control module, preferably
use megohm level impedance digital multimeter.
11C
• After disconnecting EGR valve electronic control module,
pay attention to waterproof. Not allow to contact water. 11C
Even more, not allow to put into water.
• Not allow to impact. 11C
11C
11C
11C-12 ENGINE CONTROL SYSTEM - EGR VALVE ELECTRONIC CONTROL MODULE
10. INSTALL EGR VALVE ELECTRONIC CONTROL MODULE.

NOTE
Pay attention to electrostatic protection when installing.
(a) Tighten EGR valve electronic control module retaining
bolts.
(b) Connect EGR valve electronic control module connector.



replacement”)
ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR 11C-13
EGR COOLANT TEMPERATURE SENSOR

PRINCIPLE
11C
1. EGR COOLANT TEMPERATURE SENSOR DESCRIP-
TION.
11C
(a) EGR coolant temperature sensor is used to detect the
engine temperature. Depending on the temperature of 11C
the engine to provide the best control scheme.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-14 ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR
OVERHAUL



NOTE
5. DRAIN THE COOLANT. (Refer to “Chapter 17C cooling - coolant, replacement”)
6. REMOVE EGR COOLANT TEMPERATURE SENSOR.

(a) Disconnect EGR coolant temperature sensor connector.
(b) Remove EGR coolant temperature sensor.
NOTE
not to allow tools to touch the connector (resin
parts).
ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR 11C-15
7. CHECK EGR COOLANT TEMPERATURE SENSOR.

.
(a) Dip the sensing part of EGR coolant temperature sensor

into hot water. Using the multimeter, measure resistance
of the sensor. 11C
(b) If the check result is not OK, replace it with a new one.
11C
Check condition Specified Condition (KΩ)
3.288
11C
20 ℃
40 ℃ 1.586 11C
60 ℃ 0.8
11C
80 ℃ 0.426
11C
100 ℃ 0.24
11C
CAUTION
Don’t let the water go into terminals. After checking, dry the 11C
sensor.
11C
8. INSTALL EGR COOLANT TEMPERATURE SENSOR.
CAUTION 11C
Apply sealant on thread. The specified sealant: 3M nut
locking part, type: NO.4171 or the equivalent. 11C
11C
11C
11C
(a) Install EGR coolant temperature sensor. Tighten it to
specified torque. 11C
(b) Connect EGR coolant temperature sensor connector.
11C
11C
11C
11C
11C
9. FILL COOLANT. (Refer to “Chapter 17C cooling - coolant, replacement”)

11C-16 ENGINE CONTROL SYSTEM - EGR COOLANT TEMPERATURE SENSOR


replacement”)
ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR 11C-17
THROTTLE POSITION SENSOR

PRINCIPLE
11C
(a) Throttle position sensor is used to provide EGR valve 11C
electronic control module throttle angle, engine idling
rotation rate and location information. The sensor is 11C
three-wire type. EGR valve electronic control module
detect changes by monitoring the voltage of the throttle
11C
opening.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-18 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR
INSPECTION ON VEHICLE
3. CONNECT THE SCAN TOOL TO THE DATA LINK
CONNECTOR (DLC).
5. SELECT 4 LEVEL, READ DATA STREAM.
Standard Voltage
Throttle Condition Specified Condition

Fully open 4.3 ± 01 V
Fully closed 1.0 ± 0.5 V
6. IF IT IS NOT OK, CHECK TPS, HARNESS OR EGR VALVE ELECTRONIC CONTROL MODULE.
REPLACEMENT
2. ROTATE DRIVER SEAT. 11C

(b) Rotate the driver seat. 11C
11C
11C
11C
3. OPEN THE BATTERY COVER. 11C

11C
11C
11C
11C
11C
NOTE 11C
please first turn off the ignition switch and lighting switch 11C
cable when peforming these operations. 11C
11C
11C
5. REMOVE WATER PIPE BRACKET.
(a) Loosen water pipe bracker retaining bolt. 11C
(b) Remove it aside.
11C
11C
11C
11C-20 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR
6. REMOVE THROTTLE POSITION SENSOR.

(a) Disconnect throttle position sensor connector.
(b) Remove 2 throttle position sensor retaining bolts.
7. INSTALL THROTTLE POSITION SENSOR.

(a) Tighten 2 throttle position sensor retaining bolts.
(b) Connect throttle position sensor connector.
11C
11C
11C
11C
11C
11C
11C
8. ADJUST THE THROTTLE POSITION SENSOR.
9. INSTALL WATER PIPE BRACKET. 11C
10. INSTALL WATER PIPE BRACKET RETAINING BOLTS.
11. CONNECT BATTERY NEGATIVE CABLE. 11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-22 ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR
EGR VALVE LIFT SENSOR

PRINCIPLE
1. EGR VALVE LIFT SENSOR DESCRIPTION.
(a) Based on the different conditions, the function for EGR
valve electronic control module are the following:
Calculates required quantity of exhaust gas recirculation.
Controls the EGR valve opening by controlling the EGR
vacuum regulator returns part of exhaust gas in the
exhaust pipe through recirculation to the intake manifold.
Makes it mixed with flesh air and into the combustion
chamber. Reduces the combustion temperature, so as to
pollution.
ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR 11C-23
OVERHAUL

11C
11C
11C

11C
11C
11C
11C
11C
NOTE 11C
11C
11C
replacement”) 11C
6. REMOVE BUCKLE ASSY. 11C
11C
11C

9. REMOVE EGR VALVE LIFT SENSOR.

(a) Disconnect EGR valve lift sensor connector.
10. REMOVE EGR VALVE VACUUM TUBE.
11. REMOVE 2 BOLTS RETAINING EGR VALVE TO

INTAKE MANIFOLD.
ENGINE CONTROL SYSTEM - EGR VALVE LIFT SENSOR 11C-25
12. REMOVE 2 BOLTS RETAINING EGR VALVE TO EGR

RECIRCULATION TUBE.
11C
11C
11C
11C
14. INSTALL 2 BOLTS RETAINING EGR VALVE TO EGR
RECIRCULATION TUBE. 11C
11C
11C
11C
11C
15. INSTALL 2 BOLTS RETAINING EGR VALVE TO INTAKE
MANIFOLD. 11C
11C
11C
11C
11C
16. CONNECT EGR VALVE VACUUM TUBE AND CONNECTOR.
11C
11C
11C
11C
11C
17. INSTALL 7 ENGINE COVER RETAINING BOLTS. 11C


replacement”)
ENGINE CONTROL SYSTEM - FUEL INLET SOLENOID VALVE 11C-27
FUEL INLET SOLENOID VALVE

PRINCIPLE
11C
1. FUEL INLET SOLENOID VALVE DESCRIPTION.
(a) Fuel goes through the fuel inlet solenoid valve into the 11C
pump. After turning the ignition switch OFF, the solenoid
valve is OFF. At this moment, fuel can not enter into the 11C
fuel pump, then the engine flameout. The fuel inlet
solenoid valve is directly controlled by the ignition switch.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-28 ENGINE CONTROL SYSTEM - FUEL INLET SOLENOID VALVE
OVERHAUL



NOTE
replacement”)

11C
11C
11C
11C
9. REMOVE FUEL FUEL INLET SOLENOID VALVE.
(a) Disconnect fuel inlet solenoid valve connector. 11C
11C
11C
11C
11C
10. CHECK FUEL INLET SOLENOID VALVE RESISTANCE.
11C
(a) Turn digital multimeter to Ohm range. Check resistance
between terminal 1 and shell. 11C
11C
11C
11C
(c) Remove fuel inlet solenoid valve. 11C
11C
11C
11C
11C
11C
11C-30 ENGINE CONTROL SYSTEM - FUEL INLET SOLENOID VALVE
11. INSTALL FUEL INLET SOLENOID VALVE.

(a) Install fuel inlet solenoid valve.
(b) Connect fuel inlet solenoid valve connector.


replacement”)
17. COVER AND TIGHTEN THE BATTERY COVER LOCK KNOB. 11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-32 ENGINE CONTROL SYSTEM - GLOW PLUG
GLOW PLUG
OVERHAUL



NOTE
5. REMOVE GLOW PLUG.

(a) Disconnect glow plug connector.
ENGINE CONTROL SYSTEM - GLOW PLUG 11C-33
(b) Remove 2 glow plug retaining bolts.
11C
11C
11C
11C
11C
11C
11C
6. INSTALL GLOW PLUG.
(a) Install 2 glow plug retaining bolts. 11C
(b) Connect glow plug connector.
11C
11C
11C
11C
11C
11C
7. INSTALL 7 ENGINE COVER RETAINING BOLTS. 11C

11C
11C
11C
11C
11C
11C-34 ENGINE CONTROL SYSTEM - GLOW PLUG

replacement”)
ENGINE CONTROL SYSTEM - EGR VACUUM SOLENOID VALVE 11C-35
EGR VACUUM SOLENOID VALVE

OVERHAUL
1. TURN IGNITION SWITCH OFF. 11C

11C
11C
11C

(b) Open the battery cover. 11C
11C
11C
11C
4. DISCONNECT BATTERY NEGATIVE CABLE. 11C
NOTE 11C
11C
11C
5. DISCONNECT EGR VACUUM SOLENOID VALVE CONNECTOR
AND VACUUM PIPE. 11C
NOTE
Record vacuum pipe connection location and mark it to 11C
avoid a connection error during installation.
11C
11C-36 ENGINE CONTROL SYSTEM - EGR VACUUM SOLENOID VALVE
6. REMOVE 2 EGR VACUUM SOLENOID VALVE RETAINING

BOLTS.
7. REMOVE EGR VACUUM SOLENOID VALVE.
8. CHECK EGR VACUUM SOLENOID VALVE.

(a) Turn the ignition switch OFF, disconnect EGR vacuum
solenoid valve connector. Check resistance between
solenoid valve terminal 1 and 4.
Standard resistance: 41 Ω (20 ℃ )
(b) EGR vacuum solenoid valve operating voltage is 12 V,
opening time ＜ 1 second, off time ＜ 0.2 seconds.
(c) When the vacuum is insufficient and difficulty to open,
check whether the leakage phenomenon of the
connection hose exist.
NOTE
• Inspect EGR vacuum solenoid valve, there should
not exist cracks and damages on surface. If it is
abnormal, replace it.
• Black smoke may be result from serious engine
failure.
9. INSTALL EGR VACUUM SOLENOID VALVE.
10. INSTALL 2 EGR VACUUM SOLENOID VALVE RETAINING

BOLTS.
11. CONNECT EGR VACUUM SOLENOID VALVE CONNECTOR

AND VACUUM PIPE.
NOTE
Install the vacuum pipe in accordance with the mark before
disconnecting.
ENGINE CONTROL SYSTEM - EGR VACUUM SOLENOID VALVE 11C-37

11C
11C
11C
11C
11C
Torque: 41 ~ 51 N•m 11C
11C
11C
11C
11C
11C
replacement”)
16. CONNECT BATTERY NEGATIVE CABLE. 11C
18. PUT DOWN DRIVER SEAT AND LOCK IT. 11C
11C
11C
11C
11C
11C
11C
11C
11C-38 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR

PRINCIPLE
(a) Vehicle speed sensor is the type of hall sensor. It works
together with signal wheel on output shaft. Unified meter
measures digital voltage signal through it and determines
the current speed of the vehicle.
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11C-39
1. INSPECT STEPS.
11C
(c) Connect the oscilloscope to the vehicle speed sensor. 11C
(d) Driving the vehicle, read the scan tool data stream: vehicle speed.
(e) Vehicle speed: Same value as the actual vehicle speed. 11C
(f) If the displayed value is not equal to the actual value, then check sensor, harness and EGR valve
electronic control module . 11C
(g) Raise vehicle.
(h) Turn the ignition switch ON and engine stop. check as following: 11C
• Set digital multimeter to voltage range. Check voltage 11C

between terminal 2 and 3 of the sensor. It should be 12
V. If it is not OK, replace it with a new one. 11C
11C
11C
11C
(i) Start engine. push the shift lever to gear. Using the oscilloscope, check the wave output of terminal 1 of 11C
sensor. If it’s not OK, check harness and sensor.
11C
11C
11C
11C
11C
11C
11C
11C
11C
11C-40 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR
OVERHAUL



NOTE
5. RAISE VEHICLE.

ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11C-41

NOTE
11C
11C
11C
11C
(a) Tighten vehicle speed sensor retaining bolt. 11C
Torque: 7.5 N•m
11C
NOTE
Do not allow any impact tools (such as a hammer, etc.) to 11C
11C
11C
11C
11C
11C
11C
11C
8. CONNECT VEHICLE SPEED SENSOR CONNECTOR. 11C

9. LOWER VEHICLE.
11C
11. COVER AND TIGHTEN THE BATTERY COVER LOCK KNOB. 11C
11C
11C
11C
MEMO
FUEL
11B
FUEL SYSTEM................................................................................. 12C-1
PRECAUTION............................................................................ 12C-1
PROBLEM SYMPTOMS TABLE................................................ 12C-3
FUEL TANK ASSY........................................................................... 12C-5 11B
COMPONENTS ......................................................................... 12C-5
REPLACEMENT ........................................................................ 12C-6
FUEL PRECIPITATOR ASSY ........................................................ 12C-11
REPLACEMENT ...................................................................... 12C-11 11B
FUEL LEVEL SENSOR ASSY ....................................................... 12C-15
REPLACEMENT ...................................................................... 12C-15
FUEL STRAINER ASSY ................................................................ 12C-16
REPLACEMENT ...................................................................... 12C-16
ELECTRONIC CONTROL VE DISPENSING PUMP ASSY........... 12C-17
COMPONENTS ....................................................................... 12C-17
REPLACEMENT ...................................................................... 12C-18
FUEL INJECTOR ASSY................................................................. 12C-23
OVERHAUL ............................................................................. 12C-23
FUEL FILLING DOOR.................................................................... 12C-26
REPLACEMENT ...................................................................... 12C-26
12C
FUEL - FUEL SYSTEM 12C-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12C
(a) Before working on fuel system, disconnect battery negative cable if necessary.
(b) When removing the fuel hose, use a suitable container to hold the diesel.
(d) Fuel in the ve dispensing pump and tubes remain under high pressure. In order to avoid personal
injury, do not loosen tube connector while engine is runing.
(e) Keep diesel away from rubber and leather parts.
(f) Diesel injection equipment is designed to very precise tolerances and fine clearances. To prevent fuel
system damage, it is essential that absolute cleanliness is oberved when working with these
components. Always install fuel system caps to any open orifices or tubes.
(g) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system
(h) Check if there is any dirt like mud around the fuel tube connector before this work. And clean dirt away,
(i) Keep cleaner away from the O-ring of tube connecter. Cleaner can harm seal of fuel system.
(j) Don’t bend or twist the fuel system tube and pipe by force.
(k) Before connceting fuel system tube, be sure there is no damage to tube connector. If there is damage,
crack or dirt on surface. replace it with a new tube assy.
(l) Wearing eyeshield equipment is needed when working on fuel system compoments. Failure to follow
this instruction may result in personal injury.
(m) The metal parts like zn, cu, mn are easily dissolved in diesel. coking may appears in fuel injector which
reduces the injected diesel to cylinder. So the matal parts above should not be used in high-pressure
common rail fuel system.
(n) It is essential to keep fuel system clean. especially it can not contain any impurity, such as corrosion,
welding spatter. Otherwise, these impurity can block fuel tube, engine shut down suddenly. The
common rail parts are even damaged. 12C
12C-2 FUEL - FUEL SYSTEM

(a) Disconnect electronic control VE dispensing pump fuel cut solenoid valve harness connector.
(c) Start the engine again for 5 seconds, ensure fuel manifold branch relief pressure is complete.
(d) Connect electronic control VE dispensing pump fuel cut solenoid valve harness connector.

(c) Open the fuel filling door.
(d) Raise the vehicle in place.
suitable container.
FUEL TUBE CLEAN

FUEL - FUEL SYSTEM 12C-3

12C
2. Fuel (No fuel or poor fuel quality) -
Chapter 12C fuel - fuel precipitator, replace-


4. Fuel precipitator (Blocked) ment
Engine does not start
5. Lower-pressure fuel way Chapter 12C fuel - fuel system, precaution
(Blocked or leaking)
6. Electronic control VE dispensing Chapter 12C fuel - electronic control VE

pump (Damaged) dispensing pump, overhaul
7. Heater plug (Damaged) -
8. Fuel injector (Damaged) Chapter 12C fuel - fuel injector, overhaul
1. Lower-pressure fuel circuit Chapter 12C fuel - precaution


Chapter 12C fuel - fuel precipitator,

4. Fuel precipitator (Blocked) replacement
Engine starts hardl
5. Heater plug (Out of order) -
12C
6. High-pressure fuel circuit (Low Chapter 12C fuel - electronic control VE
pressure) dispensing pump, overhaul

pump (Faulty) dispensing pump, overhaul
8. Fuel injector (Out of order) Chapter 12C fuel - fuel injector, overhaul


3. Fuel precipitator (Blocked) ment
Engine idles rough
4. Lower-pressure fuel circuit Chapter 12C fuel - fuel system, precaution
5. Fuel injector (Out of order) Chapter 12C fuel - fuel injector, overhaul

pump (Out of order) dispensing pump, overhaul
12C-4 FUEL - FUEL SYSTEM

Engine emits white or
2. Lower-pressure fuel way Chapter 12C fuel - fuel system, precaution
blue smoke
(Blocked)
3. Heater plug (Out of order) -
Engine emit black smoke 1. Fuel injector (Out of order) Chapter 12C fuel - fuel injector, overhaul
2. Lower-pressure fuel circuit Chapter 12C fuel - fuel system, precaution


Engine loss of power 3. Fuel precipitator (Blocked) ment
4. Fuel injector (Work badly) Chapter 12C fuel - fuel injector, overhaul

pump (Out of order) dispensing pump, overhaul
FUEL - FUEL TANK ASSY 12C-5
FUEL TANK ASSY

COMPONENTS
12C
1 Fuel Return Hose 5 Fuel Tank Breathe Hose
2 Fuel Inlet Hose Bracket 6 Fuel Filling Cap 12C

3 Diesel Fuel Precipitator Assy 7 Fuel Tank Cover

12C-6 FUEL - FUEL TANK ASSY
REPLACEMENT
2. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”)
3. REMOVE SPARE TIRE AND SPARE TIRE BRACKET.

NOTE
Do not remove bracket holder.
(b) Loosen the holder, put down the bracket and take off the
spare tire.

body.
4. DRAIN FUEL TANK. (Refer to “Chapter 12C fuel - fuel system, precaution”)


DISCONNECT IT.

DISCONNECT IT.
12C
9. LOOSEN FUEL INLET/RETURN HOSE CLAMPS AND

DISCONNECT THEM.

12C
(b) Lower the fuel tank slowly, disconnect the fuel level
sensor connector.
NOTE
• Check if there is any dirt like mud and tube, harness
around the fuel tank. Clean the dirt if necessary.
• When remove fuel tank, as fuel tank is large and
heavy. It is necessary to use proper tool or have
others help.

screws.

NOTE
necessary.
12. REMOVE FUEL STRAINER ASSY.

(b) Take out the fuel strainer.

NOTE
fuel strainer before this work and clean the dirty
away.

screws.
Torque: 6 ~ 8 N•m

Torque: 6 ~ 8 N•m

(a) Raise the fuel tank assy to satiable position by jack.
12C

NOTE
viberation.

CLAMP.
12C
TIGHTEN CLAMP.

TIGHTEN CLAMPS.

BOLTS.


(c) Position the spare tire and install the spare tire bracket
holder.
(d) Tighten the spare tire bracket holder retaining bolt.

With the ignition switch ON, inspect the fuel gauge display normal or not. Start engine, inspect if there is
FUEL - FUEL PRECIPITATOR ASSY 12C-11
FUEL PRECIPITATOR ASSY

REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”) 12C
2. RAISE VEHICLE.
3. REMOVE FUEL PRECIPITATOR ACCESSORIES .

(a) Loosen fuel precipitator inlet/return hose clips and
disconnect them.
(b) Disconnect fuel precipitator connector.
4. LOOSEN 2 FUEL PRECIPITATOR ASSY HAND PUMP

RETAINING BOLTS.
5. REMOVE FUEL PRECIPITATOR ASSY.

6. REPLACE FUEL PRECIPITATOR ASSY.
(a) Clean fuel precipitator suface completly and clamp diesel inlet hose.
(b) Remove the fuel precipitator assy by wrench or proper 12C

tool.
(c) Clean precipitator bottom base, be sure to tighten the
screw connector of precipitator.
(d) Apply clean diesel to the new precipitator seal surface
and fill clean diesel to new precipitator.
(e) Lightly screw the fuel precipitator into bottom base, and
tighten it until feeling resistance.
(f) Using wrench or special tool, tighten fuel precipitator.
Inspect fuel leakage.
(g) Bleed the air from fuel precipitator.
12C-12 FUEL - FUEL PRECIPITATOR ASSY
7. TIGHTEN 2 FUEL PRECIPITATOR HAND PUMP

RETAINING BOLTS.
8. INSTALL FUEL PRECIPITATOR ACCESSORIES .

(a) Conect fuel precipitator inlet/return hose and tighten the
clamps.
(b) Connect fuel precipitator connector.
9. CHECK FUEL PRECIPITATOR.

With the ignition switch ON, inspect the fuel gauge conditions. Start engine and inspect if there is fuel
leakage from pipe.
FUEL - FUEL PRECIPITATOR ASSY 12C-13
FUEL PRECIPITATOR BLEEDING

1. LOWER FUEL CIRCUIT.
(a) Push hand pump knob at 40 times/min till feel unable to 12C
press so far.
(b) Hold the push knob, loosen the air bleeding bolt on the
fuel precipitator. bleeding the air, then tighten the bleed-
ing bolt.
NOTE
Release the push knob after tighten the air bleeding bolt.
12C
(c) Push the hand pump knob and bleeding air for several
times until there is no air exhaust from the air bleeding
bolt.
2. HIGH-PRESSURE FUEL CIRCUIT

(a) Loosen the nut attaching high-pressure tube to injector.
Start the engine, bleeding the air in the high-pressure cir-
cuit.
(b) Ensure there is no air exhaust from the high-ressure
tube. Tighten the nut quickly. Use the same way bleeding
the air from the high-pressure in proper order until the
engine can be started.
(c) Ensure the hand pump had been locked.
12C-14 FUEL - FUEL PRECIPITATOR ASSY
BLEEDING WATER FROM WATER/FUEL SEPARATOR.

NOTE
During engine running, water/fuel separator indicator keeps light, it means that water in water/fuel
separator needs to be bleeded.
1. Stop the vehicle at flat and safe place.
2. BLEEDING WATER FROM WATER SEPARATOR.

(a) Put the suitable container (0.2L) under the fuel/water
seperator.
(b) Loosen drain plug (about five circles). Push and pull
knob 10 times to drain water until fuel/water seperator is
full of diesel.
(c) Tighten drain plug after bleeding the water. Pull and push
knob serval times.
(d) Start the engine to make sure that no fuel leaks from
drain plug. Check water/fuel indictor off.
NOTE
• If draining water from water/fuel sperator is frequent, it means that fuel is not qualified or there
is water in fuel tank. Please drive the vehicle to service station for repair.
• In order to ensure fuel clean, in strict accordance with maintenance requirement to operate fuel
precipitator sechudle maintenance. Replacement cycle: 15000 km.
FUEL - FUEL LEVEL SENSOR ASSY 12C-15

REPLACEMENT
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”) 12C
4. REMOVE FUEL TANK. (Refer to “Chapter 12C fuel - fuel tank, replacment”)

(a) Remove the 5 fuel level sensor sealing cover retaining
screws.

NOTE
away.

(b) Tighten the 5 fuel level sensor sealing cover retaining 12C
screws.
Torque: 6 ~ 8 N•m
7. INSTALL FUEL TANK. (Refer to “Chapter 12C fuel - fuel tank, replacement”)
8. CHECKFUEL LEVEL SENSOR ASSY.
(a) After disconnecting fuel pump connector, connect fuel level sensor connector, turn the ignition switch
ON. Slide fuel level sensor position manually. Ensure fuel gauge is in good condition from instrument
cluster.
(b) After connecting, check if the fuel tube connector and pipe are securely connected by pulling them.
leakage from pipe.
12C-16 FUEL - FUEL STRAINER ASSY
FUEL STRAINER ASSY

REPLACEMENT
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”)
4. REMOVE FUEL TANK. (Refer to “Chapter 12C fuel - fuel tank, replacment”)

(b) Take out the fuel fuel strainer.

NOTE
away.

Torque: 6 ~ 8 N•m
7. INSTALL FUEL TANK. (Refer to “Chapter 12C fuel - fuel tank, replacement”)
leakage from pipe.
FUEL - ELECTRONIC CONTROL VE DISPENSING PUMP ASSY 12C-17
ELECTRONIC CONTROL VE DISPENSING PUMP ASSY

COMPONENTS
12C
1 EGR Valve 9 ECM
2 Communication Connector 10 Timing Sensor 12C

3 Speed Sensor 11 Timing Solenoid Valve
4 Harness 12 Fuel Inlet Solenoid Valve
5 Fuel Tank 13 Accelerator position sensor
6 Fuel Strainer 14 ECT sensor
7 Fuel Precipitator 15 Fuel Outlet Solenoid Valve
8 Engine Appearance
12C-18 FUEL - ELECTRONIC CONTROL VE DISPENSING PUMP ASSY
REPLACEMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”)
2. DISCONNECT BATTERY NEGATIVE CABLE .

(b) Turn the driver seat.
4. LOOSEN ELECTRONIC CONTROL VE DISPENSING

PUMP INLET/RETURN HOSE CLAMP AND DISCON-
NECT THEM.

6. DISCONNECT 4 FUEL HIGH-PRESSURE TUBE.
12C
7. LOOSEN FUEL HIGH-PRESSURE TUBE CLAMP.
8. REMOVE ENGINE TIMING GEARS. (Refer to “Chapter 15C engine mechanical - timing gear,
overhaul”)
9. REMOVE ELECTRONIC CONTROL VE DISPENSING

PUMP TIMING GEAR RETAINING BOLT.
12C
10. SEPERATE ELECTRONIC CONTROL VE DISPENSING PUMP TIMING GEAR.

11. DISCONNECT ELECTRONIC CONTROL VE DISPENSING PUMP CONNECTORS AS FOLLOW-
ING:
• Fuel outlet solenoid valve
• Fuel inlet solenoid valve
• Timing sensor
• Speed sensor
12. REMOVE ELECTRONIC CONTROL VE DISPENSING

PUMP.
(a) Loosen 3 bolts attaching electronic control VE dispensing
pump to electronic control VE dispensing pump flange.
(b) Remove electronic control VE dispensing pump.
NOTE
• Every bolt of electronic control VEdispensing pump
has already been tighten before leaving factory. Do
not remove or adjust when using. If electronic
control VEdispensing pump has malfunction, it need
authroized engineer inspection and testing if
necessary.
• Do not knock pump shaft when installing.
• The new electronic control VEdispensing pump must
be lubricated with special equipment and correct
process at the first time. Pump fuel from inlet till no
bubble appear at fuel return flow. Normal lubrication
is needed for friction pieces and sealing area.
13. INSTALL ELECTRONIC CONTROL VE DISPENSING

PUMP.
(a) Position electronic control ve dispensing pump.
(b) Tighten 3 bolts attaching electronic control VE dispensing
pump to electronic control VE dispensing pump flange.
NOTE
• Before install VE dispensing pump, clean dirt from
drive shaft by gaslion and alcohol.
• Make sure the correct installing position is followed
when install the VE dispensing pump.
14. TIGHTEN ELECTRONIC CONTROL VE DISPENSING

PUMP TIMING GEAR RETAINING BOLT.
15. INSTALL ENGINE TIMING GEAR. (Refer to “Chapter 15C engine mechanical - timing gear,
overhaul”)
16. TIGHTEN 4 FUEL HIGH-PRESSURE TUBE NUTS.

12C
17. INSTALL FUEL HIGH-PRESSURE TUBE CLAMP.
18. CONNECT ELECTRONIC CONTROL VE DISPENSING

PUMP INLET/RETURN HOSE AND TIGHTEN CLAMP.
12C

20. CONNECT ELECTRONIC CONTROL VE DISPENSING PUMP CONNECTORS AS FOLLOWING:

• Fuel outlet solenoid valve
• Fuel inlet solenoid valve
• Timing sensor
• Speed sensor
FUEL - FUEL INJECTOR ASSY 12C-23
FUEL INJECTOR ASSY

OVERHAUL
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12C fuel - fuel system, precaution”) 12C

4. REMOVE NUTS ATTACHING HIGH PRESSURE TUBE

TO FUEL INJECTOR.
NOTE
To avoid injector bolt seat looseness, fixing related bolt
seat by other tool is needed when removing injector nut.
5. LOOSEN INJECTOR PRESSING PLATE NUTS.
12C
12C-24 FUEL - FUEL INJECTOR ASSY
6. DISCONNECT FUEL INJECT RETURN TUBE CLIP.

NOTE
• Inspect the inject with carbon deposition blocked . Clean carbon deposition by ultrasonic clean-
ing.
• Replace it with a new copper gasket after removing the injector.
NOTE
• Position injector gasket on atomizer element seal surface . slightly push injector into cylinder
injector hole.
• Apply clean oil to lubricate all seal (O type ) when installation.
9. TIGHTEN INJECTOR PLATE RETAINING BOLTS.

Torque:
First step: 7.5 ~ 9 N•m
Second step: turn 40 ~ 45°
FUEL - FUEL INJECTOR ASSY 12C-25
10. CONNECT INJECTOR FUEL RETURN TUBE

ASSEMBLY CLIP.
NOTE
Fixing Bracket of injector fuel return tube assembly must 12C
be relaced if bended.
11. INSTALL NUTS ATTACHING FUEL HIGH PRESSURE

TUBE TO FUEL INJECTOR.

13. CHECK FUEL INJECTOR.
After connecting all connectors, check if the fuel tube connector and pipe are securely connected by
pulling them. With the ignition switch ON, inspect the fuel gauge conditions. Start engine , Inspect if
there is fuel leakage from fuel filter pipe.
12C
12C-26 FUEL - FUEL FILLING DOOR
FUEL FILLING DOOR

REPLACEMENT

(c) Tighten the fuel filling door retaining bolts.
EMISSION CONTROL
13C
FUEL TANK CAP .............................................................................13C-1
INSPECTION .............................................................................13C-1
ELECTRONIC CONTROL EGR VALVE .......................................... 13C-2
COMPONENTS ......................................................................... 13C-2 13C
REPLACEMENT ........................................................................ 13C-3
VACUUM REGULATOR .................................................................. 13C-5
OVERHAUL ............................................................................... 13C-5
13C
13C
EMISSION CONTROL - FUEL TANK CAP 13C-1
FUEL TANK CAP

EMISSION CONTROL
INSPECTION
13C

(a) Visually inspect fuel tank cap and gasket. If deformed or
13C
13C-2 EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE
ELECTRONIC CONTROL EGR VALVE

COMPONENTS
1 Accelerator Position Sensor 5 EGR Circulating Pipe
2 EGR Vacuum Solenoid Valve Assy 6 ECM
3 Electronic Control EGR Valve 7 Speed Sensor
4 EGR Gasket 8 ECT Sensor

EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE 13C-3
REPLACEMENT
(a) Loosen the driver seat clamp. 13C
2. DISCONNECT ELECTRONIC CONTROL EGR VALVE

CONNECTOR AND VACUUM HOSE.
3. REMOVE 2 BOLTS ATTACHING EGR VALVE AND INTAKE

MANIFOLD.
13C
4. REMOVE 2 BOLTS ATTACHING EGR VALVE AND EGR

CIRCULATING PIPE.
5. REPLACE EGR VALVE.

NOTE
Inspect if EGR valve opens/closes smoothly or not. Replace with a new one if blocked .
6. REPLACE EGR GASKET.

13C-4 EMISSION CONTROL - ELECTRONIC CONTROL EGR VALVE
7. INSTALL 2 BOLTS ATTACHING EGR VALVE AND EGR

CIRCULATING PIPE.
8. INSTALL 2 BOLTS ATTACHING EGR VALVE AND

INTAKE MANIFOLD.
9. CONNECT ELECTRONIC CONTROL EGR VALVE

CONNECTOR AND VACUUM HOSE.

EMISSION CONTROL - VACUUM REGULATOR 13C-5
VACUUM REGULATOR
OVERHAUL
13C
2. DISCONNECT VACUUM REGULATOR CONNECTOR

AND VACUUM HOSE.
NOTE
Mark the vacuum hose position to avoid incorrect installation.
3. REMOVE VACUUM REGULATOR RETAINING BOLTS.
13C
4. TAKE OFF VACUUM REGULATOR.

NOTE
• Visully inspect vacuum regulator for deform and damage. Replace with a new one if abnormal.
• Turn the ignition switch off. Remove vacuum regulator connector, measure the resistance
between two terminals. The resistance is around 41 ohm. If not, replce with a new one. Vacuum
regulator working voltages is 12 volt, opening time is less than 1s, closing time is less than
0.2s.
• When EGR valve opens difficultly or vacuum degree absence, please check if air leakage exists.
• It can cause engine exhaust be heavy black smoke with failed vacuum regulator.
5. POSITION VACUUM REGULATOR.

13C-6 EMISSION CONTROL - VACUUM REGULATOR
6. INSTALL VACUUM REGULATOR RETAINING BOLTS.


VACUUM HOSE.
NOTE
Install the vacuum hose following the mark before remove.

INTAKE AIR
14C
INTAKE AIR SYSTEM...................................................................... 14C-1
PRECAUTION............................................................................ 14C-1
COMPONENTS ......................................................................... 14C-2
AIR STRAINING BOX ASSY ........................................................... 14C-4 14C
REPLACEMENT ........................................................................ 14C-4
AIR FILTER ASSY ........................................................................... 14C-7
REPLACEMENT ........................................................................ 14C-7
INTAKE AIR HOSE ........................................................................ 14C-12 14C
REPLACEMENT ...................................................................... 14C-12
TURBOCHARGER ASSY .............................................................. 14C-17
MAINTENANCE OF TURBOCHARGER .................................14C-17
REPLACEMENT ...................................................................... 14C-18
INTAKE MANIFOLD....................................................................... 14C-24
REPLACEMENT ...................................................................... 14C-24
14C
INTAKE AIR - INTAKE AIR SYSTEM 14C-1
INTAKE AIR SYSTEM

INTAKE AIR
PRECAUTION
1. INTAKE AIR SYSTEM PRECAUTION. 14C
(d) When using the solvent, acid or alkaline material washing, please follow the manufacturers’ advice to
wear protective clothing and goggles to avoid personal injury.
(e) When dealing with corrosive work, use skin and eye protection device to reduce the possibility of
personal injury.
(f) When using compressed air, wear appropriate goggles and protective mask. Both dust particles and
dirt will cause injury.
14C
14C-2 INTAKE AIR - INTAKE AIR SYSTEM
COMPONENTS
1 Screw 12 Elastic Double End Bolt

2 Intake Air Grille 13 Nut
3 Screw Seat 14 Seal Ring
4 Air Straining Box Assy 15 Corrugated Pipe-air Filter
5 Bolt 16 Intake Pipe
6 Clip 17 Bolt
7 Intake Hose 18 Spring Washer
8 Air Filter Assy 19 Clip
9 Split Sleeve 20 Rubber Hose
10 Spring Washer 21 Engine Intake Pipe Assy
11 Bolt 22 Stud Bolt
INTAKE AIR - INTAKE AIR SYSTEM 14C-3
14C
1 Heat Insulating Board 5 Exhaust Pipe

14C
2 Exhaust Manifold 6 Exhaust Pipe Gasket
3 Exhaust Manifold Gasket 7 Turbocharger
4 Reinforcement Board
14C-4 INTAKE AIR - AIR STRAINING BOX ASSY

REPLACEMENT
1. REMOVE AIR GRILLE.
(a) Remove 2 intake air grille retaining bolts.
(b) Remove intake air grille assy.

(a) Loosen 6 B-pillar inner guard board retaining bolts.
3. REMOVE AIR FILTER ASSY. (Refer to “Chapter 14C intake air - air filter assy, replacement”)
4. REMOVE AIR STRAINING BOX ASSY.

(a) Loosen 4 air straining box retaining bolts.
INTAKE AIR - AIR STRAINING BOX ASSY 14C-5
(b) Loosen clamp attaching air straining box and outer air
inlet hose.
14C
5. INSPECT AIR STRAINING BOX.

(a) Inspect the air straining box for any cracks or damage. If
necessary, replace it with a new one.
6. INSTALL AIR STRAINING BOX.

(a) Install the air straining box, tighten 4 air straining box 14C
retaining bolts.
(b) Connect clamp attaching air straining box and outer air
inlet hose.
14C-6 INTAKE AIR - AIR STRAINING BOX ASSY
7. INSTALL AIR FILTER ASSY. (Refer to “Chapter 14C intake air -air filter assy, replacement”)
8. INSTALL B-PILLAR INNER GUARD BOARD .

(a) Position b-pillar inner guard board and tighten 6 retaining
bolts.
9. INSTALL AIR GRILLE.

(a) Tighten 2 intake air grille retaining bolts.
INTAKE AIR - AIR FILTER ASSY 14C-7
AIR FILTER ASSY

REPLACEMENT
14C
replacement”)
4. REMOVE ENGINE SURFACING. 14C
5. REMOVE ENGINE COVER.

(a) Loosen 7 engine cover retaining bolts.
6. REMOVE AIR FILTER COVER.

(a) Loosen 3 air filter cover retaining bolts.
14C-8 INTAKE AIR - AIR FILTER ASSY

(a) Loosen air filter bellow hose clip.
NOTE
(b) Loosen 2 air filter assy intake hose clamp.
(c) Loosen 2 retaining bolts from air filter assy.

(d) Remove air filter assy.
8. DISASSEMBLE AIR FILTER ASSY.

(a) Loosen air filter lower cover knob.
(b) Remove air filter lower cover, take out the air filter.
(c) When cleaning the air filter, rotate the air filter by hand
14C
MPa.
NOTE
with water.
• Before using the compressed air, wear proper
9. REASSEMBLE AIR FILTER ASSY.
(a) Install the air filter.
(b) Install air filter lower cover and tighten knob.
14C
10. INSTALL AIR FILTER ASSY.

(a) Tighten 2 air filter assy retaining bolts.
14C-10 INTAKE AIR - AIR FILTER ASSY
(b) Connect air filter assy intake hose and tighten clamp.
(c) Connect air filter bellow hose and tighten clip.
11. INSPECT AIR FILTER ASSY.

(a) After installing air filter, check all parts and parts connection again to make sure engine operates
properly.
12. INSTALL AIR FILTER COVER.

(a) Tighten 3 air filter cover retaining bolts.
13. INSTALL ENGINE COVER RETAINING BOLTS.

(a) Tighten 7 engine cover retaining bolts.


14C
replacement”)
14C
14C-12 INTAKE AIR - INTAKE AIR HOSE
INTAKE AIR HOSE

REPLACEMENT
replacement”)

6. REMOVE AIR FILTER COVER.

(a) Loosen 3 air filter cover retaining bolts.
INTAKE AIR - INTAKE AIR HOSE 14C-13

(a) Loosen air filter bellow hose clip.
NOTE
14C
(b) Loosen intake air pipe and air filter bellow hose clip.
(c) Loosen intake air pipe and air filter hose clip.
14C
(d) Loosen 2 intake air pipe retaining bolts.

(e) Remove the intake air pipe.
(f) Loosen turbocharger intake air hose and intake air hose
clip.
8. INSPECT INTAKE AIR HOSE.

(a) Inspect the intake air hose for any cracks or damage. If necessary, replace it with a new one.
9. INSTALL INTAKE AIR HOSE.

(a) Connect turbocharger intake air hose and intake air hose
clip.
INTAKE AIR - INTAKE AIR HOSE 14C-15
(b) Tighten 2 intake air pipe retaining bolts.
14C
(c) Connect intake air pipe and air filter hose clip.
14C
(d) Connect intake air pipe and air filter bellow hose clip.
(e) Connect air filter bellow hose clip.
10. INSPECT INTAKE AIR PIPE.

(a) After installing air intake hose, check all parts and parts connection again to make sure engine operates
properly.
11. INSTALL AIR FILTER COVER.

(a) Tighten 3 air filter cover retaining bolts.
12. INSTALL ENGINE COVER.


replacement”)
INTAKE AIR - TURBOCHARGER ASSY 14C-17
TURBOCHARGER ASSY
MAINTENANCE OF TURBOCHARGER
To ensure work efficiency and reliability of turbo-charged diesel, the turbocharger must be given a 14C
regular maintenance besides the proper operation of the diesel. Turbocharger is a kind of precise
machine with high rotating speed, its maximum speed can reach 180000 r/min and even normal speed
can reach from tens of thousands per minute to hundreds of thousands per minute. Therefore
disassembly is not permitted. If the rotor is hard to rotate or the diesel engine has poor performance
due to excessive dirt or carbon deposits, replace turbocharger parts.
NOTE
Don’t have the impeller collided when replacing the turbocharger. If deformed, the blade can not be
used any more, replace it with a new one. Kerosene, gasoline or diesel oil with high quality can be
used as cleaning agent.
14C
14C-18 INTAKE AIR - TURBOCHARGER ASSY
REPLACEMENT
replacement”)

6. REMOVE HEAT INSULATING BOARD.

(a) Loosen 3 heat insulating board retaining bolts.
14C
7. REMOVE TURBOCHARGER INTAKE AIR HOSE.

(a) Loosen turbocharger intake air hose and intake air hose
clip.
14C
8. REMOVE TURBOCHARGER OIL PIPE.

(a) Loosen turbocharger oil inlet pipe retaining bolt.
(b) Loosen 2 turbocharger oil outlet pipe retaining bolts.

9. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust -

(a) Loosen 4 bolts attaching turbocharger to exhaust pipe.
(b) Remove the gasket.
(c) Loosen 4 bolts attaching turbocharger to exhaust

manifold.
(d) Remove the gasket.

NOTE
• The valve of open pressure is set by the manufacturer. It is forbidden for user to make any
adjustments for the nut on the push rod. Otherwise, it will seriously damage the engine
performance, oil economy and reliability.
• During the engine operation, if find leakage from lead tracheal or push rod not flexible enough,
please stop the engine and resolve the malfunction at once.
• Neither exhaust valve nor compressing room can be serviced. If damaged, replace the
turbocharger assy.
• Please do not replace the turbocharger unless you find out the malfunction.
(a) Check of rotor’s radial clearance: Press the compressor blades with a hand in radial direction and
measure the minimum clearance between the compressor blade and compressor case with gauge. The
measured value should not be less than 0.10mm, if not, replace the turbocharger assy.
(b) Check of rotor’s axial clearance: Fix a magnetic base on outlet flange facing of turbocharger. Let the
dial indicator touch the rotor spindle, and then push or pull the turbocharger rotor in axial direction to get
a clearance value. The measured value is the clearance value. The rotor’s axial clearance value of new
turbocharger should not be more than 0.1mm and operating limit value should not be more than
0.25mm. If the axial clearance value of turbocharger rotor exceeds the operating limit value, replace the
turbocharger.
(c) Check whether the impeller blades of compressor are damaged. If there is a damage, replace the
turbocharger. If the impeller of compressor is damaged, check whether the inlet pipe and core of filter
are damaged. Repair all damaged parts before running the engine.
(d) Check whether the turbine blades are damaged. If there is a damage, replace the turbocharger.
(e) Check whether there is an abnormal status in linked push rod. If the push rod is bent or excessive
abrasion, replace the turbocharger.
(f) Check whether there is any oil in compressor inlet and outlet of the turbocharger. If there is oil in
compressor inlet and outlet, check the upper parts of turbocharger to find out the source of oil leakage.
NOTE
A little oil and/or mist on the engine of closed crankcase ventilation system is permitted. It will be 14C
discharged into the intake pipe through the crankcase.
13. INSTALL TURBOCHARGER ASSY.

(a) Tighten 4 bolts attaching exhaust pipe to turbocharger
after installing a new gasket.
(b) Tighten 4 bolts attaching exhaust manifold to

turbocharger after installing a new gasket.
14. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER ASSY. (Refer to “Chapter 16B exhaust - 14C
15. CONNECT TURBOCHARGER OIL PIPE.

(a) Tighten 2 turbocharger oil outlet pipe retaining bolts.
Torque: 7.5 ~ 8.5 N•m
(b) Tighten turbocharger oil inlet pipe retaining bolt.

16. CONNECT TURBOCHARGER INTAKE AIR HOSE.

(a) Tighten turbocharger intake air hose and intake air hose
clip.
17. REMOVE HEAT INSULATING BOARD.

(a) Tighten 3 heat insulating board retaining bolts.

(a) After installing turbocharger, check all parts and parts connection again to make sure engine operates
properly.



14C
replacement”)
14C
14C-24 INTAKE AIR - INTAKE MANIFOLD
INTAKE MANIFOLD
REPLACEMENT
replacement”)

INTAKE AIR - INTAKE MANIFOLD 14C-25
6. REMVE INTAKE AIR PIPE.

(a) Loosen 2 bolts attaching intake pipe to turbocharger.
14C
7. REMOVE EGR VALVE. (Refer to “Chapter 13C Emission Control - EGR VALVE, replacement”)
8. REMOVE INTAKE AIR HOSE. (Refer to “Chapter 14C intake air - intake air hose, replacement”)
9. REMOVE TURBOCHARGER HOSE.

(a) Loosen turbocharger attaching bolt.
14C
10. REMOVE HEATED PLUG.

(a) Remove clip attaching heated plug to oil pipe.
(b) Remove heated plug assy.
11. REMOVE HEATED PLUG VALVE.

(a) Disconnect the connector.
(b) Loosen 2 bolts.
12. REMOVE INTAKE AIR PIPE.

(a) Loosen 4 intake air pipe attaching bolts.
13. REMOVE INTAKE MANIFOLD.

(a) Loosen 4 intake manifold attaching bolts.
(b) Remove the intake manifold gasket.
14. INSPECT INTAKE MANIFOLD.

(a) Inspect the intake manifold for any cracks or damage. If necessary, replace it with a new one.
NOTE
14C
Check the intake manifold carefully. If there is groove, scratch, craze or crank on it, please replace it
with a new one.
15. INSTALL INTAKE MANIFOLD.

(a) Replace intake manifold gasket with a new one.
(b) Tighten 4 retaining bolts by hand first, then tighten bolts
from middle to side regularly.
16. INSTALL INTAKE AIR PIPE.

(a) Replace intake air pipe gasket with a new one.
(b) Tighten 4 intake air pipe retaining bolts
17. INSTALL HEATED PLUG VALVE. 14C

(b) Connect the connector.
18. INSTALL HEATED PLUG.

(a) Install heated plug assy.
(b) Connect clip attaching heated plug to oil pipe.
19. INSTALL TURBOCHARGER HOSE.

(a) Tighten turbocharger attaching bolt.
20. INSTALL EGR VALVE. (Refer to “Chapter 13C Emission Control - EGR VALVE, replacement”)
21. INSTALL INTAKE AIR HOSE. (Refer to “Chapter 14C intake air - intake air hose, replacement”)
22. INSTALL INTAKE AIR PIPE.

(a) Tighten 2 bolts attaching intake pipe to turbocharger.
14C
23. INSPECT INTAKE MANIFOLD.

(a) After installing intake manifold, check all parts and parts connection again to make sure engine
operates properly.

14C

replacement”)
MEMO
ENGINE MECHANICAL
15C
ENGINE MECHANICAL PART ........................................................ 15C-1
PRECAUTION............................................................................ 15C-1
ENGINE MAINTENANCE AND CHECKLIST ............................ 15C-4 15C
ENGINE TECHNICAL PARAMETERS ...................................... 15C-5
ENGINE ASSY ................................................................................. 15C-6
REPLACEMENT ........................................................................ 15C-6
ENGINE ACCESSORY BELT ........................................................ 15C-27 15C
COMPONENTS ....................................................................... 15C-27
ON-VEHICLE INSPECTION .................................................... 15C-28
OVERHAUL ............................................................................. 15C-30
ENGINE TIMING GEAR COVER ................................................... 15C-35
REPLACEMENT ...................................................................... 15C-35
ENGINE TIMING GEAR ................................................................. 15C-39
COMPONENTS ....................................................................... 15C-39
OVERHAUL ............................................................................. 15C-40
CYLINDER HEAD AND VALVE..................................................... 15C-43
COMPONENTS ....................................................................... 15C-43
OVERHAUL ............................................................................. 15C-44
VALVE/VALVE SPRING ................................................................ 15C-55
OVERHAUL ............................................................................. 15C-55
CAMSHAFT.................................................................................... 15C-60
OVERHAUL ............................................................................. 15C-60 15C
ENGINE BLOCK ............................................................................ 15C-63
COMPONENTS ....................................................................... 15C-63
OVERHAUL ............................................................................. 15C-65
PISTON AND CONNECTING ROD ASSY..................................... 15C-71
COMPONENTS ....................................................................... 15C-71
OVERHAUL ............................................................................. 15C-73
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15C-1

ENGINE MECHANICAL
PRECAUTION
1. EMGINE MECHNANICAL PART PRECAUTION. 15C
(a) When using, follow the instructions of maintenance methods and regulations to adjust or maintain.
(b) Before starting the engine, check the coolant level. Fill or drain the coolant if necessary. Check the
engine oil level. Fill the engine oil if necessary.
(c) The clearance between ckp sensor and flywheel is 0.5 ~ 1.5 mm. Do not try to adjust it.
(d) Use the oil as requirement. Otherwise exacerbate engine wear.
(e) Use the original fittings. Otherwise it will damage the engine or affect the engine working condition.
(f) Do not use the high pressure water cannons wash the ecm shell though it is waterproof.
(g) The engine starting time should be less than 5s. Not more than 5 consecutive start times, each start
time between the two should not be less than 15 seconds.
(h) Keep the normal coolant temperature at 85 ～ 105 ℃ .
(i) When the engine is running at high speed, do not turn the ignition switch off. Keep the engine running in
low speed for 3~5 minutes. So that the engine radiate evenly.
(j) Before opening the radiator cap, ensure the engine is cool.
(k) Use the sealant scraper to clear the sundrise in seal surface. Confirm seal surface flat and smooth, no
pollution and foreign bodies.
(l) Disassembly sequence should be generally from inner to outer, assembly to parts. In order to improve
the efficiency and ensure the assembly and disassembly is correct, pay attention to checking and
making mark. Removed parts should be cleaned and inspected. The parts can be reused according to
the classification. Precision parts should be separated with general parts. Put them in clean containers.
(m) Assembly sequence should be from inside to outside, parts to components, components to assembly.
Pay attention to the size, location, clearance, torque, etc. When assembling, avoid the missing, 15C
mistaking, scratching and foreign parts into machine. Assemble bolts, nuts with suitable wrench,
uniform properly. Use anti-losseness device correctly. According to regulations, appropriately use split
cotters, spring washer, thrust washers, etc. In addition, in the assembly process, must pay attention to
the marks to ensure the good position.
(n) Ensure the diesel engine always in the state of complete cleaness. Before removing or assembling,
parts should be cleaned to ensure clean and high quality assembly. More complicated adjustment and
maintenance should be done indoor to prevent diesel engine internal parts from environmental
pollution.
(o) Pay attention to the security when repairing or dismantling. Improper tool or engine starting suddenly
will result in injury.
15C-2 ENGINE MECHANICAL - ENGINE MECHANICAL PART

cause of the problem. Check each part in the order shown. If necessary, repair or replace these parts
1. Battery (Low voltage or loose Chapter 20C starting and charging - battery,
connect) precaution
2. Electronic control VE Chapter 12C fuel - electronic control VE dispensing

dispensing pump (Damaged) pump, overhaul
3. Starting (Damaged) Chapter 20C starting and charging - starter, overhaul
4. Fuel system (Blocked) Chapter 12C fuel - precaution
Engine does not 6. Fuel supply system (Air inside) Chapter 12C fuel - fuel filter, replacement
start
7. Fuel injector (Damaged) Chapter 12C fuel - fuel injector, overhaul
Chapter 15C engine mechanical - piston and con-

8. Piston ring (Worn) necting rod, overhaul
Chapter 15C engine mechanical - cylinder head,

9. Valve (Air leaking) overhaul
Chapter 15C engine mechanical - timing gear,

10.Engine timing (Incorrect) overhaul
11. Engine Cylinder compressure -

(Low)
1. Fuel system (Blocked) Chapter 12C fuel - precaution
Chapter 15C engine mechanical - timing gear,

2. Engine timing (Incorrect) overhaul
3. Cylinder head gasket (Air leak- Chapter 15C engine mechanical - cylinder head,
ing) overhaul
Engine loss of
4. Engine cylinder compressure -
power
(Low)
5. Valve (Burned, warped, Chapter 15C engine mechanical - cylinder head,

excessive clearance) overhaul
6. Exhaust system (Blocked) Chapter 16C exhaust - precaution

1. Piston pin and small head Chapter 15C engine mechanical - piston and con-
bushing hole clearance necting rod, overhaul 15C
(Excessive bearing clearance)
2. Piston and cylinder sleeve Chapter 15C engine mechanical - piston and con-
clearance (Excessive bearing necting rod, overhaul
clearance)
Engine noise 3. Connecting rod bearing, main Chapter 15C engine mechanical - piston and con-
bearing (Excessive bearing necting rod, overhaul
clearance)
4. Valve and piston (Valve touch Chapter 15C engine mechanical - cylinder head and
the piston) valve, overhaul
5. Intake and exhaust valve Chapter 15C engine mechanical - cylinder head and
(Excessive clearance) valve, overhaul
1. Piston ring (Lock, excessive Chapter 15C engine mechanical - piston and con-
wear, wrong position) necting rod, overhaul
Engine exhaust 2. Piston and cylinder sleeve Chapter 15C engine mechanical - piston and con-
blue vapor clearance (Excessive bearing necting rod, overhaul
clearance)
3. Engine oil (Too much) -
1. Individual cylinder is not burning -

Engine exhaust
white vapor 15C
2. Diesel (Water inside) Chapter 12C fuel - fuel filter, replacement
1. Diesel engine overload Chapter 15C engine mechanical - precaution
Chapter 15C engine mechanical - cylinder head and

2. Valve (Excessive clearance) valve, overhaul
Engine exhaust 3. Intake air filter (Blocked) Chapter 14C intake air - intake air filter, replacement
black vapor
Chapter 13C emission control - EGR valve, replace-
4. EGR valve (Damaged) ment
5. Injector solenoid valve (Dam- Chapter 12C fuel - fuel injector, overhaul
aged)
15C-4 ENGINE MECHANICAL - ENGINE MECHANICAL PART
ENGINE MAINTENANCE AND CHECKLIST

ITEM Maintenance Intervals
2.5 5 10 15 20 25 30 35 40 45 50 month
Enging Oil R - R - R - R - R - R each 6 month
Oil Filter R - R - R - R - R - R each 6 month
Diesel Precipitator I I R - I R - I R - I each 9 month
Air Filter I I I I R I I I R I I each 12 month
Valve Clearance I - I - I - I - A - I each 24 month
Coolant - - - - I - - - R - - each 24 month
Battery Electrolyte - - I - I - I - I - I each 6 month

kilometreX1000
Accessory Belt I I I - I - I - I - I each 6 month
DTC Check I I I I I I I I I I I each 3 month
Coolant Pump - - - I - - I - - I - each 9 month
Electrical Equipment - - - I - - I - - I - each 9 month

Connector
Pcv - - - I - - I - - I - each 9 month
Bolt Tighten I I I I I I I I I I I each 3 month
Enging Working Condition - - I - I - I - I - I each 6 month
I：check， clear and adjustment A：adjustment R：replacement


Engine 4D20 15C
Four cylinder in-line, water cooling, four stroke, turbocharging, elec-

Engine Type
tronic control EGR
Chamber Type Direct injection ω type
Cylinder Bore 86 mm
Stroke 86 mm
Compression Ratio 18:1
Rated Power 52/3300 Kw/r/min
Maximum Torque 175 ≤ 2300 N•m/r/min
Minimum Fuel Consumption ≤ 230 g/kW•h
Crankshaft Direction Of Rotation anticlockwise

15C
15C-6 ENGINE MECHANICAL - ENGINE ASSY
ENGINE ASSY
REPLACEMENT
NOTE
• Before raising the vehicle, ensure the support position on the vehicle correctly.
• Turn the ignition switch off and lock the steering column assy.
• Use the fender protect cover to avoid damaging paint surface.
• Avoid damage, hold the head of the connector and connect wire carefully.
• Mark in all wires and hoses, and confirm not touch with the other wires or hoses, or interfere
with other parts.
• Drain coolant. (Refer to “Chapter 17B cooling - coolant, replacement”)


NOTE
Disconnect the negative first when removal.

replacement”)
ENGINE MECHANICAL - ENGINE ASSY 15C-7
15C
15C
9. REMOVE AIR INTAKE HOSE ASSY.

(a) Loosen clamps attaching air filter to intake bellow hose.
NOTE
The clamp only can be used for once, replace a new one
when installing.
(b) Loosen the clamp attaching intake bellow hose to intake

steel tube.
(c) Loosen the clamps attaching intake steel tube to connect

hose.
(d) Loosen 2 steel tube retaining bolts.

(e) Remove the steel tube.
(f) Loosen the clamp attaching intake connect hose to

turbocharger.
15C
10. LOOSEN ELECTRONIC CONTROL VE DISPENSING PUMP

INLET/OUTLET HOSE CLAMPS AND DISCONNECT THEM.
15C

NOTE
After disconnecting the fuel hose, using the plastic bag,
the fuel hose.


connection.
connection.
14. DRAIN STEERING FLUID, DISCONNECT STEERING

FLUID RESERVOIR INLET/OUTLET HOSE.
NOTE
Do not splash the steering fluid on the engine parts, erase
the fluid immediately.
15. DISCONNECT POWER STEERING PUMP HIGH-PRES-

SURE PIPE.
15C
16. DISCONNECT VACCUM REGULATOR CONNECTOR

AND VACCUM HOSES.
NOTE
Mark the hose connect position, avoid mistake when install-
ing.
17. DISCONNECT HEATER INLET/OUTLET HOSES ON

THE VEHICLE.
15C
18. DISCONNECT RADIATOR UPPER COOLANT HOSE.

replacement”)
21. LOOSEN BOLTS ATTACHING A/C PIPE TO A/C

COMPRESSOR.
NOTE

23. RAISE VEHICLE TO TOP PLACE.
24. REMOVE FRONT WHEEL. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)

(a) Loosen 2 bolts attaching turbocharger tail pipe to front
exhaust pipe.
(b) Remove the gasket.
replacement”)
27. REMOVE STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy,
replacement”)
propeller shaft - propeller shaft, overhaul”) 15C
29. DISCONNECT FOLLOWING ELECTRICAL CONNECTORS.
• Fuel Return Solenoid Valve
• Fuel Inlet Solenoid Valve
• Timing Solenoid Valve
• Speed Sensor
• Generator
• Glow Plug
• ECT Sensor
• ECM
• Reverse Gear Switch 15C
31. LOOSEN NUTS ATTACHING TRANSMISSION MOUNT TO

VEHICLE BODY.
32. LOOSEN BOLTS ATTACHING SUB-FRAME TO VEHICLE

BODY AND TAKE AWAY SUB-FRAME.
NOTE
Before removing front sub-frame, mark the sub- frame and
sub-frame retaining bolts.
35. LOWER ENGINE ABOUT 150 MM SLOWLY. VERIFY ALL COMPONENTS BETWEEN THE
ENGINE/TRANSMISSION AND VEHICLE ARE DISCONNECTED AGAIN.
36. REMOVE ENGINE WITH TRANSMISSION ABOVE VEHICLE.
37. LOOSEN BOLTS ATTACHING ENGINE TO SUB-FRAME

AND SEPARATE THEM.
38. LOOSEN STARTER RETAINING BOLTS AND SEPARATE

39. LOOSEN BOLTS ATTACHING ENGINE TO TRANSMISSION

15C
41. REMOVE ENGINE ACCESSORY BELT. (Refer to “Chapter 15C engine mechanical - engine

(a) Loosen vacuum pump inlet tube bolt.
(b) Loosen vacuum pump outlet tube nut.
15C
(c) Loosen generator positive cable nut.

(d) Loosen generator bracket retaining bolts.
(e) Loosen belt tensioner lock bolt.

(f) Remove generator belt.
(g) Loosen generator retaining bolt.

(h) Remove the generator.
43. LOOSEN BOLTS ATTACHING A/C COMPRESSOR TO ENGINE AND TAKE AWAY A/C
COMPRESSOR. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
44. INSTALL GENERATOR.

(a) Install generator belt.
(b) Tighten generator retaining bolt.
(c) Tighten generator bracket bolt.

15C
(d) Pry the generator with crowbar and tighten the lock bolt.
Torque: 20 ~ 24 N·m
(e) Tighten vacuum pump inlet tube bolt.

Torque: 45 N·m
(f) Tighten vacuum pump outlet tube nut.
Torque: 47 N·m
15C
(g) Tighten generator positive cable nut.

Torque: 8 ~ 12 N·m
45. TIGHTEN A/C COMPRESSOR RETAINING BOLTS. (Refer to “Chapter 61 heater and air
conditioning - compressor, overhaul”)
46. TIGHTEN CLUTCH PRESSURE PLATE RETAINING BOLTS. (Refer to “Chapter 42 clutch - clutch
47. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15C engine mechanical - engine



FRAME.
51. INSTALL ENGINE WITH TRANSMISSION FROM BOTTOM OF VEHICLE, INSTALL ENGINE LIFT
CHAIN HANGERS.

VEHICLE BODY.
Torque: 205 ~ 215 N•m
NOTE 15C
53. TIGHTEN NUTS ATTACHING TRANSMISSION MOUNT

TO VEHICLE BODY.
Torque: 110 ~ 130 N•m
54. INSTALL FRONT EXHAUST PIPE.

(a) Position new gasket to front exhaust pipe.
(b) Tighten 2 bolts attaching turbocharger tail pipe to front
exhaust pipe.
Torque: 45 ~ 55 N•m 15C
replacement”)
56. INSTALL STEERING GEAR ASSY. (Refer to “Chapter 52 steering - steering gear assy, replacement”)
replacement”)

COMPRESSOR.
NOTE

HOSES.
NOTE
Install the vaccum hoses according to the mark before
removal.
62. CONNECT HEATER INLET / OUTLET HOSES.
63. CONNECT RADIATOR UPPER COOLANT HOSE AND

TIGHTEN CLAMP.
64. CONNECT RADIATOR LOWER COOLANT HOSE AND

TIGHTEN CLAMP.
15C
65. CONNECT STEERING FLUID RESERVOIR INLET/

OUTLET HOSE.
15C
66. INSTALL POWER STEERING PUMP HIGH-PRESSURE
PIPE.


PIPELINE CONNECTOR.

CONNECTION.
connection.
connection.
70. LOWER VEHICLE.
71. CONNECT ELECTRONIC CONTROL VE DISPENSING

PUMP INLET/OUTLET HOSE AND TIGHTEN CLAMPS.
15C
73. CONNECT FOLLOWING ELECTRICAL CONNECTORS:

• Fuel Return Solenoid Valve
• Fuel Inlet Solenoid Valve
• Timing Solenoid Valve
• Speed Sensor
• EGR Vaccum Regulator 15C
• Generator
• Glow Plug
• ECT Sensor
• ECM

76. FILL CLUTCH/BRAKE FLUID.
77. INSTALL AIR INTAKE HOSE ASSY.

(a) Connect the clamp attaching intake connect hose to
turbocharger.
(b) Tighten 2 steel tube retaining bolts.
(c) Connect the clamps attaching intake steel tube to

connect hose.
(d) Connect the clamp attaching intake bellow hose to intake

steel tube.
15C
(e) Connect clamps attaching air filter to intake bellow hose.
15C



replacement”)
ENGINE MECHANICAL - ENGINE ACCESSORY BELT 15C-27

COMPONENTS
15C
15C
1 Power Steering Pump Pulley 4 Generator Assy
2 Coolant Pump Pulley 5 Crankshaft Pulley
3 A/C Compressor Assy

15C-28 ENGINE MECHANICAL - ENGINE ACCESSORY BELT
2. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE

ENVIRONMENT TEMPERATURE.
3. INSPECT ENGINE ACCESSORIES. INSPECT EACH PART

OF ENGINE ACCESSORIES CAREFULLY, IF FIND ANY
DAMAGE AS FOLLOWING, REPLACE WITH A NEW ONE.
(a) Inspect the belt back rubber for signs of aging and
glistening.

(e) Cracks in the side of the belt.
(f) Inspect the belt for abnormal abrasion in the side of the
belt.
(g) Belt for abnormal abrasion.

15C
15C
OVERHAUL
POWER STEERING PUMP AND A/C COMPRESSOR BELT OVERHAUL
1. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO THE
NORMAL TEMPERATURE.
2. LOOSEN 2 POWER STEERING PUMP BRACKET

RETAINING BOLTS.
NOTE
Do not remove pump bracket..
3. LOOSEN ADJUSTMENT BOLT.
4. TAKE POWER STEERING PUMP BELT AND A/C

COMPRESSOR BELT AWAY.
5. INSPECT EACH PART OF POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT
CAREFULLY, IF FIND ANY DAMAGE, REPLACE WITH A NEW ONE.
6. POSITION POWER STEERING PUMP BELT AND A/C

COMPRESSOR BELT.
7. ROTATE ADJUSTMENT BOLT, TENSION POWER

STEERING PUMP BELT AND A/C COMPRESSOR
BELT.
15C
8. TIGHTEN 2 POWER STEERING PUMP BRACKET

RETAINING BOLTS.
9. PRESS 100 N TO MIDDLE OF BELT AND CHECK MOVE

SPACE.
Item Deflection
New belt 5.5 ~ 7.5 mm 15C
GENERATOR BELT
1. REFRIGERATE ENGINE, LET BELT SURFACE TEMPERATURE AS CLOSE AS POSSIBLE TO
NORMAL TEMPERATURE.
2. REMOVE POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT. (Refer to “Chapter
15C engine mechanical - engine accessory belt, replacement”)
3. REMOVE SILICONE OIL FAN.

(a) Loosen 4 silicone oil fan retaining bolts.
(b) Remove silicone oil fan.
4. LOOSEN BOLT ATTACHING GENERATOR TO GENERATOR

BRACKET.
NOTE
5. LOOSEN GENERATOR LOCK BOLT.

6. LOOSEN GENERATOR BELT ADJUST BOLT.
15C
7. INSPECT EACH PART OF GENERATOR BELT CAREFULLY, IF FIND ANY DAMAGE, REPLACE
WITH A NEW ONE.
8. POSITION GENERATOR BELT.
9. TIGHTEN GENERATOR LOCK BOLT.

Torque: 23 N•m
10. ROTATE GENERATOR BELT ADJUST BOLT. 15C
11. TIGHTEN BOLT ATTACHING GENERATOR TO

GENERATOR BRACKET.
Torque: 46 N•m
12. INSTALL SILICONE OIL FAN.

(a) Tighten 4 silicone oil fan retaining bolts.
Torque: 10 N•m

DEFLECTION.
Item Deflection
New belt 6 ~ 7 mm
Used belt 7 ~ 8 mm
15. INSTALL POWER STEERING PUMP BELT AND A/C COMPRESSOR BELT. (Refer to “Chapter
15C engine mechanical - engine accessory belt, replacement”)
ENGINE MECHANICAL - ENGINE TIMING GEAR COVER 15C-35
ENGINE TIMING GEAR COVER

REPLACEMENT
15C
replacement”)
15C
15C-36 ENGINE MECHANICAL - ENGINE TIMING GEAR COVER

(a) Loosen 4 silicone oil fan retaining bolts.
(b) Remove silicone oil fan.
8. REMOVE COOLANT PUMP PULLEY.
10. REMOVE TIMING GEAR COVER RETAINING BOLTS.
11. REMOVE TIMING GEAR COVER.

12. REMOVE TIMING GEAR COVER GASKET.
13. USE SCRAPER CLEAR SEALANT ON TIMING GEAR COVER CONNECT SURFACE, REPLACE A
NEW GASKET.
ENGINE MECHANICAL - ENGINE TIMING GEAR COVER 15C-37
14. INSTALL TIMING GEAR COVER RETAINING BOLTS.

15C
15. TIGHTEN CRANKSHAFT PULLEY RETAINING BOLTS.

Torque: 280 ~ 320 N•m
15C
17. INSTALL COOLANT PUMP PULLEY.
18. TIGHTEN 4 SILICONE OIL FAN RETAINING BOLTS.

Torque: 10 N•m
15C-38 ENGINE MECHANICAL - ENGINE TIMING GEAR COVER


replacement”)
ENGINE MECHANICAL - ENGINE TIMING GEAR 15C-39
ENGINE TIMING GEAR

COMPONENTS
15C
Electronic Control Ve Dispensing Pump 3 Crankshaft Timing Gear

1
Timing Gear 15C
4 Camshaft Timing Gear
2 Idle Gear
15C-40 ENGINE MECHANICAL - ENGINE TIMING GEAR
OVERHAUL
1. REMOVE ENGINE TIMING GEAR COVER. (Refer to “Chapter 15C engine mechanical - engine
2. INSTALL CRANKSHAFT PULLEY BOLT, ROTATE BOLT

AND ALIGNED TIMING MARKS.
3. REMOVE TIMING GEAR TRAIN.

(a) Loosen the camshaft timing gear retaining bolt.
(b) Loosen the idle gear retaining bolt.
(c) Loosen the VE dispensing pump timing gear retaining

bolt.
ENGINE MECHANICAL - ENGINE TIMING GEAR 15C-41
(d) Remove the crankshaft timing gear directly.
15C
4. CHECK TIMING GEAR.

NOTE
• Can not exist missing teeth, interface galling, pitting corrosion.
• The upper and lower idle pulley should turn smoothly.
5. INSTALL TIMING GEAR TRAIN.

(a) According to the keyway on the crankshaft, install the
15C
(b) According to the keyway on the camshaft, tighten the
camshaft timing gear bolt.
(c) Install the idle gear according to the timing marks on

15C-42 ENGINE MECHANICAL - ENGINE TIMING GEAR
(d) According to the tining mark on idle gear, install electronic

control VE dispensing pump timing gear.
6. ENSURE ALL TIMING MARKS ALIGNMENT.

(a) Please confirm the following timing marks:
• The “Y”mark on electronic control VE dispensing pump
align with the“Y-Y”mark on idle gear .
• The“X”mark on crankshaft timing gear align with the“X-
X”mark on the camshaft timing gear.
7. INSTALL ENGINE TIMING GEAR COVER. (Refer to “Chapter 15C engine mechanical - engine
ENGINE MECHANICAL - CYLINDER HEAD AND VALVE 15C-43
CYLINDER HEAD AND VALVE

COMPONENTS
15C
15C
1 Valve Spring Lock 11 Cylinder Head Cover Gasket
2 Upper Valve Spring Retainer 12 Oil Filling Cap
3 Valve Spring 13 Cylinder Head Cover
4 Valve Oil Seal 14 Rocker Arm And Rocker Shaft Assy
5 Lower Valve Spring Retainer 15 Cylinder Head Bolt
6 Exhaust Valve 16 Cylinder Head Bolt (With Groove)
7 Intake Valve 17 Fuel Injector Pressure Plate Bolt
8 Rear Engine Lifting Hook 18 Fuel Injector Pressure Plate
9 Front Engine Lifting Hook 19 Fuel Injector Pressure Plate Block
10 Cylinder Head Cover Bolt

15C-44 ENGINE MECHANICAL - CYLINDER HEAD AND VALVE
OVERHAUL
replacement”)

6. REMOVE PRESSURIZATION COMPENSATOR CONNECT

HOSE.
(a) Loosen pressurization compensator connect hose hollow
retaining bolt. 15C
7. REMOVE HEATER PLUG.

(a) Loosen heater plug fuel supply pipe clamp.
15C
(b) Remove heater plug assy.

8. REMOVE HEATER PLUG SOLENOID VALVE.

(a) Disconnect solenoid valve connector.
(b) Loosen 2 solenoid valve retaining bolts.
9. REMOVE INTAKE AIR CONNECT PIPE. (Refer to “Chapter 14C intake air - intake air connect
11. DISCONNECT UPPER RADIATOR HOSE CONNECT.
12. DISCONNECT HEATER HOSES.

13. LOOSEN 3 CYLINDER HEAD COVER RETAINING

BOLTS.
15C
14. REMOVE INTAKE MANIFOLD. (Refer to “Chapter 14C intake air - intake manifold, replacement”)
15. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGE ASSY. (Refer to “Chapter 16C exhaust -
16. REMOVE FUEL INJECTORS. (Refer to “Chapter 12C fuel - fuel injector, overhaul”)
17. LOOSEN 4 ROCKER ARM AND ROCKER SHAFT

ASSY RETAINING BOLTS.
15C
18. TAKE ROCKER ARM AND ROCKER SHAFT ASSY
AWAY.
19. TAKE 8 VALVE PUSH RODS AWAY.

20. LOOSEN CYLINDER HEAD BOLTS IN SEQUENCE AS

SHOWN.
21. TAKE CYLINDER HEAD ASSY AWAY.
22. TAKE CYLINDER HEAD GASKET AWAY.


GAUGE.
Standard: 0.05 mm
Limit: 0.2 mm
NOTE
• If the service limit is exceeded, grind to meet
specification.
Grind limit: 0.2 mm (0.2 mm includes combination
with cylinder block grinding)
• Cylinder head height (new specification): 91.95 ~
92.05 mm.
• Check the cylinder head whether corroded
underside， replace with a new cylinder head if find.
25. CHOOSE A SUITABLE CYLINDER HEAD GASKET.

(a) Carefully clear the carbon deposition and residue on the top of piston and surface of cylinder head.
(b) Position a micrometer caliper on the top of piston. 15C
(c) Measure the piston protruding length. Measure it on

point (1) (3) on piston top and point (2) (4) on engine
block. Each piston need be measured.
(d) Record the highest measured values. This value will

determine the thickness of the cylinder head gasket. The
piston protruding length is 0.36 ~ 0.57 mm, divided into 15C
two groups of the four piston protruding length of the
engine in one group. If the length is out of specification,
replace the piston connecting rod according to the chart
below.
Cylinder Head Gasket Mark Piston Protruding Length Cylinder Head Gasket Thinkness
One Gap 0.36 ~ 0.47 mm 119 mm
Two Gaps 0.48 ~ 0.57 mm 1.29 mm

CAUTION
mark on the gasket, align the water and oil way. Otherwise it
will damage the engine.

28. POSITION CYLINDER HEAD ASSY.
NOTE
The cylinder head bolt only can be uesd for twice, replace a
new one after using twice.
29. CYLINDER HEAD BOLTS SHOULD BE INSTALLED AND

TIGHTENED IN SEQUENCE AS SHOWN.
Torque:
Main cylinder head bolt: 170 ~ 190 N•m
Assistant cylinder head bolt: 55 ~ 65 N•m
30. INSTALL 8 VALVE PUSH RODS.
31. INSTALL ROCKER ARM AND ROCKER SHAFT ASSY.

NOTE
When installing the rocker arm and rocker shaft assy,
15C
32. TIGHTEN ROCKER ARM AND ROCKER SHAFT ASSY

RETAINING BOLTS.
NOTE
Rocker arm and rocker shaft assy retaining bolts should be
installed and tightened in sequence as shown. Before
tightening the bolts, loosen the valve adjustment bolt to
avoid damaging the valve, push rod, camshaft and rocker 15C
arm.
33. TIGHTEN 3 CYLINDER HEAD COVER RETAINING

BOLTS.
Torque: 13 N•m
34. CONNECT UPPER RADIATOR HOSE.
35. CONNECT HEATER HOSES.
36. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14C intake air - intake manifold, replacement”)
37. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGE ASSY. (Refer to “Chapter 16C exhaust -
38. INSTALL FUEL INJECTORS. (Refer to “Chapter 12C fuel - fuel injector, overhaul”)
39. INSTALL INTAKE AIR CONNECT PIPE. (Refer to “Chapter 14C intake air - intake air connect
41. INSTALL HEATER PLUG SOLENOID VALVE.

(a) Tighten 2 solenoid valve retaining bolts.
(b) Connect solenoid valve connector.
42. INSTALL HEATER PLUG.

(a) Install heater plug assy.
15C
(b) Connect heater plug fuel supply pipe clamp.
15C
43. INSTALL PRESSURIZATION COMPENSATOR CONNECT

HOSE.
(a) Tighten pressurization compensator connect hose hollow
retaining bolt.


replacement”)
ENGINE MECHANICAL - VALVE/VALVE SPRING 15C-55
VALVE/VALVE SPRING
OVERHAUL
1. REMOVE CYLINDER HEAD. (Refer to “Chapter 15C engine mechanical - cylinder head, 15C
overhaul”)
2. USING SUITABLE TOOL, COMPRESS VALVE SPRING

AND TAKE VALVE SPRING LOCK AWAY.

NOTE
Store removed valves, spring and other parts, tag to indicate their cylinder number and location for
assembly.

(a) Check the valve spring free length/height, discard the
15C
Standard: ≤ 2°

NOTE
15C-56 ENGINE MECHANICAL - VALVE/VALVE SPRING

7. TAKE VALVE AWAY AND CHECK IT.
(b) Check valve work surface, such as burn or wear, replace it with a new one if necessary.
When the valves and valve seat wear lighting, manual polishing method of recovery can be used. The
method is as follows: first, remove valve, the valve seat catheter and coke, then in the valve cone are
coated with a thin layer of valve sand. Use the eraser bowl with wooden valve flap to absorb, combined
with the method of rotating and grinding. Each rotation is not more than 90°, until the valve cone
appears a well-balanced without burnish band width for 1.5 ~ 2 mm. Too wide band is harm for seal.
Too narrow, against heat dissipation, the valve will burned for high temperature. Sand has the different
in thick and thin. According to the wear and ablation of choice.
(c) Chenck the valve tightness.

Using pencil, draw 8 ~ 12 marks on the valve work
surface, tap the valve with the valve seat (Do not rotate
(d) Measure the valve diameter.
Item Standard
Intake Valve Φ7.945 ~ Φ7.960 mm
Exhaust Valve Φ7.945 ~ Φ7.960 mm
(e) Measure valve stem diameter and valve guide inner


8. HEAT CYLINDER HEAD AND TAKE VALVE SEAT AWAY.

9. USING A PRESSOR, PUSH VALVE GUIDE OUT TOWARD THE CYLINDER BLOCK SIDE.
10. THE VALVE GUIDE MUST BE INSTALLED FROM UPPER SIDE OF CYLINDER HEAD.
11. AFTER INSTALLING VALVE GUIDE, INSERT A NEW VALVE AND CHECK IT SLIDES SMOOTHLY.
12. FOLLOW THE MARK BEFORE REMOVAL TO INSTALL VALVE.
14. USING A SUITABLE TOOL, INSTALL NEW VALVE OIL

SEAL.
NOTE
IMPROPER INSTALLATION WILL CAUSE OIL LEAKAGE. 15C

NOTE
17. USING SUITABLE TOOL, INSTALL VALVE SPRING

LOCKER.
15C
18. INSTALL CYLINDER HEAD. (Refer to “Chapter 15C engine mechanical - cylinder head,
overhaul”)
19. ADJUST VALVE CLEARANCE.
(a) When the engine is cool, the intake valve clearance and the exhaust valve clearance is 0.35 ~ 0.40
mm. If excessive clearance, it will close lax. If the clearance is less than standard, it will damage the
valve.
(b) Rotate the crankshaft to NO.1 cylinder in compression

stroke BTDC. The crankshaft pulley first mark align to the
mark on engine timing cover, and the NO.1 cylinder
intake and exhuast valve are closed.
15C-58 ENGINE MECHANICAL - VALVE/VALVE SPRING
(c) Adjust the valve clearance as shown.
(d) Set the valve clearance feeler gauge into rocker arm and
valve top which need adjusting. Loosen the rocker arm
retaining bolt and rotate the adjustment screw until the
feeler guage moves out of nimbleness, then tighten the
rocker arm retaining bolt.
(e) After adjusting the valve clearance above, rotate the

crankshaft 360°. NO.4 cylinder is in compression stroke
BTDC. Adjust the valve clearance as shown in the same
way.
20. TIGHTEN 3 CYLINDER HEAD COVER RETAINING

BOLTS.
Torque：13 N•m


Torque：41 ~ 51 N•m 15C
replacement”)
15C
15C-60 ENGINE MECHANICAL - CAMSHAFT
CAMSHAFT
OVERHAUL
NOTE
4D20 diesel engine is adopted camshaft in the middle block.
1. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15C engine mechanical - engine timing belt,
overhaul”)
2. ROTATE CRANKSHAFT, MAKE TIMING MARK “X”

ON CRANKSHAFT TIMING GEAR ALIGN WITH “X-X”
ON CAMSHAFT TIMING GEAR.
3. REMOVE CAMSHAFT TIMING GEAR RETAINING BOLT.
4. TAKE CAMSHAFT TIMING PULLEY AWAY.
5. LOOSEN CAMSHAFT THRUST PLATE RETAINING

BOLT.

ENGINE MECHANICAL - CAMSHAFT 15C-61
15C
(a) Measure the camshaft base diameter.
Base diameter: 31 mm
(b) Measure the camshaft cam lobe height.
Cam lobe height: 6.3 mm
(c) If there is any wear or flaw on the journal, replace the

camshaft.
9. USING A BUSHING PULLER, REMOVE CAMSHAFT JOURNAL BUSHING.

(a) If there any wear or flaw on the camshaft journal bushing, replace the camshaft bushing.
15C
10. USING A SUITABLE TOOL, INSTALL NEW BUSHING.
NOTE
• When installing the bushing, align the oil hole on camshafe journal bushing with the oil hole on
engine block.
• Check the clearance between camshaft journal bushing and camshaft journal.
Ⅰ：0.06 ~ 0.13 mm
Ⅱ：0.07 ~ 0.13 mm
Ⅲ：0.07 ~ 0.14 mm
12. USING A SUITABLE TOOL, INSTALL CAMSHAFT OIL

SEAL.
15C-62 ENGINE MECHANICAL - CAMSHAFT
13. INSATLL CAMSHAFT THRUST PLATE AND TIGHTEN

RETAINING BOLTS.
14. TIGHTEN CAMSHAFT TIMING GEAR RETAINING

BOLTS.
15. ACCORDING TO TIMING MARK BEFORE REMOVAL,

ENSURE CAMSHAFT KEYWAY POSITION, INSTALL
CAMSHAFT TIMING GEAR CORRECTLY.
16. ENSURE TIMING MARK ON CAMSHAFT ALIGN WITH CRANKSHAFT GEAR TIMING MARK.
17. INSTALL ENGINE TIMING GEAR COVER. (Refer to “Chapter 15C engine mechanical - engine
ENGINE MECHANICAL - ENGINE BLOCK 15C-63
ENGINE BLOCK
COMPONENTS
15C
15C
15C-64 ENGINE MECHANICAL - ENGINE BLOCK
1 Engine Block 14 Vacuum Pump Fuel Supply Line Connector
2 Round Pin 15 Coolant Drain Plug
3 Upper Crankshaft Bearing 16 Oil Return Pipe
4 Lower Crankshaft Bearing 17 Location Pin
5 Fifth Main Bearing Cap 18 Cylinder Head Gasket
6 Third Main Bearing Cap 19 Cylinder Sleeve
7 First ,Second, Fourth Main Bearing Cap 20 Rear Engine Block Cover
8 Main Bearing Cap Bolt 21 Rear Crankshaft Oil Seal
9 Crankshaft Thrust Bearing 22 Plug
10 Front Camshaft Journal Bushing 23 Left Bracket
11 Middle Camshaft Journal Bushing 24 Engine Oil Pressure Switch Seat
12 Oil Plug 25 Engine Oil Pressure Switch
13 Right Bracket
OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15C engine mechanical - engine assy, replace-
ment”)
15C
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15C engine mechanical - cylinder head,
overhaul”)
3. REMOVE ENGINE TIMING GEAR. (Refer to “Chapter 15C engine mechanical - engine timing belt,
overhaul”)
4. REMOVE OIL PAN. (Refer to “Chapter 18C lubrication - oil pan, replacement”)
5. REMOVE OIL STRAINER AND OIL PUMP. (Refer to “Chapter 18 B lubrication - oil pump, over-
haul”)

relieve completely.
15C
9. LOOSEN REAR ENGINE BLOCK COVER RETAINING

BOLTS.
10. USING A SUITABLE TOOL, REMOVE REAR CRANKSHAFT

OIL SEAL.
12. LOOSEN MAIN BEARING CAP BOLTS IN SEQUENCE

AS SHOWN.
NOTE
Avoid installing error, there are mark number such as
"1","2" on the connecting rod cap. The arrow on the
crankshaft main bearing cap forward crankshaft pulley.
14. DISASSEMBLE UPPER CRANKSHAFT BEARING AND

THRUST BEARING ON THIRD CRANKSHAFT JOURNAL.
15. INSPECT THRUST BEARING, THERE SHOULD BE

NO SERIOUS WEAR, GALLING, PITTING.
15C
16. TAKE ENGINE BLOCK FROM FLIP FRAME AND

INSPECT IT.
(a) Visually check for scratches, rust, and corrosion. Use a
flaw detecting agent for the check as well. If defects are
found, correct or replace it.
(b) Use a straightedge and feeler gauge, check the block top
surface for warpage. Make sure that the surface is free
from gasket chips and other foreign matters.
(c) If the warpage is excessive, correct it within the allowable
limit or replace.
Grinding limit: 0.2 mm
(d) The cylinder walls should be checked for out-of-round
cylinder walls are badly scuffed or scored, the cylinder 15C
block should be replaced and install new pistons and
rings.

ROD BIG END FOR CORRECT ASSEMBLING.
NOTE

AS SHOWN.
19. USING A HAMMER HANDLE OR SIMILAR TOOL,

PUSH PISTON AND CONNECTING ROD ASSY OUT
THROUGH CYLINDER HEAD SIDE OF ENGINE
BLOCK.
20. REMOVE CRANKSHAFT.
21. PRESS CYLINDER SLEEVE TOWARD CYLINDER

HEAD DIRECTION.
22. MEASURE CYLINDER BORE AT THREE LEVELS IN

DIRECTIONS A AND B. TOP MEASUREMENT SHOULD
BE 12 MM DOWN AND BOTTOM MEASUREMENT
SHOULD BE 12 MM UP FROM BOTTOM OF BORE.
Standard:
Cylinder size: Φ89.00 ~ Φ89.02 mm9
Cylinder cylindrically: ≤ 0.01 mm
23. MEASURE MAIN BEARING INNER DIAMETER, CHOOSE SUITABLE BEARING BUSHING.
Group Number Bearing Inner Diameter Suitable Bearing Thickness

1 Φ74.980 ~ Φ75.010 mm Φ2.000 ~ Φ2.013 mm
2 Φ74.980 ~ Φ75.010 mm Φ2.000 ~ Φ2.013 mm
3 Φ74.980 ~ Φ75.010 mm Φ2.000 ~ Φ2.013 mm
24. USING A SUITABLE TOOL, PRESS CORRECT CYLINDER SLEEVE TO ENGINE BLOCK.
25. INSTALL PISTON AND CONNECTING ROD ASSY. (Refer to “Chapter 15C engine mechanical -
piston and connecting rod, overhaul”)
26. INSTALL MAIN BEARING AND THRUST BEARING.

(a) Install the main bearings with oil grooves on the cylinder
block side.
(b) Install the main bearings without oil grooves on the 15C
bearing cap.
(c) Install the 2 thrust bearings on crankshaft journal No.3.

(a) Install the main bearing caps with the arrow on the main
28. INSTALL THE MAIN BEARING CAP BOLTS.

(a) Apply clean engine oil to the threaded portion bearing surface of the bolt.
(b) Tighten the bearing cap bolts in sequence as shown.

Torque:
15C
First tighten the bolts: 40 ~ 50 N•m
Second tighten the bolts: 90 ~ 100 N•m
Third tighten the bolts: 160 ~ 180 N•m
29. USING A SUITABLE TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.

BOLTS.

Torque: 113 ~ 133 N•m

BOLTS.
Torque: 35 N•m
NOTE
35. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15C engine mechanical - engine timing belt,
overhaul”)
36. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15C engine mechanical - cylinder head,
overhaul”)
37. INSTALL ENGINE ASSY. (Refer to “Chapter 15C engine mechanical - engine assy, replacement”)
ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY 15C-71
PISTON AND CONNECTING ROD ASSY

COMPONENTS
15C
1 Crankshaft Pulley Bolt 5 Crankshaft

15C
2 Crankshaft Pulley 6 Piston And Connecting Rod Assy
3 Crankshaft Timing Pulley 7 Flywheel
4 Crankshaft Flat Key 8 Flywheel Bolt

15C-72 ENGINE MECHANICAL - PISTON AND CONNECTING ROD ASSY
1 No.1 Compression Ring 6 Connecting Rod
2 No.2 Compression Ring 7 Piston Pin
3 Oil Control Ring 8 Piston Pin Snap Spring
4 Piston 9 Connecting Rod Nut
5 Connecting Rod Bolt 10 Connecting Rod Bearing

OVERHAUL
1. REMOVE ENGINE ASSY. (Refer to “Chapter 15C engine mechanical - engine assy, replace-
ment”)
15C
2. REMOVE CYLINDER HEAD ASSY. (Refer to “Chapter 15C engine mechanical - cylinder head,
overhaul”)
3. REMOVE ENGINE TIMING BELT. (Refer to “Chapter 15C engine mechanical - engine timing belt,
overhaul”)
5. REMOVE OIL PUMP AND OIL STRAINER. (Refer to “Chapter 18B lubrication - oil pump, replacement”)
6. FIXING ENGINE BLOCK ASSY TO FLIP FRAME AND DISASSEMBLE IT.

relieve completely.
15C
9. LOOSEN REAR ENGINE BLOCK COVER RETAINING

BOLTS.
10. USING A SUITABLE TOOL, REMOVE REAR

CRANKSHAFT OIL SEAL.
12. LOOSEN CRANKSHAFT MAIN BEARING CAP BOLTS

IN SEQUENCE AS SHOWN.

ASSEMBLING.
NOTE
14. LOOSEN CONNECTING ROD CAP NUTS IN SEQUENCE

AS SHOWN.
15. USING A HAMMER HANDLE OR SIMILAR TOOL, PUSH

PISTON AND CONNECTING ROD ASSY OUT THROUGH
THE CYLINDER HEAD SIDE OF ENGINE BLOCK.
15C
16. TAKE CRANKSHAFT AWAY AND INSPECT CRANKSHAFT

MAIN JOURNALS.
(a) Check for excessive wear, roundness and scoring. If
found, check the oil hole pluged or not.
(b) Limits of out of round on any crankshaft journals should
be held to less than 30 g•cm.
Crankshaft main journals: 69.904 ~ 69.92 mm
HAND.
NOTE
Keep the disassembled pistons, piston pins and connecting rods in order according to the cylinder
number. 15C

NOTE
(b) Check the piston ring for damage, excessive wear, and breakage. Replace it if defects are found. If the
piston has been replaced with a new one, the piston rings must also be replaced with a new one.
(c) Check piston ring to groove side clearance.If the limit is


Standard 0.078 ~ 0.137 mm 0.045 ~ 0.090 mm 0.030 ~ 0.070 mm
Limit 0.20 mm 0.18 mm 0.16 mm



Standard 0.20 ~ 0.40 mm 0.60 ~ 0.85 mm 0.35 ~ 0.65 mm
Limit 0.8 mm 1.5 mm 1.2 mm
20. USING SNAP RING PLIERS, REMOVE PISTON PIN

SNAP RING.
21. CHECK SNAP RING, THERE SHOULD BE NO CRACK, WOUND. WHEN INSTALLING, SNAP RING
OPENING SHOULD STAGGER WITH NOTCH ON PISTON TOP.
22. USING A PRESSURE PUSH PISTON PIN OUT.

23. CHECK DIAMETER OF PISTON PIN BORE, AND

15C
Item Specification
Piston Pin Bore Diameter 1
Piston Pin Outer Diameter Φ27.994 ~ Φ28.000 mm
Piston Pin Bore And Piston Pin Clearance -0.05 ~ 0.018 mm
Wear Limit 0.03 mm
24. CHECK INNER DIAMETER OF CONNECTING ROD

(SMALL END). 15C
Item Specification
Connecting Rod And Piston Pin Clearance 0.0258 ~ 0.045 mm
Wear Limit 0.10 mm
25. MEASURE PISTON OUTER DIAMETER.
Mark Ⅰ Ⅱ Ⅲ
86.000~86.0 86.011~86.0 86.021~86.0
10 mm 20 mm 30 mm
26. ACCORDING TO CYLINDER SLEEVE INNER DIAMETER (AFTER INSTALLING INTO CYLINDER
BLOCK) CHOOSE SUITABLE PISTON SIZE.
Size
Item
Piston Cylinder Sleeve
Ⅰ 85.930 ~ 85.940 mm 86.000 ~ 86.010 mm
Ⅱ 85.940 ~ 85.950 mm 86.011 ~ 86.020 mm
Ⅲ 85.950 ~ 85.960 mm 86.021 ~ 86.030 mm
(a) The clearance between piston and cylinder sleeve is 0.042 ~ 0.060 mm， wear limit is 0.20 mm. Mea-
sure the clearance, if the clearance exceed the wear limit, replace the piston and cylinder sleeve.
NOTE
If replace the piston, replace the piston ring also.

(a) The piston pin center should outline with the piston center
1 mm, reduce the noise.
Mark Ⅰ Ⅱ Ⅲ
85.930~85. 85.940~85. 85.950~85.
940 mm 950 mm 960 mm
(b) When installing the connecting rod, the mark on piston

top, bulge at connect rod center should toward engine
front end.
28. INSTALL PISTON PIN SNAP RING.

29. INSTALL SPIRAL SPRING BY HAND, THEN INSTALL

OIL CONTROL RING.
NOTE
• Do not use a piston ring expander when installing oil 15C
control ring. Use of ring expander to expand the oil
control ring end gap can break the oil control ring,
unlike other piston rings.
• Ensure the ring can turn from the left to the right
freely after installation.
30. INSTALL NO.1 COMPRESSION RING, NO.2 COM-

PRESSION RING.
(a) Using a piston ring expander, install the NO.2 compression
ring, then install the NO.1 compression ring.
NOTE
• The NO.1 compression ring is the keystone ring.
15C
• The NO.2 compression ring is the cone distortion

ring.
• The compression rings have an identification mark

on the top of the ring.
(b) Oil the piston rings and piston side.
(c) Position the piston rings in the proper alignment with the
piston pin as shown:
2 Piston Pin Position
4 Spiral Spring Open Mouth
5 Oil Control Ring Open Mouth
6 Timing Gear Direction
31. USING A SUITABLE PISTON RING COMPRESSOR,

INSERT PISTON AND CONNECTING ROD ASSEMBLY
INTO CYLINDER ACCORDING TO MARK BEFORE
REMOVAL.
32. INSTALL CRANKSHAFT.
33. VERIFY MARK MADE DURING DISASSEMBLY, INSTALL

BEARING CAP TO THE CONNECTING ROD. IF
CONNECTING ROD IS NEW WITH NO MARK, MAKE
SURE THAT BEARING LOCK NOTCHES COME ON THE
SAME SIDE AS SHOWN.

NOTE
The pulge mark on the connecting rod cap is toward the
engine timing belt side.


AS SHOWN.
15C

Limit: 0.40 mm
38. ROTATE CRANKSHAFT, AVOID CRANKSHAFT BALANCE BLOCK CRASHING WITH CONNECT-
ING ROD BIG END.
Item Specification
Radial Chance Between Connecting Rod Standard 0.061 ~ 0.087 mm 15C

Bearing And Journal Wear Limit 0.20 mm
Axial Clearance Between Connecting Rod Standard 0.61 ~ 0.93 mm

And Crankshaft Journal Wear Limit 0.25 mm
39. TIGHTEN CRANKSHAFT MAIN BEARING CAP BOLTS

IN SEQUENCE AS SHOWN.
Torque:
Third step: 160 ~ 180 N•m
40. USING A SUITABLE TOOL, INSTALL REAR CRANK-

SHAFT OIL SEAL.

BOLTS.

Torque: 113 ~ 133 N•m

BOLTS.
Torque: 35 N•m
NOTE
46. INSTALL ENGINE TIMING BELT. (Refer to “Chapter 15C engine mechanical - engine timing belt,
overhaul”)
47. INSTALL CYLINDER HEAD ASSY. (Refer to “Chapter 15C engine mechanical - cylinder head,
overhaul”)
48. INSTALL ENGINE ASSY. (Refer to “Chapter 15C engine mechanical - engine assy, replacement”)
EXHAUST
16C
EXHAUST PIPE ............................................................................... 16C-1
COMPONENTS ......................................................................... 16C-1
REPLACEMENT ........................................................................ 16C-2
EXHAUST MANIFOLD..................................................................... 16C-7 16C
COMPONENTS ......................................................................... 16C-7
REPLACEMENT ........................................................................ 16C-8
16C
16C
EXHAUST - EXHAUST PIPE 16C-1
EXHAUST PIPE
EXHAUST
COMPONENTS
16C
16C
1 First Rubber Support 12 Spring Washer
Third Support Upper Hanging Bracket 13 Hexagon Nut

2
Assy
14 Hexagon Bolt
3 Rear Exhaust Pipe With Muffler Assy
15 Exhaust Pipe Gasket
4 Second Rubber Support
16 Front Exhuast Pipe Assy
Second Support Right Hanging Bracket
5 17 Purifier Assy
Assy
6 Hexagon Bolt 18 Middle Exhaust Pipe Assy
7 Flat Washer 19 First Support Front Hanging Bracket Assy
8 Spring Washer 20 Bolt
9 Hexagon Nut 21 Middle Connect Pipe
Second Support Left Hanging Bracket 22 First Heat Shield

10
Assy
23 Bolt
11 Flat Washer
24 Second Heat Shield
16C-2 EXHAUST - EXHAUST PIPE
REPLACEMENT
WARNING
NOTE
• When the exhaust pipe is in high temperature, try to remove the manifold will cause deforma-
tion. High temperature can cause metal expansion and remove the bolts more difficult, the bolt
can be easily broken.
rosion, rust, leakage, replace the exhaust pipe assy.

assy to middle connect pipe.
(b) Disconnect 2 first rubber supports.
(c) Disconnect 2 second rubber supports.

(d) Remove the rear exhaust pipe with muffler assy.
4. REMOVE MIDDLE CONNECT PIPE.

(a) Remove 2 bolts attaching middle connect pipe to middle
exhaust pipe assy.
16C

(a) Remove 2 bolts attaching purifier to middle exhaust pipe
assy.
16C
(b) Disconnect 2 first rubber supports.

(c) Remove the gasket from purifier.
6. REMOVE PUIIFIER ASSY.

(a) Remove 2 bolts attaching front exhaust pipe to purifier.
(b) Remove the purifier assy.

(a) Remove 2 bolts attaching front exhaust pipe to turbo-
charger tail pipe.
(b) Remove front exhaust pipe.
(c) Remove the gasket.
8. INSTALL FRONT EXHAUST PIPE ASSY

(a) Install a new gasket to front exhaust pipe.
(b) Install front exhaust pipe assy.
(c) Install 2 bolts attaching front exhaust pipe to turbo-
charger tail pipe.
NOTE
• Replace a new gasket after removal.
• After a long-time used, the exhaust pipe gasket will
be adhered to exhaust pipe. After remove the muffler,
using the scraper, clean the surface of exhaust pipe
and replace with a new gasket to avoid exhaust
leakage.
9. INSTALL PUIIFIER ASSY.

(a) Install a new gasket to purifier.
(b) Install 2 bolts attaching front exhaust pipe to purifier.

(a) Install a new gasket to middle exhaust pipe.
(b) install middle exhaust pipe saay and first rubber support.
(c) Install 2 bolts attaching purifier to middle exhaust pipe

assy.
16C
11. INSTALL MIDDLE CONNECT PIPE.

(a) Install new gasket to middle connect pipe.
(b) Install middle connect pipe assy.
(c) Remove 2 bolts attaching middle connect pipe to middle
exhaust pipe assy.
16C

(a) Install a new gasket to rear exhaust pipe with muffler
assy.
(b) Install rear exhaust pipe with muffler assy and second
rubber support.
(c) Connect first rubber support.

(d) Install 2 bolts attaching rear exhaust pipe with muffler

assy to middle connect pipe.
13. LOWER VEHICLE.

14. START ENGINE.
15. CHECK EXHAUST GAS LEAKAGE.
(a) If find the gas exhaust, tighten the connect bolt to prevent leakage. If necessary, replace the damaged
part.
EXHAUST - EXHAUST MANIFOLD 16C-7
EXHAUST MANIFOLD
COMPONENTS
16C
16C
1 Heat Shield 5 Exhaust Tail Pipe
2 Exhaust Manifold 6 Exhaust Tail Pipe Gasket
3 Exhaust Manifold Gasket 7 Turbocharger
4 Bracing Sheet
16C-8 EXHAUST - EXHAUST MANIFOLD
REPLACEMENT
2. REMOVE A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioner - A/C compressor,
replacement”)
3. REMOVE INTAKE MANIFOLD. (Refer to “Chapter 14C intake air - intake manifold, replacement”)

(b) Take off the exhaust manifold heat shield.
5. REMOVE EXHAUST MANIFOLD BRACING SHEET.

(a) Remove 4 exhaust manifold bracing sheet retaining bolts.
(b) Remove exhaust manifold bracing sheet.
6. REMOVE FRONT EXHAUST PIPE.

(a) Remove 2 bolts attaching exhaust tail pipe to front
exhaust pipe.
16C
7. REMOVE EXHAUST MANIFOLD WITH TURBOCHARGER

ASSY.
(a) Remove 8 bolts attaching exhaust manifold to cylinder head.
(b) Remove exhaust manifold gasket.
NOTE
The exhaust manifold retaining bolts will be rusted after a
long-time running. Use derusting spray when loosen the
nuts.
16C
8. REMOVE TURBOCHARGER ACCESSORIES. (Refer to “Chapter 14B intake air-turbocharger,

replacement”)
(a) Check whether parts have any damage or crack.
(b) Using a ruler and thickness gauge, check exhaust manifold and cylinder head surface for flatness.
Limit: 0.20 mm
(c) Clean the dirt on exhaust manifold and cylinder head surface.
10. INSTALL TURBOCHARGER. (Refer to “Chapter 14B intake air - tubo charger, replacement”）
11. INSTALL EXHAUST MANIFOLD WITH TURBOCHARGER

ASSY.
(a) Install exhaust manifold gasket.
(b) Install 8 bolts attaching exhaust manifold to cylinder
head.
NOTE
• If do not replace a new gasket, use exhaust sealant
to avoid exhaust leakage.
16C-10 EXHAUST - EXHAUST MANIFOLD
12. INSTALL INTAKE MANIFOLD. (Refer to “Chapter 14C intake air - intake manifold, replacement”)

14. INSTALL EXHAUST MANIFOLD BRACING SHEET.

(a) Install exhaust manifold bracing sheet and tighten the 4
retaining bolts.
15. INSTALL FRONT EXHAUST PIPE.

(a) Install 2 bolts attaching exhaust tail pipe to front exhaust
pipe.
16. INSTALL A/C COMPRESSOR. (Refer to “Chapter 61 heater and air conditioner - A/C compressor,
replacement”)
17. CHECK EXHAUST GAS LEAKAGE.
(a) After install the exhaust manifold, check it. If find the gas exhaust, tighten the connect bolt to prevent
leakage. If necessary, replace the damaged part.
18. PUT DOWN DRIVER SEAT.

(a) Put down driver seat and lock it.
16C
16C
MEMO
COOLING
17C
COOLING SYSTEM ......................................................................... 17C-1
PRECAUTION............................................................................ 17C-1
ON-VEHICLE INSPECT............................................................. 17C-3 17C
COOLANT ........................................................................................ 17C-5
REPLACEMENT ........................................................................ 17C-5
RADIATOR ....................................................................................... 17C-8
COMPONENTS ......................................................................... 17C-8 17C
ON-VEHICLE INSPECT............................................................. 17C-9
REPLACEMENT ...................................................................... 17C-10
SILICONE OIL FAN AND FAN COWL .......................................... 17C-17
REPLACEMENT ...................................................................... 17C-17
THERMOSTAT ............................................................................... 17C-21
OVERHAUL ............................................................................. 17C-21
COOLANT PUMP...........................................................................17C-24
OVERHAUL ............................................................................. 17C-24
17C
COOLING - COOLING SYSTEM 17C-1
COOLING SYSTEM
COOLING
PRECAUTION
1. COOLING SYSTEM PRECAUTION. 17C
(a) When disconnect the cooling hose, use a suitable container to recycle the retains of coolant. If it is not
continue to use, according to regulations for disposal.
(b) When disconnecting the pipes of cooling system, do not let debris into the pipes of cooling system. It
nozzle to prevent dirt or impurities.
(d) Coolant is poisonous, always keep it away from children and pets. If it is not continue to use, according
to regulations for disposal.
(e) Do not open the radiator cap when the engine is hot. Such as coolant temperature should be reduced
to 50 ° C (120 ° F) below, remove the radiator cap. Otherwise, the cooling liquid or vapor emitting heat
may cause personal injury.
(f) After filling the coolant, ensure bleeding the ai in cooling system, bleeding the air in cooling system,
avoid engine overheat.
(g) Use foton specified coolant, do not only use water as coolant. Water will damage the engine because of
corrosion.
(h) Regular clean radiator outside, and prevent mud or dust deposition to affect radiator.
17C
17C-2 COOLING - COOLING SYSTEM

1. Coolant (Lack or leakage) Chapter 17C cooling - coolant, replacement
2. Coolant (Non-standard) Chapter 17C cooling - coolant, replacement
3. Thermostat (Damaged) Chapter 17C cooling - thermostat, overhaul
Engine overheating 4. Engine (Rough work) -
Chapter 17C cooling - cooling system,

5. Radiator (Poor cooling) precaution
6. Silicone oil fan (Damaged) Chapter 17C cooling - cooling fan, overhaul
7. Cooling system (Block) -
1. Radiator (Damaged) Chapter 17C cooling - radiator, replacement
2. Cooling system hose (Broken) -
Coolant leakage Chapter 17C cooling - coolant pump,

3. Coolant pump (Damaged) replacement
Chapter 17C cooling - coolant reservoir,

4. Coolant reservoir (Damaged) replacement
1. Silicone oil fan (Damaged) Chapter 17C cooling - cooling fan, overhaul
Chapter 17C cooling - coolant pump,

Engine room noise 2. Coolant pump (Damaged) replacement
3. Cooling system (Damaged) -

COOLING - COOLING SYSTEM 17C-3
ON-VEHICLE INSPECT
1. CHECK COOLANT FOR LEAKAGED.
NOTE 17C
Before any check, turn the A/C switch OFF.
WARNING
tester.
drop. If the pressure drops, check the hoses, radiator or
water pump for leakage. If no external leakage is found,
check the heater core, cylinder block and head.
17C
2. CHECK ENGINE COOLANT LEVEL IN COOLANT

RESERVOIR.
”FULL” line.
NOTE
Do not use water as coolant.
17C-4 COOLING - COOLING SYSTEM

WARNING
scale around the radiator cap and radiator filler hole. The coolant should be free from oil. If excessively
(d) Tighten the drain plug and check the coolant level in the coolant reservoir. Fill the coolant if necessary.
NOTE
fins. So keep the following injection distance.
COOLING - COOLANT 17C-5
COOLANT
REPLACEMENT
WARNING 17C
Do not open the radiator cap when the engine is hot. Such as coolant temperature should be reduced


NOTE 17C
4. REPLACE COOLANT RESERVOIR COOLANT.

(a) Disconnect clamp attaching coolant reservoir hose to
coolant filling pipe.
(b) Remove coolant reservoir retaining bolt.

17C-6 COOLING - COOLANT
(c) Disconnect coolant level sensor connector.

(d) Remove coolant reservoir and drain coolant.
6. DRAIN COOLANT.
(a) Install conduit between radiator drain plug and container.
(b) Loosen coolant drain plug at radiator bottom and drain

coolant.
NOTE
Using a suitable container, hold the coolant. If do not continue
to use, according to regulations for disposal.
(c) Tighten coolant drain plug at radiator bottom.

7. LOWER VEHICLE.
COOLING - COOLANT 17C-7
8. INSTALLCOOLANT RESERVOIR.
(a) Install coolant reservoir and tighten bolt.
17C
(b) Connect coolant level sensor connector.
(c) Connect clamp attaching coolant reservoir hose to coolant

17C
filling pipe.
9. ADD COOLANT.
(a) Slowly fill the radiator with ”FOTON Long-effective coolant” .
(b) Push the radiator inlet/outlet hose several times, check the coolant level. If coolant is at the low level,
fill the coolant.
NOTE
The air in cooling system can be bled automatic.
17C-8 COOLING - RADIATOR
RADIATOR
COMPONENTS
1 Fan Cowl 6 Lower Cover
2 Bolt 7 Bolt
3 Clamp 8 Coolant Reservoir
4 Radiator Inlet Hose 9 Radiator Outlet Hose
5 Radiator Assy
COOLING - RADIATOR 17C-9
ON-VEHICLE INSPECT
17C
• If there are water stains or foreign matter on rubber packing
cracked or swollen.
• When using the cap tester, tilt it to 30° or more above the
horizontal.
pressure.

Standard value
90 ± 15 kPa
(for brand-new cap)
Minimum standard value 17C

75 kPa
(after using cap)

sub-assembly.
REPLACEMENT
WARNING


replacement”)
5. DRAIN COOLANT. (Refer to “Chapter 17C cooling- coolant, replacement”)

(a) Remove 7 engine cover retaining bolts.
9. REMOVE SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17C cooling-silicone oil fan
10. DISCONNECT RADIATOR HOSE.

(a) Disconnect radiator inlet hose.
17C
11. REMOVE RADIATOR COOLANT FILLING PIPE.

(a) Remove radiator filling pipe hose clamp.
17C
(b) Remove hose clamp attaching radiator filling pipet to

coolant reservoir.
(c) Remove radiator breather hose clamp.
(d) Remove 2 coolant filling pipe retaining nuts.
12. DISCONNECT RADIATOR OUTLET HOSE.
13. REMOVE RADIATOR ASSY.

(a) Remove radiator upper retaining nuts.
(b) Remove 2 radiator lower support retaining nuts.

(c) Remove radiator assy.
17C
14. CHECK THE RADIATOR TIGHTNESS. (Refer to “Chapter 17C cooling- coolingsystem, on-vehi-
cle inspection”)
15. INSTALL RADIATOR ASSY.

(a) Install radiator assy.
NOTE
(b) Install 2 radiator lower support retaining nuts.
17C
(c) Install radiator upper retaining nuts.
16. INSTALL SILICONE OIL FAN AND FAN COWL. (Refer to “Chapter 17C cooling-silicone oil fan
17. CONNECT RADIATOR OUTLET HOSE.

(a) Connect radiator outlet hose and tighten the clamp.
18. CONNECT RADIATOR INLET HOSE.

(a) Connect radiator inlet hose and tighten the clamp.
19. INSTALL COOLANT FILLING PIPE.

(a) Install 2 coolant filling pipe retaining nuts.
(b) Install radiator filling pipe hose clamp.

(c) Install clamps attaching radiator filling pipe to coolant

reservoir.
17C
(d) Install radiator breather hose clamp.
17C

22. CHECK THE RADIATOR TIGHTNESS. (Refer to “Chapter 17C cooling- coolingsystem, on-vehi-
cle inspection”)

(a) Position engine cover, tighten 7 retaining bolts.


replacement”)
COOLING - SILICONE OIL FAN AND FAN COWL 17C-17
SILICONE OIL FAN AND FAN COWL

REPLACEMENT
17C
replacement”)
17C

(a) Remove engine cover 7 retaining bolts.
17C-18 COOLING - SILICONE OIL FAN AND FAN COWL

(a) Remove 4 silicone oil fan retaining nuts.
(b) Remove silicone oil fan assy.
7. CHECK SILICONE OIL FAN.

(a) Visual inspection silicone oil clutch leakage, wire ablation, replace a new one when find.
(b) On vehicle inspection: Start the engine in low temperature for 1~ 2 min and stop the engine, turn the sil-
icone oil fan by hand, if the silicone oil fan can run smoothly, the silicone oil fan is OK. Srart the engine,
when the temperature reach 88 ℃ , stop the engine,turn the silicone oil fan by hand, if the silicone oil
fan can not be run, it’s OK. If the silicone oil fan can run smoothly, replace it with a new one.
8. REMOVE COOLANT FILLING PIPE.

(a) Remove 2 coolant filling pipe retaining nuts, and set it
aside
9. REMOVE FAN COWL ASSY.

(a) Remove 4 fan cowl retaining bolts.
(b) Remove fan cowl assy.
COOLING - SILICONE OIL FAN AND FAN COWL 17C-19
10. INSTALL FAN COWL ASSY.

(a) Install 4 fan cowl retaining bolts.
17C
11. INSTALL SILICONE OIL FAN.

(a) Install 4 silicone oil fan retaining nuts.
Torque: 10 N•m
17C
12. INSTALL COOLANT FILLING PIPE.

(a) Install 2 coolant filling pipe retaining nuts.

(a) Position engine cover, tighten 7 retaining bolts.

17C-20 COOLING - SILICONE OIL FAN AND FAN COWL

replacement”)
COOLING - THERMOSTAT 17C-21
THERMOSTAT
OVERHAUL
WARNING 17C
1. COOLING THE ENGINE TO NORMAL ROOM TEMPERATURE.

3. DRAIN COOLANT. (Refer to “Chapter 17C cooling - coolant, replacement”)
4. DISCONNECT THERMOSTAT OUTLET HOSE. 17C

(a) Remove thermostat outlet hose clamp.
5. REMOVE THERMOSTAT ASSY.

(a) Remove 2 thermostat retaining bolts.
(b) Remove thermostat assy.
17C-22 COOLING - THERMOSTAT
temperature.

water.
Valve opening temperature:
80 - 84 ℃
NOTE
If the valve opening temperature is not as specified, replace
the thermostat.

NOTE
If the valve lift is not as specified, replace the thermostat.
(e) Check that the valve is fully closed when the thermostat
is at low temperatures (below 77 ℃ ).
NOTE
If it does not closed, replace the thermostat.
7. INSTALL THERMOSTAT ASSY.
(a) Install a new gasket to thermostat.
(b) Install thermostat and tighten the 2 retaining bolts.
COOLING - THERMOSTAT 17C-23
8. CONNECT THERMOSTAT OUTLET HOSE.

(a) Connect thermostat outlet hose. tighten the clamp.
17C
9. FILL COOLANT. (Refer to “Chapter 17C cooling - coolant， replacement”)

17C
17C-24 COOLING - COOLANT PUMP
COOLANT PUMP
OVERHAUL
WARNING
1. COOLING THE ENGINE TO NORMAL INDOOR TEMPERATURE.
2. DRAIN COOLANT. (Refer to “Chapter 17C cooling - coolant, replacement”)
4. REMOVE SILICONE OIL FAN . (Refer to “Chapter 17C cooling- silicone oil fan and fan cowl,
overhaul”)
5. REMOVE COOLANT PUMP ASSY.

(a) Remove coolant pump belt pulley.
(b) Remove 7 coolant pump retaining bolts.
(c) Remove coolant pump gasket.
6. USING A SCRAPER, CLEAN DIRT ON COOLANT PUMP AND ENGINE BLOCK CONNECT
SURFACE.
NOTE

(a) Visual inspection of the drain hole and stomatal whether
have coolant leakage. If find, replacement the coolant
pump assy.
COOLING - COOLANT PUMP 17C-25
(b) Rotate coolant pump and it should turn smoothly.

(c) There should be no clearance between coolant pump
shaft and coolant punp bearing, and no abnormal noise
when it turns. 17C
(d) No coolant leaks around coolant pump.
8. INSTALL COOLANT PUMP GASKET.

(a) To avoid coolant leakage, use coolant pump sealant if
necessary.
NOTE
• Install the coolant pump in 3 minutes after applying
the sealant, otherwise, clean the sealant and reapply.
• Clean the oil on connect surface.
• After using the coolant pump sealant, wait for 15
minutes then fill the coolant.
17C
(b) Install 7 coolant pump retaining bolts.

9. INSTALL SILICONE OIL FAN. (Refer to “Chapter 17C cooling- silicone oil fan and fan cowl, over-
haul”)
12. CHECK COOLANT PUMP.
(a) After replacing coolant pump, start engine until cooling fan running at high speed. Check coolant for
leakage.
MEMO
LUBRICATION
18C
LUBRICATION SYSTEM ................................................................. 18C-1
PRECAUTION............................................................................ 18C-1
COMPONENTS ......................................................................... 18C-2
ENGINE OIL ..................................................................................... 18C-3 18C
REPLACEMENT ........................................................................ 18C-3
OIL FILTER ...................................................................................... 18C-5
REPLACEMENT ........................................................................ 18C-5
OIL PAN ...........................................................................................18C-8 18C
REPLACEMENT ........................................................................ 18C-8
OIL PUMP ...................................................................................... 18C-10
OVERHAUL ............................................................................. 18C-10
OIL FILTER BRACKET.................................................................. 18C-12
REPLACEMENT ...................................................................... 18C-12
18C
LUBRICATION - LUBRICATION SYSTEM 18C-1
LUBRICATION SYSTEM
LUBRICATION
PRECAUTION
4D20 diesel engine has two ways of pressure and splash lubrication. The gear type oil pump is fixed on the 18C
cylinder block. The pump inner rotor is driven by the camshaft. Oil pump strainer tube is in the sump of the oil
pan.
WARNING
skin, allergies and dermatitis. In addition, used engine oil contains potentially harmful pollutants may
cause skin cancer. Therefore, the skin must be protected in appropriate methods and with cleaning
equipment.
(b) Wear protective clothing, including waterproof work gloves.
(e) Avoid eyes contact with oil, must wear goggles, In addition, equipment must be prepared to clean the
eyes and wrapping the wound must be dealt with immediately.
(f) Frequent use of soap and water can clean, especially before meals, and make sure all the oil have 18C
been removed (skin cleansers can also be used to assist with the nail brush). After cleaning, it is
18C-2 LUBRICATION - LUBRICATION SYSTEM
COMPONENTS
1 Oil Pan 6 Camshaft
2 Oil Strainer 7 Crankshaft
3 Oli Filter 8 Piston
4 Oli Filter Bracket 9 Valve Push Rod
5 Oil Cooler 10 Valve Rocker Arm

LUBRICATION - ENGINE OIL 18C-3
ENGINE OIL
REPLACEMENT
1. PARK VEHICLE ON LEVEL ROAD, PULL OUT OIL DIPSTICK SLOWLY, AND CHECK OIL LEVEL, 18C
2. CHECK OIL WITHOUT EXCESSIVE POLLUTION, NO PETROL AND LIQUID MIXED. THERE
MUST HAVE ENOUGH CONCENTRATIONS AND LUBRICATION DEGREE.

18C

WARNING
8. USING A SPECIAL CONTAINER, COLLECT USED OIL, DISPOSAL AS REQUIRED.

18C-4 LUBRICATION - ENGINE OIL
9. REPLACE A NEW DRAIN PLUG GASKET AND TIGHTEN

PLUG.
Torque: 35 ~ 45 N.m
10. LOWER VEHICLE.

Engine oil: 4.5 ~ 5 L
NOTE
Engine oil with specifications of CF- 4, 15W-40 and 15W-30.
12. INSTALL OIL FILLER CAP.
13. PARK VEHICLE ON LEVEL ROAD, START ENGINE AND RUN FOR 5 MINUTES.
16. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK, ENSURE

MARK.

LUBRICATION - OIL FILTER 18C-5
OIL FILTER
REPLACEMENT
NOTE 18C
Without special circumstances, the oil filter should be replaced with engine oil, avoid oil pollution and
keep engine operation.

3. OPEN OIL FILLER CAP. 18C


WARNING
Be careful, the engine oil maybe hot.
7. USING SUITABLE TOOL REMOVE OIL FILTER.
8. CLEANCONNECT SURFACE OF OIL FILTER AND OIL FILTER BRACKET.

18C-6 LUBRICATION - OIL FILTER
9. APPLY OIL TO NEW OIL FILTER O-RING.
10. FILL CLEAN OIL INTO OIL FILTER.
11. TIGHTEN OIL FILTER BY HAND UNTIL O-RING

TOUCHES OIL FILTER BRACKET. USING SUITABLE
TOOL, TIGHTEN OIL FILTER.

Torque: 35 ~ 45 N.m
13. LOWER VEHICLE.

14. FILL ENGINE OIL TO SPECIFIED LEVEL, INSTALL OIL FILLER CAP.
15. PARK VEHICLE IN LEVEL ROAD, START ENGINE AND RUN FOR 5 MINUTES.
LUBRICATION - OIL FILTER 18C-7
18. AFTER 8 MINUTES, PULL OUT OIL DIPSTICK, ENSURE

MARK.
18C
18C
18C-8 LUBRICATION - OIL PAN
OIL PAN
REPLACEMENT

WARNING
7. CLEAN CONNECT SURFACE OF OIL PAN AND ENGINE BLOCK.

LUBRICATION - OIL PAN 18C-9
8. REPLACE CRANKSHAFT FRONT SIDE (CRANKSHAFT

PULLEY SIDE) OIL PAN ARC GASKET.
18C
9. REPLACE CRANKSHAFT REAR SIDE (FLYWHEEL

SIDE) OIL PAN ARC GASKET.
18C
10. INSTALL OIL PAN ARC GASKET, APPLY SEALANT ON
ROOTS OF BOTH ENDS OF CRANKSHAFT BEARING
CAP.
NOTE
Be sure to install the oil pan quickly while the sealant is wet
(within 15 minutes).
11. INSTALL OIL PAN RETAINING BOLTS DIAGONALLY.

NOTE
After installation, keep the sealant area away from the oil
for about one hour.

Torque: 35 ~ 45 N.m
13. LOWER VEHICLE, FILL ENGINE OIL TO SPECIFIED
LEVEL.
18C-10 LUBRICATION - OIL PUMP
OIL PUMP
OVERHAUL

WARNING

6. REMOVE OIL PAN. (Refer to “Chapter 15B， lubrication - oil pan, replacement”)

LUBRICATION - OIL PUMP 18C-11
8. TAKE OIL PUMP AWAY.
18C

(a) Oil pump gear and camshaft gear tooth surface should not have erosion, wear, or missing teeth. If
found, replace the oil pump assembly.
10. LOOSEN OIL PIPE CONNECTOR, REPLACE A NEW O-RING.
11. TIGHTEN OIL PUMP RETAINING BOLTS.

18C
12. INSTALL OIL PAN. (Refer to “Chapter 18B lubrication - oil pan, replacement”）
13. TIGHTEN OIL DRAIN PLUG.

14. LOWER VEHICLE, FILL ENGINE OIL TO SPECIFIED LEVEL.

15. PUT DOWN DRIVER SAET AND LOCK IT.
18C-12 LUBRICATION - OIL FILTER BRACKET
OIL FILTER BRACKET

REPLACEMENT
1. REMOVE OIL FILTER. (Refer to “Chapter 18B
lubrication - oil filter, replacement”)
2. DISCONNECT OIL COOLER INLET/OUTLET HOSE

CLAMP, DRAIN COOLANT TO A SUITABLE CON-
TAINER.
3. REMOVE 4 OIL FILTER RETAINING BOLTS.

LUBRICATION - OIL FILTER BRACKET 18C-13
4. REMOVE OIL COOLER RETAINING BOLT.
18C
5. SEPARATE OIL COOLER, TAKE OIL FILTER BRACKET AWAY.

6. REPLACE A NEW O-RING.
7. POSITION OIL COOLER TO OIL FILTER BRACKET

18C
AND TIGHTEN RETAINING BOLT.
8. TIGHTEN OIL FILTER BRACKET RETAINING BOLTS.

18C-14 LUBRICATION - OIL FILTER BRACKET
9. CONNECT OIL COOLER INLET/OUTLET HOSE AND

TIGHTEN CLAMP.
10. INSTALL OIL FILTER. (Refer to “Chapter 18B lubrication - oil filter, replacement”)
12. FILL COOLANT TO SPECIFIED LEVEL. (Refer to “Chapter 17B cooling - coolant, replacement”)
20C
STARTING AND CHARGING SYSTEM .......................................... 20C-1
PRECAUTION............................................................................ 20C-1
GENERATOR ................................................................................... 20C-4 20C
COMPONENTS ......................................................................... 20C-4
OVERHAUL ............................................................................... 20C-5
STARTER ....................................................................................... 20C-13
COMPONENTS ....................................................................... 20C-13 20C
OVERHAUL ............................................................................. 20C-14
BATTERY ....................................................................................... 20C-23
COMPONENTS ....................................................................... 20C-23
USE AND MAINTENANCE ...................................................... 20C-24
INSPECTION ...........................................................................20C-26
BATTERY COMMON PROBLEMS, THE CAUSES
20C
ANALYSIS AND TROUBLESHOOTING.................................20C-27
REPLACEMENT ...................................................................... 20C-28
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20C-1

PRECAUTION
1. STARTING AND CHARGING SYSTEM PRECAUTION. 20C
cause injury.
20C
20C-2 STARTING AND CHARGING - STARTING AND CHARGING SYSTEM

1. Starter switch control circuit -

(Open)
2. Brush and rectifier (Poor Chapter 20C starting and charging - starter,
Starter out of operation
connection) overhaul
3. Starter inside circuit (Open or Chapter 20C starting and charging - starter,
short) overhaul
Chapter 20C starting and charging - battery,

3. Rectifier (Surface damaged or Chapter 20C starting and charging - starter,

stains) overhaul
Starter lacks power, can
not srart engine 4. Brush (Wear) or Brush spring Chapter 20C starting and charging - starter,
(Loss elastic force) overhaul
5. Solenoid switch (Contacts Chapter 20C starting and charging - starter,

ablation) overhaul
6. Bearing (Wear)or commutator Chapter 20C starting and charging - starter,

(Wipe shell) overhaul
1. Starter relay (Copper contacts Chapter 20C starting and charging - starter,
bond) overhaul
Starter keep working 2. Starter commutator (Bend or Chapter 20C starting and charging - starter,
after engine start break) overhaul
3. Starter gear tooth surface contact Chapter 20C starting and charging - starter,
1. Generator connect wire (dam- -

aged)
Chapter 20C starting and charging - genera-

Generator out of opera- Chapter 20C starting and charging - genera-
tion 3. Rectifier diode (Damaged) tor, overhaul


STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20C-3

Chapter 15C engine mechanical - engine
20C
Generator lacks enough
electricity Chapter 20C starting and charging - genera-
Chapter 20C starting and charging - battery,



Generator over charging
20C
4. Generator connect wire (dam- -
aged)
20C-4 STARTING AND CHARGING - GENERATOR
GENERATOR
COMPONENTS
1 Generator Belt Pulley 8 Anchor Plate
2 Rotator Component 9 Regulator And Brush Carriage
3 Rear Bearing 10 Brush
4 Bearing Carrier 11 Brush Ring
5 Front Bearing 12 Rectifier Component
6 Front Cover 13 Back Cover
7 Stator Component
STARTING AND CHARGING - GENERATOR 20C-5
OVERHAUL
(a) Loosen the driver seat clamp. 20C

20C

NOTE
4. COOL ENGINE AND MAKE BELT TEMPERATURE AS CLOSE AS POSSIBLE TO NORMAL

TEMPERATURE.
(a) Loosen vacuum pump inlet tube bolt.
(b) Loosen vacuum pump outlet tube nut.
(c) Loosen generator positive cable nut.
(d) Loosen generator bracket retaining bolts.
(e) Loosen belt tensioner lock bolt.

(f) Remove generator belt.
(g) Loosen generator retaining bolt.

(h) Remove the generator.
20C
(a) Using pneumatic tools, loosen generator belt pulley retaining
nut.
20C
(b) Loosen retaining bolts attaching generator front cover to

stator component.
(c) Insert a screwdriver between front cover and stator then

separate them.
NOTE
• If it is difficult to be separated, slap the front cover
slightly with rubber hammer and pry it with
screwdriver.
• Do not insert screwdriver too deep to prevent stator
component damaged.
(d) Using a electric iron (180 ~ 250 w), remove stator. This
from heat.
(e) Loosen 4 retaining bolts from rectifier.
(f) Using a electric iron, remove rectifier from regulator.

NOTE
iron to diode for a long time.
(g) Remove and inspect rotor.

means the rotor is short circuit. If it is not conductive or it

assy.

Limit: 12.8 mm
(h) Remove and inspect stator.

20C

conductive.
20C
(i) Inspect stator rectifier.

are conductive. If it is not conductive in both directions, it
(j) Get rid of welding point of brush lead, then take out the
brush.
(k) If brush is so worn to reach wear limit line, replace brush.

as shown.

Torque: 6 ~ 8 N•m
(d) Before mounting rotor on rear cover, insert a steel wire

into small hole on rear cap, then erect mounted rotor by
brush, pull out steel wire.
(e) Install the rotor.

(f) Tighten the retaining bolts attaching generator front
cover to stator component.
9. INSTALL GENERATOR.
(a) Install generator belt.
(b) Tighten the generator retaining bolt.
Torque: 20 ~ 24 N•m 20C
(c) Tighten the generator bracket bolt.

20C
(d) Pry the generator with crowbar and tighten the lock bolt.
(e) Tighten the vacuum pump inlet tube bolt.

(f) Tighten the vacuum pump outlet tube nut.
(g) Tighten the generator positive cable nut.

Torque: 8 ~ 12 N·m
10. CONNECT BATTERY AND TIGHTEN RETAINING BOLTS.

NOTE

STARTING AND CHARGING - STARTER 20C-13
STARTER
COMPONENTS
20C
20C
1 Front Bracket 11 Overdrive Clutch
10 Internal Gear
20C-14 STARTING AND CHARGING - STARTER
OVERHAUL


NOTE
4. LIFT VEHICLE.
5. REMOVE STARTER.
(a) Loosen the starter eloectrical wire connecting nut and
disconnect the connector.
(b) Loosen 2 starter retaining nuts.

(c) Remove the starter.
20C

magnetic switch.
terminal.
20C
NOTE

a feeler gauge.

front bracket.

magnetic switch.
terminal.
NOTE

magnetic switch.
body.
NOTE
position.

magnetic switch.
body.
NOTE
WARNING
the pinion.
20C
20C

NOTE
When removing armature, do not lose the steel ball
mounted in the bearing ends.


(a) Do not put the parts in the detergent for cleaning. If the magnet yoke, excitation winding lead or rotor is
(b) Clean starter parts with cloth.
(c) Drive parts can not be immerged in detergent for cleaning. Before delivering out of factory, the
(d) Using a brush and dipping with detergent, clean drive parts then dry them with a cloth.
Limit: 0.1 mm
(b) Measure the diameter of the commutator.

Standard: 29.4 mm
Limit: 28.4 mm

Standard: 0.5 mm
Limit: 0.2 mm

the brush. Replace the brush holder if the height is lower than the limit.
Limit: 7.0 mm

(b) Check the pinion for abnormal waring and damage. 20C

NOTE 20C
the test.



and body A.

and M terminal.


snap ring.


20C

20C


15. INSTALL STARTER.

(a) Tighten 2 starter retaining nuts.
(b) Tighten the starter electrical wire connecting nut and

connect the connector.
16. LOWER VEHICLE.

BOLTS.
NOTE
Connect the negative cable first when installing.

STARTING AND CHARGING - BATTERY 20C-23
BATTERY
COMPONENTS
20C
20C

20C-24 STARTING AND CHARGING - BATTERY
USE AND MAINTENANCE

1. CHARGING DEVICE.
NOTE
(a) Rectifier.
2. CHARGE PRECAUTIONS.
(d) Liquid temperature should not exceed 45 ℃ and otherwise cooling measures should be taken (by
reducing filling current or stopping sharge or being cooled down in water tank)
must be firm.
4. CHARGING MODES.
(c) Quick charge.
5. AFTER CHARGING, USING THE BELOW METHODS, CHECK THE BATTERY CAPACITY IS
RESTORED TO STANDARD.
(a) Voltage method

(b) Capacity method



smash and dropout of active substances, and other failures. 20C
minutes, if can not start the engine in three times, troubleshoot, then restart.
20C
INSPECTION
(a) Observe whether the battery appearance is in good condition. Check if fixed terminal and wires are
connected firmly.
(b) Observe whether the battery shell and the center partition cracks, and use a wooden beat shell and
center partitions respectively, listen to the sound without breaking, especially the central baffle and shell
side of shell wall at the junction of four, prone to crack, should be carefully examined.
2. CAPACITY TEST.
resistance.
are troubles in the battery and it shall be repaired.
Below is the use of excel tester of discharge plan detection income cross-references.

3. VOLTAGE TEST.



TROUBLESHOOTING
20C
LONG PERIOD.
2. BATTERY EXPLODE.
• Causes analysis: 20C
4. A yellow or white paste appears on battery cover.

In order to avoid these pastes, clean the electrolyte sprayed on the battery cover and the shell with a
cloth soaked with the soda solution of 10 percents. Then wipe with water and dry with a clean cloth.
The paste on the wire ends and the studs shall be wiped with the cloth soaked with soda solution. If
there are oxides of poor conductivity, scrape them with a little knife and clean them. It would be best to
smear a coat of Vaseline or butter on the cover after the polar studs and wiring clips are fastened.
REPLACEMENT

3. REMOVE BATTERY.
(a) Loosen battery negative and positive cable retaining
bolts, then disconnect them.
NOTE
(b) Loosen battery hold down retaining bolts.
4. TAKE OUT BATTERY.

(a) Unscrew the bolt, add distilled water or electrolyte through
the hole above battery.
NOTE
Battery should be put up, placing upside down the battery
is avoided.
20C

20C
7. INSTALL BATTERY.
(a) Tighten battery hold down retaining bolts.
(b) Connect battery negative/positive cable and tighten

battery cable retaining bolts
NOTE
then apply a thin layer of grease to terminal.

(a) Tighten battery cover lock button.
MEMO
11D
CNG ENGINE CONTROL SYSTEM.................................................11D-1
PRECAUTION............................................................................ 11D-1
SYSTEM DESCRIPTION........................................................... 11D-2
INTRODUCTION OF SYSTEM FUNCTION ........................... 11D-10 11D
BASIC PRINCIPLE .................................................................. 11D-12
SYSTEM COMPONENTS DESCRIPTION .............................. 11D-17
ENGINE CONTROL MODULE (ECM) ........................................... 11D-18
PRINCIPLE .............................................................................. 11D-18 11D
REPLACEMENT ...................................................................... 11D-19
INJECTOR DRIVER ....................................................................... 11D-22
PRINCIPLE .............................................................................. 11D-22
REPLACEMENT ...................................................................... 11D-23 11D
ENGINE COOLANT TEMPERATURE SENSOR........................... 11D-26
PRINCIPLE .............................................................................. 11D-26
OVERHAUL ............................................................................. 11D-27
THROTTLE BODY ......................................................................... 11D-31
THROTTLE BODY CLEANING................................................ 11D-31
THE FIXED SPEED ADJUSTING SCREW (SAS)
ADJUSTMENT ......................................................................... 11D-32
BASIC IDLE SPEED ADJUSTMENT ....................................... 11D-33
OVERHAUL ............................................................................. 11D-34
IDLE AIR CONTROL MOTOR ....................................................... 11D-37
PRINCIPLE .............................................................................. 11D-37
ON-VEHICLE INSPECTION .................................................... 11D-38
OVERHAUL ............................................................................. 11D-39
THROTTLE POSITION SENSOR (TPS) ........................................ 11D-42
PRINCIPLE .............................................................................. 11D-42
OVERHAUL ............................................................................. 11D-44
TEMPERATURE SENSOR ............................................................ 11D-47
PRINCIPLE .............................................................................. 11D-47
OVERHAUL ............................................................................. 11D-49
CKP SENSOR ................................................................................ 11D-51
PRINCIPLE .............................................................................. 11D-51
OVERHAUL ............................................................................. 11D-52
UPSTREAM OXYGEN SENSOR ................................................... 11D-55
PRINCIPLE .............................................................................. 11D-55
OVERHAUL ............................................................................. 11D-57
DOWNSTREAM OXYGEN SENSOR............................................. 11D-59
PRINCIPLE .............................................................................. 11D-59
OVERHAUL ............................................................................. 11D-61
CANISTER SOLENOID VALVE..................................................... 11D-63
PRINCIPLE .............................................................................. 11D-63
OVERHAUL ............................................................................. 11D-65
VEHICLE SPEED SENSOR ...........................................................11D-70
PRINCIPLE ..............................................................................11D-70
ON-VEHICLE INSPECTION ....................................................11D-71
OVERHAUL .............................................................................11D-72
IGNITION CONTROL MODULE.....................................................11D-74
PRINCIPLE ..............................................................................11D-74
ON-VEHICLE INSPECTION ....................................................11D-75
OVERHAUL .............................................................................11D-76
ENGINE CONTROL SYSTEM - CNG ENGINE CONTROL SYSTEM 11D-1
CNG ENGINE CONTROL SYSTEM

PRECAUTION
1. CNG ENGINE CONTROL SYSTEM PRECAUTION. 11D
(a) Power off.
• The battery negative cable must be disconnected at first before removing or installing any electric 11D
ally. This will prevent injuring person and vehicle damage. 11D
• The ignition switch must be turned off without any special descriptions.
11D
WARNING
The ignition and illumination switches must be shut off before removing or installing the battery 11D
negative cable (the semiconductor may be damaged without doing that).
(b) Please do disassembly, assembly and testing in accordance with the provisions introduced in this 11D
(c) Clear off the sundries on the mounting surface with a sealant scraper or a wire brush and confirm the 11D
the sealant on the mounting hole, the threaded hole and the thread. 11D
(d) Tighten the fixing bolts with prescribed torque during installing the sensors, actuators or other parts.
(e) The high impedance type digital multimeter should be used to the test except the especial description 11D
of the procedure in place of the traditional analogue types multimeter.
(f) The oxygen sensor can not contact with water or other liquids. 11D
(g) When installing or carrying the sensor, ensure it not damaged. Any shock or drop may cause great
damage to its performance. 11D
(h) Battery voltage is low or starter failure, not long time starting the engine, so as not to damage the
catalytic converter. 11D
(i) Do not use the needle puncture method to inspect system signal of wire harness.
11D
(j) Fuel pump can not operate for a long time without gasoline, also it can not run in the air.
(k) Because most electric sprayed parts are un-repairable, after confirming the part is damaged, replace it
11D
as necessary.
(l) The system should use anti-type spark plugs and high-voltage, non-resistant phenotype will not only
11D
release high-voltage spark plug and interference wave, but also effect the ignition coil driver module in
the ECM.
11D
(m) ECM can’t be disassembled for test and maintenance.
11D
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11D
11D
11D-2 ENGINE CONTROL SYSTEM - CNG ENGINE CONTROL SYSTEM
SYSTEM DESCRIPTION
1. INTRODUCTION.
(a) 4GC1 engine uses CCARI-DELPHI system which is a multi-point sequential injection gasoline / Com-
pressed Natural Gas (CNG) bi-fuel control system.
(b) The electrically controlled Multi-point Injection (MPI) engine control system - 4GC1 - takes DELPHI
MT20U2 Engine Control Module (ECM) as the control center and measure various working parameters
of the engine through various sensors mounted on different components of the engine. Then the fuel
injection quantity is controlled precisely via the control injector according to the preset control program
in the ECM, which enables the engine to obtain the mixture with optimal concentration under various
working conditions. In addition, with the control program in the ECM, the electrically controlled fuel
injection system can also enable the functions of start-up enrichment, warm-up enrichment,
acceleration enrichment, full-load enrichment, deceleration dilution, forcible idle cutoff, automatic idle
speed control etc, which meets the requirements for mixture under special working conditions of the
engine and enables the engine to obtain good fuel economy and emission while enhancing the
functional performance of the vehicle. In addition, ECM has some fault diagnosis modes which can
simplify the fault location.
2. ENGINE CONTROL SYSTEM FUNCTION.
Mileage memory
Over voltage pretection
CNG control
Fuel pump control
Canister solenoid valve control
Idle air control motor control
Change of control of natural gas and gasoline

ECM control function
Totally main power relay control
A/C, coolant water box fan control
Direct ignition
Closed-loop control multi-point squence fuel injection (MAP sensor pres-

sure judgement)
Manifold absolute pressure speed-density method air measurement
Trouble self-diagnosis function

3. ENGINE CONTROL SYSTEM DIAGRAM.
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1 CNG Bottle 18 Return Pipe
2 CNG Bottle Valve 19 Fuel Tank
3 CNG Highly Compressed A Hose 20 Injector Driver
4 Filling Receptacle 21 CNG Rail
Pressure Gauge And The Cylinder 22 CNG Injector

5
Pressure Sensor
23 Ignition Coil
6 High-pressure Solenoid Valve
24 Fuel Regulator
7 Compression Release Valve
25 Throttle Body
8 CNG Bottle Pressure Sensor Signals
26 Air Intake
CNG-rail Pressure And Temperature
9 27 Oxygen Sensor
Sensors
10 Low Pressure Filter 28 Throttle Position Sensor
11 Low Pressure Pipe Manifold Absolute Pressure/Intake Air

29
Temperature Sensor
12 Carbon Canister
13 Ambient Air
31 Coolant Temperature Sensor
14 CNG Meter Display
32 Fuel Injector
15 Canister Control Valve
33 ECM
16 Fuel Filter
17 Fuel Pump
4. CNG SUPPLY SYSTEM.
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1 High Pressure Bottle 7 Filter
11D
2 CNG Bottle Valve 8 CNG Rail
3 Low Pressure Gauge 9 1 Cylinder Injector 11D

4 Filling Receptacle Valve 10 2 Cylinder Injector
11D
5 Solenoid 11 3 Cylinder Injector
11D
6 Regulator 12 4 Cylinder Injector
11D
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5. ENGINE CONTROL SYSTEM MAIN COMPONENTS DISTRIBUTION GRAPHIC.(1)
Manifold Absolute Pressure/Intake Air 4 Idle Air Control Motor

1
Temperature Sensor
5 Fuel Regulator
2 Throttle Body
6 Upstream Oxygen Sensor
11D
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1 Crankshaft Position Sensor 8 Throttle Position Sensor
2 Oil Reaction Plug 9 Idle Air Control Motor 11D

3 Ignition Control Module 10 Fuel Pressure Regulator
11D
4 Coolant Temperature Sensor Manifold Absolute Pressure/Intake Air
11
Temperature Sensor 11D
5 CNG Injector
12 Oxygen Sensor
6 Accelerator cable 11D
7 Throttle Body
11D
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11D
1 Spark Plug 5 Engine Coolant Temperature Sensor
2 CNG Injector 6 Ignition Control Module
3 Accelerator Cable 7 Oil Reaction Plug
4 Throttle Body
11D
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1 Ignition Control Module 5 Intake Manifold
2 CNG Injector 6 Idle Air Control Motor 11D

3 Spark Plug Wire 7 Throttle Position Sensor
11D
4 Oxygen Sensor 8 Accelerator Cable
11D
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11D
INTRODUCTION OF SYSTEM FUNCTION

1. IDLE SPEED CONTROL.
(a) Idle speed control function refers to system control of engine speed with the throttle valve closed. The
system makes the actual speed consistent with the target idle speed by controlling idle parameters.
(b) The system applies the idle stepper motor and realizes high precision idle speed control.
2. AIR METERING OF SPEED-DENSITY METHOD (MANIFOLD ABSOLUTE PRESSURE/INTAKE AIR
TEMPERATURE SENSOR).
With intake temperature sensor and intake manifold pressure sensor, ECM calculates and defines the
air quantity entering the cylinder. Furthermore, ECM allows air/fuel ratio to meet the requirements of
various working conditions by controlling the fuel supply.
3. CYLINDER DETECTION SEQUENCE CONTROL.
In order to realize engine sequence control, the system applies intake pressure cylinder detection
technology. The intake pressure sensor is installed near the air inlet of the intake manifold for 4
cylinders. At the moment, when the inlet valve opens, there is an instantaneous pressure drop of which
the value is around 1 kPa at the sensor. ECM detects the instantaneous pressure drop. After receiving
the signal, ECM identifies compression Top Dead Centre (TDC) signal through the software analysis
and processing.
4. CLOSED LOOP CONTROL.
The system applies closed loop control for the engine fuel supply and idle speed. The advantage of
closed loop control is that the system effectively eliminates the difference between the system and
relevant mechanical parts due to the manufacture and usage wear, which enhances the integrated
coherence of the whole vehicle and reduces the emission.
5. GROUPING CONTROL.
The system divides the engine cylinders into two groups of 1-4 and 2-3 which control the ignition
respectively. The grouping control optimizes and simplifies the system structure. Ignition timing and fuel
injection control (crankshaft position sensor) systems determine crankshaft position and measure
engine speed according to 58X gear signal, which controls the engine ignition and fuel injection timing
precisely. The opening and closing of the power transistor control the continuity of the primary current in
the ignition coils. The ignition timing control is aimed to obtain the optimal ignition time so as to meet
the requirements of various working conditions of the engine. ECM determines the ignition time
according to the engine speed, intake vacuum degree, engine cooling water temperature and
atmospheric pressure.
6. SELF-DIAGNOSIS.
(a) The system fault self-diagnosis is an essential function for the engine control system. When one or
several parts in the system operate abnormally, the system will inform the vehicle owner to perform
necessary check and repair timely with fault indicator lamp ON. When the fault occurs, the system can 11D
also control the engine operation with temporary emergency mode, so as to ensure the owner can drive
the vehicle to repair. 11D
(b) When certain sensor and actuator is detected abnormal, the engine fault inspection lamp turns on to
remind the driver. 11D
(c) When certain sensor and actuator is detected abnormal, the fault code corresponding to the fault will be
exported. 11D
(d) RAM data related to the sensor and actuator in ECM can be read by fault diagnostic apparatus. In
addition, in certain situation, the actuator can be forcibly driven. 11D
7. OVERVOLTAGE PROTECTION.
When the voltage of the charging system is too high caused by the fault, the system will go to the
11D
protection status to restrict the engine speed to avoid the ECM damage.
11D
When the A/C switch is on, the system will receive a A/C request signal and make preparations for 11D
The system will switch on or switch off the A/C according to the protection demand for air-conditioner. 11D
11D
9. THREE-WAY CATALYTIC CONVERTER.
The function of three-way catalytic converter is to convert harmful exhaust gas from the engine to 11D
harmless gas to exhaust to the atmosphere. The internal structure of three-way catalytic converter
applies the cellular pipeline design. The cellular pipeline wall has precious metal coating on it, including 11D
palladium, rhodium, platinum etc, which acts as catalytic reaction media. The three-way catalytic
converter will cause 3% - 5% of the power consumption to the engine. 11D
10. OVERHEAT SYSTEM PROTECTION FUNCTION FOR THE THREE-WAY CATALYTIC CONVERTER.
The system predicts the rising trend of the engine exhaust temperature according to actual working 11D
condition of the engine and reduces the engine combustion temperature by timely controlling the air/
fuel ratio, so as to protect the three-way catalytic converter. 11D
11. FUEL AND CNG CONVERSION CONTROL.
(a) When the CNG request switch is placed in neutral position, ECM default for gasoline operation. With 11D
the engine starting (gasoline), if the CNG switch is on the request position, ECM will automatically
detect the internal conversion conditions stored in ECM. When the engine coolant temperature, speed 11D
and system trouble-free conversion conditions of gas meet the requirements, ECM supply CNG to the
system by controlling the CNG high-pressure solenoid valve. ECM opens the fuel and CNG 11D
conversion relay, at that time, fuel injector stops working. CNG injectors start to operate through
the injector driver. The fuel and CNG conversion is complete. 11D
(b) When the vehicle running and the volume of CNG is low, the system will automatically switch to
11D
gasoline state. When the engine is converted to gasoline run-time or the engine flameout, CNG system
solenoid valves closed. System backs to gasoline mode.
(c) In addition, the system also includes other features, such as CNG display.
BASIC PRINCIPLE
1. PRINCIPLE OF START CONTROL.
(a) When turning the ignition switch on, the fuel pump will stop after running for 1.5 seconds.
(b) When the engine starts to rotate, the fuel pump will start to operate after ECM detected 2 valid 58X
signals.
(c) The fuel pump stops operating 0.8 seconds after the engine speed disappears (the analogue signal is
easy to be disturbed).
(d) Pre-injection: The pre-injection only injects once during the normal start process (if the fuel is absorbed
by the carbon deposition, the mixture dilutes, which makes it difficult to start).
(e) Preliminary stage for starting: The intake manifold internal pressure is displayed as ambient
atmospheric pressure. After the throttle valve closed, ECM specifies a fixed parameter according to the
start temperature.
(f) During the start process, the fuel injection quantity varies according to the change of the engine coolant
temperature. The ignition advance angle also adjusts continually and changes with the engine coolant
temperature, the intake air temperature and the engine speed.
(g) End of the start process: When the engine speed exceeds 600 RPM, the start working condition ends.
2. PRINCIPLE OF FUEL INJECTION CONTROL.
(a) ECM controls the injector driving time and the injection timing, which enables the engine to obtain the
mixture with optimal air/fuel ratio under various working conditions.
(b) Each cylinder is equipped with an injector at the air inlet. The fuel pump in the fuel tank pumps out the
fuel and delivers the fuel to the fuel high pressure rail. The fuel pressure regulator keeps the injection
pressure stable. The injector injects the fuel directly to the air passage of each cylinder. During each
working cycle (when the crankshaft rotates twice) of the cylinder, each cylinder injects the fuel once (the
injection sequence is 1 - 3 - 4 - 2). This injection type is called as sequential injection.
(c) When the engine operates under cold or high-load condition, ECM performs open loop control to supply
dense mixture, so as to keep good performance. When the engine operates under the normal working
condition (medium or small load), ECM performs closed loop control via the signal feedback by oxygen
sensor to obtain optimal air/fuel ratio, which enables the three-way catalytic converter to get the optimal
purifying effect.
(d) Inject pulse width control.
Signal Input ECM Control Output

A/F modify
Closed loop feedback modify
Intake manifold absolute pressure
Air charging temperature
Air charging efficiency
Self-learning modify
Calculate fuel charge Inject pulse width
Power supply modify
Exhaust cycle
Accelerate deepen
Decelerate fuel reduction
Decelerate fuel cut
Injector parameter
3. CONTROL SIGNAL DESCRIPTION
Modified Item Content
• Start air/fuel ratio. 11D

• Air/fuel ratio while engine is running.
• Air/fuel ratio at low engine coolant temperature. 11D
Air/fuel ratio • Air/fuel ratio at normal engine coolant temperature.
• Theoretical air/fuel ratio. 11D
• Enriched air/fuel ratio.
• Overheat protection air/fuel ratio. 11D
Closed loop feedback correction • Control the actual air/fuel ratio around the theoretical air/fuel ratio via the
feedback signal from the oxygen sensor. 11D
Intake manifold pressure • Read directly via the MAP mounted on the intake manifold. 11D
Self-learning • Modify the engine internal slow change due to long time operation.
11D
Power voltage • When the battery voltage changes, the voltage modification can ensure
the correct fuel injection quantity. 11D
• When ECM detects the intake manifold pressure and the opening value
of the throttle valve increases greatly, the fuel injection quantity is 11D
Acceleration enrichment
increased to avoid the engine mixture dilutes momentarily, so as to
improve the power performance. 11D
Deceleration dilution • When the system detects the vehicle is under deceleration status, it
controls the fuel cutoff to reduce the emission and fuel consumption. 11D
• When the system detects the vehicle is under deceleration status, it 11D
controls the fuel cutoff to reduce the emission and fuel consumption.
Deceleration cutoff
• When the engine speed is above the setting value, fuel cutoff starts.
11D
• When a fault occurs in the ignition system, the fuel cuts off.
• It provides the relation between the engine and the fuel injection 11D
Fuel injection parameter
quantity.
11D
(a) Modification for the engine mixture:
• Partial load control of the engine is closed loop fuel control at the normal working temperature. Then 11D
the system modifies fuel injection quantity via ECM according to the feedback voltage signal from the
oxygen sensor, so as to adjust the mixture concentration to around the theoretical air/fuel ratio, which 11D
ensures the conversion efficiency of the harmful emission gas by the three-way catalytic converter
reaches the optimal status while ensuring good fuel economy. 11D
• When the engine operates with full-load within the normal working temperature range, it applies the
open loop fuel control. At this time, in order to ensure the engine obtains the optimal power output, the 11D
system will control the fuel injection quantity with a thick air/fuel ratio. Furthermore, with the premise
that no engine knock occurs, the engine will increase the ignition advance angle moderately. The 11D
system will also control the exhaust gas temperature using the exhaust gas temperature mathematical
model established during calibration, so as to protect the engine and the three-way catalytic converter.
The system determines the full-load condition of the engine according to the signal supplied by the
throttle valve position sensor. When the throttle valve opening is above 80% ~ 90%, the system
considers the engine goes to the full-load status. When the driver presses the accelerator pedal to
accelerate the vehicle, the system will increase the fuel injection quantity moderately to ensure the
power demand when the engine accelerates. The increased fuel injection quantity goes a direct
proportion with the changing rate of the throttle valve opening. When accelerating, ECM will retard the
ignition advance angle moderately, then recover step by step. The aim is to avoid impacting to the drive
train because the torque increases too rapid when the engine accelerates sharply.
• When the acceleration working condition is near the engine full-load, the system will automatically
switch off the A/C system temporarily, so as to ensure the engine power output well when accelerating.
Whatever the situation, when the engine speed exceeds the highest speed specified in the system, the
system will cut off the fuel supply to restrict the speed increasing, so as to protect the engine and avoid
the vehicle skidding. When the engine speed returns within specified in the system, the system will
restore the fuel supply immediately.
4. PRINCIPLE OF IGNITION CONTROL.
(a) Start: The engine applies a fixed ignition advance angle when starting, which allows the gas in the
cylinder to ignite and provide the positive torque. When the engine speed increases to certain speed,
ECM caculates the ignition advance angle according to the input signal.
(b) Ignition advance angle control.
Signal Modify ECM Output Control

ECT modify
IAT modify
Elevation modify
Idle modify
Main ignition angle Calculate ignition advance angle Ignition advance angle
Decelerate fuel reduction modify
Accelerate modify
Accelerate deepen modify
A/C modify
(c) Main ignition advance angle: When the engine temperature reaches the normal value, the main ignition
angle is usually the minimum ignition angle at the optimal torque point with the throttle valve opening.
When the throttle valve closes, the ignition angle should be reduced to obtain the idle speed stability.
(d) Correction of the ignition advance angle:
• Acceleration correction: When the vehicle accelerates, ECM detects the knock signal and corrects the
ignition advance angle until the knock disappears. Furthermore, it is also used to reduce the engine
speed fluctuation caused by the drive train torsion.
• Power enrichment correction: To obtain better power and torque near the exterior feature point, the air/
fuel ratio is enriched to the thinnest air/fuel ratio with the best torque.
• Deceleration cutoff correction: When the deceleration cutoff exits, correct the ignition advance angle to
get a stable transition.
• A/C correction: Switch off the A/C when the engine is idle. Correct the ignition advance angle, which
allows the speed to get a stable transition.
5. PRINCIPLE OF IDLE CONTROL.
(a) Idle control:
• Control the air flow in the bypass of the throttle valve according to the idle condition and the engine idle
load to maintain the idle speed at the optimal speed. According to the engine coolant temperature and
the A/C load, ECM drives the IAC motor to make the engine operate under the preset target idle speed.
In addition, when the engine operates at idle speed, turn on or turn off the A/C switch. The IAC motor
will regulate the air flow in the bypass according to the engine load to avoid idle speed unstable.
(b) Calculate the target idle speed.
Input ECM Output Control

Basic target idle speed 11D
Voltage compensation
11D
Vehicle speed compensation
11D
Fan compensation Calculate target idle speed Target idle speed
Headlamp compensation 11D

A/C compensation
11D
Deceleration adjustment
11D
• Voltage compensation: When the voltage is below 12V, the system will automatically increase the target
idle speed to increase the electrical energy production of the generator. 11D
• A/C compensation: Switch on the A/C when parking the vehicle at idle speed. To compensate the
power loss of the compressor, the target idle speed increases by 150 RPM. 11D
• Headlamp compensation: After switching on the low beam, the target idle speed increases by 50 RPM
to compensate the electricity loss. 11D
• Fan compensation: When the coolant temperature increases and the fan operates, the idle speed
11D
increases by 50 RPM to compensate the electricity loss for the fan operation.
(c) Idle speed control parameters: 11D
• Control of idle air flow.
• Control of fuel injection quantity. 11D
• Control of ignition timing.
(d) Idle speed design control timing: 11D
• Calibration of idle stability.
• Calibration of acceleration working condition.
11D
• Calibration of deceleration working condition.
11D
• Deceleration cutoff.
• Calibration for the fuel supply under engine transient transition working condition. 11D
• Calibration of constant speed driving.
• Calibration of increasing and reducing the mechanical and electricity load. 11D
(e) Decisive factors for the target idle speed:
11D
• When the coolant temperature is low, the system provides a high target idle speed to accelerate the
warm-up.
11D
• When the additional load (e.g. various electrical appliances such as the headlamp, A/C, cooling fan
etc.) opens, the system will raise the idle speed to compensate the increased load and keep the idle
11D
speed stable.
6. PRINCIPLE OF CARBON CANISTER SOLENOID VALVE CONTROL.

(a) Used for controlling the air flow of carbon canister cleaning. The carbon canister is controlled by ECM
sending the duration and frequency for the electrical impulse (duty cycle) through integrated
computation according to a series of signals including engine load, engine coolant temperature, and
engine speed etc. When too much gasoline vapor is accumulated in the activated carbon canister, it will
cause the gasoline leakage, which pollutes the environment. Therefore, the effect of carbon canister
solenoid valve is to open at the proper time to allow the excess gasoline vapor to enter the intake pipe
after mixing with the air sufficiently in the carbon canister to involve in the combustion.
(b) The carbon canister will not work in the following conditions:
• During a period after the cold start of the engine.
• When the cooling water temperature is low.
• During the engine idle operation period.
• During the engine big load period.
• When the important sensors of the system have fault.
7. PRINCIPLES OF CNG INJECTION CONTROL.
When CNG engine is running, besides of receiving the system shared with the gasoline engine sensor
signals, CNG temperature and pressure sensors complete CNG mode of operation. These include
dedicated CNG ignition angle control MAP, volumetric efficiency MAP, CNG density correction,
temperature correction, CNG closed-loop correction control, transient condition correction, high-altitude
compensation. So the engine is running at stoichiometric.
SYSTEM COMPONENTS DESCRIPTION

Component Summary Quantity Function
ECM optimization control system 11D
ECM 16 bit CPU 1
depends on the sensor signal.
11D
Check oxygen concentration in
Upstream oxygen sensor With heated 1
exhaust.
11D
ECM judges whether the TWC is
Downstream oxygen sensor With heated 1 good comparing the upstream with 11D
downstream oxygen sensor signal.
Check the air inlet quantity and 11D

MAP/IAT sensor Piezoelectric type 1
BTDC.
11D
Magnetron induction coil
CKP sensor 1 Check CKP and engine RPM.
type
11D
Inject fuel depends on the sensor
Fuel injector 4 hole type 4
from ECM.
11D
Idle air control motor Electromagnetic coil type 1 Control air inlet.
11D
Control the exhaust depending on
Carbon solenoid valve Electromagnetic type 1
the digital pulse wave from ECM.
11D
3-lines type carbon film
TPS 1 Check the open of throttle.
resistor sliding indicator 11D
NTC thermal resistance
ECT sensor 1 Check ECT. 11D
type
NTC thermal resistance

IAT sensor 1 Check IAT. 11D
type
Inject CNG according to the signal 11D

CNG injector Electromagnetic type 4
from the driver.
Ignition control module Electromagnetic coil type 1 Ignite mixed gas. 11D
Electromagnetic type Supply the enough pressure fuel for 11D

Fuel pump 1
pump system.
CNG bottle Valve Parallel type 1 Ensure the safety of CNG bottle. 11D
CNG filling receptacle valve Check valve 1 Supply CNG to the system.
11D
CNG compression release
Diaphragm 1 CNG pressure reduction.
valve 11D
Injector driver Signal hold circuit 1 Drive injector.
11D
11D-18 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
ENGINE CONTROL MODULE (ECM)

PRINCIPLE
1. ECM DESCRIPTION.
(a) ECM is the electric engine control center with the micro
processor as the core that having sensor signal input
interface and the executor drive circuit. The ECM
receives and treats the engine status signal that inputted
from all sensors, sends control signal to the executor to
drive the engine running in accordance with the preset
procedures so as to make the engine run under best
status, ensure good power capability, fuel economy and
exhaust capability.
(b) Normal operating voltage: 9 ～ 16 V.
(c) Overvoltage protection: +24V/-12V ＜ 60 s.
(d) Continuity power: terminal 17, 18.
(e) Controlled by ignition switch: terminal 1.
(f) Ground wire: terminal 73.
(g) Standard 5 V power supply: terminal 20, 21.
(h) Standard 5 V ground supply: terminal 4, 5.
(i) ECM has self-protection function. It may result the
ignition failure during repair and it will resume normal
after replacement of ECM. In fact, the ECM doesn’t get
damaged, but in fact self-protection mode. ECM will
resume normal after certain time period.
ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11D-19
REPLACEMENT
2. ROTATE DRIVER SEAT. 11D

(b) Rotate the driver seat. 11D
11D
11D
11D
3. OPEN THE BATTERY COVER. 11D

11D
11D
11D
11D
11D
NOTE 11D
please first turn off the ignition switch and lighting switch 11D
cable when peforming these operations. 11D
11D
11D
replacement”) 11D
6. REMOVE BUCKLE ASSY. 11D
11D
11D

11D-20 ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM)
9. REMOVE ECM.
(a) Disconnect ECM connector.
NOTE
After disconnecting the connector, keep the junction of the
connector out of the dirty, water and other foreign matter.
(b) Remove 4 bolts.
(c) Remove ECM.

NOTE
• After disconnecting ECM, pay attention to waterproof.
• Pay attention to protect the terminals.
• Disconnect the battery negative cable more than 1
minute before removing ECM.
• Knock or impact is not allowed.
10. INSTALL ECM.

NOTE
Torque: 5 N•m
ENGINE CONTROL SYSTEM - ENGINE CONTROL MODULE (ECM) 11D-21
(b) Connect ECM connector.
11D
11D
11D
11D
11D
13. INSTALL 7 ENGINE COVER RETAINING BOLTS. 11D

11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
replacement”) 11D
11D
11D
11D-22 ENGINE CONTROL SYSTEM - INJECTOR DRIVER
INJECTOR DRIVER
PRINCIPLE
1. INJECTOR DRIVER DESCRIPTION.
(a) The basic principle of the injector drive is a peak-hold
circuit. It receives the injection signal from ECM and
change it into the required current to drive injector. It
open injector with 3 ～ 6 A current, then rapidly decreas
to 2.4 A to maintain the injector opened. It makes the
injector open fast, also avoid the injector and the ECM
overheating for long time working in high-current.
(b) Normal operating voltage: 10 ～ 16 V.
(c) Operating temperature: -40 ～ 120 ℃ .
ENGINE CONTROL SYSTEM - INJECTOR DRIVER 11D-23
REPLACEMENT

11D
11D
11D

11D
11D
11D
11D
11D
NOTE 11D
11D
11D
replacement”) 11D
11D
11D

11D-24 ENGINE CONTROL SYSTEM - INJECTOR DRIVER
9. REMOVE INJECTOR DRIVER.

(a) Disconnect injector driver connector.
NOTE
After disconnecting the connector, keep the junction of the
connector out of the dirty, water and other foreign matter.
(b) Remove 4 bolts.
(c) Remove injector driver.
NOTE
• After disconnecting injector driver, pay attention to
waterproof. Not allow to contact water. Even more,
not allow to put into water.
• Pay attention to protect the terminals.
• Disconnect the battery negative cable for 1 minute
before removing injector driver.
• Not allow to impact.
10. INSTALL INJECTOR DRIVER.

(b) Connect injector driver connector.
NOTE
• Pay attention to electrostatic protection when installation.
• The mounting hole of driver is the same as the hole
of ECM. Such as installation space allows, you can
install the two overlap. Driver can be installed in the
engine compartment, can also be installed in the
cab. But pay attention away from the heat source,
away from strong electromagnetic interference, and
can not be installed in the engine body.

ENGINE CONTROL SYSTEM - INJECTOR DRIVER 11D-25

11D
11D
11D
11D
11D
Torque: 41 ~ 51 N•m 11D
11D
11D
11D
11D
11D
replacement”)
17. PUT DOWN DRIVER SEAT AND LOCK IT. 11D
11D
11D
11D
11D
11D
11D
11D
11D
ENGINE CONTROL SYSTEM -
ENGINE COOLANT TEMPERATURE
11D-26 SENSOR
ENGINE COOLANT TEMPERATURE SENSOR

PRINCIPLE
1. ENGINE COOLANT TEMPERATURE DESCRIPTION.
(a) The Engine Coolant Temperature (ECT) sensor uses a
thermistor to control the signal voltage to the Engine
Control Module (ECM).
(b) This ECT sensor is a 2-line type. Normally a 1-line type is
to provide coolant temperature signal to the instrument.
SENSOR 11D-27
OVERHAUL

11D
11D
11D

11D
11D
11D
11D
11D
NOTE 11D
11D
11D
replacement”) 11D
11D
11D

11D-28 SENSOR
10. REMOVE THE ENGINE COOLANT TEMPERATURE

(ECT) SENSOR.
(a) Disconnect ECT sensor connector.
(b) Remove ECT sensor.

NOTE
.
11. CHECK ECT SENSOR.
(a) Dip the sensing part of ECT sensor into hot water. Using
the multimeter, measure resistance of the sensor.
(b) If the check result is not OK, replace it with a new one.
Check Condition Specified Condition
0℃ 9098 ～ 9700 Ω
10 ℃ 5494 ～ 5822 Ω
20 ℃ 3420 ～ 3602 Ω
30 ℃ 2184 ～ 2296 Ω
SENSOR 11D-29
CAUTION
Don’t let the water go into terminals. After checking, dry the
sensor.
11D
12. INSTALL ECT SENSOR.
CAUTION 11D
Apply sealant to thread. The specified sealant: 3M nut
locking part, type: NO. 4171 or the equivalent. 11D
(a) Install and tighten ECT sensor.
Torque: 29.4 N•m 11D
11D
11D
(b) Connect ECT sensor connector.
11D
11D
11D
11D
11D
11D
15. CONNECT BATTERY NEGATIVE CABLE. 11D
11D
Torque: 21 ~ 25 N•m 11D
11D
11D
11D
11D
11D
11D-30 SENSOR

replacement”)
ENGINE CONTROL SYSTEM - THROTTLE BODY 11D-31
THROTTLE BODY
THROTTLE BODY CLEANING
11D
1. CLEANING STEPS.
(a) Start the engine and warm it up until the coolant is 11D
heated to 80 ℃ or higher. Then stop the engine.
(b) Remove the air intake hose from the throttle body. 11D
(c) Plug the bypass passage inlet (arrow) of the throttle
body. 11D
CAUTION
Do not allow cleaning solvent to enter the bypass passage.
11D
(d) Spray cleaning solvent into the valve through the throttle
11D
body intake port and leave it for approximately 5 minutes.
(e) Start the engine, accelerate it several times and then idle 11D
it for about one minute. If the idle speed becomes
unstable (or if the engine stalls) due to the bypass 11D
passage being plugged, slightly open the throttle valve to
keep the engine running.
11D
(f) If the throttle valve deposits are not removed, repeat
steps 4 and 5. 11D
(g) Unplug the bypass passage inlet.
(h) Connect the air intake hose. 11D
(i) Use the scan tool to erase any diagnostic trouble code.
(j) Adjust the basic idle speed. 11D
NOTE 11D
If the engine hunts while idling after adjustment of the basic
idle speed, disconnect the battery negative cable for 10 11D
seconds or more, and then reconnect it and run the engine
at idle for about 10 minutes. 11D
11D
11D
11D
11D
11D
11D-32 ENGINE CONTROL SYSTEM - THROTTLE BODY
THE FIXED SPEED ADJUSTING SCREW (SAS) ADJUSTMENT

1. SINCE FIXED SAS IS ADJUSTED AT FACTORY, PLEASE DO NOT ADJUST “FIXED SAS” IN
NORMAL CASES UNLESS IT IS NECESSARY.
2. IF “FIXED SAS” IS ROTATED RANDOMLY, PLEASE RE-ADJUST ACCORDING TO THE
FOLLOWING STEPS:
(a) Loosen the tension of the acceleration cable.

(b) Loosen the "fixed SAS” lock nut.
(c) Turn the idle switch counterclockwise until the throttle
valve closes.
(d) Screw the “fixed SAS” clockwise until the point (i.e. the
position when throttle is started to be opened) of throttle
rail is reached.
(e) Keep the “fixed SAS” from moving when tightening the
lock nut.
(f) Adjust the acceleration cable tension.
(g) Adjust the basic idle speed.
BASIC IDLE SPEED ADJUSTMENT

1. THE STANDARD IDLE SPEED HAS BEEN ADJUSTED WITH THE SPEED ADJUSTING SCREW
(SAS) BY THE MANUFACTURER, AND THERE SHOULD BE NO NEED FOR RE-ADJUSTMENT.
11D
2. IF THE ADJUSTMENT HAS BEEN CHANGED BY MISTAKE, THE IDLE SPEED MAYBE COME TOO
HIGH OR TOO LOW WHEN TURN ON A/C, DEFOGGER, ETC. ARE PLACED ON THE ENGINE. IF
11D
THIS OCCURS, ADJUST BY THE FOLLOWING PROCEDURE.
NOTE 11D
If make the adjustment, it should be made after confirming that the spark plugs, the injectors, the idle
air control motor, compression, etc., are all normal. 11D
(a) Place the car in good condition before the inspection and
11D
adjustment.
(b) Turn the ignition switch OFF. 11D
(DLC). 11D
(d) Start the engine and run at idle speed.
(e) Check the idle speed. 11D
Standard value: 750 ± 50 RPM
11D
NOTE
• The engine speed may be 20 to 100 RPM lower than 11D
indicated above for a new vehicle, but this is normal
and no adjustment is necessary.
11D
• If the engine stalls or the engine speed is low even
though the vehicle has been driven approximately 11D
500 km (300 mile) or more, it is probable that
deposits are adhered to the throttle valve, so clean it. 11D
(f) If it is not within the standard value range, turn the Speed
Adjusting Screw (SAS) to make the necessary adjustment. 11D
NOTE
11D
If SAS gets to bottom completely, the idle speed is still more
than standard value, then check if “fixed SAS” was rotated.
11D
If yes, re-adjust “fixed SAS”.
• Turn the ignition switch OFF. 11D
• Disconnect the scan tool.
• Start the engine again and let it idle for about 10 minutes. 11D
Check that the idling condition is normal.
11D
11D
OVERHAUL



NOTE
replacement”)

11D
11D
11D
11D
11D
(a) Loosen accelerator cable adjustment nut on the throttle 11D
body.
(b) Remove accelerator cable clip. 11D
11D
11D
11D
11D
11D
11D
11D
12. REMOVE THROTTLE BODY. (Refer to “Chapter 14A
intake air - throttle body, replacement”)
11D
13. INSTALL THROTTLE BODY. (Refer to “Chapter 14A
intake air - throttle body, replacement”) 11D
11D
11D
11D
11D




replacement”)
ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR 11D-37
IDLE AIR CONTROL MOTOR

PRINCIPLE
11D
1. IDLE AIR CONTROL MOTOR DESCRIPTION.
(a) The idle air control motor is essentially one micro motor. 11D
Since the motor will revolve in various directions when
the motor coil is supplied with current in various 11D
directions. The motor revolution shaft will drive the
moving of the leading screw so as to control the open
11D
extent of the valve indirectly. ECM will send the
digitalized square wave signal to control the positive
11D
rotation and the reverse rotation of the motor so as to
control the stroke of the idle air control motor.
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-38 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR
1. OPERATING SOUND INSPECTION.
(a) Check that coolant temperature of engine is below 20 ℃ .
NOTE
If coolant temperature of engine is above 20 ℃ , remove the harness connector of engine coolant temperature
sensor, and use the less than 20 ℃ sensor for connection.
(b) Check that when ignition switch is changed into the ON position (do not start engine), the operating
sound of the motor can be heard or not.
(c) If an operating sound can be heard, check the motor drive circuit. If the circuit is good, a defective
motor or ECM is suspected.
2. CHECK ENGINE RPM.

(a) Start the engine and warm it to normal operating
temperature.
BUS\ VIEW\ENGINE\4GC1\DELPHI SYSTEM\MT20U2
CNG SYSTEM\ ACTIVE TEST”.
(f) Perform the idle air control motor test.
(g) When the scan tool control the rotation of expansion of
the idle air control motor, the engine RPM changes from
high to low in synchronism (vibration can be felt when
touching the idle air control motor).
(h) If it is not OK, check IAC motor control harness or con-
nector. If harness or connector is OK, check IAC motor or
ECM.
3. CHECK IDLE AIR CONTROL MOTOR STEPS.
available.
(e) Select the item “AUTO DIAGNOSIS\FOTON\LIGHT BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\
MT20U2 CNG SYSTEM\ READ DATA STREAM.”
• ECT: 80 ～ 95 ℃
• Accessories: OFF A/C switch: OFF → ON Add 10 ～ 70 steps
• Transmission: N
Idle air control motor
• Engine: idle
• A/C turns ON A/C switch: OFF 2 ～ 25 steps
• A/C: works
(f) If it is not OK, check idle air control motor, harness, connector or ECM.
OVERHAUL

11D
11D
11D

11D
11D
11D
11D
11D
NOTE 11D
11D
11D
(a) Disconnect idle air control motor connector. 11D
11D
11D
11D
11D-40 ENGINE CONTROL SYSTEM - IDLE AIR CONTROL MOTOR
(b) Remove 2 idle air control motor retaining bolts.
(a) Clear surface after removing.

(b) Clear the path of the idle.
(c) If necessary, clean the idle speed stepper motor surface
deposits.
7. CHECK IDLE AIR CONTROL MOTOR COIL RESISTANCE.

(a) Connect special tool (for test).
(b) Check resistance between terminal A and B of idle air
(c) Check resistance between terminal C and D of idle air
(d) If it is not OK, replace it with a new one.
8. INSTALL IDLE AIR CONTROL MOTOR.

(a) Install idle air control motor.
(b) Tighten 2 idle air control motor retaining bolts. 11D
Torque: 3.4 N•m
NOTE 11D
• Do not apply any axially type of force to press or pull
out the axle. 11D
• The axle must be in the place of the retreating before
the idle air control motor being installed into the 11D
throttle body.
11D
• After removing battery or ECM, pay attention to the
idle air control motor self-learning.
11D
• The IAC motor self-learning: Turn the ignition switch
OFF, not start at once. After 5 seconds, start it again.
11D
11D
11D
11D
11D
11D

11D
11D
11D
11D
11D
11D
11D-42 ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS)
THROTTLE POSITION SENSOR (TPS)

PRINCIPLE
(a) Throttle Position Sensor (TPS) is used to provide throttle
angle, angle speed and engine idle position information
to the ECM. Based on this, the ECM can obtain the
engine load information, operating mode (such as start,
idle, reverse towing, partial load and full-load) and
acceleration & deceleration information. This sensor is of
3-line type and the ECM will check the throttle open
extent by monitoring the voltage variation.
(b) The throttle position sensor is comprised of carbon film
resistance and slide indicator.
(c) The sensor slide indicator connects with the throttle and
rotates following the shaft. When the throttle open extent
changes following the accelerator pedal, the position of
the slide indicator will also change on the carbon film
resistance, at that moment the resistance output will also
change, which reflects the open extent of the throttle
indirectly.
ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 11D-43
OPERATING TEMPERATURE. 11D
3. CONNECT THE SCAN TOOL TO THE DATA LINK 11D
CONNECTOR (DLC) - USE THE MOST CURRENT
SOFTWARE AVAILABLE. 11D
5. SELECT THE ITEM “AUTO DIAGNOSIS \FOTON\LIGHT 11D
CNG SYSTEM\ READ DATA STREAM”. 11D
11D
11D
11D
11D
Idle position 0.3 ～ 1 V
(0%)
11D
• Ignition switch: ON Directly proportional with
TPS Open throttle slowly
• Engine stop the open degree 11D
Widely open 4.5 ～ 5.5 V

(100%) 11D
6. IF IT IS NOT OK, CHECK TPS, HARNESS OR ECM.

11D
11D
11D
11D
11D
11D
11D
11D
OVERHAUL



NOTE
5. REMOVE TPS.
(a) Disconnect TPS connector.
ENGINE CONTROL SYSTEM - THROTTLE POSITION SENSOR (TPS) 11D-45
(b) Remove 2 TPS retaining bolts.
11D
11D
11D
11D
11D
11D
11D
6. REMOVE TPS.
NOTE 11D
Clear the surface after removing.
11D
11D
11D
11D
7. CHECK TPS RESISTANCE.
(a) Measure the resistance according to the value in the 11D
table below.
11D
• Terminal A and B • Resistance: 3.5 ～ 6.5 Ω (20 ℃ ) 11D
• Open throttle from idle position to 11D

open wide.The output value is
• Terminal A and C
proportional change to the open
degree.
11D
11D
(b) If the resistance is out of the range and the value
changes unsteadily, replace it. 11D
11D
8. POSITION TPS.
(a) Tighten 2 TPS retaining bolts.
Torque: 3.4 N•m
(b) Connect TPS connector.

INTAKE TEMPERATURE SENSOR 11D-47
MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERA-

TURE SENSOR
PRINCIPLE 11D
1. MANIFOLD ABSOLUTE PRESSURE/INTAKE TEMPERATURE 11D
SENSOR DESCRIPTION.
(a) MT20U2 adopted speed-density air measurement 11D
method to check the air intake volume into the engine so
as to control the fuel injection pulse width for the precise 11D
control of engine power output. Meanwhile, this system
adopted intake pressure cylinder determination 11D
technology and the intake air sensor is installed near the
inlet opening of cylinder 4 intake manifold. At the 11D
moment when the throttle is opened, there will be one
instantaneous pressure drop at the sensor, of which the
11D
value is about 1 kPa. When the ECM detected and
received this instantaneous pressure drop. The ECM will
11D
determine the compression upper dead center signal
after software diagnosis treatment.
11D
(b) Intake air temperature sensor is a Negative Temperature
Coefficient (NTC) of resistance, with the intake air
11D
temperature increases resistance decreases, the engine
ECM contrast through the internal circuitry to detect an
11D
intake air temperature changes.
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-48 INTAKE TEMPERATURE SENSOR
5. SELECT THE ITEM “AUTO DIAGNOSIS \FOTON\LIGHT
BUS\VIEW\ENGINE\4GC1\DELPHI SYSTEM\MT20U2\CNG
SYSTEM\READ DATA STREAM”.
IAT: -20 ℃ -20 ℃
IAT: 0 ℃ 0℃
• Engine: running
IAT: 40 ℃ 40 ℃
IAT: 80 ℃ 80 ℃
6. TURN DIGITAL MULTIMETER TO VOLTAGE RANGE.

CHECK VOLTAGE OF MAP SENSOR BETWEEN
TERMINAL A OR D AND GROUND.
(a) When engine runs at idle, terminal D is 5 V, terminal A is
1.3 V.
(b) When engine runs unload, open throttle slowly, the signal
of terminal A is changed little.
(c) Open throttle quickly, the signal of terminal A is to about
4 V, then drop to 1.5 V.
(d) Turn multimeter to voltage range. Black pin to ground,
red pin to terminal C of the IAT sensor. Check IAT signal.
IAT: 0 ℃ 3.2 ～ 3.8 V

IAT: 20 ℃ 2.3 ～ 2.9 V
IAT: 40 ℃ 1.5 ～ 2.1 V
IAT: 80 ℃ 0.4 ～ 1.0 V
(e) If it is not OK, check MAP/IAT sensor, harness or ECM.

AN
INTAKE TEMPERATURE SENSOR 11D-49
OVERHAUL

11D
11D
11D

11D
11D
11D
11D
11D
NOTE 11D
11D
11D
5. REMOVE MAP/IAT SENSOR CONNECTOR.
(a) Disconnect MAP/IAT sensor connector. 11D
11D
11D
11D
11D-50 INTAKE TEMPERATURE SENSOR
6. REMOVE MAP/IAT SENSOR.

(a) Remove MAP/IAT sensor retaining bolt.
(b) Remove MAP/IAT sensor.
NOTE
7. INSTALL MAP/IAT SENSOR.

(a) Tighten MAP/IAT sensor retaining bolt.
(b) Connect MAP/IAT sensor connector.
NOTE

ENGINE CONTROL SYSTEM - CKP SENSOR 11D-51
CKP SENSOR
PRINCIPLE
11D
1. CRANKSHAFT POSITION SENSOR DESCRIPTION.
(a) The 58x reference signal is produced by the Crankshaft 11D
Position (CKP) sensor. The Engine Control Module
(ECM) uses the 58X reference signal to caculate engine 11D
RPM and CKP. The ECM constantly monitors the
number of pulses on the 58X reference circuit and
11D
compares them with the number of map signal being
received.
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-52 ENGINE CONTROL SYSTEM - CKP SENSOR
OVERHAUL



NOTE
replacement”)

ENGINE CONTROL SYSTEM - CKP SENSOR 11D-53
11D
11D
11D
11D
9. REMOVE CKP SENSOR.
(a) Disconnect CKP sensor connector. 11D
11D
11D
11D
11D
(c) Remove the CKP sensor retaining bolt.
11D
NOTE
Clear surface after removing. 11D
11D
11D
11D
10. CHECK CKP SENSOR. 11D

(a) Turn digital multimeter to Ohm range, connect terminal A
and B of sensor for check resistance value. 11D
Standard resistance: 560 Ω ± 10% (20 ℃ )
(b) If the check result is not normal, replace it. 11D
11D
11D
11. INSTALL CKP SENSOR. 11D

CAUTION
Paint a layer of engine oil on the O-ring of the CKP sensor.
11D-54 ENGINE CONTROL SYSTEM - CKP SENSOR
(a) Tighten CKP sensor retaining bolt.

Torque: 7.5 ± 10% N•m
NOTE
(b) Connect the CKP sensor connector.



replacement”)
ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11D-55
UPSTREAM OXYGEN SENSOR

PRINCIPLE
11D
1. UPSTREAM OXYGEN SENSOR DESCRIPTION.
(a) This sensor is used to provide the excess oxygen 11D
information after the injected fuel in the cylinder has
passed the full combustion in the sucked air. By means 11D
of this information, the ECM can perform the closed loop
control upon the fuel quantity so that the 3 main toxic
11D
substances in the exhaust, which named Hydrocarbon
(HC), Carbon Oxides (CO) and nitrogen oxides, can be
11D
converted and purified in the three-way catalytic
converter.
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-56 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
Specified
Displayed Item Detection Condition
Condition
Decelerate suddenly from
4000 RPM ≤ 0.2 V
1. A/F: to be rich when
acceleration
Accelerate suddenly 0.6 ～ 1 V
Upstream oxygen
Engine: idle 0.1 ～ 0.9 V
2. A/F: to be lean when
deceleration Engine: 2500 RPM 0.6 ～ 1 V

ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR 11D-57
OVERHAUL

11D
11D
11D

11D
11D
11D
11D
11D
NOTE 11D
11D
11D
5. REMOVE UPSTREAM OXYGEN SENSOR.
CAUTION 11D
Remove the exhaust pipe after cooling completely.
11D
(a) Remove upstream oxygen sensor connector.
(b) Remove harness from bracket. 11D
11D
11D-58 ENGINE CONTROL SYSTEM - UPSTREAM OXYGEN SENSOR
6. Remove upstream oxygen sensor.
7. CHECK UPSTREAM OXYGEN SENSOR.

(a) Turn digital multimeter to ohm range. Check resistance
8. INSTALL UPSTREAM OXYGEN SENSOR.

CAUTION
Paint a layer of rust-proof oil on the thread.
(a) Install upstream oxygen sensor and tighten.
9. CONNECT UPSTREAM OXYGEN SENSOR CONNECTOR.

ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11D-59
DOWNSTREAM OXYGEN SENSOR

PRINCIPLE
11D
1. DOWNSTREAM OXYGEN SENSOR DESCRIPTION.
(a) The purpose of the rear oxygen sensor is to check the 11D
oxygen concentration in the exhaust that passed three-
way catalytic converter and the sensor will convert such 11D
signal to dot signal and transmit to the ECM. After the
comparison of the signals of the upstream/downstream
11D
oxygen sensors, the ECM will judge if the three-way
catalytic converter functions work well.
11D
(b) The structure of downstream oxygen sensor is same as
the upstream oxygen sensor. 11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-60 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
• Engine: warm
Downstream oxygen
• Check A/F with oxygen Engine: running About 0.1 V
sensor
sensor

ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR 11D-61
OVERHAUL

11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
NOTE 11D
11D
11D
5. RAISE VEHICLE.
11D
6. REMOVE DOWNSTREAM OXYGEN SENSOR.
(a) Disconnect downstream oxygen sensor connector. 11D
(b) Remove the harness from bracket.
11D
11D
11D-62 ENGINE CONTROL SYSTEM - DOWNSTREAM OXYGEN SENSOR
(c) Remove downstream oxygen sensor.
7. CHECK DOWNSTREAM OXYGEN SENSOR.

(a) Turn digital multimeter to Ohm range, check resistance
8. INSTALL DOWNSTREAM OXYGEN SENSOR.

CAUTION
Paint a layer of rust-proof oil on the thread.
(a) Install downstream oxygen sensor and tighten.
(b) Connect downstream oxygen sensor connector.
9. LOWER VEHICLE.
ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE 11D-63
CANISTER SOLENOID VALVE

PRINCIPLE
11D
1. CARBON CANISTER SOLENOID VALVE DESCRIPTION.
(a) The carbon canister solenoid valve is a kind of solenoid 11D
valve mechanism and controlled by ECM. ECM will send
digitalized square wave control pulse to control the open 11D
extent of the solenoid valve. The open extent of the
carbon canister is different depending on the various
11D
engine operating modes. In case of the great load of
engine or engine idle, the carbon canister solenoid valve
11D
doesn’t operate in order to ensure the engine power
output well.
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
11D-64 ENGINE CONTROL SYSTEM - CANISTER SOLENOID VALVE
5. SELECT THE ITEM “AUTO DIAGNOSIS\FOTON\
MT20U2\CNG SYSTEM\READ DATA STREAM”.
6. CHECK THE ACTION OF CARBON CANISTER SOLENOID VALVE.

(a) Use the “action test” function of the diagnostic apparatus.
• Touch the fuel Evaporative Emission Control (EVAP) system carbon canister solenoid valve with hand.
• Perform the action test of carbon canister solenoid valve with the “action test” function of the diagnostic
apparatus.
• The carbon canister solenoid valve should vibrate slightly. If the carbon canister solenoid valve has no
slight vibration, check solenoid valve, harness and ECM.
(b) Vacuum test method.
• When the engine operates at the idle status, pull out the vacuum hose from the activated carbon
canister and check the vacuum hose for vacuum suction. If the carbon canister solenoid valve operates
normally, the solenoid valve should be closed and there should be no vacuum suction in the vacuum
hose. If there is vacuum suction in the vacuum hose now, remove the socket connector from the
solenoid valve. If there is voltage in the terminals of the harness socket connector in the carbon
canister solenoid valve, it indicates there is a fault in ECM. If there is no voltage, it indicates the carbon
canister solenoid valve is stuck in the opening position.
• Press the accelerator pedal to allow the engine speed reach above 2000 RPM and check the vacuum
hose for the vacuum suction. If the vacuum suction exists, it indicates the carbon canister solenoid
valve operates normally. If no vacuum suction exists in the vacuum hose and the voltage is normal on
the terminal of harness socket connector in the carbon canister solenoid valve, it indicates there is a
fault in the carbon canister solenoid valve. If the voltage is abnormal, it indicates there is a fault in ECM
or harness.
OVERHAUL

11D
11D
11D
11D
11D
11D
11D
11D
11D
11D
NOTE 11D
11D
11D
5. DISCONNECT CANISTER SOLENOID VALVE CONNECTOR.
11D
11D
11D
11D
6. DISCONNECT CANISTER SOLENOID VALVE INLET

HOSE CLIPS AND TAKE AWAY HOSE (CONNECTING
TO CANISTER).
NOTE
When disconnecting these hoses which used for a long time.
Twist hose to be loosed first, then operate disconnection.
7. DISCONNECT CANISTER SOLENOID VALVE OUTLET

HOSE CLIPS AND TAKE AWAY HOSE (CONNECT TO
THROTTLE BODY LOWER INTAKE MANIFOLD).
8. RELEASE CANISTER SOLENOID VALVE LOCKING

PLATES.
9. REMOVE CANISTER SOLENOID VALVE.

10. CHECK CANISTER SOLENOID VALVE.

(a) Apply battery voltage to canister solenoid valve. Sound
should be heard. At this time, blow air into the inlet port:
• If air passes, then the canister solenoid valve is OK. If it is 11D
not OK, replace it.
• If no power applies, the solenoid should be closed. No air 11D
passes.
11D
11D
11D
11D
11D
(b) Check carbon control solenoid valve resistance.
• Turn digital multimeter to Ohm range. Check resistance 11D
between terminal A and B of canister solenoid valve.
Standard resistance: 19 ~ 22 Ω (20 ℃ ) 11D
• If it is not OK, replace it.
11D
11D
11D
11. INSTALL CANISTER SOLENOID VALVE.
11D
11D
11D
11D
11D
11D
11D
11D
12. CONNECT CANISTER SOLENOID VALVE OUTLET

HOSE CLIPS (CONNECTING TO THROTTLE BODY
LOWER INTAKE MANIFOLD).
13. CONNECT CANISTER SOLENOID VALVE INLET

HOSECLIPS (CONNECTING TO CANISTER ).
14. CONNECT CANISTER SOLENOID VALVE CONNECTOR.


11D
11D
11D
11D
11D
Torque: 41 ~ 51 N•m 11D
11D
11D
11D
11D
11D
replacement”)
11D
11D
11D
11D
11D
11D
11D
11D
11D-70 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR

PRINCIPLE
(a) ECM uses the sensor to receive the digital pulse signal.
ECM can get the vehicle speed from the signal.
ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11D-71
OPERATING TEMPERATURE. 11D
3. CONNECT THE KT600 SCAN TOOL TO THE DATA 11D
CURRENT SOFTWARE AVAILABLE. 11D
5. SELECT THE ITEM “AUTO DIAGNOSIS\FOTON\ 11D
MT20U2\CNG SYSTEM\READ DATA STREAM”. 11D
6. DRIVE THE VEHICLE, READ THE SCAN TOOL DATA
STREAM: VEHICLE SPEED.
11D
7. VEHICLE SPEED: THE SAME VALUE AS THE
11D
ACTUAL VEHICLE SPEED.
8. IF THE DISPLAYED VALUE IS NOT EQUAL TO THE 11D
ACTUAL VALUE, CHECK SENSOR, HARNESS AND
ECM. 11D
11D
10. TURN THE IGNITION SWITCH ON AND NOT START ENGINE. CHECK AS FOLLOWING:
(a) Set digital multimeter to voltage range. Check voltage 11D

between terminal 2 and 3 of the sensor. It should be 12
V. If it is not OK, replace it. 11D
(b) Start engine, pull into gear. Using the oscilloscope, check
11D
the wave output of terminal 3 of sensor. If it is not OK,
check harness and sensor.
11D
11D
11D
11D
11D
11D
11D
11D-72 ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR
OVERHAUL



NOTE
5. RAISE VEHICLE.

ENGINE CONTROL SYSTEM - VEHICLE SPEED SENSOR 11D-73

NOTE
Clear surface after installation. 11D
11D
11D
11D
7. INSTALL VEHICLE SPEED SENSOR. 11D

(a) Tighten vehicle speed sensor retaining bolt.
Torque: 7.5 N•m 11D
NOTE
Do not allow any impact tools (such as a hammer, etc.) to 11D
11D
11D
(b) Connect vehicle speed sensor connector. 11D
11D
11D
11D
11D
11D
8. LOWER VEHICLE.
11D
11D
11D
11D-74 ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE
IGNITION CONTROL MODULE

PRINCIPLE
1. IGNITION CONTROL MODULE DESCRIPTION.
。
(a) Adopting group ignition technology, taking advantage of the

theory that the mutual induction of the electromagnetic coils
can generate high energy, controlling the switch-on/switch-
off time of the primary coil, and taking advantage of the high
voltage power of the secondary coil to puncture the spark
plug gap so as to generate strong spark to ignite the mixed
air. Since the air ionization is very great and the resistance
is very low during the engine exhaust process, only low
voltage power is required to puncture the spark plug gap.
Therefore, this system adopts group ignition technology so
as not to waste the energy.
ENGINE CONTROL SYSTEM - IGNITION CONTROL MODULE 11D-75
(a) Start the engine and warm it to normal operating 11D
temperature.
(b) Turn the ignition switch OFF. 11D
(DLC) - use the most current software available. 11D
11D
11D
CNG SYSTEM\READ DTC”.
(f) Dynamic detection of the ignition control module. 11D
(g) Using the KT600 scan tool, confirm that there is no DTC.
If there is DTC, record it. Ensure that the DTC is resolved 11D
even if nothing to do with the ignition system.
(h) Pull out fuel pump relay. 11D
(i) Lightly pull out spark plug wire and remove the spark
plug. 11D
(j) Install a new spark plug to the spark plug wire, connect
spark plug negative to the engine cylinder block. 11D
(k) Start engine, check the flash over.
11D
(l) If the flash over is weak or no flash over, replace with a
new ignition coil. After replacing, the flash over become
strong. We can ensure the ignition coil has been 11D
damaged. If there is still no flash over, check the ignition
circuit and inspect the spark plug. 11D
(m) Using KT600 scan tool, clear DTC.
11D
11D
11D
11D
11D
11D
11D
OVERHAUL



NOTE
replacement”)

11D
11D
11D
11D
11D
10. REMOVE IGNITION CONTROL MODULE.
(a) Disconnect ignition control module connector. 11D
11D
11D
11D
11D
(b) Remove and inspect spark plug wire.
11D
NOTE
Before disconnecting the spark plug wire on the ignition 11D
coil, confirm the spark plug position on the ignition coil and
mark it. 11D
• Check if the spark plug wire has been broken down.
• Make sure the spark plug wire resistance isn’t less than 4 11D
KΩ.
11D
(c) Remove ignition control module retaining bolts. 11D
11D
11D
11D
11D
11. REMOVE AND CHECK IGNITION CONTROL MODULE.

(a) Check whether carbon crack exists on the surface of the ignition control module.
(b) Primary resistance of ignition control module: 0.52 ± 0.05 Ω (23 ± 5 ℃ )

(a) Check spark plug insulator outer surface for the
existence of cracks.
(b) Check spark plug flash over for carbon deposition.
(c) Check spark plugs for positive negative ablation.
(d) Check spark plug gap.
14. INSTALL THE IGNITION CONTROL MODULE RETAIN-

ING BOLTS.
Torque: 5 ~ 8 N•m
15. CONNECT IGNITION CONTROL MODULE CONNEC-

TOR.
16. INSTALL SPARK PLUG WIRE TO IGNITION CONTROL MODULE AS THE MARKS BEFORE
REMOVING.


11D
11D
11D
11D
11D
Torque: 41 ~ 51 N•m 11D
11D
11D
11D
11D
11D
replacement”)
11D
11D
11D
11D
11D
11D
11D
11D
MEMO
FUEL
12A
FUEL SYSTEM................................................................................. 12D-1
PRECAUTION............................................................................ 12D-1
PROBLEM SYMPTOMS TABLE................................................ 12D-3
FUEL TANK ASSY........................................................................... 12D-5 12A
COMPONENTS ......................................................................... 12D-5
REPLACEMENT ........................................................................ 12D-6
FUEL FILTER ASSY ...................................................................... 12D-11
REPLACMENT......................................................................... 12D-11 12A
FUEL LEVEL SENSOR ASSY ....................................................... 12D-12
REPLACMENT......................................................................... 12D-12 12D
FUEL PUMP ASSY ........................................................................ 12D-13
OVERHAUL ............................................................................. 12D-13
FUEL INJECTOR ASSY................................................................. 12D-15
OVERHAUL ............................................................................. 12D-15
CNG SUPPLY SYSTEM................................................................. 12D-19
COMPONENTS ....................................................................... 12D-19
TECHNICAL PARAMETERS TABLE....................................... 12D-20
REPLACEMENT ...................................................................... 12D-21
FUEL FILLING DOOR.............................................................. 12D-26
REPLACEMENT ...................................................................... 12D-26
FUEL - FUEL SYSTEM 12D-1
FUEL SYSTEM
FUEL
PRECAUTION
1. FUEL SYSTEM PRECAUTION. 12D
(a) Before working on fuel system, disconnect battery negative cable.
(b) When removing the fuel hose, use a suitable container to hold the fuel.
(d) Fuel in the fuel pump, railway and tubes remain under high pressure. In order to avoid personal injury,
do not loosen tube connector while engine is running.
(e) Keep gasoline away from rubber and leather parts.
(f) Before disconncting any of the fuel system tubes or fuel system components, relieve the fuel system
12D
(g) Check if there is any dirt like mud around the fuel tube connector before this work. And clean dirt away,
(h) Keep cleaner away from the o-ring of tube connector. Cleaner can corrode the seal of fuel system.
(i) Don’t bend or twist the fuel system tube and pipe by force.
(j) Before connceting fuel system tube, be sure there is no damage to tube, connector. If there is any
damage, crack or dirt on surface, replace it with a new tube assy.
(k) Gas cylinder installation:
In accordance with the regulations, be sure to install the air diversion pipe at the cylinder valve, it can
transfer leak gas export compartment, and manual valve on the cylinder valve to facilitate user
operations.
(l) High-pressure pipe installation:
Keep the high pressure pipe away from heat sources such as engine exhaust pipe, etc., suggestions
arrange with brake pipe layout in the car chassis synchronization.
(m) High-pressure pipe connector:
The pipe length between two connectors must be long enough to avoid tension and vibration directly
on the connector.
(n) When a cng leak, immediately stop the vehicle, close the gas cylinder valve. Re-opening the gas
cylinder valve after repaired the leakage.
(o) When operations in the cng system, we must know the state of the cng in the pipeline. When replace
the pipe, be sure to close the cylinder valve. Start the engine, burned the residual gas in the
pipeline,then further operations.
(p) after replace the CNG components, use the compressed air clean the pipe, avoid any impurities into
the gas path.
(q) CNG filter is recommended to be replaced or cleaned every 40,000 km according to service conditions
and air cleanliness.
12D-2 FUEL - FUEL SYSTEM

(a) Disconnect the fuel pump connector.
(c) Start the engine again for 5 seconds, ensure fuel rail pressure relief is complete.
(d) Connect the fuel pump connector.

(c) Open the fuel filling cap.
(d) Raise the vehicle.
suitable container.
FUEL TUBE CLEAN

FUEL - FUEL SYSTEM 12D-3

12D
1. Fuel pump (Damaged) Chapter 12D fuel - fuel pump, overhaul
2. Fuel tube (Choked) Chapter 12D fuel - fuel syste, precaution

Engine does not start pressure too low)
4. Fuel tank (No fuel) -
5. Fuel pump relay(Damaged) -

12D
6. Fuel injector (Damaged) Chapter 12D fuel - fuel injector, overhaul
1. Fuel tube (Obstructed) Chapter 12D fuel - fuel syste, precaution

pressure too low)
3. Fuel injector (Leaking or Chapter 12D fuel - fuel injector, overhaul

obstructed)
Engine start hard
4. Fuel pump (Out of order) Chapter 12D fuel - fuel pump, overhaul
5. Fuel injector control system Chapter 04 diagnostics - engine control system

(Out of order)
6. Fuel pressure regulator or fuel -

pump (Return valve damaged)

pressure too low)
2. Fuel injector (Leakage or Chapter 12D fuel - fuel injector, overhaul

obstructed)
Engine idles rough
3. Fuel tube (Obstructed) Chapter 12D fuel - fuel syste, precaution
4. Air supply line (Blocked) -
5. Gas injector( Out of order) -

12D-4 FUEL - FUEL SYSTEM

pressure too low)
2. Fuel injector (Leakage or Chapter 12Dfuel - fuel injector, overhaul

obstructed)
3. Fuel pump (Out of order) Chapter 12D fuel - fuel pump, overhaul
Engine loss of power 4. Fuel tube (Obstructed) Chapter 12D fuel - fuel system, precaution
6. Air supply line (Blocked) -
7. Gas injector( Out of order) -
8. Gas cylinder( Lack gas） -

FUEL - FUEL TANK ASSY 12D-5
FUEL TANK ASSY

COMPONENTS
12D
12D
1 Fuel Filter 5 Fuel Tank Breathe Hose
2 Fuel Return Tube 6 Fuel Filling Cap
3 Fuel Inlet Sensor 7 Fuel Tank Cover

12D-6 FUEL - FUEL TANK ASSY
REPLACEMENT
2. REMOVE SPARE TIRE AND SPARE TIRE BRACKET.

NOTE
(b) Loosen the holder and put down the bracket, then take
off the spare tire.

body.
3. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12D fuel - fuel system, precaution”)
4. DRAIN FUEL TANK. (Refer to “Chapter 12D fuel - fuel system, precaution”)


DISCONNECT IT.

DISCONNECT IT.
12D
9. LOOSEN FUEL INLET / RETURN HOSE CLAMPS

12D

(b) Lower the fuel tank slowly, disconnect fuel pump and fuel
level sensor connectors.
NOTE
• Check if there is any dirt like mud and tube, harness
around the fuel tank. Clean the dirt if necessary.
• When remove fuel tank, as fuel tank is large and
heavy. It is necessary to use proper tool or have
others help.

screws.

NOTE
necessary.

(b) Take out the fuel pump.

NOTE
• Check if there is any dirty or other material around
necessary.

screws.
Torque: 6 ~ 8 N•m

Torque: 6 ~ 8 N•m

(a) Raise the fuel tank assy to proper position by jack.
12D

NOTE 12D
viberation.

CLAMP.

TIGHTEN CLAMP.

TIGHTEN CLAMPS.

BOLTS.


(c) Position the spare tire and install the spare tire bracket
holder.
(d) Tighten the spare tire bracket holder retaining bolts.

FUEL - FUEL FILTER ASSY 12D-11
FUEL FILTER ASSY

REPLACMENT
1. RELIEVE FUEL PRESSURE. (Refer to “Chapter 12D fuel - fuel system, precaution”) 12D
3. LOOSEN 2 FUEL FILTER CLIPS.
12D
4. REMOVE THE FUEL FILTER.

(a) Loosen the fuel filter retaining belt bolt.
(b) Take off the fuel filter.
5. INSTALL NEW FUEL FILTER.

(a) Tighten the fuel filter and tighten the retaining belt bolt.
NOTE
Follow the arrow on the fuel filter when install the fuel filter.
6. CONNECT FUEL FILTER HOSE AND TIGHTEN CLIPS.
7. CHECK FUEL TUBE.

12D-12 FUEL - FUEL LEVEL SENSOR ASSY

REPLACMENT
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12D fuel - fuel system, precaution”)
4. REMOVE FUEL TANK. (Refer to “Chapter 12D fuel - fuel tank, replacment”)

screws.
(b) Take out fuel level sensor.

NOTE
fuel level sensor before this work and clean the dirt
if necessary.

screws.
Torque: 6 ~ 8 N•m
7. INSTALL FUEL TANK. (Refer to “Chapter 12D fuel - fuel tank, replacment”)
(a) After disconnecting fuel pump connector, connect fuel level sensor connector. With the ignition switch
ON, slide fuel level sensor position manually and then check the fuel gauge’s conditions in instrument
panel.
(b) In condition that all connectors are connected properly, turn the ignition switch on and check fuel
FUEL - FUEL PUMP ASSY 12D-13
FUEL PUMP ASSY

OVERHAUL
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12D fuel - fuel system, precaution”) 12D
4. REMOVE FUEL TANK. (Refer to “Chapter 12D fuel - fuel tank, replacment”)

12D
(b) Take out the fuel pump assy.

NOTE
necessary.
6. INSPECT FUEL PUMP RESISTANCE.

(a) Apply battery voltage to two terminals, check the pump
injection flow. If less than the injection flow, replace a
new fuel pump.
Stardand: ≥ 16g/s
(b) Apply battery voltage to two terminals. Check that the
pump’s operation. If the fuel pump has abnormal noise,
replace it.
NOTE
• Keep fuel pump as far away from the battery as
possible.
• Always do the switching at the battery side.
7. REPLACE FUEL PUMP ASSY.

12D-14 FUEL - FUEL PUMP ASSY

Torque: 6 ~ 8 N•m
9. INSTALL FUEL TANK. (Refer to“Chapter 12D fuel - fuel tank, replacment”)
FUEL - FUEL INJECTOR ASSY 12D-15
FUEL INJECTOR ASSY

OVERHAUL
1. RELIEVE THE FUEL PRESSURE. (Refer to “Chapter 12D fuel - precaution”) 12D

12D
4. LOOSEN FUEL RAIL INLET / RETURN HOSE

CLAMPS AND DISCONNECT THEM.
NOTE
seal up the fuel hose connector, prevent the dust from
entering the fuel hose.
5. REMOVE UPPER INTAKE MANIFOLD. (Refer to “Chapter 14D intake air- intake manifold,
replacement”)
6. DISCONNECT 4 FUEL INJECTOR CONNECTORS.

12D-16 FUEL - FUEL INJECTOR ASSY

(a) Loosen 2 fuel rail retaining bolts.
(b) Take off the injector assy lightly.
8. REMOVE 4 INJECTORS FROM FUEL RAIL.
9. PULL CLIP AND REMOVE FUEL PRESSURE

REGULATOR.
10. USE AN OHMMETER TO MEASURE RESISTANCE BETWEEN TWO TERMINALS OF INJECTOR.

Resistance: 13 ~ 16 Ω
11. CHECK IF THERE IS ANY CARBON DEPOSITION OR DIRTY AROUND INJECTOR NOZZLE,
CLEAR IT AWAY IF BLOCKED.
12. IF NECESSARY, TAKE INJECTOR ON INJECTOR TEST

TABLE, CHECK INJECTOR LEAKAGE OR NOT.
13. INSPECT RETURN SPRING OF FUEL PRESSURE REGULATOR OPERATION.

FUEL - FUEL INJECTOR ASSY 12D-17
14. INSTALL NEW INSULATOR TO EACH FUEL

INJECTOR.
12D
15. APPLY A LIGHT COAT OF SPINDLE OIL OR GASOLINE TO A NEW O-RING, AND INSTALL IT TO
EACH FUEL INJECTOR.
NOTE 12D
Do not use engine oil or brake fluid.
16. INSTALL EACH FUEL INJECTOR TO FUEL RAIL.
17. INSTALL FUEL PRESSURE REGULATORS.
NOTE
Inspect if fuel pressure regulator turns smoothly. If not, it means that O-ring is clamped. Reinstall it
with new O-ring.

(a) Slightly push the each injector toinstall injector into hole
position properly.
(b) Install 2 fuel injector assy retaining bolts.
19. CONNECT 4 INJECTOR CONNECTORS.
20. INSTALL UPPER INTAKE MANIFOLD. (Refer to “Chapter 14A intake air- intake manifold,
replacement”)
12D-18 FUEL - FUEL INJECTOR ASSY
21. CONNECT FUEL RAIL INLET/RETURN HOSE AND

TIGHTEN CLAMPS.

FUEL - CNG SUPPLY SYSTEM 12D-19
CNG SUPPLY SYSTEM

COMPONENTS
12D
12D
1 CNG Filling Valve 6 Pressure Reducer
2 Gas Cylinder 7 Low-pressure Pipeline Filter
3 Gas Cylinder Valve 8 CNG Rail
4 High-pressure Pipeline Pressure Gage 9 CNG Injector
5 High-pressure Solenoid Valve

12D-20 FUEL - CNG SUPPLY SYSTEM
TECHNICAL PARAMETERS TABLE

Gas Cylinder Valve Working pressure 200 bar (15 ℃ )
MWP 260 bar (85 ℃ )
Working temperature -40 ℃～ 70 ℃
Pressure rupture disk 300 bar
CNG Filling Valve Working pressure 200 bar

High-pressure Pipeline Pressure Gage Working pressure 0 ～ 20 MPa

High-pressure Pipeline And Connector Working pressure 0 ～ 20 MPa

Pressure Reducer input pressure 1MPa ～ 25 MPa

output pressure 230±5 kPa
Low-pressure Pipeline Filter Working pressure ＜ 4bar

CNG Injector Medium pressure differential Max 392 kPa

REPLACEMENT
1. ENSURE RELEASE CNG SELECT SWITCH ON
INSTRUMENT PANEL. 12D

(a) Loosen the battery cover lock knob. 12D
4. REMOVE GAS CYLINDER VALVE.

(a) Close the manual valve on the gas cylinder.
(b) Disconnect gas cylinder valve and high-pressure

pipeline.
(c) Disconnect gas cylinder valve and CNG filling valve

pipeline.
(d) Remove gas cylinder valve.

5. REMOVE GAS CYLINDER PROTECTION COVER.
6. REMOVE GAS CYLINDER RETAINING BELT BOLT

BEHIND REAR PASSENGER SEAT.
7. REMOVE GAS CYLINDER CAREFULLY.

8. DISCONNECT PRESSURE GAGE LOCATED BETWEEN HIGH-PRESSURE PIPELINE.
9. DISCONNECT PRESSURE REDUCER CONNECTOR, REMOVE IT FROM HIGH-PRESSURE PIPE-
LINE.
10. REMOVE LOW-PRESSURE FILTER BRACKET

RETAINING BOLTS, DISCONNECT LOWER-PRES-
SURE FILTER HOSE.
11. REMOVE LOWER-PRESSURE FILTER.
12. REMOVE CNG INJECTOR.

(a) Disconnect CNG injector connector.
(b) Loosen 2 CNG injector bracket retaining bolts.
12D
(c) Disconnect CNG injector and intake manifold clamp.
12D
13. REMOVE CNG INJECTOR AND CHECK O-RING. IF FIND ANY GASH, VARIANT REPLACE A NEW
ONE.
14. INSTALL CNG INJECTOR.

(a) Connect CNG injector and intake manifold clamp.
(b) Tighten 2 CNG injector bracket retaining bolts.

(c) Connect CNG injector connector.
15. TIGHTEN LOW-PRESSURE FILTER BRACKET

RETAINING BOLTS, THEN CONNECT LOW-PRES-
SURE FILTER HOSE.
16. INSTALL PRESSURE GAUGE TO HIGH-PRESSURE PIPELINE.

17. POSITION PRESSURE REDUCER, AND CONNECT PRESSURE REDUCER CONNECTOR .
18. INSTALL GAS CYLINDER, THEN TIGHTEN RETAIN-

ING BELT BOLT BEHIND REAR PASSENGER SEAT.
19. INSTALL GAS CYLINDER VALVE.

(a) Install gas cylinder valve to gas cylinder.
(b) Connect gas cylinder valve and CNG filling valve
pipeline.
(c) Disconnect gas cylinder valve and high-pressure

pipeline.
12D
(d) Open the manual valve on the gas cylinder.
12D
21. INSTALL BATTERY COVER AND LOCK KNOB.
22. ENSURE CNG FILLING PORT ON FILLING DOOR IS

INSTALLED FIRMLY.
FUEL FILLING DOOR

REPLACEMENT

(c) Tighten the fuel filling door retaining bolts.
EMISSION CONTROL
13D
FUEL TANK CAP .............................................................................13D-1
13D
13D
EMISSION CONTROL - FUEL TANK CAP 13D-1
FUEL TANK CAP

EMISSION CONTROL
Refer to “Chapter 13A EMISSION CONTROL“.
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
13D
MEMO
INTAKE AIR
14D
INTAKE AIR SYSTEM...................................................................... 14D-1
14D
INTAKE AIR - INTAKE AIR SYSTEM 14D-1
INTAKE AIR SYSTEM

INTAKE AIR
Refer to “Chapter 14A INTAKE AIR“.
14D
14D
MEMO
ENGINE MECHANICAL
15D
ENGINE MECHANICAL PART ........................................................ 15D-1
15D
ENGINE MECHANICAL - ENGINE MECHANICAL PART 15D-1

ENGINE MECHANICAL
Refer to “Chapter 15A ENGINE MECHANICAL”.
15D
15D
MEMO
EXHUAST
16D
EXHAUST PIPE ............................................................................... 16D-1
16D
EXHAUST - EXHAUST PIPE 16D-1
EXHAUST PIPE
EXHAUST
Refer to “Chapter 16A EXHAUST”.
16D
16D
16D
MEMO
COOLING
17D
COOLING SYSTEM ......................................................................... 17D-1
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
17D
COOLING - COOLING SYSTEM 17D-1
COOLING SYSTEM
COOLING
Refer to “Chapter 17A COOLING”.
17D
17D
MEMO
LUBRICATION
02
LUBRICATION SYSTEM ................................................................. 18D-1
18D
LUBRICATION - LUBRICATION SYSTEM 18D-1
LUBRICATION SYSTEM
LUBRICATION
Refer to “Chapter 18A LUBRICATION”.
18D
18D
19A
MEMO
20D
STARTING AND CHARGING SYSTEM .......................................... 20D-1
20D
STARTING AND CHARGING - STARTING AND CHARGING SYSTEM 20D-1

Refer to “Chapter 20A STARTING AND CHARGING”.
20D
20D
MEMO
FRONT SUSPENSION
31
FRONT SUSPENSION ....................................................................... 31-1
PRECAUTION.............................................................................. 31-1
PROBLEM SYMPTOMS TABLE.................................................. 31-2
ROAD TEST ................................................................................ 31-4
COMPONENTS ........................................................................... 31-5
ON-VEHICLE INSPECTION ........................................................ 31-7 31
FRONT WHEEL ALIGNMENT ........................................................... 31-8
ADJUSTMENT ............................................................................. 31-8
FRONT SHOCK ABSORBER .......................................................... 31-10
OVERHAUL ............................................................................... 31-10
TORSION BAR SPRING .................................................................. 31-13
REPLACEMENT ........................................................................ 31-13
UPPER CONTROL ARM.................................................................. 31-15
REPLACEMENT ........................................................................ 31-15
LOWER CONTROL ARM................................................................. 31-17
REPLACEMENT ........................................................................ 31-17
STABILIZER BAR ............................................................................ 31-21
REPLACEMENT ........................................................................ 31-21
STRUT ROD ..................................................................................... 31-25
REPLACEMENT ........................................................................ 31-25
FRONT SUSPENSION - FRONT SUSPENSION 31-1
FRONT SUSPENSION
FRONT SUSPENSION
PRECAUTION
1. FRONT SUSPENSION PRECAUTION. 31
(a) When installing rubber parts, the tires must be on the ground in no-load condition at final tightening. Oil
will shorten the life of rubber liner. Must clean the spilled oil.
(b) After installing the suspension parts, check wheel alignment. If necessary, adjust it.
(c) When removing or installing brake lines, use the pipeline nut wrench.
(d) Always tighten brake lines when installing.
(e) Lock nut is not reusable. Use new one at every installation. When replacing new parts, do not clean the 31
lubrication oil on the lock nut before tightening it.
31-2 FRONT SUSPENSION - FRONT SUSPENSION

the likely cause of the problem. Check each part in order. If necessary, replace these parts
1. Lubrication oil (Excess) -
Shock absorber oil 2. Seals (Failure or damaged) -

leakage
Chapter 31 front suspension - front shock
3. Shock absorber (Failure) absorber, overhaul
1. Tire (Worn or improperly inflated) Chapter 33 tire and wheel - tire and wheel,
overhaul
Chapter 31 front suspension - front wheel

2. Wheel alignment (Incorrect) alignment, adjustment
Chapter 51 steering column - steering

3. Steering linkage (Loose or worn) column system, overhaul
Pulling to one side
Chapter 34 axle and propeller shaft - front
4. Hub bearing (Worn) wheel hub, overhaul
Chapter 52 power steering - steering gear,

5. Steering gear (Maladjusted or damaged) overhaul
Chapter 31 front suspension - front

6. Suspension parts (Worn) suspension, inspection
1. Vehicle (Overloaded) -
Bottoming
2. Shock absorber (Worn or damaged) absorber, overhaul
Chapter 33 tire and wheel - tire and wheel,

1. Tire (Worn or improperly inflated) overhaul

Sways/tilt
Chapter 31 front suspension - stabilizer bar,
3. Stabilizer bar (Bent or broken) replacement

4. Shock absorber (Failure) absorber, overhaul

1. Tire (Worn or improperly inflated) overhaul
31
2. Wheel (Out of balance) overhaul

3. Shock absorber (Worn) absorber, overhaul

4. Wheel alignment (Incorrect) alignment, adjustment 31
Front wheel
shimmy Chapter 31 front suspension - upper and
5. Ball joint (Worn) lower control arm, replacement
Chapter 34 axle and propeller shaft - hub

6. Hub bearing (Worn) and steering knuckle, on-vehicle inspection

8. Steering gear (Out of adjustment or Chapter 52 power steering - steering gear,

damaged) overhaul

1. Wheel alignment (Incorrect) alignment, adjustment

2. Tire (Worn or improperly inflated) on vehicle inspection
Abnomal tire wear
3. Wheel (Out of balance) adjustment

4. Shock absorber (Worn) absorber, overhaul
ROAD TEST
NOTE
This is a flow chart for vehicle pull.
COMPONENTS
31
31
1 Wheel Nut 6 Torsion Bar Assy
2 Front Wheel Rim Cover 7 Bolt
3 Steering Knuckle With Brake Disc Assy 8 Washer
4 Nut 9 Upper Control Arm Assy
5 Cotter Pin
1 Front Suspension Lateral Stabilizer Bar 12 Spring Washer
2 Nut 13 Hexagon Nut
3 Front Shock Absorber Assy 14 Upper Accessory Assy
4 Upper Damping Block Assy 15 Lock Nut
5 Bolt 16 Spring Washer
6 Bolt 17 Hexagon Nut
7 Strut Rod 18 Lower Control Arm Cam
8 Spring Washer 19 Lower Control Arm Assy
9 Bolt 20 Lower Damping Block Assy
10 Spring Washer 21 Lower Control Arm Camshaft Assy
11 Hexagon Nut
1. CHECK TIRES FOR WEAR AND INFLATION PRESSURE.
For vehicles equipped with 195/70R15C tires, the front tire pressure is 325 kPa and rear tire pressure is
450 kPa. The allowable variation is ±5 kPa. The maximum of the same axle tires pressure shall not 31
exceed 10 kPa.
2. CHECK TIRES FOR RADIAL RUNOUT ERROR.
The quantity of wheel sway is less than 1.2 mm.
3. CHECK FRONT WHEEL BEARING FOR LOOSENESS.
4. CHECK FRONT SUSPENSION PARTS FOR LOOSENESS. 31
5. CHECK STEERING ROD FOR LOOSENESS.
6. PERFORM A STANDARD FLEXIBILITY TEST AND CHECK IF SHOCK ABSORBER WORKS NORMALLY.
7. MEASURE HEIGHT OF UNLOADED VEHICLE.
(a) Park the vehicle onto an inspection platform and bounce the vehicle to set the suspension system.
Bounce the front bumper for 5~10 times, then keep the bumper in free state. Measure ground
clearance at bumper center. Repeat the steps for another time. The difference between two
measurements should be no more than 10 mm.
(b) For vehicles equipped with 195/70R15C tires, measure the ground clearance at front center point of
lower arm adjusting bolt. The value is 277 ± 3 mm (also use a self-made measurable tool to measure
height in pit). If the measured value is not within specified value, adjust the torsion mounting bolt to
meet the specified requirement.
31-8 FRONT SUSPENSION - FRONT WHEEL ALIGNMENT
FRONT WHEEL ALIGNMENT

ADJUSTMENT
1. INSPECT TIRE. (Refer to “Chapter 33 - tire and wheel, on-vehicle inspection”）
2. MEASURE HEIGHT OF WHEELS.
NOTE
• Before inspecting the wheel alignment, adjust the vehicle height to meet the specified value and
maintain steering wheel center.
• If the vehicle height is not within the specified value, try to adjust it by pushing down or lifting
the body.
3. INSPECT TOE-IN.
Toe-in (total) C - D: 3±1
If toe-in value is out of the specification, adjust toe-in by the left

and right tie rods.
4. ADJUST TOE-IN.
(a) Remove protection shield clip.
(b) Loosen tie rod lock nut.
(c) Turn the outer tie rod RH/LH by an equal amount to
adjust the toe-in within the specified value.
NOTE
Measure the length of the left and right tie rod, and make
them in the same length. Length difference between the
right and left tie rod: 3.0 mm or less.
(d) Tighten the tie rod lock nut.
Torque: 88 N·m。
(e) Install the shield to the retainer and then tighten.
NOTE
Do not twist the shield.
5. INSPECT WHEEL ANGLE.

A：Inside
B：Outside
(a) Turn the steering wheel fully and measure the turning
angle.
Wheel turning angle：
Inside wheel 37°±18′
Outside wheel 34°±18′
If the maximum steering angles are out of the specification,

adjust LH/RH tie rod length.
FRONT SUSPENSION - FRONT WHEEL ALIGNMENT 31-9
6. ADJUST WHEEL TURNING ANGLE.

(a) Remove the steering knuckle stop bolt cap.
(b) Loosen lock nut.
(c) Screw the steering knuckle stop bolt to the bottom. 31
(d) If steering angle of the left wheel is different from the right wheel, adjust the length of the tie rods to
eliminate the difference of steering angle.
(e) Rotate the steering wheel fully, and loosen the steering knuckle stop bolt until touching the lower arm.
(f) Make sure the value to the specifications and then tighten lock nut.
Torque: 44 N·m
(g) Install the steering knuckle stop bolt cap. 31
(h) Check the toe-in.
If the front wheel steering angle is out of the specification after adjustment, check other steering parts.
7. INSPECT FRONT WHEEL CAMBER, KINGPIN INCLINATION

AND KINGPIN CASTER.
Front wheel camber, kingpin inclination and kingpin caster:
Front Wheel -0°20′±30′ (Difference between left and

Camber right ≤ 30′)
10°50′±30′(Difference between left and right

Kingpin Inclination
≤ 30′)
1°15′±30′(Difference between left and right

Kingpin Caster
≤ 30′)
If the kingpin caster is out of the specified value, adjust it by tur-

ing the strut rod nut.
NOTE
The range of adjusting bolt from the initial position can be
no more than 3 thread. Rotating one revolution is equal to a
change of approx 30′ in kingpin caster.
8. ADJUST CAMBER.
(a) Adjust the front camber by rotating cam. Each scale of
cam means a 18′ change in camber. It is not allowed to
rotate cam from the center line over 4.5 scales.
31-10 FRONT SUSPENSION - FRONT SHOCK ABSORBER
FRONT SHOCK ABSORBER

OVERHAUL
1. REMOVE FRONT WHEEL RH ASSY. (Refer to “chapter 33 tire and wheel - front tire and wheel,
replacement”)
2. REMOVE FRONT SHOCK ABSORBER RH.

(a) Remove the bolt attaching the front shock absorber RH
to the lower control arm.
(b) Remove 2 nuts attaching the front shock absorber RH to

the lower frame.
(c) Take out the front shock absorber RH.
3. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.

(a) If the oil leaks from the shock absorber, replace it with a new one.
FRONT SUSPENSION - FRONT SHOCK ABSORBER 31-11
4. CHECK SHOCK ABSORBER CONNECTING PARTS.

(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any
damage, replace it with a new one.
5. CHECK SHOCK ABSORBER EFFICIENCY. 31
(a) Compress and extend the shock absorber rod for 2~3 times and then check that there is no abnormal
resistance or unusual noise during operation. If there is any abnormality, replace the shock absorber
with a new one.
6. INSTALL FRONT SHOCK ABSORBER ASSY RH.

(a) Tighten the nut attaching the front shock absorber RH to 31
the lower frame.
(b) Tighten the bolt attaching the front shock absorber RH to

the lower control arm.
31-12 FRONT SUSPENSION - FRONT SHOCK ABSORBER
7. INSPECT AFTER INSTALLATION.

(a) After the vehicle is assembled, drive it on a bad road for a distance about ten kilometers and park it,
then touch the surfaces of the two shock absorbers with hands. If difference in temperature of the two
shock absorbers is large, correspondingly, difference in resistance of them is also large and the
absorber with a low temperature has small resistance. If the temperature of the two shock absorbers
doesn’t exceed air temperature, it indicates that the shock absorbers have no resistance and disabled.
It is necessary to replace with a new one.
(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive
vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber,
keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several
times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pull-
down resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of
oil or the valve part is damaged. It is necessary to repair it or replace with a new part.
(c) After a fault or invalidation on shock absorber is determined, firstly check whether there is any oil
leakage or mark of oil leakage. Oil seal gasket and seal gasket are broken or damaged; nut of oil tank
is loose. The oil seal and seal gasket may be damaged and disabled, so it is necessary to replace with
a new sealing. If the oil leakage still exists, pull out the shock absorber, when a seizure or unbalance
weight is found, further check whether there is a wide clearance between piston and cylinder block or
whether the piston rod of the shock absorber is bent or whether there are cracks or drawing marks on
surface of piston rod and cylinder block.
(d) If the shock absorber has no oil leakage or sign of oil leakage, check whether there is any damage,
loose welding, crack or peeling off on connecting pins of shock absorber, connecting rod, connecting
hole and rubber spacer etc. If the above parts are in normal condition after check, further disassemble
the shock absorber to check whether there is a wide clearance between piston and cylinder block,
whether there is a strain on cylinder block, whether the valve sealing is in good status, whether the
valve flaps are tightly closed to the valve seat and whether the draw spring of the shock absorber is too
soft or broken. Repair or replace parts according to concrete situations.
(e) In addition, the shock absorber may produce noise during use, this is because the shock absorber is
crashed with spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is
deformed and oil is insufficient. It is necessary to find out the root of the fault and repair it.
(f) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar
passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up
and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance
when pulling down, stretching resistance is restored compared with resistance before repair, and you
don’t feel no-running status, it indicates that the shock absorber is in normal condition.
8. REMOVE FRONT SHOCK ABSORBER LH.

NOTE
Remove the LH side by the same procedures as the RH side.
FRONT SUSPENSION - TORSION BAR SPRING 31-13
TORSION BAR SPRING

REPLACEMENT
31
1. REMOVE TORSION BAR SPRING ASSY RH.
(a) As the illustration shows, measure the length of the
extension bolt end A.
NOTE
When adjusting the vehicle hight, value A will serve as
reference. At the end of the torsion bar spring, there are left 31
and right indicator. Do not install it to opposite direction.
(b) Remove 2 torsion bar spring RH adjusting nuts.
(c) Remove the torsion bar spring RH.

31-14 FRONT SUSPENSION - TORSION BAR SPRING
2. INSTALL TORSION BAR SPRING RH.

(a) Position the torsion bar spring RH properly.
(b) Tighten the adjusting nut by hand, and make the bolt
extention length to be 5 mm (B).
(c) Tighten the adjusting nut, press the bolt 60.5 mm (C).
3. INSPECT VEHICLE HEIGHT. IF THE HEIGHT IS OUT OF STANDARD, USE TORSION BAR SPRING
ADJUSTING NUT TO ADJUST.
4. REMOVE TORSION BAR SPRING LH.
NOTE
FRONT SUSPENSION - UPPER CONTROL ARM 31-15
UPPER CONTROL ARM

REPLACEMENT
1. REMOVE FRONT WHEEL ASSY RH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, 31
replacement”)
2. REMOVE FRONT BRAKE DISC ASSY RH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
3. REMOVE TORSION BAR SPRING RH. (Refer to chapter 31 front suspension - torsion bar spring,
replacement”)
31
4. REMOVE UPPER CONTROL ARM ASSY RH.
(a) Remove 3 bolts attaching the torsion bar spring RH to
upper control arm RH.
(b) Remove 4 nuts attaching the upper control arm ball joint
RH to upper control arm RH.
(c) Remove 2 bolts attaching the upper control arm RH to

the frame.
(d) Take out the upper control arm RH.
5. INSTALL UPPER CONTROL ARM ASSY RH.

(a) Tighten 2 bolts attaching the upper control arm RH to the
frame.
Torque: 142 ~ 152 N·m
31-16 FRONT SUSPENSION - UPPER CONTROL ARM
(b) Tighten 4 nuts attaching the upper control arm ball joint
RH to upper control arm RH.
(c) Tighten 3 bolts attacthing the torsion bar spring RH to

upper control arm RH.
Torque: 137 ~ 147 N·m
6. INSTALL TORSION BAR SPRING RH. (Refer to chapter 31 front suspension - torsion bar spring,
replacement”)
7. INSTALL FRONT BRAKE DISC ASSY RH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
8. INSTALL FRONT WHEEL ASSY RH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
9. REMOVE UPPER CONTROL ARM LH.
NOTE
10. INSPECT AND ADJUST FRONT WHEEL ALIGNMENT. (Refer to “Chapter 31 front suspension -
front wheel alignment, adjustment”)
FRONT SUSPENSION - LOWER CONTROL ARM 31-17
LOWER CONTROL ARM

REPLACEMENT
1. REMOVE FRONT WHEEL ASSY RH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, 31
replacement”)
2. REMOVE FRONT BRAKE DISC ASSY RH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
3. REMOVE LOWER CONTROL ARM RH.

(a) Remove the nuts attaching the stabilizer bar link RH to 31
stabilizer bar.
(b) Remove the bolt attaching the front shock absorber RH

to lower control arm RH.
31-18 FRONT SUSPENSION - LOWER CONTROL ARM
(c) Remove 4 nuts attaching the lower control arm ball joint
RH and strut rod RH to lower control arm RH.
(d) Remove the bolt attaching the uppper control arm RH to

the frame.
(e) Take out the lower control arm RH carefully.
FRONT SUSPENSION - LOWER CONTROL ARM 31-19
4. INSTALL LOWER CONTROL ARM RH.

(a) Position the lower control arm RH properly.
(b) Tighten the bolt attaching the lower control arm RH to the
frame. 31
Torque: 192 ~ 208 N·m
31
(c) Tighten 4 nuts attaching the lower control arm ball joint
RH and strut rod RH to lower control arm RH.
31-20 FRONT SUSPENSION - LOWER CONTROL ARM
(d) Tighten the bolt attaching the front shock absorber RH to

lower control arm RH.
(e) Tighten the nuts attacting the stabilizer bar link RH to

stabilizer bar.
5. INSTALL FRONT BRAKE DISC ASSY RH. (Refer to “Chapter 35 brake - front brake disc,
overhaul”)
6. INSTALL FRONT WHEEL ASSY RH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
7. REMOVE LOWER CONTROL ARM LH.
NOTE
FRONT SUSPENSION - STABILIZER BAR 31-21
STABILIZER BAR
REPLACEMENT
31
1. REMOVE STABILIZER BAR.
(a) Remove the condenser bracket mounting bolt.
31
(b) Remove the nuts attaching the stabilizer bar link LH and
RH to the stabilizer bar.
31-22 FRONT SUSPENSION - STABILIZER BAR
(c) Remove the mounting bolts of the brackets of the stabilizer

bar.
(d) Remove the stabilizer bar carefully.
2. INSPECT STABILIZER BAR BUSHING.

(a) Inspect the stabilizer bar bushing for ageing. If there is any ageing, replace the bushing with new one.
3. INSTALL STABILIZER BAR.

(a) Position the stabilizer bar properly.
FRONT SUSPENSION - STABILIZER BAR 31-23
(b) Tighten the nuts attaching the stabilizer bar link LH and
RH to the stabilizer bar.
31
31
NOTE
As illustration shows, tighten the nut until the extention
length is 4.5 ~ 6 mm.
(c) Tighten the mounting bolts of the brackets of the stabilizer

bar.
31-24 FRONT SUSPENSION - STABILIZER BAR
(d) Tighten the condenser bracket mounting bolt.

FRONT SUSPENSION - STRUT ROD 31-25
STRUT ROD
REPLACEMENT
31
1. REMOVE STRUT ROD RH.
(a) Using a wrench, lock the head of the bolts attaching the
strut rod RH to the lower control arm RH.
31
(b) Remove 2 nuts attaching the strut rod RH to the lower

control arm RH.
(c) Remove the nut attaching the strut rod RH to the frame.
(d) Take out the strut rod RH.
31-26 FRONT SUSPENSION - STRUT ROD
2. INSTALL STRUT ROD RH.

(a) Position the strut rod RH properly.
(b) Using a wrench, lock the head of the bolts attaching the
strut rod LH to the lower control arm RH.
(c) Tighten 2 nuts connecting the strut rod RH to the lower

control arm RH.
Torque: 113 ~ 123 N·m
(d) Tighten the nut attaching the strut rod RH to the frame.
Torque: 114.5 ~ 125.5 N·m
3. REMOVE STRUT ROD LH.

NOTE
REAR SUSPENSION
32
REAR SUSPENSION ......................................................................... 32-1
COMPONENTS ........................................................................... 32-2
ON-VEHICLE INSPECTION ........................................................ 32-3 32
REAR SHOCK ABSORBER .............................................................. 32-4
OVERHAUL ................................................................................. 32-4
REAR LEAF SPRING ASSY.............................................................. 32-6
OVERHAUL ................................................................................. 32-6 32
REAR SUSPENSION - REAR SUSPENSION 32-1
REAR SUSPENSION
REAR SUSPENSION

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the 32
1. Lubrication oil (Excess) -
2. Seals (Failure or damaged) -

Shock absorber oil leakage
Chapter 32 rear suspension - rear shock
3. Shock absorber (Failure) absorber, overhaul 32
1. Shock absorber (Worn or Chapter 32 rear suspension - rear shock

damaged) absorber, overhaul
Chapter 32 rear suspension - rear leaf

2. Leaf spring (Worn or damaged) spring, overhaul
Suspension noise Chapter 32 rear suspension - rear leaf
3. Bushing (Worn or damaged) spring, overhaul
4. Shock absorber and leaf spring Chapter 32 rear suspension - rear shock
mounting bolt (Loosen or absorber, overhaul
damaged)

1. Leaf spring pin (Over worn) spring, overhaul

2. U-bolt (Loosen or damaged) spring, overhaul
Sways/tilt
3. Leaf spring (Elastic decline or Chapter 32 rear suspension - rear leaf
stiffness inconsistent) spring, overhaul

4. Leaf spring (Broken) spring, overhaul
1. Tire (Worn or improperly Chapter 33 tire and wheel - tire and wheel,
inflated) on-vehicle inspection 3232
Abnomal tire wear, pull-
ing to one side Chapter 33 tire and wheel - tire and wheel,
2. Wheel (Out of balance) adjustment
32-2 REAR SUSPENSION - REAR SUSPENSION
COMPONENTS
1 Bolt 15 Anchor Plate
2 Rear Stopper Assy 16 Rear Leaf Spring Assy
3 Bolt 17 U-bolt
4 Small Hole Upper Gasket 18 Leaf Spring Shackle Pin
5 Rear Shock Absorber Upper Bushing 19 Leaf Spring Shackle Inner Plate
6 Large Hole Upper Gasket 20 Leaf Spring Shackle Pin Bushing
7 Rear Shock Absorber Assy 21 Leaf Spring Shackle Outer Plate
8 Small Hole Lower Gasket 22 Leaf Spring Shackle Bracket Bushing
9 Rear Shock Absorber Lower Bushing 23 Spring Washer, Heavy Type
10 Large Hole Lower Gasket 24 Spring Washer
11 Leaf Spring Pin 25 Spring Washer
12 Leaf Spring Pin Nut 26 Bolt
13 U-bolt Nut 27 Spring Washer
14 Washer
REAR SUSPENSION - REAR SUSPENSION 32-3
1. ON-VEHICLE INSPECTION.
(a) Check shock absorber for oil leakage.
32
(b) Check shock absorber ring rubber bushing for aging, cracking, deforming. replace it when necessary.
(c) Leaf spring shackle bushing, every leaf springpin shoule be replaced frequently.
(d) Check u-bolt for cracking, flaw, thread for damage. replace it when necessary.
(e) U-bolt should be tightened in uniform cross tightened method and step by step tight U-bolt to specified
value. Tighten the U-bolts again when the leaf spring laminating closely with the car full loaded. In some
cases that leaf springs can not be campacted because of the bolts and nuts being rusted. It is needed
to attack thread with taps if necessary, which can make bolts and nuts fit well.
(f) For slide type-leaf spring, a layer of lubricating grease should be applied between the leaf spring and 32
shackle bracket to reduce the wear and tear of the slide-type leaf spring.
3232
32-4 REAR SUSPENSION - REAR SHOCK ABSORBER
REAR SHOCK ABSORBER

OVERHAUL
1. REMOVE REAR SHOCK ABSORBER LH.
(a) Remove the upper retaining bolt of the rear shock
absorber.
(b) Remove the lower retaining bolt of the rear shock

absorber.
(c) Take out the rear shock absorber LH with caution.
2. CHECK SHOCK ABSORBER FOR OIL LEAKAGE.

(a) If the oil leaks from the shock absorber, replace it with a new part.
3. CHECK SHOCK ABSORBER CONNECTING PARTS.
(a) Check the shock absorber connecting rod, bushing or other connecting parts for damage. If there is any
damage, replace it with a new one.
4. CHECK SHOCK ABSORBER EFFICIENCY.
(a) Compress and extend the shock absorber rod and then check that there is no abnormal resistance or
unusual noise during operation. If there is any abnormality, replace the shock absorber with a new one.
5. INSTALL REAR SHOCK ABSORBER LH.

(a) Position the rear shock absorber LH properly.
(b) Tighten the lower retaining bolt of the rear shock
absorber.
Torque: 38.7 ~ 47.3 N·m
REAR SUSPENSION - REAR SHOCK ABSORBER 32-5
(c) Tighten the upper retaining bolt of the rear shock

absorber.
Torque: 21.6 ~ 26.7 N·m
32

32
(a) After the vehicle is assembled, drive it on a bad road for a distance about 10 KM and park it, then touch
the surfaces of the two shock absorbers with hands. If difference in temperature of the two shock
absorbers is large, correspondingly, difference in resistance of them is also large and the absorber with
a low temperature has small resistance. If the temperature of the two shock absorbers doesn’t exceed
air temperature, it indicates that the shock absorbers have no resistance and disabled. It is necessary
to replace with a new one.
(b) When the vehicle is running slowly and given an emergent brake, if the vehicle has an excessive
vibration, it indicates that there is a fault on shock absorber. Disassemble and erect the shock absorber,
keep the lower part jointing ring clamping the vise, pull and press the shock absorber rod for several
times. It should have stable resistance,the pull-up (restoration) resistance should be no less than pull-
down resistance. If the resistance is unstable or there is no resistance, the shock absorber may lack of
oil or the valve part is damaged. It is necessary to repair it or replace with a new part.
(c) After a fault or invalidation on shock absorber is determined, first check whether there is any oil leakage
or mark of oil leakage. Oil seal gasket and seal gasket are broken or damaged; nut of oil tank is loose.
The oil seal and seal gasket may be damaged and disabled, so it is necessary to replace with a new
sealing. If the oil leakage still exists, pull out the shock absorber, when a seizure or unbalance weight is
found, further check whether there is a wide clearance between piston and cylinder block or whether
the piston rod of the shock absorber is bent or whether there are cracks or drawing marks on surface of
piston rod and cylinder block.
(d) If the shock absorber has no oil leakage or mark of oil leakage, check whether there is any damage,
loose welding, crack or peeling off on connecting pins of shock absorber, connecting rod, connecting
hole and rubber spacer etc. If the above parts are in normal condition after check, further disassemble
the shock absorber to check whether there is a wide clearance between piston and cylinder block, 3232
whether there is a strain on cylinder block, whether the valve sealing is in good status, whether the
valve flaps are tightly closed to the valve seat and whether the draw spring of the shock absorber is too
soft or broken. Repair or replace parts according to concrete situations.
(e) In addition, the shock absorber may produce noise during use, this is because the shock absorber is
crashed with spring, frame or shaft, rubber washer is damaged or fallen off, and dust wrapper is
deformed and oil is insufficient. It is necessary to find out the root of the fault and repair it.
(f) If it is impossible to conduct a test, we can take some experiential measures to check it: let an iron bar
passing through the lower hoisting ring, step the two ends with feet, hold the hoisting ring and pull up
and down for 2-4 times with hands. If there is large resistance when pulling up and almost no resistance
when pulling down, stretching resistance is restored compared with resistance before repair, and you
don’t feel no-running status, it indicates that the shock absorber is in normal condition.
7. REMOVE REAR SHOCK ABSORBER RH.

NOTE
Remove the RH side by the same procedures as the LH side.
32-6 REAR SUSPENSION - REAR LEAF SPRING ASSY
REAR LEAF SPRING ASSY

OVERHAUL
1. REMOVE REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock
absorber, overhaul”)
2. REMOVE REAR LEAF SPRING ASSY LH.

(a) Using proper jacks, withstand the rear leaf spring. (Refer
to “Chapter 1 introduction - repair instruction, vehicle lift
and support location” )
(b) Remove brake oil tube retaining clamp bolt.
(c) Remove 4 U-bolt nuts.

(d) Slowly lower the jack witch holds the leaf spring, remove
U-bolt and rear leaf spirng anchor plate.
NOTE
Check U-bolt, if there are any damages such as deformation
and flaw, replace it in time.
(e) Remove leaf spring pin nut.
(f) Remove leaf spring shackle pin upper bolt.

REAR SUSPENSION - REAR LEAF SPRING ASSY 32-7
(g) Remove leaf spring shackle pin lower nut.

(h) Remove shackle inner&outer plates and shackle pin.
(i) Remove rear leaf spring LH with caution.
32
3. CHECK LEAF SPRING FOR AGING, FLAW AND SERIOUS RUSTING. IF THERE IS ANY ONE,
REPLACE IT WITH A NEW ASSEMBLY. 32
4. CHECK LEAF SPRING ARCH HEIGHT AT.
Vehicle Specified Value Limited Value

493 and except 493 short wheelbase 142 mm 136 ～ 148 mm
Except 493 long wheelbase 129 mm 123 ～ 135 mm
NOTE
The defference value of left and right sagitta should not be more than 4 mm, or it will cause body sway.
5. INSTALL REAR LEAF SPRING LH.

(a) Position the shackle inner&outer plates and shackle pin
properly.
(b) Tighten the shackle pin upper bolt.
(c) Tighten the shackle pin lower nut. 3232

Torque: 142 ~ 152 N·m
32-8 REAR SUSPENSION - REAR LEAF SPRING ASSY
(d) Tighten the leaf spring pin nut.

Torque: 142 ~ 152 N·m
(e) Slowly withstand the rear leaf spring with jack, make U-
bolts cross the rear leaf spring bolt-holes and tighten the
nuts with hand.
(f) Tighten the U-bolt nuts.
Torque: 118 ~ 128 N·m
(g) Tighten the brake oil tube rataining clamp bolt.
6. INSTALL REAR SHOCK ABSORBER LH. (Refer to “Chapter 32 rear suspension - rear shock
absorber, overhaul”)
7. TIGHTEN U-BOLTS NUTS AGAIN AFTER A 3 ~ 5 KM DRIVE.
8. REMOVE REAR LEAF SPRING RH.
NOTE
TIRE AND WHEEL
33
TIRE AND WHEEL SYSTEM ............................................................. 33-1
PRECAUTION.............................................................................. 33-1
COMPONENTS ........................................................................... 33-2
PROBLEM SYMPTOMS TABLE.................................................. 33-3 33
ON-VEHICLE INSPECTION ........................................................ 33-4
ADJUSTMENT ............................................................................. 33-7
FRONT TIRE AND WHEEL................................................................ 33-8
REPLACEMENT .......................................................................... 33-8 33
REAR TIRE AND WHEEL.................................................................. 33-9
REPLACEMENT .......................................................................... 33-9 33
TIRE AND WHEEL - TIRE AND WHEEL SYSTEM 33-1
TIRE AND WHEEL SYSTEM

TIRE AND WHEEL
PRECAUTION
1. TIRE AND WHEEL SYSTEM PRECAUTION. 33
(a) Use special tools to remove the tires. Do not remove them by huge hammer or sharp tool.
(b) Do not use different type, size, speed rating, pressure and load index tire on the same axle.
(c) Please pay attention to the mark of rolling direction when installing directional tread pattern tire.
(d) Must rotate each tire once after runing 5000 ~ 6000 km, make each tire wear well distributedly.
(e) After rotating tires, reset proper inflation pressure according to the tire position.
(f) Operate inflation according to this manual’s specification, and measure tire pressure at cold state by
tire gauge. Before inflating, check the tire valve whether matching valve core flatly and then clean the
dirt. Inflating air is not allowed to contain with water and oil spray. After inflating, tighten the tire valve
core, and check the tire leakage.
33
(g) Check inflation pressure according to the standard service data. It is not allowed that the tire pressure is
lower or higher.
(h) Termly check front wheel toe-in. Avoid unnecessary increase the running resistance, the fuel
consumption and excessive tire wear.
33-2 TIRE AND WHEEL - TIRE AND WHEEL SYSTEM
COMPONENTS
1 Wheel Rim Cover 4 Balance Weight
2 Wheel Rim 5 Tubeless Tire Valve
3 Tire

33
1. Wheel toe-in (Improper value) alignment, adjustment
2. Tire ( Improperly inflated) Chapter 33 tire and wheel - tire and wheel
assy, on-vehicle inspection
Abnomal tire wear
3. Wheel (Out of balance) Chapter 33 tire and wheel - tire and wheel
assy, adjustment
4. Steering system (Distortion) Chapter 51 steering system - steering gear,

replacement 33
1. Front wheel (Different tire Chapter 33 tire and wheel - tire and wheel
pressure) assy, on-vehicle inspection
Chapter 33 tire and wheel - tire and wheel

2. Wheel (Out of balance) assy, adjustment
Front wheel swing or
vibration
3. Shock absorber (Wear or fault) absorber, overhaul
Chapter 51 steering system - steering gear,

4. Steering system (Wear serious) replacement

1. Tire (Exceed specified pressure) assy, on-vehicle inspection

absorber, overhaul
Uncomfortableness when 2. Shock absorber (Failure) Chapter 32 rear suspension - rear shock
running absorber, overhaul
Chapter 31 front suspension - torsion bar

assy, overhaul
3. Spring weak (Failure) Chapter 32 rear suspension - rear leaf
spring assy, overhaul
1. Wheel toe-in (It is not within Chapter 31 front suspension - front wheel
specified value) alignment, adjustment
Front wheel side slipping
2. Tire (Inflating pressure is not Chapter 33 tire and wheel - tire and wheel
within specified value) assy, on-vehicle inspection
1. MEASURE TIRE TREAD DEPTH.
Depth ≥ 1.6 mm
If the tire tread depth is less than 1.6 mm, replace it with a new one.
NOTE
Replace a pair of tires at the same wheel side.
2. CHECK TIRES ABNORMAL WEAR.

(a) Visually inspect the tires shoulder wear. If the tire wears,
measure the inflation pressure. Inflate and rotate the
wheel if tire pressure is lower or overload.
(b) Visually inspect the wear tires at center. If the tire wears,
release exceed pressure and rotate the wheel assy.
(c) Visually inspect the tire inner edge (shoulder) wear. The
inner Edge (shoulder) wear is usually caused by excessive
toe-out and/or excessive negative camber, suspension
parts loose. Avoid running at high speed when turning. 33
Adjust and rotate the wheel assy.
33
(d) Visually inspect the tire outer edge (shoulder ) wear. The
outer edge (shoulder) wear is usually caused by excessive
toe-in and/or excessive positive camber, suspension parts
loose. Avoid running at high spped when turning. Adjust
and rotate the wheel assy.
(e) Visually inspect the tire feathering wear that occurs along
both inside and outside shoulder ribs. This kind of wear
is usually caused by excessive toe-in. Check/adjust the
wheel alignment and rotate the wheel assy.
(f) Visually inspect the tire corrugate wear. This kind of wear
is caused by improper inflation pressure, wheel out of
balance, hub bearing loose or worn and rim deformation.
Adjust and rotate the wheel assy.
3. MEASURE COLD TIRE INFLATION PRESSURE.
Tire Specification Front Tire Rear Tire Spare Tire

195/70R15C 325±10 kPa 450±10 kPa 450±10 kPa
If tire size or inflation pressure doesn’t match standard service data, adjust or replace it with a new wheel as
necessary.
4. INSPECT TIRE CROWN, TIRE SHOULDER, TIRE EDGE.
Replace the tire with a new one, if bent, cut, cracked, dented, deformation and abrasion exists.
5. INSPECT TIRE VALVE.
If air leaks from tire valve, replace it with a new one.
6. INSPECT RIM.
Replace the rim with a new one If it is deformation, corrosion and crack.
7. INSPECT WHEEL BOLT AND NUT.
Check the tightening torque one by one according to the standard service data.
ADJUSTMENT
1. TIRE ROTATION.
NOTE 33
Illustration arrow shows the front of vehicle.
(a) Illustration A is cross rotation every tire with spare tire.
(b) Illustration B is cross rotation every tire without spare tire.
33
2. WHEEL OFF-THE-CAR BALANCE.

(a) Clean dirt, stone and used balance block from measured
wheel.
(b) Measure tire pressure and inflate as recommended.
(c) Select the match cone based on size of rim center hole
to tighten by fast nut.
(d) Turn on the balance tester power.
(e) Measure rim width.
(f) Measure tire diameter.
(g) Measure the distance between the rim edge and the
balance tester.
(h) Pull off wheel protect cover and then start test.
(i) After test completed, fix balance block based on measurement
result.
(j) Repeat aforementioned procedure, adjust till the data to
match specification.
(k) Demount wheel assy.
3. FRONT WHEEL TOE-IN. (Refer to Chapter 31 front suspention - front wheel alignment ,
adjustment )
4. TIRE REPAIR SHALL BE EXECUTED BY LOCAL REGULATIONS.
33-8 TIRE AND WHEEL - FRONT TIRE AND WHEEL
FRONT TIRE AND WHEEL

REPLACEMENT
1. LIFT VEHICLE.
2. REMOVE FRONT WHEEL RH.

(a) Remove 5 front wheel RH nuts.
NOTE
Loosen all front wheel nuts diagonally.
(b) Remove the front wheel RH
3. INSTALL FRONT WHEEL RH.

(a) Position the front wheel RH properly.
(b) Tighten 5 front wheel RH nuts.

Torque: 120 ～ 150 N•m
NOTE
Tighten all front wheel nuts diagonally.
4. REMOVE FRONT WHEEL LH.

NOTE
TIRE AND WHEEL - REAR TIRE AND WHEEL 33-9
REAR TIRE AND WHEEL

REPLACEMENT
1. LIFT VEHICLE. 33
2. OPERATE PARKING BRAKE.
3. REMOVE REAR WHEEL RH.

(a) Remove 5 rear wheel RH nuts.
NOTE
Loosen all rear wheel nuts diagonally.
33
(b) Remove the rear wheel RH from vehicle.
4. INSTALL REAR WHEEL RH.

(a) Position the rear wheel RH properly.
(b) Tighten 5 rear wheel RH nuts.

Torque: 120 ～ 150 N•m
NOTE
Tighten all rear wheel nuts diagonally.
5. REMOVE REAR WHEEL LH ASSY.

NOTE
MEMO
34
PROPELLER SHAFT ASSY .............................................................. 34-1
PRECAUTION.............................................................................. 34-1
COMPONENTS ........................................................................... 34-3 34
INSPECTION ............................................................................... 34-4
OVERHAUL ................................................................................. 34-5
U-JOINT ............................................................................................. 34-9
COMPONENTS ........................................................................... 34-9 34
OVERHAUL ............................................................................... 34-10
CENTER SUPPORT BEARING ....................................................... 34-14
COMPONENTS ......................................................................... 34-14
OVERHAUL ............................................................................... 34-15 34
AXLE HUB AND STEERING KNUCKLE......................................... 34-19
ON-VEHICLE INSPECTION ...................................................... 34-21
AXLE HUB ....................................................................................... 34-23
COMPONENTS ......................................................................... 34-23
OVERHAUL ............................................................................... 34-25
STEERING KNUCKLE ..................................................................... 34-35
COMPONENTS ......................................................................... 34-35
OVERHAUL ............................................................................... 34-36
REAR AXLE ..................................................................................... 34-48
PRECAUTION............................................................................ 34-48
COMPONENTS ......................................................................... 34-51
FINAL DRIVE OIL ............................................................................ 34-55
REPLACEMENT ........................................................................ 34-55
AXLE SHAFT ASSY......................................................................... 34-58
OVERHAUL ............................................................................... 34-58
REAR AXLE HOUSING WELDING ASSEMBLY ............................ 34-60
OVERHAUL ............................................................................... 34-60
DIFFERENTIAL ASSY ..................................................................... 34-65
COMPONENTS ......................................................................... 34-65
INSPECTION AND ADJUSTMENT ........................................... 34-66
OVERHAUL ............................................................................... 34-70
DRIVE PINION ................................................................................. 34-80
COMPONENTS ......................................................................... 34-80
INSPECTION ............................................................................. 34-81
OVERHAUL ............................................................................... 34-84
AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY 34-1
PROPELLER SHAFT ASSY

PRECAUTION
1. PROPELLER SHAFT ASSY PRECAUTION. 34
(a) Do not disassemble the propeller shaft assy unless absolutely necessary.
(b) If disassembly of propeller shaft assy is required, be sure to clean all separated parts before assembly.
(c) After disassembling of propeller shaft assy, be sure to check all separated parts one by one and
perform repairing or replacing when necessary.
34
34-2 AXLE AND PROPELLER SHAFT - PROPELLER SHAFT ASSY


Chapter 34 axle and propeller shaft -
1. Propeller shaft assy (Loose) propeller shaft assy, overhaul
2. Lubrication (Insufficient) -
Abnormal noise Chapter 34 axle and propeller shaft - U-joint,

of propeller shaft 3. U-joint (Worn or damaged) overhaul
assy
4. Center support bearing (Worn or Chapter 34 axle and propeller shaft - center
damaged) support bearing, overhaul

5. Slip spline (Worn) propeller shaft assy, inspection

1. Propeller shaft assy (Loose) propeller shaft assy, overhaul
Chapter 34 axle and propeller shaft - center

2. U-joint yoke (Incorrectly installation) support bearing, overhaul

3. Propeller shaft assy (Bent or twisted) propeller shaft assy, overhaul
Propeller shaft
assy vibration Chapter 34 axle and propeller shaft -
4. Propeller shaft assy (Unbalanced) propeller shaft assy, overhaul
5. Center support bearing rubber grommet Chapter 34 axle and propeller shaft - center
(Aging or damaged) support bearing, overhaul
6. Center suppor bearing (Worn or Chapter 34 axle and propeller shaft - center
damaged) support bearing, overhaul
1. Center support with rubber grommet Chapter 34 axle and propeller shaft - center
(Incorrectly installation) support bearing, overhaul
Center support
bearing overheat 2. Lubrication (Insufficient) -
Chapter 34 axle and propeller shaft - center

3. Oil seal (Too tight) support bearing, overhaul
COMPONENTS
34
34
1 Nut 5 Bolt And Washer Set
2 Spring Washer 6 Carrier
3 Bolt 7 Bolt
4 Propeller Shaft Assy

INSPECTION
1. INSPECT VIBRATION OF POWERTRAIN.
(a) Check front wheels for dynamic balance. (Refer to “Chapter 33 tire and wheel - tire and wheel assy,
adjustment”)
(b) Check rear wheels for dynamic balance. (Refer to “Chapter 33 tire and wheel - tire and wheel assy,
adjustment”)
(c) Perform the road test. Check the powertrain for vibration when vehicle is moving or stops.
2. INSPECT PROPELLER SHAFT ASSY DIAMETER RUNOUT.

(a) Using V-block and dial indicator, measure the diameter
runout of propeller shaft assy.
Limit: ≤ 0.7 mm
If the diameter runout is out of the specification, correct the
propeller shaft assy using press machine. If the diameter runout
is still out of the specification after correction, replace with a new
propeller shaft assy. (Chapter 34 axle and propeller shaft -
propeller shaft assy, overhaul)
3. INSPECT PROPELLER SHAFT ASSY DYNAMIC BALANCE.

(a) Using dynamic balancer, check the propeller shaft assy.
Dynamic unbalance: ≤ 27 g.cm ( r/min)
If the dynamic unbalance is out of the specification, weld balance
blocks at the corresponding position on the both ends of propeller
shaft assy.
NOTE
• It is no more than 3 balance blocks at each end if weld-
ing.
• Perform step (a) again to check whether dynamic
unbalance is within the specification.
4. INSPECT SLIP SPLINE CLEARANCE.

(a) Using feeler gauge, measure the tangential clearance
between sleeve yoke and spline on transmission output
shaft.
Standard: 0.15 mm
Limit: 0.35 mm
If the clearance is out of the specification, replace with a new
propeller shaft assy. (Refer to “Chapter 34 axle and propeller
shaft - propeller shaft assy, overhaul”)
OVERHAUL
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - propeller shaft assy, precaution”)
2. REMOVE PROPELLER SHAFT ASSY. 34

(a) Mark on the front propeller shaft U-joint and transmission
dust-proof cover.
NOTE
Make sure the marks are clear.
(b) Mark on the rear propeller shaft U-joint and pinion flange.
NOTE 34
(c) Remove the 4 bolts and carrier.

NOTE
There are 2 carriers in total.
(d) Remove the 4 bolts.

NOTE
Discard the loose bolts.
(e) Lower the propeller shaft and set it aside.

NOTE
When performing this operation, another operator who holds the
propeller shaft up is required.
(f) Remove the 2 bolts.

NOTE
• Discard the loose bolts.
• When performing this operation, another operator who
holds the propeller shaft up is required.
(g) Lower the center support with rubber grommet.

NOTE
(h) Pull out the sleeve yoke from transmission dust-proof

cover and remove the propeller shaft assy.
NOTE
Be sure to store the propeller assy carefully.
3. INSPECT PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
shaft assy, inspection”)
4. INSPECT U-JOINT. (Refer to “Chapter 34 axle and propeller shaft - U-joint, overhaul”)
34
5. INSTALL PROPELLER SHAFT ASSY.
(a) Insert the sleeve yoke into transmission dust-proof cover
according to the marks.
NOTE
• Be sure to perform this operation according to the
marks.
(b) Position the center support with rubber grommet properly.

34
NOTE
(c) Tighten the 2 bolts.

Torque: 40 N•m.
NOTE
• Be sure to use new bolts.
(d) Position the propeller shaft properly according to the marks.

NOTE
marks.
• Align the marks by rotating the pinion flange when
necessary.
(e) Tighten the 4 bolts.

Torque: 20 N·m
NOTE
Be sure to use new bolts.
(f) Install the carrier.

Torque: 20 N•m
NOTE
There are 2 carriers in total.
AXLE AND PROPELLER SHAFT - U-JOINT 34-9
U-JOINT
COMPONENTS
34
34
1 Sleeve / Tube / End / Flange Yoke 4 Snap Ring
2 Round Bearing 5 Tube / End Yoke
3 Dust-proof Cover 6 Cross Spider

34-10 AXLE AND PROPELLER SHAFT - U-JOINT
OVERHAUL
2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
shaft assy, overhaul”)
3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT

ASSY.
(a) Mark on the end yoke, cross spider and tube yoke.
NOTE
(b) Using snap ring pliers, remove the 4 snap rings.

NOTE
Discard the removed snap rings.
(c) Using copper rod and hammer, remove the round bearing.
NOTE
Do not hammer the round bearing and do not clamp the
propeller shaft with vice directly.
(d) Remove the 4 round bearings and the 4 dust-proof

covers.
NOTE
Discard the removed dust-proof cover. 34
(e) Remove the cross spider.
(f) Separate the end yoke from tube yoke.
4. DISASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

NOTE
Disassemble the front U-joint by the same procedures as the middle U-joint.
5. DISASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.
NOTE 34
Disassemble the rear U-joint by the same procedures as the middle U-joint.
6. INSPECT CROSS SPIDER.
(a) Check the cross spider for wear and tear.
(b) Using the micrometer caliper, measure the cross spider

journal.
Standard: 30 mm
Limit: 29.85 mm
If the cross spider is excessively worn, replace with a new part.
(c) Using the dial indicator, measure the clearance between

round bearing and yoke.
Clearance: 0 mm (Interference fit)
If clearance exits, replace with new round bearing and yoke.
NOTE
Insert the round bearing into yoke. Measure the clearance
by shaking bearing along radial direction lightly.
(d) Using the vice and the dial indicator, measure the radial
clearance between round bearing and cross spider.
Radial clearance: 0.05 ～ 0.15 mm
If the radial clearance is out of the specification, replace with
new round bearing and cross spider.
CAUTION
Wrap the cross spider with rag to prevent the spider where
is clamped by vice from being damaged.
34-12 AXLE AND PROPELLER SHAFT - U-JOINT
NOTE
Hitch the cross spider with round bearing. Measure the radial
clearance by shaking bearing along radial direction lightly.
(e) Using dial indicator, measure the axial clearance between

round bearing and cross spider.
Axial clearance: 0.10 ～ 0.30 mm
If the axial clearance is out of the specification, replace with new
round bearing and cross spider.
NOTE
Hitch the cross spider with round bearing. Measure the
axialclearance by shaking bearing along axial direction
lightly.
7. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY.

(a) Coat the grease on the mating surfaces of cross spider and round bearing.
Grease: lithium base grease No.2
NOTE
• Only coat the grease on the mating surface of cross spider and round bearing.
• If the coating grease is excessive, it will cause problem for further operations.
(b) Position the end yoke and tube yoke properly according to
the marks.
(c) Install the 4 round bearings and the 4 dust-proof covers at
ouside of yoke.
(d) Install the cross spider at inside of yoke.
(e) Using the copper rod and the hammer, install the 4 round
bearings and the 4 dust-proof covers properly.
NOTE
• Be sure to use new dust-proof covers.
marks.
(f) Using snap ring pliers, install the 4 snap rings.

NOTE
Be sure to use new snap rings.
34
8. ASSEMBLE FRONT U-JOINT OF PROPELLER SHAFT ASSY.

NOTE
Reassemble the front U-joint by the same procedures as the middle U-joint.
9. ASSEMBLE REAR U-JOINT OF PROPELLER SHAFT ASSY.
NOTE 34
Reassemble the rear U-joint by the same procedures as the middle U-joint.
10. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
34-14 AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING

COMPONENTS
1 Nut 5 Center Support Bearing
2 Flat Washer 6 Bearing Cup
3 End Yoke Center Support With Rubber Grommet

7
Assy
4 Oil Seal
8 Middle Propeller Shaft
AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING 34-15
OVERHAUL
2. REMOVE PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
34
3. DISASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - U-joint, overhaul”)
4. REMOVE END YOKE.

(a) Remove the nut.
NOTE
Discard the loose nut.
34
(b) Remove the flat washer.
(c) Mark on the end yoke and spline.

NOTE
• Make sure the marks are clear.
• Make sure the yoke direction of U-joint is consistent.
(d) Using a puller, remove the end yoke.

5. REMOVE CENTER SUPPORT WITH RUBBER GROMMET

ASSY.
CAUTION
Do not damage the rubber grommet.
6. REMOVE CENTER SUPPORT BEARING.

(a) Using a puller, remove the center support bearing assy.
(b) Remove the 2 oil seals on both side.

NOTE
Discard the removed oil seals.
(c) Using hammer and copper rod, remove the center support
bearing from bearing cup.
7. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support bearing can be rotated freely.
(b) Check whether the center support bearing is worn excessively.
(c) If any fault is found, replace with a new part.
AXLE AND PROPELLER SHAFT - CENTER SUPPORT BEARING 34-17
8. INSTALL CENTER SUPPORT BEARING ASSY.

(a) Coat the grease on the center support bearing and bearing cup.
34
(b) Using hammer and copper rod, install the center support
bearing to bearing cup.
(c) Coat the grease on the oil seal lip.
NOTE
Be sure to use new oil seals.
(d) Install the 2 oil seals on both side.

34
(e) Install the center support bearing assy with hammer and
copper rod.
9. INSTALL CENTER SUPPORT WITH RUBBER GROMMET

ASSY.
CAUTION
Do not damage the rubber grommet when operation.
10. INSTALL END YOKE.

(a) Position the end yoke properly according to the marks.
NOTE
marks.
• Make sure the yoke direction of U-joint is consistent.
(b) Install the flat washer.
(c) Tighten the nut.

NOTE
Be sure to use a new nut.
11. INSPECT CENTER SUPPORT BEARING.

(a) Check whether the center support with rubber grommet can be rotated freely without deviation when
rotating it by hands.
(b) Replace with new center support bearing, bearing cup and support with rubber grommet assy if necessary.
12. ASSEMBLE MIDDLE U-JOINT OF PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and
propeller shaft - U-joint, overhaul”)
13. INSTALL PROPELLER SHAFT ASSY. (Refer to “Chapter 34 axle and propeller shaft - propeller
AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE 34-19
AXLE HUB AND STEERING KNUCKLE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of the likely 34

1. Tire type (Incorrect) assy, on-vehicle inspection

2. Tire (Worn) assy, on-vehicle inspection

3. Tire pressure (Incorrect) assy, on-vehicle inspection
Chapter 32 rear suspension - rear wheel

4. Wheel alignment (Incorrect) alignment, adjustment 34
Wandering / Chapter 34 axle and propeller shaft - axle
Pulling 5. Axle hub bearing (Worn) hub and steering knuckle, on-vehicle
inspection

6. Front shock absorber (Damaged) absorber, overhaul
7. Suspension (Loose or damaged) -
Chapter 52 power steering - steering box,

8. Steering tie rod (Loose or worn) overhaul
Chapter 32 rear suspension - rear stabilizer

9. Stabilizer bar (Bent or fractured) bar, replacement

1. Wheel (Unbalanced or worn excessively) assy, adjustment
Chapter 34 axle and propeller shaft - axle

2. Axle hub bearing (Worn) hub and steering knuckle, on-vehicle
inspection

absorber, overhaul
3. Shock absorber (Worn or damaged) Chapter 32 rear suspension - rear shock
Wheel vibration
absorber, overhaul
Chapter 31 front suspension - lower control

4. B-joint (Worn) arm, replacement

5. Steering tie rod (Loose or worn) overhaul

6. Steering box (Damaged) overhaul
34-20 AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE

Chapter 52 power steering - steering
1. Power steering fluid level (Low) fluid,replacement

2. Steering knuckle (Worn) steering knuckle, overhaul

Abnormal noise 3. Steering propeller shaft (Worn) propeller shaft assy, overhaul
Chapter 52 power steering - power steering

4. Power steering pump (Worn or damaged) pump assy, replacement

AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE 34-21
1. INSPECT FRONT AXLE HUB.
(a) Remove the front wheel assy. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)
34
(b) Remove the front disk brake caliper assy. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Using a screwdriver, remove the front axle hub grease

cap.
CAUTION
Do not press the spherical sureface to prevent deformation.
NOTE
Pry the grease cap out lightly along the edge.
34
(d) Using dial indicator, measure the back lash around the
center of front axle hub.
Back lash: ≤ 0.05 mm
If the back lash is out of the specification, replace with new front
axle hub bearings.
NOTE
• Measure the back lash by shaking the front axle hub
along the axial direction lightly.
• When perfprming the measurment, make the dial indi-
cator be close to the center of axle hub.
(e) Using dial indicator, measure the deviation at the edge of

front axle hub.
Deviation: ≤ 0.1 mm
If the deviation is out of the specification, replace with a new front
axle hub.
NOTE
• Measure the deviation by rotating the front axle hub
slowly.
• When performing the measurement, make the dial
indicator be close to the edge of axle hub.
34-22 AXLE AND PROPELLER SHAFT - AXLE HUB AND STEERING KNUCKLE
(f) Using hammer and copper rod, install the front axle hub
grease cap.
CAUTION
Do not press the spherical surface to prevent deformation.
NOTE
Hammer the grease cap with copper rod lightly along the
edge to install it properly.
(g) Install the front disk brake caliper assy. (Refer to

“Chapter 35 brake - front brake, overhaul”)
(h) Install the front wheel assy. (Refer to “Chapter 33 tire and
wheel - front tire and wheel, replacement”)
2. INSPECT REAR AXLE HUB.

(a) Remove the rear wheel assy. (Refer to “Chapter 33 tire and wheel - rear tire and wheel, replacement”)
(b) Remove the rear brake drum. (Refer to “Chapter 35 brake - rear brake, overhaul”)
(c) Using dial indicator, measure the back lash around the
center of rear axle hub.
Back lash: ≤ 0.13 ~ 0.18 mm
If the back lash is out of the specification, replace with new rear
axle hub bearings.
NOTE
• Measure the back lash by shaking the rear axle hub
along the axial direction lightly.
• When performing the measurement, make the dial indi-
cator be close to the center of axle hub.
(d) Using dial indicator, measure the deviation at the edge of

rear axle hub.
If the deviation is out of the specification, replace with a new rear
axle hub.
NOTE
• Measure the deviation by rotating the rear axle hub
slowly.
cator be close to the edge of axle hub.
(e) Install the rear brake drum. (Refer to “Chapter 35 brak -

rear brake, overhaul”)
(f) Install the rear wheel assy. (Refer to “Chapter 33 tire and
wheel - rear tire and wheel, replacement”)
AXLE AND PROPELLER SHAFT - AXLE HUB 34-23
AXLE HUB
COMPONENTS
FRONT AXLE HUB 34
34
1 Front Axle Hub Grease Cap 9 Front Brake Caliper
2 Front Axle Hub Nut Cover 10 Washer
3 Cotter Pin 11 Plug
4 Front Axle Hub Nut 12 Brake Fluid Tube
5 Front Axle Hub Washer 13 Bolt
6 Front Axle Hub Bearing 14 Front Axle Hub Inner Bearing
7 Front Axle Hub 15 Oil Seal
8 Front Brake Disk

34-24 AXLE AND PROPELLER SHAFT - AXLE HUB
REAR AXLE HUB
1 Cotter Pin 12 C-washer
2 Hole Plug Rear Brake Automatic Adjusting Lever

13
Spring
3 Rear Axle Hub
14 Rear Brake Automatic Adjusting Lever
4 Rear Brake Backing Plate
15 Rear Brake Drum
5 Leading Shoe
16 Dust Boot
6 Parking Brake Shoe Strut Set
17 Piston
7 Hold Spring
18 Rubber Cover
8 Hold Spring Cover
19 Bolt
9 Return Spring
20 Rear Wheel Brake Cylinder
10 Trailing Shoe
21 Bleeding Plug
11 Parking Brake Shoe Lever
22 Spring
OVERHAUL
FRONT AXLE HUB
1. REMOVE FRONT AXLE HUB LH. 34
(a) Remove the front wheel assy LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replace-
ment”)
(b) Remove the front disk brake caliper assy LH. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Using a screwdriver, remove the front axle hub grease

cap.
CAUTION
Do not press the spherical surface to prevent deformation.
NOTE
Pry the grease cap out lightly along the edge.
34
(d) Remove the cotter pin.

NOTE
Discard the removed cotter pin.
(e) Remove the front axle hub nut cover.
(f) Remove the front axle hub nut.

NOTE
Discard the loose front axle hub nut.
(g) Remove the front axle hub washer.

(h) Remove front axle hub bearing outside.
34
34
(i) Separate the axle hub LH from bake disc LH.
(j) Remove the 5 bolts.
NOTE
• Store the brake disc carefully.
• Discard the loose bolts.
(k) Remove front axle hub inner bearing and oil seal. Clear
and check the bearing,replace it if nessary.
NOTE
Discard the oil seal.
2. REMOVE FRONT AXLE HUB RH.

NOTE
3. INSTALL FRONT AXLE HUB LH.

(a) Coat the grease on the steering knuckle LH.
NOTE
Coat the grease to cover the entire surface of steering knuckle LH.
(b) Install the front brake disk with axle hub assy LH.
(c) Install the front axle hub inner bearing and oil seal.
(d) Tighten the 5 bolts sequently.
Torque：145 N·m
NOTE
• Before tightening bolts, install the 5 bolts firstly.
(e) Install front axle hub bearing.

NOTE
Fill the grease into the bearings for more than 1/2.
(f) Install the front axle hub washer.

(g) First of all pretension front axle hub nut.

(h) Turn the brake disc and tighten the front axle hub nut.
Torque: 160 ～ 170 N·m
34
NOTE
Be sure to use a new nut.
34
(i) Rotate the front axle hub LH by 2 ～ 3 turns.
(j) Using a spring scale, measure the primal rotating force of
front axle hub LH.
Primal rotating force: ≤ 13 ~ 26 N·m
If the primal rotating force is out of the specification, adjust the front
axle hub nut.
(k) Using dial indicator, measure the back lash around the
center of front axle hub LH.
If the back lash is out of the specification, replace with new front
axle hub bearings.
NOTE
• Measure the back lash by shaking the front axle hub
LH along the axial direction lightly.
• When performing the measurment, make the dial indi-
cator be close the center of axle hub.
(l) Using dial indicator, measure the deviation at the edge of

front axle hub LH.
If the deviation is out of the specification, replace with a new front
axle hub LH.
NOTE
• Measure the deviation by rotating the front axle hub
LH slowly.
cator be close to the edge of axle hub.
(m) Coat the grease on the front axle hub nut.
(m) Coat the grease on the front axle hub cover.

(n) Install the front axle hub cover.
(o) Install the cotter pin.

NOTE
Be sure to use a new cotter pin.
(p) Using hammer and copper rod, install the front axle hub
grease cap.
NOTE
• Don’t press the spherical surface to prevent deformation.
• Hammer the grease cap with copper rod lightly along
the edge to install it properly.
(q) Install the front disk brake caliper assy LH. (Refer to
(r) Install the front wheel assy LH. (Refer to “Chapter 33 tire
and wheel - front tire and wheel, replacement”)
4. INSTALL FRONT AXLE HUB RH.

NOTE
Install the RH side by the same procedures as the LH side.
REAR AXLE HUB

1. REMOVE REAR AXLE HUB LH.
(a) Remove the rear tire and wheel assy LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”) 34
(b) Remove the rear brake drum LH.

NOTE
Loose brake shoe clearance if necessary.
(c) Using a puller, remove the rear axle hub LH. 34
(d) Loosen connecting LH brake lin to LH brake cylinder.

NOTE
Dicconnect the rear parking brake cable assy LH.
(e) Remove the 4 nuts and brake plate LH.

NOTE
Store brake plate carefully.
(f) Remove bearing retainer snap ring with pliers.

NOTE
Discard the removed snap ring.
(g) Remove bearing retainer.
NOTE
Discard the removed bearing retainer.
(h) Separate brake plate and bearing sleeve and remove
bearing oil seal.
NOTE
Discard the removed bearing oil seal.
(i) Using hammer and copper rod, remove the rear axle hub
bearing.
2. REMOVE REAR AXLE HUB RH.

NOTE
3. INSTALL REAR AXLE HUB LH.
(a) Position the bearing oil seal properly, install bearing oil seal.
NOTE
Be sure to use a new seal oil.
(b) Attach the brake plate to bearing sleeve.
(c) Insert the rear axle and hub LH into bearing sleeve.
(d) Using hammer and copper rod, install the rear axle hub bearing.
NOTE
Fill the grease into the bearings for more than 1/2.
(e) Install bearing retainer.
NOTE
Be sure to use a new bearing retainer.
(f) Using pliers, install the snap ring properly.
NOTE
Be sure to use a new snap ring.
(g) Insert the rear wheel hub and rear axle shaft into the rear
axle housing.
(h) Tighten the 4 nuts.

NOTE
Do not drag the parking brake cable assy LH.
34
(i) Connect LH brake lin to LH brake cylinder and tighten

the nuts, connect the rear parking lines.
34
(j) Using dial indicator, measure the back lash around the
center of rear axle hub LH.
If the back lash is out of the specification, replace with new rear
axle hub bearings.
NOTE
• Measure the back lash by shaking the rear axle hub
LH along the axial direction lightly.
indicator be close to the center of axle hub.
(k) Using dial indicator, measure the deviation at the edge of

rear axle hub LH.
If the deviation is out of the specification, replace with a new rear
axle hub LH.
NOTE
• Measure the deviation by rotating the rear axle hub
LH slowly.
indicator be close to the edge of axle hub.
(l) Install the rear brake drum LH.
(m) Rotate the rear axle hub LH 2 ～ 3 turns.

(n) Using a spring scale, measure the primal rotating force of
rear axle hub LH.
Primal rotating force: ≤ 13 ~ 26 N·m
(o) Install the rear wheel assy LH. (Refer to “Chapter 33 tire
and wheel - rear tire and wheel, replacement”)
4. INSTALL REAR AXLE HUB RH.
NOTE
5. BRAKE SYSTEM REFILLING AND BLEEDING. (Refet to “Chapter 35 braking system - brake fluid,
bleeding”)
AXLE AND PROPELLER SHAFT - STEERING KNUCKLE 34-35
STEERING KNUCKLE
COMPONENTS
34
34
1 Splash Shield 7 Steering Tie Rod
2 Bolt 8 Steering Knuckle
3 Cotter Pin 9 Lower Control Arm
4 Slotted Nut 10 Lower Control Arm B-joint
5 Upper Control Arm 11 Nut
6 Steering Knuckle Arm 12 Bolt

34-36 AXLE AND PROPELLER SHAFT - STEERING KNUCKLE
OVERHAUL
1. REMOVE STEERING KNUCKLE LH.
(a) Remove front wheel assy LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel, replacement”)
(b) Remove the front disk brake caliper assy LH. (Refer to “Chapter 35 brake - front brake, overhaul”)
(c) Remove the front brake disk with axle hub assy LH. (Refer to “Chapter 34 axle and propeller shaft -
axle hub, overhaul”)
(d) Separate the steering tie rod B-joint LH from the steering
knuckle arm LH.
• Remove the cotter pin.
NOTE
• Remove the slotted nut.

NOTE
Discard the loose slotted nut.
• Set the steering tie rod LH aside.
(e) Remove the 2 cotter pins.

NOTE
Discard the removed cotter pins.
(f) Loosen the 2 slotted nuts.
NOTE
• Discard the loose slotted nuts.
• Removing the 2 bolts is not required.
(g) Remove the steering knuckle arm LH simultaneously.
34
(h) Remove the splash shield LH.

• Remove the bolt.
34
• Pull the 2 bolts out.

NOTE
These 2 bolts are loose.
• Remove the splash shield LH.

(i) Remove the lower control arm B-joint LH.

NOTE

NOTE
• Loosen the 4 sets of bolts and nuts.

NOTE
Discard the loose bolts and nuts.
34
34
• Using hammer and copper rod, remove the lower control

arm B-joint LH.
(j) Separate the steering knuckle LH from the upper control

arm B-joint LH.
NOTE
• Loosen the slotted nut.

NOTE
• Using hammer and copper rod, remove the steering knuckle

LH.
34
34
2. REMOVE STEERING KNUCKLE RH.

NOTE
3. INSPECT B-JOINT.
(a) Check the contact area between steering tie rod B-joint
and steering knuckle arm.
• Apply red lead evenly to the steering tie rod B-joint shaft and
hole of steering knuckle arm.
• Insert the steering tie rod B-joint shaft into the hole of
steering knuckle arm, then pull it out again. Check the
contact area.
Standard: red area ≤ 3/4 shaft length,evenly
If any problem is found, replace with a new steering box and
steering knuckle arm. (Refer to “Chapter 52 power steering -
steering box, overhaul”, “Chapter 34 axle and propeller shaft -
steering knuckle, overhaul”)
(b) Check the contact area between lower control arm B-joint
and steering knuckle.
• Apply red lead evenly to the lower control arm B-joint
shaft and hole of steering knuckle.
• Insert the lower control arm B-joint shaft into the hole of
steering knuckle, then pull it out again. Check the contact
area.
If any problem is found, replace with a new lower control arm B-
joint and steering knuckle. (Refer to “Chapter 31 front suspension
- lower control arm, replacment”, “Chapter 34 axle and propeller

shaft - steering knuckle, overhaul”)
(c) Check the contact area between upper control arm B-joint
.
and steering knuckle.

• Apply red lead evenly to the upper control arm B-joint
shaft and hole of steering knuckle.
• Insert the upper control arm B-joint shaft into the hole of
steering knuckle, then pull it out again. Check the contact
area.
If any problem is found, replace with a new lower control arm B-
joint and steering knuckle. (Refer to “Chapter 31 front
suspension - upper control arm, replacment”, “Chapter 34 axle
and propeller shaft - steering knuckle, overhaul”)
4. INSTALL STEERING KNUCKLE LH.

(a) Install the steering knuckle LH.
• Using hammer and copper rod, position the steering
knuckle LH properly.
• Tighten the slotted nut.

Torque: 135 ～ 145 N·m
NOTE
Be sure to use a new slotted nut.
34
34
• Install the cotter pin.

NOTE
(b) Install the lower control arm B-joint LH.

• Using hammer and cooper rod, position the lower control
arm B-joint LH properly.
NOTE
Align the holes of B-joint and lower control arm LH.
• Tighten the 4 sets of bolts and nuts.

Torque: 69 ～ 77 N·m
NOTE
Be sure to use new bolts and nuts.

Torque: 137 ～ 147 N·m
NOTE
34
34

NOTE
(c) Install the splash shield LH.

• Position the splash shield LH properly.
• Insert the 2 bolts.

NOTE
• Simultaneously position the steering knuckle arm LH
properly.
• Installing 2 slotted nuts is not required during this
operation.
(d) Tighten the 2 slotted nuts.

NOTE
Be sure to use new slotted nuts.
(e) Install the 2 cotter pins.
NOTE
Be sure to use new cotter pins
(f) Conntect the steering tie rod LH to the steering knuckle

arm LH.
• Insert the steering tie rod B-joint LH into the hole in
steering knuckle arm LH.

NOTE

NOTE
34
(g) Install the front brake disk with axle hub assy LH. (Refer
to “Chapter 34 axle and propeller shaft - axle hub, over-
haul”)
(h) Install the front disk brake caliper assy LH. (Refer to
34
(i) Install the front wheel assy. (Refer to “Chapter 33 tire and
wheel - front tire and wheel, replacement”)
5. INSTALL STEERING KNUCKLE RH.
NOTE
6. INSPECT FRONT WHEEL ANGLE. (Refer to “Chapter 31 front suspension - front wheel alignment,
adjustment”)
34-48 AXLE AND PROPELLER SHAFT - REAR AXLE
REAR AXLE
PRECAUTION
1. PRECAUTION ON MAITAINING FINAL DRIVE OIL.
(a) Be sure to use the specified final drive oil.
Final drive oil:
Viscosity
Type Grade Capacity
≤ 18 ℃ ＞ 18 ℃
Hypoid final drive oil GL-5 SAE 80W SAE 90W 1.6 L
(b) Be sure to replace the final drive oil regularly. (Refer to “Chapter 34 axle and propeller shaft - final drive
oil, replacement”)
• Replace with new final drive oil during the primal Level 2 maintenance.
• Replace with new final drive oil in the primal 40000 Km or 24 months.
• Replace with new final drive oil in the primal 80000 Km or 48 months. Then repeat this operation in
each following 50000 Km.
(c) Check regularly, at least every 4 times for Level 2 maitenances:
• Check the final drive oil for discolouration, thinning, etc.
If any fault is found, replace with new final drive oil. (Refer to “Chapter 34 axle and propeller shaft - final
drive oil, replacement”)
2. PRECAUTION ON MAINTAINING FINAL DRIVE ASSY.

(a) Be sure to check the vent plug regularly. Clean it when
necessary.
NOTE
• Remove and clean the vent plug during each Level1
maintenance.
• The stuffy vent plug may raise the oil pressure inside
the final drive assy, even cause leakage.
• Check the final drive oil level simultaneously.
(b) Disassemble and clean the final drive assy during the
Level 3 maintenance. Then assemble the final drive assy
according to the specification.
(c) Check the rear brake shoe and brake drum regularly for
wear and tear. (Refer to “Chapter 35 brake - rear brake,
on-vehilce inspection”)
AXLE AND PROPELLER SHAFT - REAR AXLE 34-49
3. SERVICING PRECAUTION ON FINAL DRIVE ASSY.

(a) Be sure to replace the mating parts as a set.
(b) Discard all removed rubber parts (O-rings, oil seal, grommet, etc. ).
(c) With the method of visual check, red lead, etc., check all parts carefully for faults below: 34
Uneven wear Eccentric wear Scratch Crack
Deformation Bend Loose Rusting
Invalidation or weakness Deterioration (Brake

Discolouration Abnormal noise (Bearing)
(Spring) shoes)
(d) When assembling the final drive assy, make sure all parts are clean without oil fouling and metal scrap.
Without special introduction, coat the final drive oil on the parts for lubrication before performing opera-
tions.
Final drive oil:
34
Viscosity
Type Grade Capacity
≤ 18 ℃ ＞ 18 ℃
4. PRECAUTION ON VEHICLE DRIVING.

(a) Never overload when driving vehicle.
(b) Never release the clutch pedal too quickly when driving vehicle.
CAUTION
Releasing the clutch pedal too quickly will strick the gear and cause damage.

Symptom Suspect area Reference

Continuous 1. Side pinion thrust washer (Worn) differential assy, overhaul
knocking
(Turning) Chapter 34 axle and propeller shaft -
2. Side pinion (Worn) differential assy, overhaul
1. Drive pinion, crown gear (Excessive back Chapter 34 axle and propeller shaft -
Continuous lash or worn) differential assy, inspection and adjustment
knocking
(At high speed) 2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
lash) differential assy, inspection and adjustment
1. Drive pinion, crown gear (Excessive back Chapter 34 axle and propeller shaft -
Continuous lash or worn) differential assy, inspection and adjustment
knocking
(Accelerating) 2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
lash) differential assy, inspection and adjustment
1. Axle shaft spline (Excessive back lash or Chapter 34 axle and propeller shaft - axle
worn) shaft assy, replacement
Intermittent
knocking 2. Drive pinion, crown gear (Excessive back Chapter 34 axle and propeller shaft -
(Running) lash or worn) differential assy, inspection and adjustment
Chapter 34 axle and propeller shaft - final

3. Final drive assy (Impurity entry) drive oil, replacement
Chapter 34 axle and propeller shaft - rear

1. Vent plug (Jam) axle, precaution

drive, on-vehicle inspection
2. Final drive oil level (High) Chapter 34 axle and propeller shaft - final
Leakage
(Final drive) drive oil, replacement

3. Bolts (Loose or worn) differential assy, overhaul

4. Final drive housing (Crack or fracture) drive, on-vehicle inspection

1. Final drive oil level (Low) drive oil, replacement
2. Drive pinion, crown gear (Undersize back Chapter 34 axle and propeller shaft -
Overheat lash) differential assy, inspection and adjustment
(Final drive)
Chapter 34 axle and propeller shaft - drive
3. differential bearing (Too tight) pinion, overhaul
4. Rear brake (Stuck) Chapter 35 brake - rear brake, overhaull

COMPONENTS
34
34
1 Oil Filler Plug 15 Rear Brake Assy
2 Gasket 16 Oil Catcher
3 Long Stud 17 Axle Hub
4 Spring Washer 18 Paper Gasket
5 Nut 19 Brake Drum
6 Short Stud 20 Hub Nut
7 Final Drive Assy 21 Hub Bolt
8 Axle Shaft 22 Bolt
9 Axle Shaft Oil Seal 23 O-seal Ring
10 Bearing Retainer Snap Ring 24 Spring Washer
11 Bearing Retainer 25 Nut
12 Bearing 26 Oil Drain Plug
13 Bearing Sleeve 27 Breather Plug
14 Oil Seal 28 Rear Axle Housing Welding Assy

1. INSPECT DRIVE AXLE BASH LASH.
(a) Park the vehicle on level road with applied parking brake.
(b) Shift in the neutral position.
(c) Lift rear wheels off the ground with jack or lift.
(d) Separate the propeller shaft assy from pinion flange.

• Mark on the rear propeller shaft U-joint and pinion flange.
NOTE
Make the marks are clear.
• Remove the 4 bolts.

NOTE
• Lower the propeller shaft and set it aside.

NOTE
Support the propeller shaft with a bracket.
(e) Measure the drive axle back lash.

• Rotate counterclockwise the pinion flange until it becomes
hard to rotate.
• Mark on the final drive housing and pinion flange.
NOTE
• Rotate clockwise the pinion flange until it becomes hard

to rotate.
• The distance between the 2 marks is the drive axle back
lash. 34
(f) Connect the propeller shaft to pinion flange.

• Position the propeller shaft properly according to the
marks.
NOTE
• Be sure to perform this operation according to the 34
marks.
• Align the marks by rotating the pinion flange when
necessary.
• Tighten the 4 bolts.

Torque: 20 N·m
NOTE
2. CHECK FINAL DRIVE OIL LEVEL.

(a) Using a wrench, remove the filler plug.
(b) Check the distance between the filler hole of final drive
and final drive oil level, distance is about 1 ～ 2mm.
CAUTION
• Higher and lower final drive oil level can cause prob-
lem.
• Fill or drain the final drive oil when necessary. (Refer
to “Chapter 34 axle and propeller shaft - final drive
(c) Using a wrench, install the filler plug.
3. INSPECT FINAL DRIVE HOUSING.

(a) Check the final drive housing for crack, leakage, etc. Replace it when necessary.
AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL 34-55
FINAL DRIVE OIL

REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - rear axle, precaution”) 34
2. DRAIN FINAL DRIVE OIL.

(a) Remove the vent plug.
34
(b) Using a wrench, remove the drain plug.

(c) Drain the final drive oil completely.
NOTE
Use a container for final drive oil when performing this operation.
(d) Using a wrench, install the drain plug.

34-56 AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL
3. FILL FINAL DRIVE OIL.

(a) Using a wrench, remove the filler plug.
(b) Fill the final drive oil.

Final drive oil:
Viscosity
Type Grade Capacity
≤ 18 ℃ ＞ 18 ℃
(c) Check the distance between the filler hole of final drive
and final drive oil level, distance is about 1 ～ 2mm.
CAUTION
• Higher and lower gear oil level can cause problem.
• Fill or drain the final drive oil when necessary. (Refer
to “Chapter 34 axle and propeller shaft - final drive
(d) Using a wrench, install the filler plug.

AXLE AND PROPELLER SHAFT - FINAL DRIVE OIL 34-57
(e) Install the vent plug.
34
34
34-58 AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY
AXLE SHAFT ASSY

OVERHAUL
1. REMOVE AXLE SHAFT ASSY LH.
(a) Remove the rear wheel assy LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
(b) Remove the rear axle hub LH. (Refer to “Chapter 34 axle and propeller shaft - axle hub, overhaul”)
(c) Using a SST, remove the rear axle hub LH and axle shaft
assy.
NOTE
• Discard rear wheel oil seal.
• Discard bearing retainer.
• Discard bearing retainer snap ring.
2. REMOVE AXLE SHAFT ASSY RH.

NOTE
3. INSPECTION AXLE SHAFT ASSY.

(a) Using V-block and dial indicator, measure the diameter
runout of the axle shaft assy and flange end face runout.
Diameter runout: ≤ 2.0 mm
End face runout: ≤ 0.2 mm
If the diameter runout and end face runout are out of the specifi-
cation, correct the axle shaft assy. Replace the new one if nec-
essary.
(b) Using magnetic testing method, inspect axle shaft

whether there is crack.
(c) Check the axle shaft splines for fracture, worn an
deformation.
If any fault is detected, replace with a new axle shaft assy.
AXLE AND PROPELLER SHAFT - AXLE SHAFT ASSY 34-59
4. INSTALL AXLE SHAFT ASSY LH.

(a) Install the rear axle hub LH. (Refer to “Chapter 34 axle
and propeller shaft - axle hub, overhaul”)
NOTE 34
• Insert the axle shaft assy and hub into the rear axle
housing together.
• Be sure to use a new bearing oil seal.
• Be sure to use a new bearing retainer.
• Be sure to use a new bearing retainer snap ring.
(b) Inspect the rear wheel hub. (Refer to “Chapter 34 axle

and propeller shaft - steering knuckle, on-vehicle
inspection”)
5. INSTALL AXLE SHAFT ASSY RH.
NOTE 34
6. BRAKE FLUID REFILL AND BLEEDING. (Refer to “Chapter 35 brake system - brake fluid, bleed-
ing”)
34-60 AXLE AND PROPELLER SHAFT - REAR AXLE HOUSING WELDING ASSEMBLY
REAR AXLE HOUSING WELDING ASSEMBLY

OVERHAUL
1. PRECAUTION. (Refer to “Chapter 34 axle and propeller shaft - rear axle, precaution”)
2. DRAIN FINAL DRIVE OIL. (Rrefer to “Chapter 34 axle propeller shaft - final drive oil, replace-
ment”)
3. REMOVE REAR BRAKE LINES AND PARKING CABLE.

NOTE
Before removing rear brake lines, operate brake bleeding
firstly.
(a) Loosen brake line LH connector nut and remove bolts.
(b) Remove middle brake line bolts and praking cable nut.
NOTE
Make sure to prevent the brake lines from deformation.
(c) Loosen brake line RH bolts and remove parking cable

bracket bolts.
NOTE
(d) Loosen brake line RH connector nut.

NOTE
Make sure to prevent brake lines from deformation.
(e) Remove rear brake lines.

NOTE
AXLE AND PROPELLER SHAFT - REAR AXLE HOUSING WELDING ASSEMBLY 34-61
(f) Remove the 2 bolts, separate valve from rear axle hous-
ing.
34
4. REMOVE AXLE SHAFT ASSY LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - axle
5. REMOVE MAIN DIFFERENTIAL.

(a) Separate the propeller shaft assy from pinion flange.
• Mark on the rear propeller shaft U-joint and pinion flange. 34
NOTE
(b) Remove the 4 bolts.

NOTE
(c) Lower the propeller shaft and set it aside.

NOTE
(d) Remove nuts and the final drive assy.

NOTE
6. REMOVE REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy,
overhaul”)
7. Remove the rear axle welding housing assy.

NOTE
8. INSPECT THE REAR HOUSING ASSY.

(a) Check rear axle welding housing for surface crack and oil leakage, replace it if nessary.
9. Install rear axle welding housing assy.

NOTE
Support the housing with a bracket.
10. INSTALL REAR SUSPENSION. (Refer to “Chapter 32 rear suspension - rear leaf spring assy,
overhaul”)
11. INSTALL MAIN DIFFERENTIAL.

(a) Tighten nuts and install the final drive assy.
NOTE
AXLE AND PROPELLER SHAFT - REAR AXLE HOUSING WELDING ASSEMBLY 34-63
(b) Install the propeller shaft properly according to the

marks.
NOTE
Support the propeller shaft with a bracket. 34
(c) Tighten the 4 nuts.

Torque: 20 N·m
NOTE
34
12. INSTALL AXLE SHAFT ASSY LH AND RH. (Refer to “Chapter 34 axle and propeller shaft - axle
13. INSTALL REAR BRAKE LINES AND PARKING CABLE.

(a) Tighten the 2 bolts and connect valve to rear axle housing.
(b) Install brake line RH connector nut.

NOTE
(c) Install brake line RH bolts and tighten parking cable

bracket bolts.
NOTE
(d) Install middle brake line bolts and praking cable nut.
NOTE
(e) Install brake line LH connector nut and tighten bolts.

NOTE
14. FILL BRAKE FLUID. (Refer to “Chapter 35 brake system - brake fluid, bleeding”)
15. FILL THE FINAL DRIVE OIL. (refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
AXLE AND PROPELLER SHAFT - DIFFERENTIAL ASSY 34-65
DIFFERENTIAL ASSY
COMPONENTS
34
34
1 Bolt 15 Nut
2 Lock Plate Pressure Bolt 16 Final Drive Housing
3 Spring Washer 17 Drive Pinion Gear
4 Lock Plate 18 Differential Housing
5 Differential Bearing Cap 19 Washer
6 Differential Bearing Adjusting Nut 20 Drive Axle Side Gear
7 Differential Bearing 21 Washer
8 Shim 22 Differential Pinion
9 Drive Pinion Gear Inner Bearing 23 Shaft Locking Pin
10 Bearing Spacer Sleeve 24 Differential Pinion Shaft
11 Drive Pinion Gear Outer Bearing 25 Bolt
12 Oil Slinger 26 Crown Gear Lock Plate
13 Oil Seal 27 Crown Gear
14 Pinion Flange
34-66 AXLE AND PROPELLER SHAFT - DIFFERENTIAL ASSY
INSPECTION AND ADJUSTMENT

1. INSPECT CROWN GEAR DEVIATION.
(a) Rotate the crown gear with hands.
(b) Using dial indicator, measure the deviation at the surface
mating with differential case along the edge.
If the deviation is out of the specification, replace with a new
crown gear. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, overhaul”)
2. INSPECT CROWN GEAR BACK LASH.

(a) Rotate the crown gear counterclockwise and clockwise
with hands lightly.
(b) Using dial indicator, measure the back lash.
Back lash: 0.13 ～ 0.18 mm
If the back lash is out of the specification, check the contact area
between drive pinion and crown gear. Perform adjustment pro-
cedures if necessary. (Refer to “Chapter 34 axle and propeller
shaft - differential assy, inspection and adjustment”)
NOTE
• Measure the back lash at 4 points distributed uniformly
on the circumference.
• Make sure the dial indicator is perpendicular to the tooth
surface.
3. INSPECT CONTACT AREA.

(a) Apply red lead to 3 ～ 4 teeth of 3 different positions on
the crown gear.
(b) Rotate the crown gear counterclockwise and clockwise
several turns.
(c) Check the red area.
Locate: center of the tooth surface, the distance
away from small end ≥ 2 mm
Length：≥ 60% tooth length
Width：≥ 60% tooth width
If the red area is out of the specification, adjust differential
bearing adjusting nut and replace drive pinion adjusting shim
when necessary. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, inspection and adjustment”, “Chapter 34 axle
and propeller shaft - drive pinion, overhaul”)
4. ADJUST CONTACT AREA.
Contact area Causation Measures

34
Normal No need adjust
Lateral clearance small

Distance between drive pinion and
crown gear is too close (loose left, adjust right adjustment
nut)
Lateral clearance large

crown gear is too far (loose right, adjust left adjustment
nut)
34
Crown gear contact surface is too
crown gear is too far
high
(reduce shim thickness)

Crown gear contact surface is too
crown gear is too close
low
(increase shim thickness)
NOTE
• Adjust the differential bearing adjusting nut. (Refer to “Chapter 34 axle and propeller shaft -
differential assy, inspection and adjustment”)
• Adjust the drive pinion. (Replace the drive pinion adjusting shim. Refer to “Chapter 34 axle and
propeller shaft - drive pinion, overhaul”)
• Check the contact area again. Perform adjustment when necessary until the contact area is within
the specification.
5. INSPECT DRIVE AXLE SIDE GEAR AND PINION BACK

LASH.
(a) Using dial indicator, measure the back lash at the center
of tooth surface.
If the back lash is out of the specification, inspect the drive axle
side gear clearance. (Refer to “Chapter 34 axle and propeller
NOTE
• Make the drive axle side gears and pinions close to
the differential case and secure one of the gears.
• Make sure the dial indicator is perpendicular to the tooth
surface.
• Perform this operation on 3 points of each gear.
6. INSPECT DRIVE AXLE SIDE GEAR CLEARANCE.

(a) Using feeler gauge, measure the drive axle side gear
clearance.
Drive axle side gear clearance: 0 ～ 0.15 mm
NOTE
• The drive axle side gear clearance of both sides should
be the same.
• If the drive axle side gear clearance is out of the
specification and if there is abnormal noise when turning,
disassemble the diffterential assy and replace with new
thrust washers of drive axle side gear and pinion. (Refer
to “Chpater 34 axle and propeller shaft - differential assy,
overhaul”)
• If the drive axle side gear clearance is within the
specification and if there is no abnormal noise when
turning, disassembling the differential assy is not
required.
7. ADJUST DIFFERENTIAL BEARING ADJUSTING NUT.

(a) Remove the bolt and bearing cap adjusting nut lock
plate.
(b) Using spring, measure crown gear turn up power.

Turn up power: 0.7 ~ 1.6 N·m
If the measurment value is out of specification, adjust differential
bearing adjusting nut.
(c) Using differential wrench, adjust bearing adjusting nut

and make sure both sides of adjusting nut are at the
same angle to avoid the vaule of crown gear back lash
changing.
(d) Measure the crown gear turn up power again, repeat

step (b) and (c) if nessary.
NOTE
After adjusting, make sure crown gear is without axial runout. 34
(e) Install bearing cap adjusting nut lock plate and tighten it.
34
OVERHAUL
2. DRAIN FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
3. REMOVE FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - rear axle welding
housing, overhaul”)
4. REMOVE DIFFERENTIAL BEARING CAP.

(a) Mark on the final drive housing and differential bearing cap.
(b) Mark on tne differential bearing adjusting nut and differ-
ential bearing cap.
(c) Remove bolt and bearing cap adjusting nut lock plate.
(d) Using differential wrench, remove the differential bearing

adjusting nut.
NOTE
Before this procedure, make sure to loosen the bearing cap
bolts.
(e) Remove the 2 bolts and differential bearing caps.

NOTE
Store the each side of bearing cap at different place, use a
tag to separate right and left bearing caps.
5. REMOVE DIFFERENTIAL ASSY.

(a) Using copper rod and lift, hang the differential assy, remove
the differential assy from housing.
34
(b) Remove the 2 differential bearing caps.

NOTE
• Store the differential bearing caps carefully.
• Use a tag to record right and left bearing caps.
34
6. Remove crown gear.

(a) Release the 5 lock plates.

(c) Remove the 5 lock plates.
(d) Remove the crown gear.

LASH.
of tooth surface.
NOTE
• Make the drive axle side gears and pinions be close
to the differential case and secure one of the gears.
• Make sure the dial indicator is perpendicular to the
tooth surface.

clearance.
NOTE
• The drive axle side gear clearance of both sides should
be the same.
• If the drive axle side gear clearance is out of the

specification and if there is abnormal noise when turning,
disassemble the diffterential assy and replace with new
thrust washers of drive axle side gear and pinion. (Refer 34
to “Chpater 34 axle and propeller shaft - differential assy,
overhaul”)
• If the drive axle side gear clearance is within the
specification and if there is no abnormal noise when
turning, disassembling the differential assy is not
required.
9. DISASSEMBLE DIFFERENTIAL ASSY.

(a) Using hammer and copper rod, remove the pinion shaft
retainer.
CAUTION
Discard the removed pinion shaft retainer. 34
(b) Using hammer and copper rod, remove the pinion shaft.
(c) Remove the drive axle side gear, differential pinion and
thrust washer.
NOTE
• Store the gears and washers carefully.
• Use a tag to record right / left and upper / lower wash-
ers.
(d) Using vice and dial indicator, measure the radial clearance
between differential pinion and pinion shaft.
If the clearance is out of the specification, check the differential
pinion and pinion shaft for wear and tear. Replace with new parts
when necessary. (Refer to “Chapter 34 axle and propeller shaft -
CAUTION
Do not clamp the pinion shaft without any wrap with the
vice directly.
(e) Using vice and dial indicator, measure the radial clearance
between drive axle side gear and differential case.
If the clearance is out of the specification, check the differential
case and gear for wear and tear. Replace with new parts when
necessary. (Refer to “Chapter 34 axle and propeller shaft -
(f) Using vice and dial indicator, measure the output flange
back lash.
If the back lash is out of the specification, check the drive axle
side gear and output flange for wear and tear. Replace with new
parts when necessary. (Refer to “Chapter 34 axle and propeller
shaft - differential assy, overhaul”)
CAUTION
Do not clamp the output flange without any wrap with the
vice directly.
(g) Measure the thrust washer thickness of drive axle side

gear and pinion.
Thickness:
Thickness
Thrust washer
Standard
Drive axle side gear 0.6 mm
1.6 mm
Differential pinion 1.7 mm
1.8 mm
(h) If the thickness is out of the specification, replace with new

thrust washers of drive axle side gear and pinion. (Refer to
“Chapter 34 axle and propeller shaft - differential assy,
overhaul”)
NOTE
Be sure to select the correct drive axle side gear thrust
washer according to the colour marks on the drive axle side
gear.
10. REMOVE DIFFERENTIAL BEARING.

(a) Using a puller, remove the 2 differential bearings from the
differential case.
NOTE
• Be sure to store the removed differential bearing by
right and left with bearing cap together.
• Store the left and right part at different place.
11. INSTALL DIFFERENTIAL BEARING.

(a) Install the 2 differential bearings to the differential case.
NOTE
Be sure to perform this operation according to the tag.
34
12. REASSEMBLE DIFFERENTIAL ASSY.

(a) Install the drive axle side gear, differential pinion and
thrust washer.
NOTE
• Be sure to perform this operation according to the 34
tag.
• Be sure to select the correct drive axle side gear
washer according to the colour marks on the drive
axle side gear when replacing with new parts.
• Do not install more than a thrust washer at each side.
(b) Using hammer and copper rod, install the pinion shaft.
(c) Using hammer and copper rod, install the pinion shaft
retainer.
NOTE
Be sure to use a new pinion shaft retainer.

LASH.
of tooth surface.
NOTE
• Make the drive axle side gears and pinions be close
to the differential case and secure one of the gears.
• Make sure the dial indicator is perpendicular to the
tooth surface.

clearance.
NOTE
The drive axle side gear clearance of both sides should be
the same.
15. INSTALL CROWN GEAR.

(a) Check the tooth surface for wear and tear. Perform repairing or replacement when necessary. (Refer to
“Chapter 34 axle and propeller shaft - differential assy, overhaul”)
CAUTION
Be sure to replace with new drive pinion and crown gear together at the same time.
NOTE
• Repair it when there is only micro-crack on the tooth surface.
• Replace it when there is scoring, spalling, rusting, fracture or excessive wear on the tooth
surface.
(b) Position the crown gear properly.
(c) Position the 5 lock plates properly.
34
34
(d) Coat the sealant on the 10 bolts.
(e) Tighten the 10 bolts by the sequence shown in the illustration.
(f) Apply the 5 lock plates to “LOCK”.

(g) Install the 2 differential bearing caps properly.

NOTE
Be sure to perform this operation according to the tag.
16. INSTALL DIFFERENTIAL ASSY.

(a) Using copper rod and lift, hang the differential assy,
install the differential assy into the housing.
17. INSTALL BEARING CAP.

(a) Coat the gear oil on bearing outer and inside ring.
(b) Put the bearing cap on differential housing freely and properly, insert bearing adjusting nut into the
mounting position with hands.
NOTE
Make sure this operation is according to the marks.
Install the bearing adjusting nut and do not tighten it.
(c) Tighten the 2 bearing cap bolts and fix the bearing caps.
(d) Using differential wrench, tighten the adjusting nut.

18. ADJUST THE BEARNING ADJUSTING NUT. (Refer to “Chapter 34 axle and propeller shaft,
inspection and adjustment”)
19. INSPECT CROWN GEAR DEVIATION.
20. INSPECT CROWN GEAR BACK LASH. 34
21. INSPECT CONTACT AREA. (Refer to “Chapter 34 axle and propeller shaft - differential assy,
inspection and adjustment”)
22. INSTALL FINAL DRIVE ASSY. (Refer to “Chapter 34 axle and propeller shaft - final drive assy,
replacement”)
23. FILL FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil, replacement”)
34
34-80 AXLE AND PROPELLER SHAFT - DRIVE PINION
DRIVE PINION
COMPONENTS
1 Drive Pinion Gear 6 Oil Slinger
2 Adjusting Shim 7 Oil Seal
3 Inner Bearing 8 Pinion Flange
4 Bearing Spacer Sleeve 9 Nut
5 Outer Bearing
AXLE AND PROPELLER SHAFT - DRIVE PINION 34-81
INSPECTION
1. INSPECT PINION FLANGE.
(a) Using dial indicator, measure the pinion flange back lash.
34
If the back lash is out of the specification, replace with new
pinion inner and outer bearing and collapsible spacer. (Refer to
“Chapter 34 axle and propeller shaft - drive pinion, overhaul”)
34
(b) Using dial indicator, measure the pinion flange deviation.

pinion flange. (Refer to “Chapter 34 axle and propeller shaft -
drive pinion, overhaul”)
2. INSPECT PRELOAD.
(a) Pry the lock plate out.
(b) Loosen the pinion nut.
(c) Tighten the pinion nut.

Torque: 196 N·m
(d) Using a torque wrench, measure the primal rotating force

of drive pinion.
Primal rotating force: 1.3 ～ 2.2 N·m
WARNING
Never loosen the pinion nut to reduce the primal rotating
force of drive pinion.
NOTE
• If the primal rotating force is more than the specification,
replace with a new collapsible spacer. (Refer to “Chapter
34 axle and propeller shaft - drive pinion, overhaul”)
• If the primal rotating force is less than the specification,
perform the following operations.
(e) Tighten the pinion nut further.

Torque (Increment): 13 N·m
Torque (Maximum): 343 N·m
(f) Using a torque wrench, measure the primal rotating force

of drive pinion again.
NOTE
• If the primal rotating force is still less than the
specification, repeat step (e) ～ (f) until the primal
rotating force is within the specification.
specification when the pinion nut retaining torque
exceeds the maximum, replace with a new collapsible
spacer. (Refer to “Chapter 34 axle and propeller shaft
- drive pinion, overhaul”)
(g) Fold the lock plate up.
34
34
OVERHAUL
2. DRAIN FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil,
replacement”)
3. REMOVE DRIVE PINION.

(a) Pry the lock plate out.
(b) Remove the pinion nut.
(c) Mark on the pinion flange and final drive housing.

NOTE
(d) Using a puller, pull the pinion flange out.

(e) Remove the oil seal.

NOTE
Discard the removed oil seal.
(f) Remove the washer.
34
(g) Remove the pinion outer bearing.
34
(h) Remove final drive assy. (Refer to “Chapter 34 axle and

propeller shaft - final drive assy, replacement”)
(i) Remove the differential assy. (Refer to “Chapter 34 axle
and propeller shaft - differential assy, overhaul”)
(j) Remove the drive pinion.
(k) Remove the collapsible spacer.
(l) Using puller, loosen inner bearing.

(m) Remove the pinion inner bearing.
(n) Remove the drive pinion adjusting shim.
(o) Using hammer and copper rod, remove the pinion inner
and outer bearing caps inside the final drive housing.
4. INSPECT DRIVE PINION.
(a) Check tooth surface of the drive pinion for wear and tear, repair or replace it when necessary. (Refer to
“Chapter 34 axle and propeller shaft - differential assy, overhaul.”)
CAUTION
Be sure to replace with new drive pinion and crown gear together at the same time.
NOTE
• Repair it when there is only micro-crack on the tooth surface.
• Replace it when there is scoring, spalling, rusting, fracture or excessive wear on the tooth
surface.
(b) Check journal of the drive pinion for wear and tear.
If excessive wear is found, replace with new drive pinion and crown gear.
5. INSTALL DRIVE PINION.
(a) Using hammer and copper rod, install the pinion inner and outer bearing cap into the final drive
housing.
(b) Replace new drive pinion adjusting shims.

Specification: 0.1mm, 0.25mm Added total thickness
is within 1.25 ～ 2mm
Replace with new drive pinion adjusting shims，make sure contact
area of differential is within specification. (Refer to “Chapter 34 axle
and propeller shaft - differential assy, inspection and adjustment”)
(c) Install the drive pinion adjusting shim.
(d) Install the pinion inner bearing.
34
(e) Install the collapsible spacer.
34
(f) Insert the drive pinion into the final drive housing.
(g) Install the differential assy. (Refer to “Chapter 34 axle
and propeller shaft - differential assy, overhaul”)
(h) Inspect contact area. (Refer to “Chapter 34 axle and
propeller shaft - differentila assy, inspection and adjustment”)
(i) Inspect crown gear back lash.
(j) Install final drive assy. (Refer to “Chapter 34 axle and
propeller shaft - rear axle housing welding assy, overhaul”)
(k) Install the pinion outer bearing.
(l) Install the washer.
(m) Coat the grease on the oil seal lip.

(n) Coat the sealant on the outer surface of oil seal.
(o) Coat the grease on the inner surface of oil seal.
NOTE
Be sure to use a new oil seal.
(p) Install the oil seal.
(q) Install the pinion flange according to the marks.

NOTE
Be sure to perform this operation according to the marks.
(r) Tighten the pinion nut.

Torque: 196 N·m
(s) Using a torque wrench, measure the primal rotating force

of drive pinion.
WARNING
Never loosen the pinion nut to reduce the primal rotating
force of drive pinion.
NOTE
• If the primal rotating force is more than the specification,
replace with a new collapsible spacer. (Refer to “Chapter
34 axle and propeller shaft - drive pinion, overhaul”)
• If the primal rotating force is less than the specification,
perform the following operations.
(t) Tighten the pinion nut further.

Torque (Increment): 13 N·m
Torque (Maximum): 343 N·m
34
(u) Using a torque wrench, measure the primal rotating force

of drive pinion again.
NOTE
• If the primal rotating force is still less than the 34
specification, repeat step (e) ～ (f) until the primal
rotating force is within the specification.
specification when the pinion nut retaining torque
exceeds the maximum, replace with a new collapsible
spacer. (Refer to “Chapter 34 axle and propeller shaft -
(v) Fold the lock plate up.

6. INSPECT PINION FLANGE.

(a) Using dial indicator, measure the pinion flange back lash.
If the back lash is out of the specification, replace with new
pinion inner and outer bearing and collapsible spacer. (Refer to
“Chapter 34 axle and propeller shaft - drive pinion, overhaul”)
(b) Using dial indicator, measure the pinion flange deviation.

pinion flange. (Refer to “Chapter 34 axle and propeller shaft -
7. FILL FINAL DRIVE OIL. (Refer to “Chapter 34 axle and propeller shaft - final drive oil, replacement”)
BRAKE
35
BRAKE SYSTEM ............................................................................... 35-1
PRECAUTION.............................................................................. 35-1
BRAKE FLUID.................................................................................... 35-4 35
BLEEDING ................................................................................... 35-4
BRAKE PEDAL .................................................................................. 35-6
ADJUSTMENT ............................................................................. 35-6
REPLACEMENT .......................................................................... 35-8 35
BRAKE MASTER CYLINDER ASSY............................................... 35-10
COMPONENTS ......................................................................... 35-10
OVERHAUL ............................................................................... 35-11
BRAKE VACUUM BOOSTER ASSY............................................... 35-15
REPLACEMENT ........................................................................ 35-16
35
FRONT BRAKE................................................................................ 35-19
COMPONENTS ......................................................................... 35-19
OVERHAUL ............................................................................... 35-20
REAR BRAKE .................................................................................. 35-30
COMPONENTS ......................................................................... 35-30
OVERHAUL ............................................................................... 35-32
LOAD SENSING PROPORTIONING AND BY- PASS
VALVE(LSP&BV) ............................................................................. 35-42
COMPONENTS ......................................................................... 35-42
ADJUSTMENT ........................................................................... 35-43
REPLACEMENT ........................................................................ 35-44
HYDRAULIC PRESSURE REGULATOR ........................................ 35-48
REPLACEMENT ........................................................................ 35-48
VEHICLE SPEED SENSOR ............................................................. 35-50
REPLACEMENT ........................................................................ 35-50
BRAKE - BRAKE SYSTEM 35-1
BRAKE SYSTEM
BRAKE
PRECAUTION
1. BRAKE SYSTEM PRECAUTION. 35
(a) Care must be taken to replace each part properly, because it could affect the performance of the brake
system and result in a driving hazard, replace with the parts which have the same part number or
equivalent.
(b) It is very important to keep parts and the area clean when repairing the brake system.
(c) To avoid spreading brake dust, do not clean any brake components with sand paper, dry brush and
compressed air. only use a water dampende towel to clean brake components.
35
35-2 BRAKE - BRAKE SYSTEM

1. Brake fluid (Lacking) Chapter 35 brake - brake fluid, bleeding
2. Brake system (Leaking) -
3. Brake pad (Worn) Chapter 35 brake - front brake, overhaul

Low pedal or spongy pedal
4. Brake master cylinder assy Chapter 35 brake - brake master cylinder
(Failure) assy, overhau
5. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding
6. Brake caliper (Failure) Chapter 35 brake - front brake, overhaul
1. Brake system (Air in system) -
2. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul
3. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul

Brake drag Chapter 34 axle and propeller shaft -
4. Axle hub bearing (Loose) wheel axle hub assy and front axle assy,
on vehicle inspection
5. Brake pedal free play (Out of Chapter 35 brake - brake pedal,

adjustment) adjustment
Chapter 33 tire and wheel - tire and

1. Tire (Improperly inflated) wheel system, on vehicle inspection
2. Brake shoe (Oily) -
3. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul
4. Brake pad (Oily) -
Pull to one side 5. Brake pad (Worn) Chapter 35 brake - front brake, overhaul
6. Disk (Warped) Chapter 35 brake - front brake, overhaul
7. Brake drum (Warped) Chapter 35 brake - front brake, overhaul
8. Brake caliper (Brake force unequal) Chapter 35 brake - front brake, overhaul
9. Brake cylinder (Brake force Chapter 35 brake - rear brake, overhaul

unequal)
2. Brake caliper (Bolt loose) Chapter 35 brake - front brake, overhaul
Braking instability 3. Brake caliper mounting (Bolt loose) Chapter 35 brake - front brake, overhaul
4. Brake caliper (Sticking) Chapter 35 brake - front brake, overhaul
5. Brake cylinder (Sticking) Chapter 35 brake - rear brake, overhaul

BRAKE - BRAKE SYSTEM 35-3
Lack of braking force 2. Brake shoe (Worn) Chapter 35 brake - rear brake, overhaul 35
3. Brake system (Air in system) Chapter 35 brake - brake fluid, bleeding
35
35-4 BRAKE - BRAKE FLUID
BRAKE FLUID
BLEEDING
NOTE
• If any work is done on the brake system or if air in the brake line is suspected, bleed the air from
the system.
• Brake fluid damages painted surfaces and irritates skin. If brake fluid is spilled on any painted
surfaces or skin, wash it off immediately with water.
1. FILL THE FLUID RESERVOIR WITH BRAKE FLUID.

Brake fluid: DOT3
NOTE
Brake fluid damage painted surfaces and irritate skin. If
brake fluid is spilled on any painted surfaces or skin, wash
it off immediately with water.
2. BLEED BRAKE MASTER CYLINDER ASSY.

(a) Disconnect the 2 brake lines from the brake master
cylinder.
NOTE
If the brake cylinder has been removed or if the brake fluid
reservoir assy becomes empty, bleed the air from the master
cylinder assy.
(b) Rapidly depress the brake pedal and hold it.
(c) Block off the outer holes with fingers, and release the brake
pedal.
(d) Repeat steps (b) and (c) 3 or 4 times until all the air in the
fluid has been bled out.
BRAKE - BRAKE FLUID 35-5
3. BLEED BRAKE LINE.

(a) Connect the hose to the bleeder plug of rear wheel brake
cylinder.
(b) Rapidly depress the brake pedal several times, then 35
loosen the bleeder plug.
(c) When brake fluid stops flowing, tighten the bleeder plug,
then release the brake pedal.
Torque: 4 ~ 6 N•m
(d) Repeat steps (b) and (c) 3 or 4 times until all the air in the
(e) Connect the hose to the bleeder plug of front disk brake
caliper.
35
(f) Rapidly depress the brake pedal several times, then
loosen the bleeder plug.
(g) When brake fluid stops flowing, tighten the bleeder plug,
then release the brake pedal.
Torque: 4 ~ 6 N•m
(h) Repeat steps (f) and (g) 3 or 4 times until all the air in the
(i) Repeat the above procedures to bleed the air out of the
brake line for each wheel.
NOTE
SEQUENCE OF BRAKE LINE BLEEDING: REAR LH - REAR
RH - FRONT RH - FRONT LH
4. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with brake
fluid if necessary.
35-6 BRAKE - BRAKE PEDAL
BRAKE PEDAL
ADJUSTMENT
1. INSPECT BRAKE PEDAL HEIGHT.
(a) Inspect the height between brake pedal and floor H.
Specification: 150 ~ 155 mm
2. ADJUST BRAKE PEDAL HEIGHT.

(a) Remove the stop lamp switch. (Refer to “Chapter 35 brake - brake pedal, replacement”)
(b) Disconnect the push rod from the brake pedal. (Refer to “Chapter 35 brake - brake pedal, replacement”)
(c) Loosen the lock nut, then adjust the brake pedal by
truning the push rod clevis. Tighten the lock nut after
adjusting.
(d) Connect the push rod to the brake pedal. (Refer to

“Chapter 35 brake - brake pedal, replacement”)
(e) Install stop lamp switch. (Refer to “Chapter 35 brake -
brake pedal, replacement”)
(f) Push the brake pedal down about 5 ~ 10 mm and turn
the stop lamp switch in the position where the stop lamp
goes off, then tighten the lock nut.
(g) After installation, check that stop lamp comes on when
depressing the brake pedal about 5 ~ 10 mm.
BRAKE - BRAKE PEDAL 35-7
3. INSPECT BRAKE PEDAL FREE PLAY.

(a) Stop the engine and depress the brake pedal several
times until there is no more vacuum left in the vacuum
booster. 35
(b) Depress the brake pedal until the pedal resistance begins
to be felt, then inspect the brake pedal free play L.
(c) Measure the brake pedal free play
Specification: 1 ~ 3 mm
35
35-8 BRAKE - BRAKE PEDAL
REPLACEMENT
1. REMOVE STOP LAMP SWITCH.
(a) Disconnect the connector from stop lamp switch.
(b) Loosen the lock nut from stop lamp switch.

(c) Remove the stop lamp switch.
2. DISCONNECT THE CONNECTION BETWEEN PUSH

ROD CLEVIS AND BRAKE PEDAL.
(a) Remove the pin roll and split pin then disconnect the
push rod clevis from brake pedal.
3. REMOVE BRAKE PEDAL.

(a) Remove the pin roll, shaft sleeve and return spring.
(b) Remove the brake pedal.
4. INSTALL BRAKE PEDAL AND INSTALL RETURN SPRING, SHAFT SLEEVE AND PIN ROLL.
BRAKE - BRAKE PEDAL 35-9
5. CONNECT PUSH ROD CLEVIS TO BRAKE PEDAL.

(a) Install the pin roll and split pin
35
6. INSTALL STOP LAMP SWITCH.

(a) Install the stop lamp switch and tighten the lock nut of
stop lamp switch.
35
(b) Connect the connector to stop lamp switch.
(c) Adjust the distance between stop lamp and brake pedal.
(Refer to “Chapter 35 brake - brake pedal, adjustment”)
7. INSPECT AND ADJUST BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal,
adjustment”)
8. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, adjustment”)
35-10 BRAKE - BRAKE MASTER CYLINDER ASSY
BRAKE MASTER CYLINDER ASSY

COMPONENTS
1 Brake Master Cylinder Assy 4 Snap Ring
2 Washer 5 Spring
3 Limiting Bolt 6 Piston

BRAKE - BRAKE MASTER CYLINDER ASSY 35-11
OVERHAUL
1. DRAIN BRAKE FLUID COMPLETELY.
NOTE 35
Brake fluid damages painted surfaces and irritates skin. If brake fluid is spilled on any painted surfaces
or skin, wash it off immediately with water.
2. REMOVE DASHBOARD ASSY AND VENT DUCT LH. (Refer to “Chapter 83 instrument panel -
dashboard,replacement”)
3. REMOVE BRAKE MASTER CYLINDER ASSY.

(a) Remove the 2 clamps and disconnect 2 hoses from brake
master cylinder.
35
(b) Loosen the 2 nuts and disconnect the 2 tubes from brake
master cylinder.
(c) Looen 4 nuts and remove brake master cylinder assy.
4. DISASSEMBLE BRAKE MASTER CYLINDER ASSY.

(a) Fix the brake master cylinder with a bench vice. While
pushing the push rod, using snap ring plier, remove the
snap ring and washer.
(b) Remove the limiting bolt and washer.
(c) Pull out the 2 pistons and springs horizontally.

NOTE
Be careful not to damage the inside of the cylinder body.
Please remove the piston parellel to the cylinder body.
5. CHECK BRAKE MASTER CYLINDER.

(a) Check the cylinder inside for rust or scoring.
6. CLEAR UP EACH PART OF BRAKE MASTER CYLINDER ASSY AND REPLACE ALL
THE SEALING ELEMENT.
7. ASSEMBLE BRAKE MASTER CYLINDER ASSY.
(a) Fix the brake master cylinder with a bench vice. Apply
grease to the piston and install pistons and springs.
NOTE
Please install the piston parellel to the cylinder body.
(b) Push the push rod, using snap ring plier, install the snap
ring and washer.
BRAKE - BRAKE MASTER CYLINDER ASSY 35-13
(c) Install the limiting bolt and washer.
35
8. INSTALL BRAKE MASTER CYLINDER ASSY.

(a) Install brake master cylinder assy and tighten 4 nuts.
NOTE
Before installation, fill the brake master cylinder with brake
fluid.
35
(b) Connect the 2 tubes to brake master cylinder and tighten

the 2 nuts.
(c) Connect the 2 hoses to brake master cylinder and Install

the 2 clamps
9. INSTALL DASHBOARD ASSY AND VENT DUCT LH. (Refer to “Chapter 83 instrument panel -
10. FILL THE FLUID RESERVOIR WITH BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid, bleeding”)
11. BLEED BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake fluid, bleeding”)
12. BLEED BRAKE LINE. (Refer to “Chapter 35 brake - brake fluid, bleeding”)
14. CHECK BRAKE FLUID FOR LEAKING.
BRAKE - BRAKE VACUUM BOOSTER ASSY 35-15
BRAKE VACUUM BOOSTER ASSY

35
1. INSPECT BRAKE VACUUM BOOSTER FOR AIR
TIGHTNESS.
(a) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
NOTE
If the pedal goes down farthest at the 1st time, but gradually
rises after the 2nd or 3rd time, the booster is operating
properly.
(b) Depress the brake pedal while the engine is running, and
stop the engine with the pedal depressed.
NOTE
If there is no change in the pedal reserve distance after 35
holding the pedal for 30 seconds, the booster is operating
properly.
2. OPERATION CHECK.
(a) Turn the ignition switch LOCK and then depress the
brake pedal several times. Check that there is no change
in the pedal reserve distance.
(b) Depress the pedal and start the engine.
NOTE
If the pedal goes down slightly, the booster is operating
properly.
3. INSPECT VACUUM CHECK VALVE.

(a) Remove the clamp and disconnect the vacuum hose
from check valve.
(b) Remove the vacuum check valve.
(c) Check that there is ventilation from the booster to engine,

and no ventilation from the engine to the booster. If any
fault is found, replace with a new check valve.
35-16 BRAKE - BRAKE VACUUM BOOSTER ASSY
REPLACEMENT
3. REMOVE STOP LAMP SWITCH. (Refer to “Chapter 35 brake - brake pedal, replacement”)
NOTE
If brake fluid is spilled on any painted surfaces or skin, wash it off immediately with water.
4. REMOVE CLAMP AND DISCONNECT VACUUM HOSE FROM CHECK VALVE.
5. REMOVE BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake master
cylinder assy, overhaul”)
6. LOOSEN 3 BOLTS AND REMOVE ACCELERATOR

PEDAL.
7. REMOVE BRAKE VACUUM BOOSTER ASSY.

(a) Disconnect the connection between push rod clevis and brake pedal. (Refer to “Chapter 35 brake -
brake pedal, replacement”)
(b) Loosen the 4 nuts.

BRAKE - BRAKE VACUUM BOOSTER ASSY 35-17
(c) Remove the brake vacuum booster assy.
35
8. INSTALL BRAKE VACUUM BOOSTER ASSY.

(a) Install the brake vacuum booster assy and tighten the 4
nuts.
35
(b) Connect the push rod clevis to the brake pedal. (Refer to
“Chapter 35 brake - brake pedal, replacement”)
9. INSTALL ACCELERATOR PEDAL AND TIGHTEN THE

3 BOLTS.
10. INSTALL BRAKE MASTER CYLINDER ASSY. (Refer to “Chapter 35 brake - brake master
cylinder assy, overhaul”)
11. CONNECT VACUUM HOSE TO CHECK VALVE AND INSTALL CLAMP.
13. INSTALL STOP LAMP SWITCH. (Refer to “Chapter 35 brake - brake pedal, replacement”)
17. INSPECT BRAKE PEDAL HEIGHT. (Refer to “Chapter 35 brake - brake pedal, replacement”)
18. INSPECT BRAKE PEDAL FREE PLAY. (Refer to “Chapter 35 brake - brake pedal, replacement”)
35-18 BRAKE - BRAKE VACUUM BOOSTER ASSY

BRAKE - FRONT BRAKE 35-19
FRONT BRAKE
COMPONENTS
35
35
1 Brake Tube 9 Bolt
2 Plug 10 Front Brake Disk
3 Washer 11 Front Axle Hub Washer
4 Front Disk Brake Caliper 12 Front Axle Hub Bearing
5 Bolt 13 Front Axle Hub Nut
6 Front Disk Brake Caliper Mounting 14 Front Axle Hub Nut Cover
7 Anti - Squeal Shim 15 Front Axle Hub Grease Cap
8 Brake Pad 16 Split Pin

35-20 BRAKE - FRONT BRAKE
OVERHAUL
1. REMOVE FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
NOTE
3. REMOVE FRONT DISK BRAKE CALIPER ASSY LH.

(a) Remove plug and disconnect brake tube from front disk
brake caliper assy LH.
(b) Remove the 2 nuts and front disk brake caliper assy LH.
4. REMOVE BRAKE PAD ASSY.

(a) Remove outer brake pad assy from front disk brake caliper
assy LH.
35
(b) Remove inner brake pad assy from front disk brake caliper
assy LH.
35
5. REMOVE FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Remove the 2 nuts and front disk brake caliper mounting
LH.
(b) Check the piston for rust and scoring.
6. CHECK FRONT DISK BRAKE CALIPER ASSY FOR LEAKING, REPLACE IF NECESSARY.
7. INSPECT BRAKE PAD THICKNESS.

(a) Measure the brake pad thickness.
Specification: 10 mm
Minimum value: 2 mm
8. INSPCTE DISK THICKNESS.

(a) Measure the disk thickness.
Ultimate value: 23 mm
9. REMOVE FRONT DISK.

(a) Remove the front axle hub cap.
(b) Remove the split pin.
35
(c) Remove the front axle nut cover.

35
(d) Remove the front axle hub nut.

(e) Remove the front axle hub washer.
(f) Remove the outer bearing of front axle hub.
(g) Remove front disk with front axle hub.

(h) Remove the 5 bolts and front disk.
10. INSPECT FRONT DISK RUNOUT.

(a) Temporarily fasten the front disk with knuckle nut.
(b) Measure the disk runout at the position where is 10 mm
away from the outer edge of the disk. 35
Ultimate value: 0.03 mm
(c) If the disk runout is the maximum value or is outside the
maximum value, inspect the clearance of axle hub and
axle hub runout. If the clearance of axle hub and axle
hub runout is nomal, adjust the disk runout or grind it on
a “On-vehical” brake lathe.
11. REMOVE FRONT BRAKE RH.

NOTE 35
12. INSTALL FRONT DISK.

NOTE
Select the installation position which the front disk has the
minimum runout.
(a) Install the front disk with front axle hub and tighten the 5
bolts.
Torque: 145 N•m
NOTE
Checked the inner bearing, replace with a new axle hub if
necessary. (Refer to “Chapter 34 axle and propeller shaft -
axle hub, overhaul”)
(b) Install front disk with front axle hub and the outer bearing.
(c) Install the front axle hub washer.
(d) Check wheel bearing preload and tighten the front axle
hub nut.
Torque: 160 ~ 170 N•m
(e) Install the front axle nut cover.

(f) Install the split pin.

NOTE
Install a new split pin.
35
(g) Install front axle hub cap.

35
13. INSTALL FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Install front disk brake caliper mounting LH with 2 nuts.
Torque: 113 ~ 138 N•m
14. INSTALL BRAKE PAD ASSY.

(a) Install inner brake pad assy to front disk brake caliper
assy LH.
NOTE
• Replace the anti-squeal shim when replacing the brake
pad.
• Keep the friction surface of brake pad and front disk
away from oil and grease.
(b) Install outer brake pad assy to front disk brake caliper
assy LH.
NOTE
• Replace the anti-squeal shim when replacing the brake
pad.
• Keep the friction surface of brake pad and front disk
away from oil and grease.
15. INSTALL FRONT DISK BRAKE CALIPER MOUNTING

LH.
(a) Install the front disk brake caliper assy LH and tighten
the 2 nuts.
Torque: 138 ~ 168 N•m
(b) Install brake tube and plug to disk brake caliper assy LH.
35
16. INSTALL FRONT BRAKE RH.

NOTE 35
17. FILL THE FLUID RESERVOIR WITH BRAKE FLUID. (Refer to “Chapter 35 brake - brake fluid,
bleeding”)
22. INSATLL FRONT WHEEL LH. (Refer to “Chapter 33 tire and wheel - front tire and wheel,
replacement”)
35-30 BRAKE - REAR BRAKE
REAR BRAKE
COMPONENTS
1 Split Pin 12 C-washer
2 Hole Plug Rear Brake Automatic Adjusting Lever

13
Spring
3 Rear Axle Hub
14 Rear Brake Automatic Adjusting Lever
4 Rear Brake Backing Plate
15 Rear Brake Drum
5 Leading Shoe
16 Dust Boot
6 Parking Brake Shoe Strut Set
17 Piston
7 Hold Spring
18 Rubber Cover
8 Hold Spring Cover
19 Bolt
9 Return Spring
20 Rear Wheel Brake Cylinder
10 Trailing Shoe
21 Bleeder Plug
11 Parking Brake Shoe Lever
22 Spring
BRAKE - REAR BRAKE 35-31
1. CHECK BRAKE SHOE THICKNESS.
(a) Remove the brake lining inspection hole plug and check 35
the brake shoe thickness through the brake lining
inspection hole.
35
OVERHAUL
1. RELEASE PARKING BRAKE.
2. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
NOTE
4. REMOVE REAR BRAKE DRUM LH.
5. REMOVE PARKING BRAKE SHOE TENSION SPRING.

(a) Remove parking brake shoe strut set and tension spring.
WARNING
The parking brake tension spring is under great pressure.
To avoid injury, use caution when removing the parking
brake tension spring.
(b) Remove the parking brake tension spring from parking

brake shoe strut set.
6. REMOVE RETURN SPRING.

7. REMOVE TRAILING SHOE.

(a) Remove the trailing shoe hold spring.
WARNING
The trailing shoe hold spring is under great pressure. To
35
avoid injury, use caution when removing the trailing shoe
hold spring.
(b) Remove the trailing shoe.
35
8. INSPECT BRAKE SHOE THICKNESS.

Specification: 5.0 mm
Ultimate value: 1.0 mm
CAUTION
If the thickness is at the minimum thickness or less, or if it
appears severe uneven wear, replace with a new brake
shoe.
9. DISCONNECT THE PARKING BRAKE STEEL CABLE

FROM BRAKE SWINGING ARM. (Refer to” Chapter
35 brake - rear brake, overhaul”)
10. REMOVE LEADING SHOE.

(a) Remove the leading shoe hold spring.
WARNING
The leading shoe hold spring is under great pressure. To
avoid injury, use caution when removing the leading shoe
hold spring.
(b) Remove the parking brake steel cable.
(c) Remove the leading shoe.

11. REMOVE REAR BRAKE AUTOMATIC ADJUSTING LEVER

AND PARKING BRAKE SHOE LEVER.
(a) Remove the automatic adjusting spring.
35
(b) Remove the C-washer.

(c) Remove the rear brake automatic adjusting lever. 35
(d) Remove rear brake shoe lever.
12. INSPECT BRAKE SHOE THICKNESS.

Minimum value: 5mm
CAUTION
If the thickness is at the minimum thickness or less, or if it
appears severe uneven wear, replace with a new brake shoe.
13. INSPECT REAR BRAKE DRUM INSIDE DIAMETER.

Ultimate value: 275 mm
CAUTION
If the inside diameter is outside ultimate value, replace with
a new rear brake drum.
14. INSPECT REAR BRAKE DRUM AND BRAKE SHOE

FOR PROPER CONTACT.
(a) Apply chalk to the inside of the rear brake drum, then
grind brake shoe on the surface of the drum. If the
contact between the rear brake drum and the brake shoe
is improper, repair brake shoe by a brake shoe grinder or
replace the rear brake drum.
15. REMOVE REAR WHEEL BRAKE CYLINDER ASSY

LH.
(a) Loosen the nut and disconnect the brake fluid tube from
rear wheel brake cylinder.
(b) Remove the bleeder plug from rear wheel brake cylinder.
(c) Remove the 2 bolts from rear wheel brake cylinder.
(d) Remove rear wheel brake cylinder.

16. INSTALL REAR WHEEL BRAKE CYLINDER ASSY LH.

(a) Install the 2 bolts to rear wheel brake cylinder.
35
(b) Install the bleeder plug to rear wheel brake cylinder.

Torque: 4 ~ 6 N•m
35
(c) Connect the brake fluid tube to rear wheel brake cylinder
and tighten the nut.
17. INSTALL REAR BRAKE AUTOMATIC ADJUSTING

LEVER AND PARKING BRAKE SHOE LEVER.
(a) Install the rear brake shoe lever.
(b) Install the rear brake automatic adjusting lever.
(c) Install the C-washer.
(d) Install the automatic adjusting spring.
18. INSTALL LEADING SHOE.

(a) Install the parking brake steel cable.
(b) Install the leading shoe.
(c) Install leading shoe hold spring.

WARNING
The leading shoe hold spring is under great pressure. To
avoid injury, use caution when installing the leading shoe
hold spring.
19. CONNECT THE PARKING BRAKE STEEL CABLE TO

BRAKE SWINGING ARM. (Refer to” Chapter 35 brake
- rear brake, overhaul”)
35
20. INSTALL TRAILING SHOE.

(a) Install the trailing shoe. 35
(b) Install the trailing shoe hold spring.
WARNING
The trailing shoe hold spring is under great pressure. To
avoid injury, use caution when installing the trailing shoe
hold spring.
21. INSTALL RETURN SPRING.
22. INSTALL PARKING BRAKE SHOE TENSION SPRING.

(a) Assemble parking brake shoe strut set.
CAUTION
Apply the heat resisting grease to the areas indicated by
the arrows.
(b) Install parking brake tension spring to parking brake shoe

strut set.
(c) Install parking brake shoe strut set with tension spring to
brake shoes.
WARNING
The parking brake tension spring is under great pressure.
To avoid injury, use caution when installing the parking
brake tension spring.
23. INSPECT BRAKE SHOES AND REAR BRAKE DRUM

INSTALLATION.
(a) Check that each part is installed properly.
(b) Measure the inside diameter of rear brake drum and the
diameter of brake shoes. Inspect the clearance between
rear brake drum and brake shoes.
Specification: 0.2 ~ 0.45 mm
NOTE
There should be no oil or grease adhering to the friction
surface between brake shoe and rear brake drum.
24. ADJUST CLEARANCE BETWEEN REAR BRAKE DRUM

AND BRAKE SHOES.
(a) Remove the hole plug.
(b) Adjust the clearance between brake shoes and rear
brake drum.
25. INSTALL REAR BRAKE DRUM LH.
35
26. INSTALL REAR BRAKE DRUM RH.

NOTE
35
30. CHECK FLUID LEVEL IN BRAKE FLUID RESERVOIR. (Refer to “Chapter 35 brake - brake fluid,
bleeding”)
32. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel, replacement”)
35-42 BRAKE - LOAD SENSING PROPORTIONING AND BY- PASS VALVE(LSP&BV)
LOAD SENSING PROPORTIONING AND BY- PASS

VALVE(LSP&BV)
COMPONENTS
1 Bleeder Plug 7 Load Sensing Spring
2 LSP & BV Assy Bracket 8 Heat Insulator

3 LSP & BV Assy 9 Cushion
4 LSP & BV Assy Fluid Pipe 10 Shackle
5 Clamp 11 Cushion Retainer
6 Cushion Retainer
BRAKE - LOAD SENSING PROPORTIONING AND BY- PASS VALVE(LSP&BV) 35-43
ADJUSTMENT
1. CHECK FLUID PRESSURE AND ADJUST IT IF NECESSARY.
(a) Adjust the length A. 35
Standard: 50 mm
Low pressure - Lengthen A
Hith pressure - Shorten A
(b) If fluid pressure cannot be adjusted, raise or lower the

valve body
Low pressure - Lower
Hith pressure - Raise
(c) Tighten the bolt.
35
Torque: 13 N•m
(d) Check and adjust length A again, If it cannot be adjusted,
replacement LSP & BV.
REPLACEMENT
NOTE
2. DISCONNECT SHACKLE FROM AXLE HORSING.

(a) Loosen the nut and disconnect the shackle from axle
horsing.
(b) Remove the cushion retainer and collar.
3. REMOVE LSP & BV ASSY.

(a) Disconnect the 3 fluid pipes from LSP & BV assy.
(b) Loosen the 2 bolts of LSP & BV bracket and remove LSP
& BV.
4. REMOVE LSP & BV BRACKET.

(a) Loosen the nut and remove the bracket from LSP & BV.
5. REMOVE LOAD SENSING SPRING.

(a) Remove the clamp and disconnect the load sensing
spring from valve body.
35
(b) Remove bolt and nut, then remove heat insulator,

shackle and the 2 washers.
35
(c) Remove load sensing spring.
6. CHECK VALVE PISTON PIN AND LOAD SENSING

SPRING CONTACT SURFACE FOR WEAR.
7. INSTALL LOAD SENSING SPRING.

(a) Install the load sensing spring.
NOTE
Do not mistake the valve side for the shackle side of the
load sensing spring.
(b) Install the heat insulator, shackle and the 2 washers then
tighten bolt and nut.
Torque: 18 N•m
(c) Connect the load sensing spring to valve body and install
the clamp.
8. INSTALL LSP & BV BRACKET.

(a) Install the bracket to LSP & BV and tighten the nut.
Torque: 18 N•m
9. INSTALL LSP & BV ASSY.

(a) Install the LSP & BV and tighten the 2 bolts.
Torque: 19 N•m
(b) Connect the 3 fluid pipes to LSP & BV assy.

Torque: 20 ±1 N•m
10. CONNECT SHACKLE TO AXLE HORSING.

(a) Install the cushion retainer and collar.
(b) Install the loading sensing spring and tighten the nut.
Torque: 13 N•m 35

35
35-48 BRAKE - HYDRAULIC PRESSURE REGULATOR
HYDRAULIC PRESSURE REGULATOR

REPLACEMENT
NOTE
3. REMOVE HYDRAULIC PRESSURE REGULATOR.

(a) Disconnect the connector from hydraulic pressure regulator.
NOTE
The hydraulic pressure regulator is located at the left of
chassis and is in front of the rear wheel LH.
(b) Disconnect the 2 fluid pipes from hydraulic pressure

regulator.
(c) Loosen the 3 bolts of hydraulic pressure regulator

bracket and remove hydraulic pressure regulator.
4. INSTALL HYDRAULIC PRESSURE REGULATOR.

(a) Install the hydraulic pressure regulator.
BRAKE - HYDRAULIC PRESSURE REGULATOR 35-49
(b) Connect the 2 fluid pipes to hydraulic pressure regulator.
35
(c) Connect the connector to hydraulic pressure regulator.
35

35-50 BRAKE - VEHICLE SPEED SENSOR

REPLACEMENT

(a) Disconnect the connector from vehicle speed sensor.
(b) Loosen the bolt and remove the vehicle speed sensor.

(a) Install the speed sensor and tighten the bolt.
(b) Connect the connector to the vehicle speed sensor.

PARKING BRAKE
15A
PARKING BRAKE SYSTEM.............................................................. 36-1
ADJUSTMENT ............................................................................. 36-2
PARKING BRAKE OPERATION HANDLE ASSY ............................ 36-3 15A
COMPONENTS ........................................................................... 36-3
REPLACEMENT .......................................................................... 36-4
BRAKE ACTUATOR LEVER SUB-ASSY ......................................... 36-9
COMPONENTS ........................................................................... 36-9 15A
REPLACEMENT ........................................................................ 36-10
36
PARKING BRAKE - PARKING BRAKE SYSTEM 36-1
PARKING BRAKE SYSTEM

PARKING BRAKE

Use the table below to help you find the cause of the problem. The numbers indicate the priority of 36
1. Parking brake operation handle stroke Chapter 35 brake - rear brake, overhaul
(Out of adjustment)
2. Return spring (Damaged) Chapter 35 brake - rear brake, overhaul

Brake drag
3. Parking brake tension spring (Damaged) Chapter 35 brake - rear brake, overhaul
4. Parking brake return spring (Damaged) Chapter 35 brake - rear brake, overhaul
36
36-2 PARKING BRAKE - PARKING BRAKE SYSTEM
ADJUSTMENT
1. REMOVE REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
2. INSPECT BRAKE SHOES AND REAR BRAKE DRUM INSTALLATION. (Refer to “Chapter 35
brake - rear brake, overhaul”)
3. ADJUST CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to “Chapter
4. INSTALL REAR WHEEL LH. (Refer to “Chapter 33 tire and wheel - rear tire and wheel,
replacement”)
5. INSPECT PARKING BRAKE OPERATION HANDLE STROKE.
(a) Pull the parking brake operation handle to the fully applied position, and count the number of clicks.
PARKING BRAKE OPERATION HANDLE STROKE: Pull slowly the parking brake operation
handle at 200 N. Parking brake will produce specific brake force when 18 ~ 24 clicks.
WARNNING
Adjust parking brake operation handle stroke if necessary.
6. ADJUST PARKING BRAKE OPERATION HANDLE

STROKE.
(a) Remove the adjusting nut of front parking brake cable
until the parking brake operation handle stroke is correct.
PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY 36-3
PARKING BRAKE OPERATION HANDLE ASSY

COMPONENTS
36
36
1 Bolt 10 Upper Templet
2 Parking Brake Front Part Assy 11 Parking Brake Control Rear Part Assy
3 Parking Brake Front Cable Assy 12 Rear Cable Bracket No.1
4 Clip 13 Rear Cable Bracket No.2
5 Bolt Rear Cable Bracket No.2 Connecting

14
Sleeve
6 Clip
15 Balance Bracket
7 Front Cable Bracket
16 Lock Pin
8 Parking Brake Control Rocker Arm Spring
17 Washer
Parking Brake Control Rocker Arm With
9
Bracket Assembly 18 Split Pin
36-4 PARKING BRAKE - PARKING BRAKE OPERATION HANDLE ASSY
REPLACEMENT
1. REMOVE DASHBOARD ASSY. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
2. REMOVE PARKING BRAKE SWITCH.

(a) Disconnect the connector from parking brake switch.
(b) Remove the parking brake switch.
3. REMOVE PARKING BRAKE FRONT PART ASSY.

(a) Loosen 2 bolts by upside.
(b) Loosen 2 bolts by downside.

(c) Remove the clip.
36
(d) Disconnect the connecting between parking brake front

cable and parking brake control rocker arm.
36
(e) Disconnect the connecting between parking brake front
cable and chassis.
(f) Remove parking brake front part assy.
4. REMOVE PARKING BRAKE REAR PART ASSY.

(a) Disconnect the connecting between parking brake rear
part assy and brake actuator lever.
(b) Disconnect the connecting between parking brake rear

part assy and parking brake control rocker arm.
(c) Disconnect the connecting between parking brake rear

part assy and brackets.
(d) Remove parking brake rear part assy.
5. INSTALL PARKING BRAKE REAR PART ASSY.

(a) Connect the parking brake rear part assy to brackets.
(b) Connect the parking brake rear part assy to parking

brake control rocker arm.
(c) Connect the parking brake rear part assy to brake

actuator lever.
6. INSTALL PARKING BRAKE FRONT PART ASSY.

(a) Install the parking brake front part assy and tighten 2
bolts by upside.
36
(b) Tighten 2 bolts by downside.
36
(c) Install the clip.
(d) Connect the parking brake front cable to parking brake

control rocker arm.
(e) Connect the parking brake front cable to chassis.

7. INSTALL PARKING BRAKE SWITCH.

(a) Install parking brake switch.
(b) Connect the connector to parking brake switch.
8. INSTALL DASHBOARD ASSY. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

PARKING BRAKE - BRAKE ACTUATOR LEVER SUB-ASSY 36-9
BRAKE ACTUATOR LEVER SUB-ASSY

COMPONENTS
36
36
1 Brake Plate Assembly 5 Actuator Lever Dust Boot
2 Spring 6 Brake Actuator Lever
3 Pin Roll 7 Split Washer
4 Actuator Lever Bracket 8 Bolt

36-10 PARKING BRAKE - BRAKE ACTUATOR LEVER SUB-ASSY
REPLACEMENT
1. REMOVE BRAKE ACTUATOR LEVER AND ACTUATOR
LEVER BRACKET.
(a) Remove the parking brake steel cable. (Refer to“
Chapter 35 brake - rear brake, overhaul”)
(b) Remove the spring.

WARNING
The spring is under great pressure. To avoid injury, use
caution when removing the spring.
(c) Disconnect the connecting between parking brake rear

part assy and brake actuator lever. (Refer to “Chapter 36
parking brake - parking brake operation handle assy,
replacement”)
(d) Loosen 2 bolts.
(e) Remove the brake actuator lever and actuator lever

bracket.
PARKING BRAKE - BRAKE ACTUATOR LEVER SUB-ASSY 36-11
2. INSTALL BRAKE ACTUATOR LEVER AND ACTUATOR

LEVER BRACKET.
(a) Install the brake actuator lever and actuator lever bracket
36
then tighten 2 bolts.
(b) Connect the parking brake rear part assy to brake

actuator lever. (Refer to “Chapter 36 parking brake -
parking brake operation handle assy, replacement”)
(c) Install the spring.

WARNING
The spring is under great pressure. To avoid injury, use
caution when installing the spring.
36
(d) Install the parking brake steel cable. (Refer to” Chapter
3. ADJUST CLEARANCE BETWEEN REAR BRAKE DRUM AND BRAKE SHOES. (Refer to “Chapter
MEMO
TRANSMISSION
41
TRANSMISSION OPERATION MECHANISM ASSY ........................ 41-1
COMPONENTS ........................................................................... 41-1
REPLACEMENT .......................................................................... 41-4
TRANSMISSION ASSY...................................................................... 41-7 41
COMPONENTS ........................................................................... 41-9
REPLACEMENT ........................................................................ 41-10
OVERHAUL ............................................................................... 41-15 41
OUTPUT SHAFT ASSY ................................................................... 41-42
COMPONENTS ......................................................................... 41-42
OVERHAUL ............................................................................... 41-43
COUNTER SHAFT ASSY AND REVERSE IDLER
GEAR SHAFT................................................................................... 41-57
COMPONENTS ......................................................................... 41-57
REPLACEMENT ........................................................................ 41-58
INPUT SHAFT ASSY ....................................................................... 41-59
COMPONENTS ......................................................................... 41-59
OVERHAUL ............................................................................... 41-60
41
TRANSMISSION (TC5RYA4/5RYL) - TRANSMISSION OPERATION MECHANISM ASSY 41-1
TRANSMISSION OPERATION MECHANISM ASSY

TRANSMISSION (TC5RYA4/5RYL)
COMPONENTS
TC5RYA4 41
41
41-2 TRANSMISSION (TC5RYA4/5RYL) - TRANSMISSION OPERATION MECHANISM ASSY
1 Shifting Control Lever Ball 12 Washer
2 Dust Boot 13 Soldering Cup Pressure Plate
3 Control Box 14 Cross Shaft Assy No.1
4 Bolt 15 Cross Shaft Assy No.2
5 Screw 16 Pin Roll
6 Washer Gear Shifting Plumbing Arm Rubber

17
Sleeve
7 Shifting Control Lever Assy
18 Gear Shifting Plumbing Arm Shaft Sleeve
Gear Shifting Vertical Lever With
8
Soldering Cup Assy 19 Gear Selecting Long Tie Rod Assy
Gear Selecting Vertical Lever With 20 Gear Shifting Long Tie Rod Assy
9
Soldering Cup Assy
21 Gear Shifting Short Tie Rod Assy
10 Vertical Lever Soldering Cup
22 Gear Selecting Short Tie Rod Assy
11 Bolt
5RYL
41
41
1 Shifting Control Lever Ball 9 Vertical Lever Soldering Cup
2 Dust Boot 10 Soldering Cup Pressure Plate
3 Bolt 11 Washer
4 Screw 12 Bolt
5 Shifting Control Lever Assy 13 Clip
6 Washer 14 Gear Shifting Flexible Shaft Assy
Gear Shifting Vertical Lever With 15 Gear Selecting Flexible Shaft Assy
7
Soldering Cup Assy
16 Nut
Gear Selecting Vertical Lever With
8
Soldering Cup Assy
REPLACEMENT
1. STOP THE ENGINE AND PARK THE VEHICLE ON LEVEL GROUND WITH PARKING BRAKE.
2. REMOVE CONTROL BOX.

(a) Remove 2 screws of control box by left side.
(b) Remove 2 screws of control box by right side.

(c) Remove the control box.
3. REMOVE SHIFTING CONTROL LEVER ASSY.

(a) Loosen 2 nuts then disconnect gear shifting vertical lever
and gear selecting vertical lever from shifting control
lever assy.
(b) Loosen 4 bolts and remove shifting control lever assy.
41
4. INSTALL SHIFTING CONTROL LEVER ASSY.

(a) Install shifting control lever assy and tighten 4 bolts.
Model Torque
TCRYA4 30 ~ 50 N•m
5RYL 30 ~ 50 N•m
(b) Connect gear shifting vertical lever and gear selecting 41

vertical lever to shifting control lever assy and tighten 2
nuts.
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
5. INSTALL CONTROL BOX.

(a) Install the control box and tighten 2 screws by left side.
(b) Tighten 2 screws of control box by right side.

TRANSMISSION (TC5RYA4/5RYL) - TRANSMISSION ASSY 41-7
TRANSMISSION ASSY
the likely cause of the problem. Check each part in order. If necessary, replace these parts. .
1. Transmission fluid (Low viscosity) -
2. Transmission fluid (Level low) -
Chapter 41 transmission (TC5RYA4/5RYL) -

3. Bearing (Worn or damaged) transmission assy, overhaul

4. Shift fork and synchronizer sleeve transmission assy, overhaul
(Improper engagement) Chapter 41 transmission (TC5RYA4/5RYL) -
Noisy output shaft assy, overhaul

transmission assy, overhaul
5. Synchronizer (Worn or damaged) Chapter 41 transmission (TC5RYA4/5RYL) -
output shaft assy, overhaul
Chapter 41 transmission (TC5RYA4/5RYL) - 41

6. Gear tooth (Damaged) transmission assy, overhaul
7. Transmission case (Warped) -
1. Transmission fluid (High viscosity) -
Chapter 42 clutch - clutch pedal, adjustment

2. Clutch (Does not disengage) Chapter 42 clutch - clutch sub - assy, overhaul

3. Bearing (Worn or damaged) transmission assy, overhaul

Hard to shift or transmission assy, overhaul
4. Synchronizer (Damaged) Chapter 41 transmission (TC5RYA4/5RYL) -
does not shift

5. Shift fork (Warped or damaged) transmission assy, overhaul

6. Shift rail (Warped or damaged) transmission assy, overhaul

7. Steel ball (Worn) transmission assy, overhaul
41-8 TRANSMISSION (TC5RYA4/5RYL) - TRANSMISSION ASSY

1. Gear (Excessive radial clearance) transmission assy, overhaul

2. Engage side (Worn) transmission assy, overhaul

transmission assy, overhaul
3. Synchronizer (Damaged) Chapter 41 transmission (TC5RYA4/5RYL) -
Jump out of
gear Chapter 41 transmission (TC5RYA4/5RYL) -
4. Bearing （Axial moving） transmission assy, overhaul

5. Shift fork (Warped or damaged) transmission assy, overhaul

6. Locating spring (Failure or damaged) transmission assy, overhaul

7. Steel ball (Worn) transmission assy, overhaul

Erratic shifting 1. Inter-lock pin (Worn) transmission assy, overhaul
1. Transmission fluid (Excess) -
2. Sealing parts (Failure or damaged) -
Oil leakage 3. Fastener (Loose) -
4. Transmission case (Warped) -
5. Sealant (uneven) -
COMPONENTS
41
41
1 Clutch Housing 7 Transmission Case
2 Input Shaft Front Bearing Retainer 8 Intermediate Plate Sub-assy
3 Snap Ring 9 Drain Plug
4 Back- Up Lamp Switch 10 Filler Plug
5 Shift Lever Housing Assy 11 Odometer Driven Gear
6 Gasket 12 Extension Housing

REPLACEMENT
1. STOP THE ENGINE. PARK VEHICLE ON LEVELGROUND WITH PARKING BRAKE AND SHIFT IN
NEUTRAL POSITION.
3. REMOVE DRAIN PLUG BY DOWNSIDE AND DRAIN

TRANSMISSION FLUID COMPLETELY. TIGHTEN
DRAIN PLUG.
Model Torque
TCRYA4 30 ~ 50 N•m
5RYL 30 ~ 50 N•m
NOTE
• Keep vent plug unblocked and loosen the filler plug
before draining fluid. In order to drain transmission
fluid completely, drain the fluid when it is hot.
• Use container for transmission fluid when draining.
4. DISCONNECT TRANSMISSION ASSY FROM OTHER

PARTS.
(a) Disconnect the gear selecting short tie rod from trans-
mission assy.
(b) Disconnect the gear shifting short tie rod from transmis-
sion assy.
(c) Disconnect the transmission operation mechanism assy

from transmission assy.
(d) Disconnect the exhaust pipe bracket from transmission

assy. (5RYL)
WARNING
Be careful not to be scalded by exhaust pipe. 41
(e) Remove the clutch slave cylinder assy. (Refer to

“Chapter 42 clutch - clutch slave cylinder assy, overhaul”)
(f) Remove the back-up lamp switch connector.
41
(g) Remove the vehicle speed sensor connector.
(h) Remove propeller shaft assy. (Refer to “Chapter 34 axle

and propeller shaft - propeller shaft assy, overhaul”)
(i) Remove 4 nuts and disconnect the transmission from

lifting lug.
WARNING
Use jack to support transmission assy and engine before
operation.
(j) Remove 8 nuts and disconnect transmission assy from

engine. Remove the transmission assy.
5. CONNECT OTHER PARTS TO TRANSMISSION ASSY.

(a) Support the transmission assy by jack and shift in one of
forward gears. Rotate the input shaft and align with the
spline of clutch disk at the same time. Then insert the
input shaft completely and shift in neutral position.
WARNING
Adopt protective measures to prevent from injuring when
supporting by jack.
(b) Install 8 bolts with hand.
(c) Support the transmission assy by jack and connect the

transmission assy to lifting lug. Install 4 bolts with hand.
WARNING
Adopt protective measures to prevent from injuring when
supporting by jack.
(d) Tighten 4 nuts of lifting lug.
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
(e) Connect transmission assy to engine and tighten 8 bolts.
Model Torque
TCRYA4 30 ~ 45 N•m
5RYL 30 ~ 45 N•m
NOTE
Diagonally tighten all bolts in order to install closely.
(f) Install the propeller shaft assy. (Refer to “Chapter 34 axle
and propeller shaft - propeller shaft assy, overhaul”) 41
(g) Install the vehicle speed sensor.
Model Torque
TCRYA4 30 ~ 50 N•m
5RYL 30 ~ 50 N•m
(h) Install the back-up lamp switch.
Model Torque
TCRYA4 30 ~ 50 N•m
5RYL 30 ~ 50 N•m 41
(i) Install the clutch slave cylinder assy. (Refer to “Chapter

42 clutch - clutch slave cylinder assy, overhaul”)
(j) Connect the transmission operation mechanism assy to

transmission assy
Model Torque
TCRYA4 30 ~ 45 N•m
5RYL 30 ~ 45 N•m
(k) Connect the exhaust pipe bracket to transmission assy.

(5RYL).
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
(l) Connect the gear shifting short tie rod to transmission

assy.
(m) Connect the gear selecting short tie rod to transmission
assy.
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
6. FILL TRANSMISSION FLUID AND TIGNTEN FILLER

PLUG.
Model Torque
TCRYA4 30 ~ 50 N•m
5RYL 30 ~ 50 N•m
CAUTION
• According to demand, fill transmission fluid GL-5 75W/
90, GL-5 80w/90 or GL-5 85W/90 for 2.0 L.
• Do not mix different kind of transmission fluid.
• Parking the vehicle on the levelground when checking
fluid level. The fluid level must be with in 5 mm from the
lowest position of the filler plug.
7. TRANSMISSION RUNNING - IN TEST.
(a) Keep the rotate speed around 1500 r/min; keep the fluid temperature upper 15 centidegree; without
load; keep transmission run more than 15 min in neutral position; keep transmission run more than 15
min in other positions.
(b) Inspect the transmission for smooth shifting.
(c) Check there is no fricative and clash during running-in test.
(d) Check there is no leakage around trasmission.
(e) Drain out transmission fluid and clean inside of transmission after running-in test. Fill transmission fluid.
OVERHAUL
1. REMOVE CLUTCH HOUSING.
(a) Remove 9 nuts and clutch housing. 41
2. REMOVE INPUT SHAFT FRONT BEARING RETAINER.

(a) Remove 8 bolts and remove the input shaft front bearing
retainer.
41
(b) Remove oil seal from front bearing retainer.
3. REMOVE INPUT SHAFT BEARING SNAP RING WITH

SNAP RING PLIERS.
4. REMOVE COUNTER SHAFT FRONT BEARING.
5. REMOVE SHIFT LEVER HOUSING ASSY.

(a) Loosen 6 bolts and remove shift lever housing assy.
6. REMOVE EXTENSION HOUSING SUB-ASSY.

(a) Remove 8 bolts and than remove the extension housing
sub-assy.
(b) Remove the extension housing dust-proof cover and oil

seal from extension housing.
(c) Remove the odometer driven gear oil seal, odometer

driven gear bracket, odometer driven gear, O-sealing
ring and snap ring from extension housing.
41
7. REMOVE TRANSMISSION CASE.
8. REMOVE 4 SETS OF LOCATING SPRING PLUG,

41
FORK LOCATING SPRING AND STEEL BALL.
9. INSPECT GEAR AND GEAR PAIRS FOR WEAR.

(a) Make red marks on each of gear pair. Check that engaging position occupies more than 60% of each
gear end-face. Replace with a new part if necessary.
(b) Check that the wear of each gear end-face is less than 15%. Replace with a new part if necessary.
10. REMOVE INPUT SHAFT ASSY.
11. REMOVE 3RD-4TH SHIFT RAIL SNAP RING WITH

SNAP RING PLIERS.
12. REMOVE COUNTER SHAFT OVERDRIVE CONNECTING

GEAR.
(a) Remove the counter shaft overdrive connecting gear
snap ring with snap ring pliers.
(b) Remove the counter shaft overdrive connecting gear lock

nut. (5RYL)
NOTE
The lock nut can not be used again. 41
(c) Remove the counter shaft overdrive connecting gear.
41
13. REMOVE OVERDRIVE SHIFT FORK PIN.

(a) Remove the overdrive shift fork pin.
(b) Remove the overdrive shift fork lock nut (5RYL).
14. REMOVE OVERDRIVE SHIFT FORK AND OVERDRIVE

SYNCHRONIZER SLEEVE.
(a) Remove overdrive shift fork and overdrive synchronizer
sleeve.
NOTE
Be careful do not lose synchronizer block and synchronizer
spring.
15. REMOVE COUNTER SHAFT OVERDRIVE GEAR.

(a) Remove the counter shaft overdrive gear.
(b) Remove the needle roller bearing of counter shaft

overdrive gear.
41
(c) Remove the thrust washer of counter shaft overdrive

gear.
41
16. REMOVE ODOMETER DRIVING GEAR.

(a) Remove the odometer driving gear upper snap ring with
snap ring pliers.
(b) Remove the odometer driving gear.

CAUTION
Be careful do not lose steel ball.
(c) Remove the odometer driving gear lower snap ring with
snap ring pliers.
17. REMOVE OUTPUT SHAFT OVERDRIVE GEAR.

(a) Remove output shaft overdrive gear snap ring with snap
ring pliers.
(b) Remove the output shaft overdrive gear.
41
18. REMOVE OUTPUT SHAFT REAR BEARING BAFFLE.

(a) Loosen 4 bolts and than remove output shaft rear
bearing baffle.
41
19. REMOVE OUTPUT REAR BEARING.

(a) Remove the output shaft rear bearing snap ring with
snap ring pliers.
(b) Remove the output shaft rear bearing.
20. REMOVE COUNTER SHAFT REAR BEARING.

(a) Remove the counter shaft rear bearing snap ring with
snap ring pliers.
(b) Remove the counter shaft rear bearing.

21. REMOVE REVERSE IDLER GEAR SHAFT PRESSURE

PLATE.
(a) Remove the bolt and reverse idler gear shaft pressure
plate. 41
22. REMOVE COUNTER SHAFT ASSY.
41
23. REMOVE REVERSE IDLER GEAR SHAFT.

(a) Remove the reverse idler gear sub-assy.
(b) Remove the reverse idler gear shaft.
24. REMOVE OUTPUT SHAFT ASSY.
25. REMOVE OD-REVERSE SHIFT RAIL SNAP RING AND

3RD-4TH SHIFT RAIL SNAP RING.
26. REMOVE 1ST-2ND SHIFT FORK PIN AND BOLTS.
41
27. REMOVE 3RD-4TH SHIFT BLOCK AND REVERSE

SPEED ROCKER ARM PIN.
41
28. REMOVE AII SHIFT RAILS, SHIFT FORKS, SHIFT

BLOCKS, INTER-LOCK PINS AND REVERSE ROCKER
ARM BRACKET SUB-ASSY.
CAUTION
Be careful do not lose any iner-lock pins.
29. INSTALL AII SHIFT RAILS, SHIFT FORKS, SHIFT

BLOCKS, INTER-LOCK PINS AND REVERSE ROCKER
ARM BRACKET SUB-ASSY.
CAUTION
• Inspect each shift rail for wear and warped. Replace
with a new part if necessary.
• Inspect each inter-lock pin for wear and warped.
Replace with a new part if necessary.
• Inspect reverse rocker arm bracket sub-assy for
wear and warped. Replace with a new part if
necessary.
30. INSTALL 3RD-4TH SHIFT BLOCK AND REVERSE

SPEED ROCKER ARM PIN.
31. INSTALL 1ST-2ND SHIFT FORK PIN AND BOLTS.

32. INSTALL OD-REVERSE SHIFT RAIL SNAP RING AND

3RD-4TH SHIFT RAIL SNAP RING.
41
33. INSTALL OUTPUT SHAFT ASSY.
41
34. INSTALL REVERSE IDLER GEAR SHAFT.

(a) Install the reverse idler gear shaft.
(b) Install the reverse idler gear sub-assy.
35. INSTALL COUNTER SHAFT ASSY.

CAUTION
Check the counter shaft gear tooth for wear. Replace with a
new part if necessary.
36. INSTALL REVERSE IDLER GEAR SHAFT PRESSURE

PLATE.
(a) Install the bolt and reverse idler gear shaft pressure
plate.
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
37. INSTALL COUNTER SHAFT REAR BEARING.

(a) Install the counter shaft rear bearing.
CAUTION
Check the bearing for wear or damaged. Replace with a new
41
part if necessary.
NOTE
Apply grease to the bearing to prevent dry friction.
(b) Install the counter shaft rear bearing snap ring with snap
ring pliers.
CAUTION
Check snap ring for warped before installation. Replace
41
38. INSTALL OUTPUT REAR BEARING.

(a) Install the output rear bearing.
CAUTION
Check the internal surface and outside surface of bearing.
(b) Install the output shaft rear bearing snap ring with snap
ring pliers.
CAUTION
Check the snap ring for warped before installation. Replace
39. INSTALL OUTPUT SHAFT REAR BEARING BAFFLE.

(a) Install the output shaft rear bearing baffle and 4 bolts.
Apply sealant to 4 bolts before installation.
Model Torque
TCRYA4 21 ~ 30 N•m
5RYL 21 ~ 30 N•m
40. INSTALL OUTPUT SHAFT OVERDRIVE GEAR.

(a) Install the output shaft overdrive gear.
(b) Install the output shaft overdrive gear snap ring with snap
ring pliers.
CAUTION
Check the snap ring for warped before installation. Replace 41
41. INSTALL ODOMETER DRIVING GEAR.

(a) Install the odometer driving gear lower snap ring with
snap ring pliers.
CAUTION
with a new part if necessary. 41
(b) Install the odometer driving gear.

CAUTION
Do not forget to install steel ball.
(c) Install the odometer driving gear upper snap ring with
snap ring pliers.
CAUTION
42. INSTALL COUNTER SHAFT OVERDRIVE GEAR.

(a) Install the thrust washer of counter shaft overdrive gear.
NOTE
Apply grease to thrust washer to prevent dry friction.
(b) Install the needle roller bearing of counter shaft overdrive

gear.
CAUTION
• Check the needle roller bearing and make sure it is
not higher than gear end-face. Inspect the assemble
position or replace with a new part if necessary.
• Shake and check the needle roller bearing.
NOTE
Apply grease to needle roller bearing to prevent dry friction.
(c) Install the counter shaft overdrive gear.
41
43. INSTALL OVERDRIVE SHIFT RAIL FORK AND

OVERDRIVE SYNCHRONIZER SLEEVE.
(a) Install the overdrive shift fork and overdrive synchronizer
sleeve.
CAUTION
Do not forget to install the synchronizer block and 41
synchronizer ring.
(b) Inspect the od-reverse synchronizer ring for wear and

damage.
(c) Turn the od-reverse synchronizer ring in one direction
while pushing it to the gear cone. Check the braking
effect of the synchronizer ring. If the braking effect is
insufficient, apply a small amount of the fine lapping
compound between the synchronizer ring and gear cone.
Lightly rub the synchronizer ring and gear cone together.
(d) Inspect the axial clearance between od-reverse synchronizer

ring and overdrive connecting gear.
Axial Clearance
Model
Specification Ultimate value
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
If the clearance is out of specification, replace with a new
synchronizer ring or (and) gear.
(e) Inspect radial clearance between od-reverse synchronizer

ring and overdrive connecting gear.
Radial Clearance
Model
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
(f) Install the overdrive synchronizer ring.
NOTE
Apply grease to synchronizer ring to prevent dry friction.
44. INSTALL OVERDRIVE SHIFT FORK PIN.

(a) Install the overdrive shift fork pin.
(b) Tighten the overdrive shift fork lock nut. (5RYL)

45. INSTALL COUNTER SHAFT OVERDRIVE CONNECTING

GEAR.
(a) Install the counter shaft overdrive connecting gear.
41
(b) Install the counter shaft overdrive connecting gear snap

ring with snap ring pliers.
CAUTION
41
(c) Tighten the counter shaft overdrive connecting gear lock

nut. (5RYL)
NOTE
Use a new lock nut.
46. INSTALL 3RD-4TH SHIFT RAIL SNAP RING WITH

SNAP RING PLIERS.
47. INSTALL INPUT SHAFT ASSY.
48. INSTALL 4 SETS OF LOCATING SPRING PLUG,

FORK LOCATING SPRING AND STEEL BALL.
49. INSTALL TRANSMISSION CASE.
41
50. INSTALL EXTENSION HOUSING SUB-ASSY.

(a) Install the odometer driven gear oil seal, odometer driven
gear bracket, odometer driven gear, O-sealing ring and
snap ring to extension housing.
CAUTION
Install a new O-seal to ensure great sealability.
(b) Install the extension housing dust-proof cover and oil

41
seal from extension housing.
CAUTION
Install a new O-seal to ensure great sealability.
(c) Install 8 bolts and extension housing sub-assy.
Model Torque
TCRYA4 30 ~ 45 N•m
5RYL 30 ~ 45 N•m
CAUTION
Apply sealant to extension housing before installation.
51. INSTALL SHIFT LEVER HOUSING ASSY.

(a) Install the shift lever housing assy and tighten 6 bolts.
Model Torque
TCRYA4 30 ~ 45 N•m
5RYL 30 ~ 45 N•m
52. INSTALL COUNTER SHAFT FRONT BEARING SNAP

RING.
(a) Install the counter shaft front bearing snap ring with snap
ring pliers.
CAUTION
53. INSTALL INPUT SHAFT BEARING SNAP RING.

(a) Install the input shaft bearing snap ring with snap ring
pliers.
CAUTION
54. INSTALL INPUT SHAFT FRONT BEARING RETAINER.

(a) Install the oil seal to front bearing retainer.
CAUTION
• Apply grease to oil seal before installation.
• Install a new oil seal to ensure great sealability.
(b) Apply grease to input shaft front bearing retainer and

install it to transmission case. Tighten 8 bolts.
Model Torque
TCRYA4 15 ~ 20 N•m
5RYL 15 ~ 20 N•m
55. INSTALL CLUTCH HOUSING.

(a) Install the clutch housing with 9 nuts.
Model Torque 41
TCRYA4 30 ~ 45 N•m
5RYL 30 ~ 45 N•m
41
41-42 TRANSMISSION (TC5RYA4/5RYL) - OUTPUT SHAFT ASSY
OUTPUT SHAFT ASSY

COMPONENTS
1 Snap Ring 10 Output Shaft
2 Synchronizer Spring 11 2nd Speed Gear Sub-assy
3 Synchronizer Block 12 1st Speed Gear
4 Synchronizer Hub 13 1st Speed Gear Sleeve
5 Synchronizer Sleeve 14 Output Shaft Rear Bearing
6 Synchronizer Ring 15 Output Shaft Rear Bearing Snap Ring
7 3rd Speed Gear Sub-assy 16 Overdrive Gear
8 Needle Roller Bearing 17 Odometer Driving Gear
9 Steel Ball
TRANSMISSION (TC5RYA4/5RYL) - OUTPUT SHAFT ASSY 41-43
OVERHAUL
1. REMOVE 3RD-4TH SPEED SYNCHRONIZER ASSY.
(a) Remove the 3rd-4th speed synchronizer snap ring with 41
snap ring pliers.
(b) Remove the 3rd-4th speed synchronizer assy from

output shaft.
41
(c) Remove the synchronizer sleeve, synchronizer hub,

synchronizer ring and synchronizer block.
(d) Remove the 3rd synchronizer ring.
2. REMOVE OUTPUT SHAFT 3RD SPEED GEAR SUB-

ASSY.
(a) Remove the 3rd speed gear sub-assy.
(b) Remove the needle roller bearing .

3. REMOVE OUTPUT 1ST SPEED GEAR.

(a) Remove the 1st speed gear sleeve.
41
(b) Remove the 1st speed gear.
41
(c) Remove 2 needle roller bearings .

4. REMOVE 1ST-2ND SPEED SYNCHRONIZER ASSY.

(a) Remove the 1st synchronizer ring.
(b) Remove the 1st-2nd speed synchronizer assy from

output shaft.
(c) Remove the synchronizer sleeve, synchronizer hub,

(d) Remove the 2nd synchronizer ring.
41
5. REMOVE 2ND SPEED GEAR SUB-ASSY.

(a) Remove the 2nd speed gear sub-assy.
41
(b) Remove the needle roller bearing of 2nd speed gear sub-
assy.
6. INSTALL 2ND SPEED GEAR SUB-ASSY.

(a) Install the needle roller bearing of 2nd speed gear sub-
assy.
CAUTION
NOTE
(b) Install the 2nd speed gear sub-assy.
7. INSTALL 1ST-2ND SPEED SYNCHRONIZER ASSY.

(a) Inspect the 2nd synchronizer ring for wear and damage.
(b) Turn the 2nd synchronizer ring in one direction while
pushing it to the gear cone. Check the braking effect of
the synchronizer ring. If the braking effect is insufficient,
apply a small amount of the fine lapping compound
between the synchronizer ring and gear cone. Lightly rub
the synchronizer ring and gear cone together.
(c) Inspect the axial clearance between 2nd synchronizer

ring and 2nd speed gear.
Axial Clearance
Model
TC5RYA4 1 ~ 2 mm 1 ~ 2 mm
5RYL 1 ~ 2 mm 1 ~ 2 mm
CAUTION
41
(d) Inspect the radial clearance between 2nd synchronizer
ring and 2nd speed gear.
Radial Clearance
Model
TC5RYA4 1 ~ 2 mm 1 ~ 2 mm
5RYL 1 ~ 2 mm 1 ~ 2 mm
CAUTION
(e) Install the 2nd synchronizer ring.

NOTE
41
(f) Inspect the sliding between synchronizer sleeve and

synchronizer hub.
(g) Inspect the clearance between synchronizer sleeve and

shift fork.
(h) Install synchronizer sleeve, synchronizer hub, synchronizer

ring and synchronizer block.
NOTE
When installing the synchronizer ring, make sure that the
steps of synchronizer rings are positioned on synchronizer
block but not on the same one.
(i) Install the 1st-2nd speed synchronizer assy to output

shaft.
(j) Inspect the 1st synchronizer ring for wear and damage.
(k) Turn the 1st synchronizer ring in one direction while
(l) Inspect the axial clearance between 1st synchronizer

ring and 1st speed gear.
Axial Clearance
Model 41
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
(m) Inspect the radial clearance between 1st synchronizer

ring and 1st speed gear.
Radial Clearance
Model
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm 41
CAUTION
(n) Install the 1st synchronizer ring.

NOTE
8. INSTALL OUTPUT 1ST SPEED GEAR.

(a) Install 2 needle roller bearings of 1st speed gear.
CAUTION
NOTE
(b) Install the 1st speed gear.
(c) Install the 1st speed gear sleeve.

9. INSTALL OUTPUT SHAFT 3RD SPEED GEAR SUB-

ASSY.
(a) Install the needle roller bearing of 3rd speed gear sub-
assy. 41
CAUTION
NOTE
(b) Install the 3rd speed gear sub-assy.
41
10. INSTALL 3RD-4TH SPEED SYNCHRONIZER ASSY.

(a) Inspect the 3rd synchronizer ring for wear and damage.
(b) Turn the 3rd synchronizer ring in one direction while
(c) Inspect the axial clearance between 3rd synchronizer

ring and 3rd speed gear.
Axial Clearance
Model
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
(d) Inspect the radial clearance between 3rd synchronizer

ring and 3rd speed gear.
Radial Clearance
Model
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
(e) Install 3rd synchronizer ring.

NOTE
(f) Inspect the sliding between synchronizer sleeve and

synchronizer hub.
(g) Inspect the clearance between synchronizer sleeve and

shift fork.
41
(h) Install the synchronizer sleeve, synchronizer hub,

NOTE
When installing the synchronizer ring, make sure that the
steps of synchronizer rings are positioned on synchronizer
block but not on the same one. 41
(i) Install the 3rd-4th speed synchronizer assy to output

shaft.
CAUTION
Ensure the installation direction when installing 3rd-4th
speed synchronizer assy.
(j) Install the 3rd-4th speed synchronizer snap ring with

snap ring pliers.
CAUTION
TRANSMISSION (TC5RYA4/5RYL) - COUNTER SHAFT ASSY AND REVERSE IDLER
GEAR SHAFT
41-57
COUNTER SHAFT ASSY AND REVERSE IDLER GEAR

SHAFT
COMPONENTS 41
41
1 Snap Ring 10 Snap Ring
2 Counter Shaft Bearing Snap Ring 11 Synchronizer Spring
3 Counter Shaft Bearing 12 Synchronizer Sleeve
4 Counter Shaft 13 Synchronizer Ring
5 Steel Ball 14 Counter Shaft Overdrive Connecting Gear
6 Overdrive Gear Thrust Washer 15 Reverse Idler Gear Shaf
7 Needle Roller Bearing 16 Reverse Idler Gear Sub-assy
8 Synchronizer Block 17 Reverse Idler Gear Shaft Pressure Plate
9 Counter Shaft Overdrive Gear 18 Bolt

41-58 TRANSMISSION (TC5RYA4/5RYL) - COUNTER SHAFT ASSY AND REVERSE IDLER
GEAR SHAFT
REPLACEMENT
”Refer to “Chapter 41 transmission (TC5RYA4/5RYL) - transmission assy, overhaul”
TRANSMISSION (TC5RYA4/5RYL) - INPUT SHAFT ASSY 41-59
INPUT SHAFT ASSY

COMPONENTS
41
41
1 Snap Ring 4 Input Shaft
2 Input Shaft Bearing Snap Ring 5 Output Shaft Needle Roller Bearing
3 Input Shaft Bearing

41-60 TRANSMISSION (TC5RYA4/5RYL) - INPUT SHAFT ASSY
OVERHAUL
1. DISASSEMBLE INPUT SHAFT ASSY.
(a) Remove the input shaft snap ring with snap ring pliers.
(b) Using a press machine, remove the input shaft bearing.
2. INSPECT INPUT SHAFT.

(a) Inspect the 4th synchronizer ring for wear and damage.
(b) Turn the 4th synchronizer ring in one direction while
(c) Inspect axial clearance between 4th synchronizer ring

and 4th speed gear.
Clearance
Model
TC5RYA4 1 ~ 2 mm 0.8 mm
5RYL 1 ~ 2 mm 0.8 mm
CAUTION
TRANSMISSION (TC5RYA4/5RYL) - INPUT SHAFT ASSY 41-61
3. ASSEMBLE INPUT SHAFT ASSY.

(a) Using a press machine, install the input shaft bearing.
41
(b) Install the input shaft snap ring with a snap ring pliers.
41
MEMO
CLUTCH
17A
CLUTCH SYSTEM ............................................................................. 42-1
PRECAUTION.............................................................................. 42-1
CLUTCH FLUID.................................................................................. 42-3 17A
BLEEDING ................................................................................... 42-3
CLUTCH PEDAL ................................................................................ 42-4
ADJUSTMENT ............................................................................. 42-4
REPLACEMENT .......................................................................... 42-5 17A
CLUTCH MASTER CYLINDER ASSY............................................... 42-7
COMPONENTS ........................................................................... 42-7
REPLACEMENT .......................................................................... 42-8
CLUTCH SLAVE CYLINDER........................................................... 42-12
COMPONENTS ......................................................................... 42-12
OVERHAUL ............................................................................... 42-13
CLUTCH SUB - ASSY...................................................................... 42-15
COMPONENTS ......................................................................... 42-15
OVERHAUL ............................................................................... 42-16
42
CLUTCH - CLUTCH SYSTEM 42-1
CLUTCH SYSTEM
CLUTCH
PRECAUTION
1. CLUTCH SYSTEM PRECAUTION. 42
(a) To avoid spreading clutch dust, do not clean any clutch components with sand paper, dry brush or
compressed air. only use a water dampened towel to clean clutch components.
42
42-2 CLUTCH - CLUTCH SYSTEM

1. Clutch pedal free play(Out of Chapter 42 clutch - clutch pedal, adjustment

adjustment)
2. Clutch disk (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch slips
3. Flywheel ( Warped) Chapter 42 clutch - clutch subassy, overhaul
4. Clutch cover (Warped) Chapter 42 clutch - clutch subassy, overhaul
5. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul
1. Clutch pedal free play (Out of Chapter 42 clutch - clutch pedal, adjustment
adjustment)
2. Diaphragm spring (Failure) Chapter 42 clutch - clutch subassy, overhaul
3. Clutch master cylinder Chapter 42 clutch - clutch master cylinder

(Leaking) assy, replacement
Chapter 42 clutch - clutch slave cylinder assy,

4. Clutch slave cylinder (Leaking) replacement
Clutch does not disengage
5. Clutch line (Air in line) Chapter 42 clutch - clutch fluid, bleeding
7. Clutch cover (Warped) Chapter 42 clutch - clutch subassy, overhaul
8. Clutch release bearing (Worn) Chapter 42 clutch - clutch subassy, overhaul
9. Clutch release fork (Worn) Chapter 42 clutch - clutch subassy, overhaul
1. Torsion spring (Fracture) Chapter 42 clutch - clutch subassy, overhaul

Clutch noisy
3. Clutch release bearing (Loose) Chapter 42 clutch - clutch subassy, overhaul
4. Clutch pedal (Warped) Chapter 42 clutch - clutch pedal, replaecment
1. Clutch disk (Worn or warped) Chapter 42 clutch - clutch subassy, overhaul
2. Flywheel (Worn) Chapter 42 clutch - clutch subassy, overhaul
3. Clutch cover (Worn) Chapter 42 clutch - clutch subassy, overhaul

Clutch chatters
4. Torsion spring (Fracture or Chapter 42 clutch - clutch subassy, overhaul
warped)
5. Diaphragm spring (Warped) Chapter 42 clutch - clutch subassy, overhaul
6. Engine mount (Loose) -

CLUTCH - CLUTCH FLUID 42-3
CLUTCH FLUID
BLEEDING
42
1. FILL THE FLUID RESERVOIR WITH CLUTCH FLUID.
Clutch fluid: DOT3
NOTE
Clutch fluid will damage painted surfaces and irritate skin. If
clutch fluid is spilled on any painted surfaces or skin, wash
2. BLEED CLUTCH SLAVE CYLINDER ASSY.

(a) Connect a hose to the bleeder plug.
(b) Depress the clutch pedal several times, then loosen the
bleeder plug with the pedal held down.
(c) When clutch fluid stops flowing, tighten the bleeder plug,
then release the clutch pedal.
(d) Repeat steps (b) and (c) until all the air in the system has
been bled out.
42
3. CHECK FLUID LEVEL IN FLUID RESERVOIR.

(a) Check the fluid level and fill the fluid reservoir with clutch
fluid if necessary.
42-4 CLUTCH - CLUTCH PEDAL
CLUTCH PEDAL
ADJUSTMENT
1. INSPECT CLUTCH PEDAL HEIGHT H AND PUSH
ROD PLAY L.
(a) Inspect the height between the clutch pedal and floor.
(b) Inspect the push rod play.
Specification: 1 ～ 5 mm
2. ADJUST CLUTCH PEDAL HEIGHT AND PUSH ROD
PLAY.
(a) Loosen the lock nut and turn the stop bolt until the height
is correct. Tighten the lock nut.
Torque: 25 N•m
NOTE
B is the clutch pedal height adjustment point.
(b) Loosen the lock nut and turn the push rod until the clutch
pedal free play is correct.
Torque: 25 N•m
NOTE
A is the push rod play adjustment point.
3. ADJUST CLUTCH PEDAL FREE PLAY L1.

(a) Depress the clutch pedal until the pedal resistance
begins to be felt. Inspect the clutch pedal free play L1.
Specification: 5 ～ 12 mm
4. ADJUST CLUTCH PEDAL FREE PLAY.
(a) Loosen the lock nut and turn the push rod until the clutch
pedal free play is correct. Tighten the lock nut.
(b) After adjusting the pedal free play, inspect the clutch
pedal height.
CLUTCH - CLUTCH PEDAL 42-5
REPLACEMENT
1. RELEASE RETURN SPRING FROM CLUTCH PEDAL.
42
2. REMOVE SPLIT PIN AND CLUTCH MASTER CYLINDER

PUSH ROD PIN.
3. LOOSEN NUT AND REMOVE CLUTCH PEDAL PIN,

BUSHING AND RETURN SPRING. 42
4. REMOVE CLUTCH PEDAL.

42-6 CLUTCH - CLUTCH PEDAL
5. INSTALL CLUTCH PEDAL PIN, BUSHING AND RETURN

SPRING, THEN TIGHTEN NUT.
NOTE
Before installation, apply grease to the bushing.
6. INSTALL SPLIT PIN AND CLUTCH MASTER CYLINDER

PUSH ROD PIN.
7. INSTALL RETURN SPRING TO CLUTCH PEDAL.
8. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch
pedal, adjustment”)
9. INSPECT AND ADJUST THE CLUTCH PEDAL FREE PLAY AND PUSH ROD PLAY. (Refer to
“Chapter 42 clutch - clutch pedal, adjustment”)
CLUTCH - CLUTCH MASTER CYLINDER ASSY 42-7
CLUTCH MASTER CYLINDER ASSY

COMPONENTS
42
42
1 Clutch Master Cylinder 7 Dust Boot
2 Spring 8 Lock Nut
3 Piston 9 Split Pin
4 Clutch Master Cylinder Push Rod 10 Push Rod Clevis
5 Washer 11 Clutch Master Cylinder Push Rod Pin
6 Snap Ring
42-8 CLUTCH - CLUTCH MASTER CYLINDER ASSY
REPLACEMENT
1. DRAIN CLUTCH FLUID COMPLETELY.
NOTE
Clutch fluid will damage painted surfaces and irritate skin. If clutch fluid is spilled on any painted
3. REMOVE CLUTCH MASTER CYLINDER ASSY.

(a) Remove split pin and clutch master cylinder push rod pin.
(b) Remove the clamp, then disconnect the hose from fluid
reservoir.
NOTE
Clutch fluid will damage painted surfaces and irritate skin. If
clutch fluid is spilled on any painted surfaces or skin, wash
(c) Loosen the nut and disconnect the clutch master cylinder
tube from the clutch master cylinder.
(d) Loosen 2 nuts and remove the clutch master cylinder

assy.
42
4. DISASSEMBLE CLUTCH MASTER CYLINDER.

(a) Loosen the lock nut and remove the push rod clevis.
(b) Remove the lock nut and dust boot.
(c) Fix the clutch master cylinder with a bench vice. While
pushing the push rod, use snap ring plier to remove the
NOTE
The piston may pop up out of the cylinder body. Therefore, 42
slowly remove the push rod from the cylinder body.
(d) Remove the spring and piston.

NOTE
Please remove the piston parellel to the cylinder body.
5. ASSEMBLE CLUTCH MASTER CYLINDER.

(a) Apply grease to the piston in the areas indicated by the
arrows.
(b) Fix the clutch master cylinder with a bench vice. While
pushing the push rod, use snap ring plier to install the
(c) Install the lock nut and dust boot.
(d) Install the lock nut and the push rod clevis.
42-10 CLUTCH - CLUTCH MASTER CYLINDER ASSY
6. INSTALL CLUTCH MASTER CYLINDER .

(a) Install the clutch master cylinder assy then tighten 2 nuts.
Torque: 12 N•m
(b) Connect the clutch master cylinder tube to the clutch

master cylinder.
Torque: 15 N•m
(c) Connect the hose to the clutch master cylinder and install
the clamp.
(d) Install clutch master cylinder push rod pin and split pin.
8. BLEED AIR FROM CLUTCH SYSTEM. (Refer to “Chapter 42 clutch - clutch fluid, bleeding”)
42
9. INSPECT AND ADJUST THE CLUTCH PEDAL HEIGHT. (Refer to “Chapter 42 clutch - clutch
pedal, adjustment”)
10. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,
bleeding”)
42
42-12 CLUTCH - CLUTCH SLAVE CYLINDER
CLUTCH SLAVE CYLINDER

COMPONENTS
1 Bleeder Plug 4 Piston
2 Clutch Slave Cylinder 5 Dust Boot
3 Spring 6 Clutch Slave Cylinder Assy Push Rod

CLUTCH - CLUTCH SLAVE CYLINDER 42-13
OVERHAUL
1. DRAIN CLUTCH FLUID COMPLETELY.
NOTE 42
Clutch fluid will damage painted surfaces and irritate skin. If clutch fluid is spilled on any painted
2. REMOVE CLUTCH SLAVE CYLINDER ASSY.

(a) Loosen the nut, then disconnect the hose from clutch
slave cylinder.
(b) Remove 2 bolts from the clutch slave cylinder then

remove the clutch slave cylinder.
42
3. DISASSEMBLE CLUTCH SLAVE CYLINDER ASSY.

(a) Remove the bleeder plug, dust boot and push rod.
(b) Remove the piston and spring.

42-14 CLUTCH - CLUTCH SLAVE CYLINDER
4. ASSEMBLE CLUTCH SLAVE CYLINDER ASSY.

(a) Install the piston and spring.
(b) Install the bleeder plug, dust boot and push rod.
5. INSTALL CLUTCH SLAVE CYLINDER ASSY.

(a) Install clutch slave cylinder and tighten 2 bolts .
(b) Connect the hose to the clutch slave cylinder and tighten
the nut.
6. BLEED AIR FROM CLUTCH SYSTEM. (Refer to “Chapter 42 clutch - clutch fluid, bleeding”)
7. CHECK FLUID LEVEL IN CLUTCH FLUID RESERVOIR. (Refer to “Chapter 42 clutch - clutch fluid,
bleeding”)
CLUTCH - CLUTCH SUB - ASSY 42-15
CLUTCH SUB - ASSY

COMPONENTS
42
42
1 Flywheel 6 Clutch Release Bearing Hub Clip
2 Clutch Disk 7 Clutch Release Fork Dust Boot
3 Clutch Cover 8 Clutch Release Fork
4 Bolt 9 Release Fork Support
5 Clutch Release Bearing

42-16 CLUTCH - CLUTCH SUB - ASSY
OVERHAUL
1. REMOVE TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (TC5RYA4/5RYL) -
transmission assy, replacement”)
2. REMOVE CLUTCH RELEASE BEARING AND CLUTCH

RELEASE FORK.
(a) Remove clutch release bearing hub clip.
(b) Remove clutch release bearing.
(c) Remove clutch release fork.
3. REMOVE CLUTCH RELEASE FORK DUST BOOT.

4. REMOVE CLUTCH COVER.

(a) Make sure the marks on the clutch cover align with the
one on the flywheel.
(b) Diagonally loosen each bolt one turn at a time until 42
spring tension is released. Then remove 6 bolts.
(c) Remove the clutch cover.

NOTE
Do not drop the clutch disk assy.
42
5. REMOVE CLUTCH DISK.

NOTE
Keep the clutch disk away from oil and grease.
6. INSPECT CLUTCH DISK.

(a) Measure the rivet head depth with a vernier caliper.
Replace the clutch disk if necessary.
Minimum value: 0.3 mm
(b) Measure the runout of the clutch disk with a dial indicator.
(c) Check the surface of the clutch disk for loose rivets,
uneven contact or adhesion of oil or grease. Replace
(d) Check the torsion spring for clearance and wear.
7. INSPECT CLUTCH COVER.

(a) Measure the depth and width of diaphragm spring for
wear with a vernier caliper.
Specification (DEPTH) : 0.6 mm
Specification (WIDTH) : 5.0 mm
(b) Measure the height of the diaphragm spring. Replace the
clutch disk if necessary.
(c) Inspect the surface of the clutch cover for wear and
cracks. Replace the clutch disk if necessary.
(d) Inspect the strap plate rivets for looseness. Replace with
the clutch cover if necessary.
8. INSPECT FLYWHEEL.
(a) Measure the runout of flywheel with a dial indicator.
9. INSPECT CLUTCH RELEASE BEARING.

(a) Inspect the clutch release bearing for wear, noise or
improper rotation. Inspect the friction surface between
the clutch release bearing and the diaphragm spring for
wear. Replace all worn parts as necessary.
NOTE
The bearing is permanently lubricated and requires no
cleaning or lubrication.
CAUTION
• Inspect the inside and outside surface for wear or
damage. Replace with new part if necessary.
• Inspect the friction surface of clutch release bearing 42
and release fork for wear. Replace with new part if
necessary.
10. INSPECT CLUTCH RELEASE FORK.

(a) Inspect the position of the clutch release fork as shown
by arrows for wear and shape change. Replace if
necessary.
11. INSTALL CLUTCH DISK.

(a) Install the clutch disk with a special tool.
NOTE
Take care not to install the clutch disk in the wrong direction.
42
12. INSTALL CLUTCH COVER.

(a) Make sure the marks on the clutch cover align with the
one on the flywheel.
(b) Install the clutch cover with a special tool.
(c) Diagonally tighten all 6 bolts.

Torque: 24 N•m
13. INSPECT AND ADJUST CLUTCH COVER.

(a) Inspect the height of the diaphragm spring after installation.
Adjust the tip of the diaphragm spring if necessary.
14. INSTALL CLUTCH RELEASE FORK DUST BOOT.
15. INSTALL CLUTCH RELEASE BEARING AND CLUTCH

RELEASE FORK.
(a) Apply grease to the release fork in the areas indicated by
the arrows.
(b) Install clutch release fork.

CAUTION
Install the clutch release fork to the release fork support.
42
(c) Install clutch release bearing.

NOTE
Apply grease to the friction surface between the clutch
release bearing and the release fork before installation.
(d) Install clutch release bearing hub clip.
42
16. INSTALL TRANSMISSION ASSY. (Refer to “Chapter 41 transmission (TC5RYA4/5RYL) - transmission

assy, replacement”)
MEMO
STEERING COLUMN
18A
STEERING SYSTEM.......................................................................... 51-1
PRECAUTION.............................................................................. 51-1
COMPONENTS ........................................................................... 51-5 18A
STEERING WHEEL ASSY................................................................. 51-7
OVERHAUL ................................................................................. 51-7
COMBINATION SWITCH ASSY ...................................................... 51-11 18A
COMPONENTS ......................................................................... 51-11
REPLACEMENT ........................................................................ 51-12
STEERING COLUMN ASSY ............................................................ 51-15
OVERHAUL ............................................................................... 51-15
STEERING PROPELLER SHAFT ASSY......................................... 51-20
OVERHAUL ............................................................................... 51-20
51
STEERING COLUMN - STEERING SYSTEM 51-1
STEERING SYSTEM
STEERING COLUMN
PRECAUTION
1. STEERING SYSTEM PRECAUTION. 51
(a) Be careful when replacing parts.
(b) Incorrect service may affect the performance of the steering system and result in danger.
51
51-2 STEERING COLUMN - STEERING SYSTEM

1. Front axle (Overloaded) -
Chapter 33 tire and wheel - tire and wheel, on-

2. Tire (Insufficient pressure) vehicle inspection
Chapter 52 power steering - steering fluid,

3. Power steering fluid level (Low) replacement
Chapter 52 power steering - steering fluid

4. Steering fluid reservior (Filter jammed) reservior, replacement
Chapter 52 power steering - steering box,over-

5. Power steering system (Leaking) haul

6. Drive belt (Loose or skid) system, on-vehicle inspection

7. Front wheel alignment (Incorrect) alignment, adjustment
Chapter 34 axle and propeller shaft - steering

Steering heavily 8. Steering knuckle (Worn) knuckle, overhaul

9. Steering knuckle arm (Worn) knuckle, overhaul

10. Ball joint (Worn) knuckle, overhaul
Chapter 51 steering column - steering column

11. Steering column (Bent) assy, overhaul
Chapter 51 steering column - steering propeller

12.Steering propeller shaft (Deformed) shaft assy, overhual
13.Power steering pump (Worn or Chapter 52 power steering - power steering

damaged) pump, replacement

14.Steering box (Damaged) overhual

15.Power steering line assy (Jammed) line assy, replacement

51
2. Tire (Different pressure) vehicle inspection

3. Steering knuckle (Loose or worn) knuckle, overhaul

4. Steering knuckle arm (Loose or worn) knuckle, overhaul
Wandering
5. Steering column (Loose or worn) assy, overhual
6. Steering propeller shaft (U-joint loose or Chapter 51 steering column - steering propeller
worn) shaft assy, overhual

7. Steering box (Loose or damaged) overhual

8. Power steering pump (Jammed) pump, replacement


Chapter 52 power steering - steering fluid, 51

3. Power steering system (Invading air) bleeding

4. Return hose (Curving or jammed) line assy, replacement

Poor return 5. Front wheel alignment (Incorrect) alignment, adjustment


7. Steering propeller shaft (Deformed) shaft assy, overhaul
8. Power steering pump (Worn or Chapter 52 power steering - power steering



Chapter 51 steering column - steering wheel
1. Steering wheel (Worn) assy, overhaul
2. Steering propeller shaft (U-joint loose or Chapter 51 steering column - steering propeller
worn) shaft assy, overhaul

3. Steering knuckle (Worn) knuckle, overhaul
Excessive
steering wheel Chapter 34 axle and propeller shaft - steering
4. Ball joint (Worn) knuckle, overhaul
free play
Chapter 34 axle and propeller shaft - axle hub,
5. Front hub bearing (Worn) overhaul

6. Steering box (Loose or damaged) overhaul
Chapter 52 power steering - steering column

7. Steering column (Worn) assy, overhaul

2. Steering fluid reservior (Filter jam) chapter 52 steering fluid reservior, replacement


Abnormal noise Chapter 51 steering column - steering propeller
5. Steering propeller shaft (Worn) shaft assy, overhaul


7. Steering Box (Damaged) overhaul

8. Power steering line assy (Jam) line assy, replacement


Steering not Chapter 51 steering column - steering column

smooth 3. Steering column (Worn) assy, overhaul

4. Steering propeller shaft (Worn) shaft assy, overhaul

5. Steering box (Worn or damaged) overhaul
COMPONENTS
51
51
1 Steering Wheel Assy 9 Bolt
2 Nut 10 Nut
3 Bolt 11 Bolt
4 Steering Column Assy 12 Bolt
5 Bolt 13 Steering Drive Shaft Protection Cover A
6 Column Base Frame Assy 14 Lower Steering Shaft Assy
7 Nut 15 Steering Drive Shaft Protection Cover B
8 Bolt
1. CHECK STEERING WHEEL FREE PLAY.
(a) Stop the vehicle.
(b) Turn the steering wheel to its straight position and face the
tires straight ahead.
(c) Turn the steering wheel gently left and right, check the
steering wheel free play.
Free play: ± 10 °
If the free play is out of the specification, then:
• Inspect interrelated parts. (Refer to ”Chapter 51 steering
column - steering system, problem symptoms table”)
• Inspect the maximum front wheel steering angle, adjust it if
necessary. (Refer to “Chapter 31 front suspension - front
wheel alignment, adjustment”)
2. CHECK THE OFF TRACK.

(a) Drive straightly the vehicle and along the center line of the road .
(b) Release the steering wheel and continue traveling straightly for 30 m.
(c) Measure the offset.
Offset LH: ＜ 2 m
Offset RH: ＜ 1 m
If the checking value is out of specification, there is fault on the off track for this vehicle.
STEERING COLUMN - STEERING WHEEL ASSY 51-7
STEERING WHEEL ASSY

OVERHAUL
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”) 51
2. DISCONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging -
battery, replacement”)
3. DISCONNECT BATTERY POSITIVE CABLE.
4. REMOVE HORN SWITCH ASSY.

(a) Turn the steering wheel to its straight position and face the
(b) Remove the horn switch assy directly.
51
CAUTION
Horn switch assy should be stored with the top surface
upward. Also, do not put any things on top surface of horn
switch assy.
51-8 STEERING COLUMN - STEERING WHEEL ASSY
5. REMOVE STEERING WHEEL ASSY.

(a) Remove the nut.
NOTE
Store it carefully to prevent it from being missing.
(b) Mark on the steering wheel and steering column assy.

NOTE
(c) Pull out the steering wheel from the steering column.
6. INSPECT STEERING WHEEL ASSY.

(a) Check the steering wheel for warp, micro-cracks or fracture.
(b) Check the spline for deformation or damaged above 2 teeth. If any fault is detected, replace it with a
new steering wheel.
STEERING COLUMN - STEERING WHEEL ASSY 51-9
7. INSTALL STEERING WHEEL ASSY.

(a) Align the marks on the steering wheel assy and steering
column assy.
(b) Install the steering wheel to steering column. 51
NOTE
• Be sure to perform this procedure according to the
marks.
• Make sure the tires face ahead straightly.

51
8. INSPECT STEERING WHEEL TURNING FORCE.

(a) Using a spring scales, pull the steering wheel rim tangentially,
measure the steering wheel turning force (engine stopped).
Steering wheel turning force (engine stopped): ＜ 200 N
If steering wheel turning force exceeds the maximum, inspect
interrelated parts. (Refer to “Chapter 51 steering column -
steering system, problem symptoms table”)
NOTE
For measurment, turn the steering wheel to both sides in
the range of 80°.
9. INSTALL HORN SWITCH ASSY.
(a) Install the horn switch assy.
51-10 STEERING COLUMN - STEERING WHEEL ASSY
NOTE
• There should be no interference between the horn
switch assy and steering wheel.
• The clearance between the horn switch assy and
steering wheel assy should be uniform.
10. CONNECT BATTERY POSITIVE CABLE.

11. CONNECT BATTERY NEGETIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
12. INSPECT HORN ASSY FUNCTION.
STEERING COLUMN - COMBINATION SWITCH ASSY 51-11
COMBINATION SWITCH ASSY

COMPONENTS
51
51
1 Combination Switch Upper Cover 3 Combination Switch Lower Cover
2 Combination Switch Assy

51-12 STEERING COLUMN - COMBINATION SWITCH ASSY
REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”)
4. REMOVE HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
5. REMOVE STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
6. REMOVE COMBINATION SWITCH ASSY.

(a) Remove 6 screws.
(b) Remove combination switch upper and lower cover.
(c) Disconnect combination switch assy connector.

• Remove wire harness tie belt.
• Remove conncetor from bracket.
• Disconnect the connector.

STEERING COLUMN - COMBINATION SWITCH ASSY 51-13
(d) Remove 4 screws.
51
(e) Remove the combination switch assy.
7. INSTALL COMBINATION SWITCH ASSY.

(a) Install the combination switch to steering column assy.
51
(b) Tighten 4 screws.
(c) Connect the connector , tie the wire harness and install-
the connector to its bracket.
51-14 STEERING COLUMN - COMBINATION SWITCH ASSY
(d) Install the combination switch upper and lower cover.
(e) Tighten 6 screws.
8. INSTALL STEERING WHEEL ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
9. INSTALL HORN SWITCH ASSY. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
11. CONNECT BATTERY NEGATIVE CABLE. (Refer to “Chapter 20 starting and charging - battery,
replacement”)
12. INSPECT COMBINATION SWITCH ASSY FUNCTION.
STEERING COLUMN - STEERING COLUMN ASSY 51-15
STEERING COLUMN ASSY

OVERHAUL
1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”) 51
overhaul”)
overhaul”)
6. REMOVE COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination
switch assy, replacement”)
7. REMOVE STEERING COLUMN LOWER COVER.

(b) Remove steering column lower cover. 51
(c) Disconnect the speaker connector and remove the speaker.

NOTE
Store the steering column lower cover carefully.
8. REMOVE IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal&installation
and disassembly&assembly”)
51-16 STEERING COLUMN - STEERING COLUMN ASSY
9. REMOVE STEERING COLUMN ASSY.

(a) Lift the vehicle and remove the engine guard plate.
(b) Mark on the steering column and steering propeller shaft.

NOTE
• Keep the front tires from turning.
(c) Remove bolt and nut.
(d) Pull the U-joint of the steering column assy up from the
steering propeller assy.
(e) Lower the vehicle.

(f) Remove 4 bolts.
51
(g) Pull out and remove the steering column assy.

NOTE
When storage, cover the splines with gum cap or soft cloth
on the both sides to prevent damage.
51
CAUTION
Be sure to store the steering column carefully, especially
for the splines.
10. INSPECT STEERING COLUMN ASSY.

(a) Inspect the splines.
• Check for rusting, crack and fracture.
• Check for deformation or damaged above 2 teeth.
If any fault is detected, replace it with a new steering column assy.
51-18 STEERING COLUMN - STEERING COLUMN ASSY
11. INSTALL STEERING COLUMN ASSY.

(a) Positon the steering column assy properly.
(b) Tighten 4 bolts.
(c) Lift the vehicle.

(d) Install the steering propeller shaft to the steering column
assy according to the marks.
NOTE
marks.
(e) Tighten the bolt and nut.

(f) Install engine guard plate.

• Positon the engine guard plate properly.
• Tighten 4 bolts.
• Lower the vehicle.
12. INSTALL IGNITION SWITCH ASSY. (Refer to “Chapter 91 vehicle control system - removal &
installation and disassembly & assembly”)
13. INSTALL STEERING COLUMN LOWER COVER.

51
(a) Install speaker and connect its connector.
(b) Positon the steering column lower cover properly.
(c) Tighten 3 screws.
51
14. INSTALL COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination
overhaul”)
overhaul”)
replacement”)
51-20 STEERING COLUMN - STEERING PROPELLER SHAFT ASSY
STEERING PROPELLER SHAFT ASSY

OVERHAUL
1. REMOVE ENGINE LOWER GUARD PLATE.
(a) Remove 4 bolts.
(b) Remove the engine guard plate.
2. REMOVE STEERING PROPELLER SHAFT ASSY.

(a) Mark on the steering propeller shaft and the steering
column assy.
NOTE
(b) Remove the bolt and nut.
(c) Pull the U-joint of steering column assy up from the

steering propeller shaft assy.
STEERING COLUMN - STEERING PROPELLER SHAFT ASSY 51-21
(d) Remove 3 bolts.
51
(e) Remove the propeller shaft protective housing.
(f) Mark on the steering box and the steering propeller shaft.
NOTE
• Keep the front tire from turning.
51
(g) Remove the bolt and nut.
(h) Loosen 2 bolts and 1 nut of the retarder.

51-22 STEERING COLUMN - STEERING PROPELLER SHAFT ASSY
(i) Remove the steering properller assy from vehicle chassis.

CAUTION
Be sure to store the steering propeller shaft carefully to
prevent damage, expecially the splines.
3. INSPECT THE STEERING COLUMN ASSY.

(a) Check the steering column assy for bend.
Replace with a new steering propeller shaft when necessary.
(b) Inspect the splines, splined sleeves and U-joint yoke.
• Check for warp, micro-cracks or fracture.
• Check for deformation or damaged above 2 teeth.
If any fault is detected, replace with a new steering propeller shaft assy.
(c) Inspect the steering propeller shaft U-joint.
• Check bearing surface for crack, fault or needle insufficiency.
• Check bearing gasket and seal cover for damaged.
• Check U-joint for cross shaft wear and crack.
• Check U-joint for rolling smooth.
Replace with a new steering propeller shaft when necessary.
• Measure the clearance between the cross shaft necks and bearings.
Clearance: ≤ 0.15 mm
If the clearance exceeds the manximum, replace it with a new steering propeller shaft.
4. INSTALL STEERING PROPELLER SHAFT.

(a) Insert the steering propeller shaft assy from venicle chassis.
NOTE
Make sure the steering propeller shaft assy is in the correct direction.
(b) Install the steering propeller shaft to the steering column

NOTE
marks.
(c) Tighten the bolt and nut.

STEERING COLUMN - STEERING PROPELLER SHAFT ASSY 51-23
(d) Position retarder properly.

(e) Tighten 2 bolts and 1 nut.
51
(f) Install the steering propeller shaft to the steering box

NOTE
marks.
(g) Tighten the bolt and nut.

51
(h) Install protective housing of steering propeller shaft assy.

5. INSTALL ENGINE GUARD PLATE.

(a) Position the engine guard plate properly.
MEMO
POWER STEERING
52
POWER STEERING SYSTEM ........................................................... 52-1
PRECAUTION.............................................................................. 52-1
COMPONENTS ........................................................................... 52-5 52
STEERING FLUID ............................................................................ 52-15
REPLACEMENT ........................................................................ 52-15
BLEEDING ................................................................................. 52-17 52
POWER STEERING FLUID RESERVIOR ....................................... 52-19
REPLACEMENT ........................................................................ 52-19
POWER STEERING PUMP ASSY................................................... 52-22
REPLACEMENT ........................................................................ 52-22
POWER STEERING LINE ASSY ..................................................... 52-27
REPLACEMENT ........................................................................ 52-27
STEERING BOX............................................................................... 52-30
OVERHAUL ............................................................................... 52-30
52
52
POWER STEERING - POWER STEERING SYSTEM 52-1
POWER STEERING SYSTEM

POWER STEERING
PRECAUTION
1. POWER STEERING SYSTEM PRECAUTION. 52
(a) Be careful when replacing parts.
(b) Incorrect service may affect the performance of the steering system and result in danger.
2. MAINTAINING THE POWER STEERING SYSTEM PRECAUTION.
(a) Be sure to use the specified steering fluid.
Steering fluid: ATF- Ⅱ / Ⅲ
(b) Replace the steering fluid and clean the fluid reservior in the first 2500 Km for a new steering box. Then
repeat these two operations in each following 5000 Km or 1 year. (Refer to “Chapter 52 power steering
- steering fluid, replacement”)
(c) Check the steering fluid level and whether the fluid goes bad or impurities exist every month. (Refer to
“Chapter 52 power steering - power steering system, on-vehicle inspection”)
(d) Regularly check at least each 5000 Km.
• Check for loose.
• Check steering system operation.
52
52-2 POWER STEERING - POWER STEERING SYSTEM

1. Front axle (Overloaded) -


Chapter 52 power steering - steering fluid

4. Steering fluid reservior (Filter jammed) reserrvior, replacement

5. Power steering system (Leaking) overhaul


7. Front wheel alignment (Incorrect) alignment, adjustment

Steering heavily 8. Steering knuckle (Worn) knuckle, overhaul

9. Steering knuckle arm (Worn) knuckle, overhaul
Chapter 31 front suspension - lower control

10. B-joint (Worn) arm, replacement


12.Steering propeller shaft (Deformed) propeller shaft assy, overhaul
13.Power steering pump (Worn or Chapter 52 power steering - power steering


14.Steering box (Damaged) overhaul

15.Power steering line assy (Jammed) line assy, replacement

52
2. Tire (Different pressure) vehicle inspection


Wandering 4. Steering knuckle arm (Worn) knuckle, overhaul

5. Steering column (Loose or worn) assy, overhaul
6. Steering propeller shaft (U-joint loose Chapter 51 steering column - steering

or worn) propeller shaft assy, overhaul

7. Steering box (Loose or damaged) overhaul
1. Overload -
Steering box
overheat 2. Operation (Incorrect) -
(It exceeds the
enviromental 3. Power steering pump (Exsessive flow) pump, replacement
temperature more
than 65 ℃ ) 4. Power steering line assy (Deformed or Chapter 52 power steering - power steering
jammed) line assy, replacement

1. Tire (Insufficient pressure) vehicle inspection 52


4. Return hose (Curving or jammed) line assy, replacement

Poor return 5. Front wheel alignment (Incorrect) alignment, adjustment

6. Steering column (Bent) assy, inspection

7. Steering propeller shaft (Deformed) propeller shaft assy, overhaul



1. Steering wheel (Worn) assy, overhaul
2. Steering propeller shaft (U-joint loose Chapter 51 steering column - steering

or worn) propeller shaft assy, overhaul

Excessive 3. Steering knuckle (Worn) knuckle, overhaul
steering wheel
free play Chapter 34 axle and propeller shaft - steering
4. B-joint (Worn) knuckle, overhaul
Chapter 34 axle and propeller shaft - axle hub,

5. Front hub bearing (Worn） overhaul

6. Steering Box (Loose or damaged) overhaul

hapter 52 power steering - steering fluid

2. Steering fluid reservior (Filter jammed) reservior, replacement


Abnormal noise
5. Steering propeller shaft (Worn) propeller shaft assy, overhaul

damaged) pump, overhaul


8. Power steering line assy (Jammed) line assy, replacement

2. Power steering system (Invading air) Chapter 52 power steering - steering fluid,
bleeding
Steering irregular- 3. Steering column (Worn) Chapter 51 steering column - steering column
ity assy, overhaul
4. Steering propeller shaft (Worn) Chapter 51 steering column - steering

propeller shaft assy, overhaul

5. Steering box (Worn or damaged) overhaul
COMPONENTS
LHD
52
52
1 Front Shield Plug 12 High Pressure Oil Pipe Assy
2 Front Protection Clip 13 Bolt
3 Bolt 14 Oil Pump Pulley
4 Steering Box Stop Plate Lh 15 Oil Pump Assy With Bracket
5 Bolt 16 Tensioner With Bracket Assy
6 Steering Box Stop Plate Rh 17 Tensioner Bracket
7 Bracket Assy Rh 18 Hexagon Bolt And Washer
8 Bracket Bushing Rh 19 Steering Pump
9 Bracket Bushing Lh 20 Tie Rod
10 Bracket Assy Lh 21 Automobile V-belt
11 Bolt 22 Inlet Pipe

23 Cotter Pin 30 Steering Pump Bracket
24 Nut 31 Hexagon Nut
25 Plain Washer 32 Hollow Bolt
26 Spring Washer 33 Washer
27 Hexagon Bolt 34 Retarder Bracket Assy
28 Hexagon Bolt 35 Steering Retard Assy
29 Hexagon Bolt
STEERING BOX(RHD)
52
52
1 Steering Box 6 Bracket Assy
2 Nut 7 Bolt
3 Cotter Pin 8 Steering Box Stop Plate
4 Bolt 9 Bolt
5 Bracket Bushing
1. INSPECT DRIVE BELT.
(a) Visual check for exsessive wear, etc.
If any fault is found, replace the drive belt.
NOTE
Cracks on the rib side of a belt are considered acceptable. If
the missing chunks from the ribs are found on the belt, it
should be replaced.
(b) Check the deflection.

• Apply a force of 98 N to push the middle of the drive belt
and adjust deflection if necessary.
Deflection (Gasoline vehicle) : ≤ 4.0 ～ 6.0 mm
Deflection (Diesel vehicle) : ≤ 6.0 ～ 8.0 mm
CAUTION
Make sure the engine is stopped before performing this
operation.
2. CHECK STEERING FLUID LEVEL.
(a) Park the vehicle on a flat road.
(b) Check the steering fluid level.

• Fill the steering fluid if necessary. (Refer to “Chapter 52
power steering - steering fluid, replacement”)
NOTE
• Make sure the egnine is stopped.
• Check that the fluid level is within the COLD range, if
the fluid is cold.
• Check that the fluid level is within the HOT range, if
the fluid is hot.
(c) Start the engine and run it at idle.

(d) Turn the steering wheel fully to the right and left several
times to get fluid temperature high.
Fluid temperature: - 40 ～ 120 ℃
NOTE
• Make sure the time will not exceed 4 seconds when
steering wheel stays at full lock position, otherwise it
will damage the power steering pump. 52
• Lift front wheels off the ground with jack or lift.
(e) Check fluid for foam and emulsification.

If foam or emulsification is identified, bleed the power steering
sysytem. (Refer to “Chapter 52 power steering - steering fluid,
bleeding”)
(f) With the engine idling, measure the steering fluid level in
the fluid reservior.
NOTE
Check that the fluid level is within the HOT range, if the fluid
is hot.
(g) Stop the engine.
(h) Wait a few minutes, measure the steering fluid level in
the fluid reservior again.
NOTE
52
the fluid is cold.
the fluid is hot.
(i) Check steering fluid level between procedure (f) and (h).
Steering fluid level difference: ≤ 5 mm
If the difference is out of the specification, bleed the power
steering system. (Refer to “Chapter 52 power steering - steering
fluid, bleeding”)
(j) Check the steering fluid level finally and fill the steering
fluid if necessary.
3. CHECK STEERING FLUID PRESSURE.

(a) Turn over the driver seat.
(b) Drain the steering fluid. (Refer to “Chapter 52 power
steering - steering fluid, replacement”)
(c) Separate the high-pressure tube from power steering

pump.
CAUTION
Be sure to keep tube clean and prevent dirt entry.
• Diesel vehicles
• Gasoline vehicles
(d) Connect the SST, as shown in the illustration.

CAUTION
• Be sure to keep it clean and prevent dirt entry.
• Check that the valve of the SST is in “OPEN” position.
• Diesel vehicles.
52
• Gasoline vehicles.
52
(e) Fill the steering fluid. (Refer to “Chapter 52 power

(f) Bleed the power steering system. (Refer to “Chapter 52
power steering - steering fluid, bleeding”)
(g) Start the engine and run it at idle.
(h) Turn the steering wheel fully to the right and left several
times to get fluid temperature high.
Fluid temperature: - 40 ～ 120 ℃
CAUTION
• Make sure the time will not exceed 4 seconds when
steering wheel stays at full lock position, otherwise it
will damage the power steering pump.
• Lift front wheels off the ground with jack or lift.
(i) When the engine idling, close the valve of the SST.
(j) Check the measurment value on the SST.
If measurment value is abnormal, inspect the fulid line between
the steering pump assy and steering fulid reservior, steering
pump assy and steering fulid reservior. (Refer to “Chapter 52
power steering - power steering system, problem symptoms
table”)
CAUTION
• Do not close the valve for more than 4 seconds.
• Do not let the fluid temperature become too high.
(k) When the engine idling, open the valve of the SST.
(l) Measure the fluid pressure when engine is running at
1000 rpm and 3000 rpm.
If measurment value is abnormal, inspect interrelated parts.
(Refer to “Chapter 52 power steering - power steering system,
problem symptoms table”)
CAUTION
Do not turn the steering wheel.
(m) When the engine idling and the valve fully opened, turn
the steering wheel to full lock position.
(n) Check the measurment value on the SST.
Pressure: ≤ 8 MPa
If measurment value is out of specification, inspect interrelated
parts. (Refer to “Chapter 52 power steering - power steering
system, problem symptoms table”)
CAUTION
• Do not close the valve for more than 4 seconds.
• Do not let the fluid temperature become too high.
(o) Drain the steering fluid. (Refer to “Chapter 52 power

steering system - steering fulid, replacement”)
(p) Remove the SST.
CAUTION
Be sure to keep tube clean and prevent dirt entry.
(q) Replace the seal gasket and coat the sealant on the
high-pressure tube connector.
(r) Install the high-pressure tube to power steering pump.

CAUTION
Be sure to keep it clean and prevent dirt entry.
• Diesel vehicles.
• Gasoline vehicles.
52
(s) Fill the steering fluid. (Refer to “Chapter 52 power

(t) Bleed the power steering system. (Refer to “Chapter 52
power steering - steering fluid, bleeding ”)
4. INSPECT STEERING WHEEL TURNING FORCE.

(b) Remove the horn switch assy. (Refer to “Chapter 51

steering column - steering wheel assy, overhaul”)
52
(c) Start the engine and run it at idle.
(d) Using a torque wrench, measure the steering wheel turning

force (engine idling)
Steering wheel turning force (engine idling): ＜ 45 N
NOTE
Take the tire type, pressure and contact surface into your
consideration before diagnosis.
(e) Tighten the steering wheel lock nut.

(f) Install the horn switch assy. (Refer to “Chapter 51 steering

column - steering wheel assy, overhaul”)
5. CHECK THE OFF TRACK.
(a) Driving straightly (40Km/h) along the center line of the road.
(b) Release the steering wheel and continue traveling straightly for 30 m.
(c) Measure the offset in 30 m distance.
Offset LH: ＜ 2 m
Offset RH: ＜ 1 m
If the measurement value is out of the specification, there is fault on the off track for this vehicle.
POWER STEERING - STEERING FLUID 52-15
STEERING FLUID
REPLACEMENT
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”) 52
2. DRAIN STEERING FLUID.

(a) Remove the steering fluid reservior cap when turning it
counterclockwise.
CAUTION
(b) Lift front wheels off the ground with jack or lift.
(c) Remove engine guard plate.

(d) Loosen the nut and separate the low-pressure pipe from
steering box.
CAUTION
(e) Start the engine and run it at idle.

(f) Drain the steering fluid.
52
(g) Turn the steering wheel fully to the right and left several
times until steering fluid is drained fully.
CAUTION
• Do not perform this operation for more than 10 seconds.
• Make sure the time when steering wheel stays at full
lock position will not exceed 4 seconds, otherwise it
will damage the power steering pump.
(h) Stop the engine.
3. FILL STEERING FLUID.

(a) Lift the vehicle.
(b) Install the low-pressure pipe to steering box and tighten
it.
CAUTION
(c) Lower the vehicle.

52-16 POWER STEERING - STEERING FLUID
(d) Fill the steering fluid.

Volumn: 0.4 L
(e) Start the engine and run it at idle.
(f) Turn the steering wheel fully to the right and left several
times until the fluid will not be emulsifiable and the level
will no longer drop down.
CAUTION
Make sure the time when steering wheel stays at full lock
position will not exceed 4 seconds, otherwise it will damage
the power steering pump.
(g) Check the steering fluid level and fill the steering fluid if
necessary. (Refer to “Chapter 52 power steering - power
steering system, on-vehicle inspection”)
NOTE
the fluid is cold.
the fluid is hot.
(h) Install the reservior cap when turning it clockwise.

CAUTION
(i) Stop the engine.

(j) Lift the vehicle.
(k) Check the steering box and steering line for leakage.
(l) Lower the vehicle.
POWER STEERING - STEERING FLUID 52-17
BLEEDING
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system”)
2. BLEED POWER STEERING SYSTEM.
52
(a) Lift front wheels off the ground with jack or lift.
(b) Remove the steering fluid reservior cap when turning it

counterclockwise.
CAUTION
(c) Turn the steering wheel fully to the right and left several
times.
(d) Start the engine and run it at idle.
(e) Turn the steering wheel.
• Turn the steering wheel to left full lock position for 2 ～ 3
seconds, then turn to the opposite full lock position for 2
～ 3 seconds.
• Repeat the previous procedure several times.
CAUTION
Make sure the time when steering wheel stays at full lock
position will not exceed 4 seconds, otherwise it will damage 52
the power steering pump.
(f) Stop the engine.
(g) Check for foam or emulcification.

If foam or emulsification is identified, repeat the procedures (c)
～ (f).
NOTE
If the system has to be bled twice becauce of foam or
emulcification, check for fluid leakage in the system.
52-18 POWER STEERING - STEERING FLUID
(h) Check the steering fluid level and fill the steering fluid if
necessary. (Refer to “Chapter 52 power steering - power
steering system, on-vehicle inspection”)
NOTE
the fluid is cold.
the fluid is hot.
(i) Install the reservior cap when turning it clockwise.

CAUTION
(j) Stop the engine.

(k) Lower the vehicle.
POWER STEERING - POWER STEERING FLUID RESERVIOR 52-19
POWER STEERING FLUID RESERVIOR

REPLACEMENT
2. TURN OVER THE DRIVER SEAT.
3. DRAIN FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
4. REMOVE STEERING FLUID RESERVIOR.

(a) Diesel vehicles:
• Separate the fluid line from the power steering pump assy
and steering box.
CAUTION
• Remove bolts and the steering fluid reservior. 52

CAUTION
(b) Casoline vehicles:

• Separate the fluid line from the power steering pump assy
and steering box.
CAUTION
52-20 POWER STEERING - POWER STEERING FLUID RESERVIOR
• Remove bolts and the steering fluid reservior.

CAUTION
5. INSTALL STEERING FLUID RESERVIOR.

• Tighten bolts and install the steering fluid reservior.
• Connect the fluid line from the power steering pump assy
and steering box to steering fluid reservior.
CAUTION
(b) Casoline vehicles:

• Tighten bolts and install the steering fluid reservior.
• Connect the fluid line from the power steering pump assy
and steering box to steering fluid reservior .
CAUTION
POWER STEERING - POWER STEERING FLUID RESERVIOR 52-21
6. FILL THE STEERING FLUID. (REFER TO “CHAPTER 52 POWER STEERING - STEERING FLUID,
REPLACEMENT”)
7. BLEED THE POWER STEERING SYSTEM. (REFER TO “CHAPTER 52 POWER STEERING -
STEERING FLUID, BLEEDING”) 52
52
52-22 POWER STEERING - POWER STEERING PUMP ASSY
POWER STEERING PUMP ASSY

REPLACEMENT
CAUTION
• Do not disassemble the power steering pump because of its high precision.
• If steering pump damaged, relace the new steering pump.
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”)
2. TURN OVER THE DRIVER SEAT.
3. DRAIN THE STEERING FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)
4. REMOVE STEERING FLUID RESERVIOR. (refer to “Chapter 53 power steering - steering fluid
reservior, replacement”)
5. SEPARATE POWER STEERING ASSY LINE FROM

STEERING BOX.
• Diesel vehicles
CAUTION
• Gasoline vehicles
CAUTION
POWER STEERING - POWER STEERING PUMP ASSY 52-23
6. REMOVE DRIVE BELT.

NOTE
The diesel vehicle procedure is same as the gasoline vehi-
cle. 52
(a) Loosen the retaining bolt from the tensioner.
NOTE
Do not remove the bolt, loosen it only.
(b) Adjust the tensioner adjusting bolt to loosen the drive

belt.
(c) Remove the drive belt.
52
7. REMOVE STEERING PUMP PULLEY.

NOTE
cle.
(a) Remove bolts.
(b) Remove steering pump pulley.

8. REMOVE THE POWER STEERING PUMP ASSY.

• Remove 2 bolts.
• Remove the power steering pump assy
(b) Gasoline vehicles:

• Remove 2 bolts.
• Remove the power steering pump assy.
9. INSTALL THE POWER STEERING PUMP ASSY.

• Position the power steering pump assy properly.
NOTE
Install the power steering pump pulley temporarily, check
whether the pump pulley is on the same plane with the
engine crankshaft pulley and tensioner .
POWER STEERING - POWER STEERING PUMP ASSY 52-25
• Position the power steering pump pulley properly.

NOTE
Make sure the power steering pump pulley is on the same
plane with the engine crankshaft pulley and tensioner. 52
• Tighten the bolts.

(b) Gasoline vehicles:

• Position the power steering pump assy properly.
NOTE
Make sure the power steering pump pulley is on the same
plane with the engine crankshaft pulley and accessory 52
pulley.
• Position the power steering pump pulley properly.
• Tighten the bolts.

10. INSTALL DRIVE BELT.

NOTE
cle.
• Install the drive belt (ribbed belt).
• Adjust the tensioner adjusting bolt to tighten the drive

belt.
• Tighten the bolt.
• Apply a force of 98 N to middle of the drive belt and
check the deflection. Adjust the tensioner adjusting bolt if
necessary.
WARNING
Be sure to make sure the egnine is stopped before performing
this operation.
11. CONNECT POWER STEERING ASSY LINE FROM STEERING BOX.

(a) Replace the seal gasket and coat the sealant on the high-pressure tube connector.
(b) Diesel vehicles:

• Replace the seal gasket and coat the sealant on the
• Install the high-pressure tube to power steering pump.
CAUTION
(c) Gasoline vehicle:

CAUTION
12. INSTALL STEERING FLUID RESERVIOR. (Refer to “Chapter 53 power steering - steering fluid
reservior, replacement”)
13. FILL THE STEERING FLUID. (Refer To “chapter 52 Power Steering - Steering Fluid, Replacement”)
14. BLEED THE POWER STEERING SYSTEM. (Refer To “chapter 52 Power Steering - Steering Fluid,
Bleeding”)
POWER STEERING - POWER STEERING LINE ASSY 52-27
POWER STEERING LINE ASSY

REPLACEMENT
3. REMOVE POWER STEERING LINE ASSY.

(a) Remove 2 power steering line assy retaining bolts.
NOTE
Loosen the 2 bolts on gasoline vehicles by the same procedures
as diesel vehicles, although the two power steering lines look
different.
(b) Separate the power steering line assy from the power
steering pump and the steering fluid reservior.
Diesel vehicles:
• Separate the high-pressure tube from the power steering
pump.
CAUTION
• Loosen the clamp and separate the low-pressure hose

52
from the steering fluid reservior.
CAUTION
Gasoline vehicles:
• Separate the high-pressure tube from the power steering
pump.
CAUTION
• Separate the low-pressure pipe from the steering fluid
reservior.
CAUTION
52-28 POWER STEERING - POWER STEERING LINE ASSY
(c) Separate the power steering line assy from the steering
box.
• Separate the high-pressure tube from the steering box.
CAUTION
• Separate the low-pressure pipe from the steering box.
CAUTION
(d) Remove the power steering line assy.

(e) Loosen 3 bolts to separate the high-pressure line assy
from the low-pressure line assy.
NOTE
Separate the high-pressure line assy from the low-pressure
line assy on gasoline vehicles by the same procedures as
diesel vehicles, although these two lines look different.
4. INSTALL POWER STEERING LINE ASSY.
(a) Tighten 3 bolts attaching the high-pressure line assy to the low-pressure line assy.
NOTE
Connect the power steering line assy on gasoline vehicles by the same procedures as diesel vehicles,
although these two lines look different.
(b) Position the power steering line assy properly.
(c) Connect the power steering line assy to the power steer-
ing pump .
Diesel vehicles:
CAUTION
Be sure to keep it clean and prevent dirt entry
• Connect the low-pressure hose to fluid reservior and

tighten the clamp.
CAUTION
POWER STEERING - POWER STEERING LINE ASSY 52-29
Gasoline vehicles:
• Install the high-pressure tube to power steering pump. 52
CAUTION
• Connect the low-pressure pipe to fluid reservior and
tighten the clamp.
CAUTION
(d) Connect the power steering line assy to the steering box.
• Connect the hig-pressure tube to the steering box.
CAUTION
• Connect the low-pressure pipe to the steering box and
tighten the nut.
CAUTION
52
(e) Tighten 2 bolts to fix power steering lines.
NOTE
Tighten the 2 bolts on gasoline vehicles by the same procedures
as diesel vehicles, although the two power steering lines look
different.
5. FILL FLUID. (Refer to “Chapter 52 power steering - steering fluid, replacement”)

Bleeding”)
52-30 POWER STEERING - STEERING BOX
STEERING BOX
OVERHAUL
NOTE
Remove and check the RHD steering box assy by the same procedures as the LHD.
CAUTION
• Do not disassemble the power steering pump because of its high precision.
• If the steering box damaged, replace the new one.
1. PRECAUTION. (Refer to “Chapter 52 power steering - power steering system, precaution”)
3. TURN STEERING WHEEL STRAIGHTLY.

tires to straight ahead.
4. SEPARATE STEERING TIE ROD FROM STEERING

KNUCKLE.
(a) Separate the steering tie rod LH from the steering knuckle
arm LH.
• Remove the split pin.
NOTE
Do not reuse the removed cotter pin.

POWER STEERING - STEERING BOX 52-31
• Set the steering tie rod LH aside.
52
(b) Separate the steering tie rod RH from the steering knuckle
RH.
NOTE
Separate the RH side by the same procedures as the LH
side.
5. SEPARATE POWER STEERING LINE ASSY FROM

STEERING BOX.
(a) Separate the high-pressure tube from the steering box.
CAUTION
(b) Separate the low-pressure pipe from the steering box.
CAUTION
(c) Loosen 2 retaining bolts from power steering line assy.

52
NOTE
Loosen the 2 bolts on gasoline vehicles by the same
procedures as diesel vehicles, although the two power
steering lines look different.
6. SEPARATE STEERING PROPELLER SHAFT FROM

STEERING BOX.
(a) Mark on the steering propeller shaft and the steering box.
NOTE
(b) Remove the bolt and nut.
7. REMOVE STEERING BOX.

(a) Remove 4 bolts.
(b) Remove the steering box.

NOTE
Take care because the steering box is quite heavy.
8. INSPECT STEERING BOX.

(a) Check the steering box for crack by magnetic testing.
If any fault is detected, replace with a new steering box.
(b) Check the contact area between steering tie rod B-joint
and steering knuckle arm.
• Apply red lead evenly to the steering tie rod B-joint shaft
and hole of steering knuckle arm.
• Insert the steering tie rod B-joint shaft into the hole of
steeering knuckle arm and tighten with nut, then remove
the nut and pull it out again. Check the contact area.
Standard: red area ≤ 3/4 shaft length, evenly
The red area is out of specification, replace with a new steering box
and steering knuckle arm. (Refer to “Chapter 52 power steering -
steering box, overhaul”, “Chapter 34 axle and propeller shaft -
steering knuckle, overhaul”)
(c) Inspect the bush of steering box, replace new bush if it is

worn.
POWER STEERING - STEERING BOX 52-33
9. INSTALL STEERING BOX.

(a) Position the steering box properly.
NOTE
Take care because the steering box is quite heavy.
52

10. CONNECT STEERING PROPELLER SHAFT TO STEERING

BOX.
(a) Install the steering propeller shaft to the steering box
NOTE
Be sure to perform this operation according to the marks. 52
11. CONNECT POWER STEERING LINE ASSY TO STEERING BOX.

(a) Replace the seal gasket and coat the sealant on the high-pressure tube connector.
(b) Install the high-pressure tube to steering box.

CAUTION
(c) Connect the low-pressure pipe to steering gear assy and
tighten it.
CAUTION
(d) Tighten 2 bolts attaching power steering line assy to the

steering box.
NOTE
• Make sure the line assy does not be bended.
• Tighten the 2 bolts on gasoline vehicle by the same
procedure as diesel vehicle, although the power steering
lines look different.
12. CONNECT STEERING TIE ROD TO STEERING KNUCKLE.

(a) Connect the steering tie rod LH to the steering knuckle LH.
• Insert the steering tie rod LH B-joint shaft into the steering
knuckle arm LH hole.


NOTE
(b) Connect the steering tie rod LH to the steering knuckle
arm LH.
NOTE
Connect the LH side by the same procedures as the RH
side.
13. FILL FLUID. (Refer to “Chapter 52 power steering - power steering system, replacement”)
Bleeding”)
61
HEATER AND AIR CONDITIONING SYSTEM ................................. 61-1
PRECAUTION.............................................................................. 61-1
COMPONENTS ........................................................................... 61-3
PROBLEM SYMPTOMS TABLE.................................................. 61-5 61
VENT DUCT ..................................................................................... 61-10
COMPONENTS ......................................................................... 61-10
REPLACEMENT ........................................................................ 61-11 61
HEATER PIPE .................................................................................. 61-13
REPLACEMENT ........................................................................ 61-13
FRONT HEATER ASSY ................................................................... 61-16
REPLACEMENT ........................................................................ 61-16
REFRIGERANT ................................................................................ 61-21
REPLACEMENT ........................................................................ 61-27
COMPRESSOR OIL ......................................................................... 61-30
INSPECTION ............................................................................. 61-30
REPLACEMENT ........................................................................ 61-31
A/C PIPE .......................................................................................... 61-32
REPLACEMENT ........................................................................ 61-32
FRONT EVAPORATOR ASSY ........................................................ 61-37
OVERHAUL ............................................................................... 61-37
REAR EVAPORATOR ASSY........................................................... 61-42
REPLACEMENT ........................................................................ 61-42
COMPRESSOR ................................................................................ 61-45
COMPONENTS ......................................................................... 61-45
OVERHAUL ............................................................................... 61-46 61
FRONT BLOWER............................................................................. 61-48
REPLACEMENT ........................................................................ 61-48
CONDENSER ................................................................................... 61-50
OVERHAUL ............................................................................... 61-51
RECIEVER TANK............................................................................. 61-54
REPLACEMENT ........................................................................ 61-54
A/C CONTROLLER.......................................................................... 61-56
REPLACEMENT ........................................................................ 61-56
HEATER AND AIR CONDITIONING - HEATER AND AIR CONDITIONING SYSTEM 61-1
HEATER AND AIR CONDITIONING SYSTEM

PRECAUTION
1. HEATER AND AIR CONDITIONING PRECAUTION. 61
(a) Expressions of ignition switch.


Expression
(b) Power off.

• Before removing or installing any electrical devices, please disconnect the negative cable to prevent
damage to the device or personal injury.
NOTE
For the vehicle equipped with the power door locks, before disconnecting the negative battery cable,
do not leave the key in the vehicle and avoid the door to be locked.
• Make sure ignition switch is OFF if no specific instructions.
(c) When disconnecting negative battery cable, memory of the audio system will be erased.
NOTE
When work is finished, reset the audio systems as they were before. ( Refer to “Audio system owner
manual”)
(d) Do not handle refrigerant in an enclosed area or near

the flame.
61
(e) Do not do welding operation to the parts filled with

refrigerant.
(f) Always wear eye protection glasses.
(g) Be careful not to get liquid refrigerant in your eyes or on

your skin.
If liquid refrigerant gets in your eyes or on your skin:
• Wash the area with cool water.
NOTE
Do not rub your eyes or skin.
• Apply clean petroleum jelly to the skin.
• Go to a physician or hospital immediately for professional
treatment.
61-2 HEATER AND AIR CONDITIONING - HEATER AND AIR CONDITIONING SYSTEM
(h) Never heat container or expose it to naked flame.

(i) Be careful not to drop container and not to apply physical
shocks to it.
(j) Do not operate compressor without enough refrigerant in

refrigerant system.
If there is no enough refrigerant in the refrigerant system,
oil lubrication will be insufficient and compressor will be
burned out. So take care to avoid this condition.
(k) Do not open high pressure manifold valve while
compressor is operating.
If the high pressure valves opened, refrigerant flows in
the reverse direction and could cause the charging
cylinder to rupture. So only open and close the lower
pressure valve.
(l) Be careful not to overcharge system with refrigerant.

If refrigerant is overcharged, it causes problems such as insufficient cooling, poor fuel economy, engine
overheating, etc.
(m) When removing refrigerant components from a vehicle, immediately cap (seal) the component to
minimize the entry of moisture from the atmosphere.
(n) When installing refrigerant components to a vehicle, do not remove the caps (unseal) until just before
connecting the components. Connect all refrigerant loop components as quickly as possible to
minimize the entry of moisture into the system.
(o) Only use the specified compressor oil from a sealed container. Immediatedly reseal containers of
compressor oil. Without proper sealing, compressor oil will become moisture saturated and should not
be used.
(p) Avoid breathing A/C refrigerant and compressor oil vapor or mist. Exposure may irritate eyes, nose and
throat. Remove R-134a from the A/C system using certified service equipment meeting requirements of
R-134a recycling equipment. If accidental system discharge occurs, ventilate work area before
resuming service. Additional health and safety information may be available from refrigerant and
compressor oil manufacturers.
(q) Do not allow compressor oil to contact with styrofoam parts. Otherwise, damage may occurr.
(r) Do not store or heat refrigerant containers above 52 ℃ .
(s) Do not intentionally drop, puncture, or incinerate refrigerant containers.
(t) Do not do pressure test or leakage test R-134a service equipment and/or vehicle air conditioning
systems with compressed air during repairing. Some mixtures of air and R-134a have been proved to
be combustible at high pressure. These mixtures, if ignited, may cause injury or property damage.
Additional health and safety information may be available from refrigerant manufacturers.
COMPONENTS
61
61
1 Nut 13 Reciever Tank
2 Blower Motor Assy 14 Bolt
3 Bolt 15 Rear Evaporator Suction Line Assy
4 Washer 16 Clamp
5 Screw 17 Clamp
6 Front Evaporator Assy 18 Composited Tube Assy
7 Nut 19 Bolt
8 Bolt 20 Three-hole Cover Assy
9 Front Heater Assy 21 Bolt
10 Nut Three-hole Cover Water Hose Rubber

22
Ring
11 Front Evaporator Suction Line Assy
23 Three-hole Cover Small Rubber Ring
12 Bolt
24 Three-hole Cover Big Rubber Ring 36 Bolt
25 Rear Evaporator Drip Pipe Assy 37 Clamp
26 Rear Evaporator Suction Pipe Assy B 38 Bolt
27 Rear Evaporator Exhaust Pipe Assy A 39 Low-Pressure Pipe
28 Nut 40 Rear Evaporator Exhaust Pipe Assy B
29 Bolt 41 Bracket Assy
30 Rear Evaporator Assy 42 Bolt
31 Upper Drip Pipe 43 Nut
32 Lower Drip Pipe 44 Condenser Assy
33 Front Evaporator Exhaust Pipe Assy B 45 Bolt
34 Clamp 46 High-pressure Pipe
35 Bolt

1. COOLING SYSTEM DOES NOT FUNCTION. 61
1. Fuse (Burned) -
2. Belt (Loose) -
3. A/C clutch (Damaged) -
4. A/C cut relay (Damaged) -
Chapter 61 heater and air conditioning - A/C

5. A/C switch (Damaged) controller, replacemrnt
6. Dual function pressure switch -

(Damaged)
Air flow normal,
compressor not 7. In-vehicle temperature sensor Chapter 61 heater and air conditioning - evaporator,
work (Damaged) replacement
8. A/C amplifier (Damaged) -
9. A/C clutch relay (Damaged) -
10.A/C relay (Damaged) -
11. ECM (Damaged) -
12.Harness (Open or short) -

13.Compressor (Damaged) compressor, replacement 61
1. Fuse (Damaged) -
2. Harness (Open or short) -

3. Blower switch (Damaged) controller, replacemrnt
Blower inoperative
Chapter 61 heater and air conditioning - blower,
4. Blower resistor (Damaged) replacement

5. Blower (Damaged) replacement

1. Refrigerant (Leaking) Refrigerant, on-vehicle inspection
Cooling insufficient
(air flow normal, 2. Compressor (Damaged) compressor, replacement
compressor work)
Chapter 61 heater and air conditioning - reciever
3. Reciever tank (Blocked) tank, replacement
2. COOLING SPORADIC.
1. Harness (Poor contact) -
2. Relay (Poor contact) -

Air flow sporadic Chapter 61 heater and air conditioning - blower,

5. Blower (Inner poor contact) replacement
Chapter 61 heater and air conditioning - vent duct,

6. Vent duct (Blocked) replacement
1. Belt (Slipping) -
2. A/C clutch (Slipping) -

3. A/C switch (Damaged) controller, replacemrnt
4. Dual function pressure switch -

Compressor work (Damaged)
sporadic Chapter 61 heater and air conditioning - evaporator,
5. In-vehicle temperature sensor
(Damaged) replacement
6. A/C amplifier (Damaged) -

7. Compressor (Damaged) compressor, replacement
Blower and 1. In-vehicle temperature sensor Chapter 61 heater and air conditioning - evaporator,
compressor (Loose) replacement
normal, but cooling
sporadic 2. System block intermittently -
3. COOLING INSUFFICIENT.
2. Relay (Poor contact) -

Air abnormal Chapter 61 heater and air conditioning - blower,

5. Blower (Inner poor contact) replacement

6. Vent duct (Blocked) replacement
1. A/C clutch (Slipping) -
2. Belt (Slipping) - 61
Air flow normal, 3. Harness (Poor contact) -

compressor
abnormal Chapter 61 heater and air conditioning -

5. Reciever tank (Blocked) tank, replacement
Chapter 61 heater and air conditioning - refrigerant,

1. Refrigerant (Leaking) on-vehicle inspection
Pressure low on
both low and high 2. Reciever tank (Outlet blocked) tank, replacement
pressure sides
3. Condenser (Frosting) on-vehicle inspection

1. Refrigerant (Redundancy) on-vehicle inspection

Pressure high on 2. Air mixed in refrigerant system on-vehicle inspection
both low and high
pressure sides 3. Condenser (Surface filth -
blocked)
4. Expansion valve (filth blocked) -
Pressure too high

on low pressure
side, Chapter 61 heater and air conditioning -
Pressure too low 1. Compressor (Damaged) compressor, replacement 61
on high pressure
side.
1. Reciever tank (Inlet or inner Chapter 61 heater and air conditioning - reciever
Pressure too high blocked) tank, replacement
on high pressure
side, Chapter 61 heater and air conditioning - condenser,
Pressure too low 2. Condenser (Blocked) replacement
on low pressure
side. 3. Pipeline between compressor Chapter 61 heater and air conditioning - A/C pipe,
and reciever tank (Blocked) replacement
1. Temperature control switch Chapter 61 heater and air conditioning - A/C

(Damaged) controller, replacemrnt
Others
Chapter 61 heater and air conditioning - front
2. Blend door (Damaged) evaporator, replacement
4. COOLING SYSTEM BIG NOISE.
1. Belt (Loose) -
2. Compressor bracket (Damaged) -

System outer noise 4. Compressor oil (Less than Chapter 61 heater and air conditioning -
specification) compressor oil, replacement

5. A/C clutch (Slipping) compressor, replacement


1. Refrigerant (Incorrect) on-vehicle inspection
2. Air mixed in refrigerant system Chapter 61 heater and air conditioning - refrigerant,
System inner noise (Slipping) on-vehicle inspection
3. Pressure too high on high Chapter 61 heater and air conditioning - refrigerant,
pressure side (Compressor on-vehicle inspection
abnormal)
5. NO HEATING OR HEATING INSUFFICIENT


2. Blower relay (Damaged) replacement

3. Vent duct (Shedding) replacement
No heating
Chapter 61 heater and air conditioning - evaporator,
4. Blend door (Damaged) replacement
5. A/C controller (Manual A/C) Chapter 61 heater and air conditioning - A/

(Cable shedding) Ccontroller, replacemrnt
6. Heater valve (Damage) -
1. Coolant (Insufficient) -
Chapter 61 heater and air conditioning - front

2. Heater core (Deformation) heater, replacemrnt
Heating insufficient
3. Heater hose (Fouling or air in Chapter 61 heater and air conditioning - heater
hose) hose, replacemrnt
4. Heater valve (Damage) -

1. COMPRESSOR ASSY WITH CLUTCH.
(a) Connect the positive pole from the battery to cable and negative lead to the body ground.
61
(b) Check the clutch energized or not.
If operation is not as specified, replace the compressor assy.
2. HEATER CORE.
Add coolant to heater core and then check for leakage.
3. A/C PIPE.
Water immersion: With dry nitrogen pipe inside, high-pressure pipe is 3.5 MPa and low-pressure is 1.67 MPa.
Immerse them in the water for 5 minutes to see whether there is bubble on the surface.
4. EVAPORATOR.
Water immersion: Pump 1.67 MPa pressure into the evaporator, then immerse it in the water for 5 minutes to
see whether there is bubble on the surface.
5. CONDENSER.
Water immersion: Pump 3.5 MPa pressure into the condenser, then immerse it in the water for 3 minutes to
see whether there is bubble on the surface.
61
61-10 HEATER AND AIR CONDITIONING - VENT DUCT
VENT DUCT
COMPONENTS
1 Front Windshield Defroster Vent Duct MID 8 Air Outlet Duct RH
2 Defroster Vent Duct RH 9 Air Guide Duct
3 Defroster Vent RH 10 Front Heater To Air Guide Duct RH
4 Defroster Connector 11 Front Heater To Air Guide Duct MID
5 Defroster Vent Duct LH 12 Front Heater To Air Guide Duct LH
6 Defroster Vent LH 13 Air Inlet Duct LH
7 Air Inlet Duct RH 14 Air Guide Duct LH

HEATER AND AIR CONDITIONING - VENT DUCT 61-11
REPLACEMENT
1. REMOVE INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
2. REMOVE VENT DUCT LH. 61

(a) Loosen 2 screws and remove vent duct LH.
3. REMOVE VENT DUCT RH.

(a) Loosen 2 screws and remove vent duct RH.
4. REMOVE VENT DUCT MID.

(a) Loosen 10 screws and remove vent duct MID.
61
5. INSTALL VENT DUCT LH.

(a) Position vent duct LH properly and tighten 2 screws.
61-12 HEATER AND AIR CONDITIONING - VENT DUCT
6. INSTALL VENT DUCT RH.

(a) Position vent duct RH properly and tighten 2 screws.
7. INSTALL VENT DUCT MID.

(a) Position vent duct MID properly and tighten 10 screws.
8. INSTALL INSTRUMENT PANEL. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

HEATER AND AIR CONDITIONING - HEATER PIPE 61-13
HEATER PIPE
REPLACEMENT
1. DRAIN COOLANT. (Refer to “Chapter 17A cooling - coolant, replacement”) 61
2. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replace-
ment”)
3. REMOVE FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
(a) Remove front water valve control cable.
(b) Loosen 2 hose clamps and remove front water valve.
(c) Loosen 2 hose clamps and remove 2 hoses.
61
(d) Loosen the clamp attaching the front heater water-inlet

hose to the engine, then pull out the hose.
61-14 HEATER AND AIR CONDITIONING - HEATER PIPE
(e) Loosen the clamp attaching the front heater water-outlet

hose to the engine, then pull out the hose.
4. INSTALL FRONT HEATER WATER-INLET AND WATER-

OUTLET HOSES.
(a) Position front water valve properly and tighten 2 clamps.
(b) Install front water valve control cable.
(c) Install 2 hoses and tighten 2 hose clamps.
(d) Install the front water-inlet hoses connecting to the engine,

then tighten the clamp.
HEATER AND AIR CONDITIONING - HEATER PIPE 61-15
(e) Install the front water-outlet hoses connecting to the

engine, then tighten the clamp.
61

6. CHECK HOSE CONNECTOR FOR LEAKAGE.
7. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior amd interior trim - front grille, replace-
ment”)
61
61-16 HEATER AND AIR CONDITIONING - FRONT HEATER ASSY
FRONT HEATER ASSY

REPLACEMENT
ment”)
replacement”)

OUTLET HOSES.
(a) Loosen 2 hose clamps and remove 2 hoses.
6. LOOSEN 2 BOLTS ATTACHING HIGH-PRESSURE

AND LOW-PRESSURE PIPES TO EVAPORATOR.
7. REMOVE FRONT BLOWER RESISTOR.

HEATER AND AIR CONDITIONING - FRONT HEATER ASSY 61-17
(b) Loosen the screw.

(c) Remove front blower resistor.
61
8. REMOVE FRONT EVAPORATOR ASSY AND HEATER

ASSY.
(a) Loosen 3 in-vehicle bolts.
(b) Loosen 9 nuts and 2 bolts.

(c) Take out front evaporator assy and front heater assy with
caution.
61
(d) Loosen the screw and separate the front heater assy and
front evaporator assy.
9. REMOVE FRONT HEATER CORE.

(a) Loosen 2 screws.
(b) Take out the front heater core.
10. INSPECT FRONT HEATER CORE.

(a) Fill coolant to the front heater core to check for leakage.
(b) Check heater core fins for tidiness. If there are skew,
crushing, collapsed, repair it with fin comb.
11. INSTALL FRONT HEATER CORE.

(a) Position the front heater core properly.
12. INSTALL FRONT HEATER ASSY AND FRONT

EVAPORATOR ASSY.
(a) Tighten the screw to connect the front evaporator assy
and front heater assy.
HEATER AND AIR CONDITIONING - FRONT HEATER ASSY 61-19
(b) Position the front evaporator assy and front heater assy.
(c) Tighten 3 in-vehicle bolts.
61
(d) Tighten 9 nuts and 2 bolts.

61
13. INSTALL FRONT BLOWER RESISTOR.

(a) Tighten the mounting screw.
14. TIGHTEN 2 BOLTS ATTACHING HIGH-PRESSURE


OUTLET HOSES.
(a) Install 2 hoses and tighten 2 hose clamps.
18. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant,
replacement”)
19. CHECK REFRIGERANT FOR LEAKAGE. (Refer to “Chapter 61 heater and air conditioning -
refrigerant, on-vehicle inspection”)
ment”)
HEATER AND AIR CONDITIONING - REFRIGERANT 61-21
REFRIGERANT
1. INSPECT REFRIGERANT PRESSURE WITH MANIFOLD GAUGE SET. 61
(a) This is a method in which the trouble is located by using a manifold gauge set. Read the manifold
gauge pressure when these conditions are established.
Test conditions:
• Temperature at the air inlet is 30 ~ 35 ℃ .
• Engine running at 1500 RPM.
• Blower switch at “HI” position.
• Temperature control switch at “COOL” position
• A/C switch ON.
• Full open doors.
NOTE
These gauge indications are shown when the refrigerant system has been opened and the refrigerant
charged without vacuum purging.
• Normally function refrigerant system.
Gauge reading:
Low pressure side: 0.15 ~ 0.25 MPa
High pressure side: 1.37 ~ 2.37 MPa
• Moisture present in refrigerant system (Condition: Periodically cools and then fails to cool)
61
Symptom Probable Cause Diagnosis Remedy

Moisture in refrigerating 1. Reciever tank in
system freezes at oversaturated state 1. Replace condenser
During operation, expansion valve orifice
pressure on low pressure 2. Moisture in 2. Remove moisture in
causing a temporary stop refrigerating system cycle by repeatedly
side sometimes becomes of cycle. However, when it
a vacuum and sometimes freezes at expansion evacuating air
melts, normal state is valve orifice and 3. Supply proper amount
normal. restored. blocks circulation of of new refrigerant
refrigerant.
61-22 HEATER AND AIR CONDITIONING - REFRIGERANT
• Insufficient cooling (Condition: Cooling system does not function effectively.)
1. Check for gas leakage

and repair if necessary
2. Supply proper amount
of new refrigerant
Pressure low on both low 3. If indicated pressure
and high pressure sides Gas leakage in Insufficient refrigerant value is closed to 0
Insufficient cooling refrigeration system Refrigerant leakage when connecting to
performance gauge, create the
vacuum after
inspecting and
repairing location of
leak
• Poor circulation of refrigerant (Condition: Cooling system does not function effectively.)

Pressure low on both low
Refrigerant flow
and high pressure sides
obstructed by dirt in Reciever tank clogged Replace reciever tank
Frost on pipe from
reciever tank
condenser to unit
• Refrigerant does not circulate (Condition: Cooling functions intermittently.)
61
1. Check expansion
valve
2. Clean out dirt in
1. Refrigerant flow expansion valve by air
Vacuum indicated on low
obstructed by moisture blowing
pressure side, very low
or dirt in refrigerant
pressure indicated on 3. Replace condenser
system
high pressure side Refrigerant not circulate 4. Evacuate air and
Frost or dew seen on pipe 2. Refrigerant flow
obstructed by gas supply proper amount
before and after reciever of new refrigerants
tank or expansion valve leaked from expansion
valve 5. For gas leakage from
expansion valve,
replace expansion
valve
• Refrigerant overcharged or insufficient cooling of condenser (Condition: Cooling system does not
function effectively.)
61
1. Clean condenser
1. Unable to develop 1. Excessive refrigerant 2. Check cooling fan with
sufficient performance in cycle cooling fan motor
Pressure too high on both
due to excessive use 2. Condnser cooling operation
low and high pressure
of refrigeration system insufficient condenser 3. If 1 and 2 are in normal
sides
2. Insufficient cooling of fins state, check refrigerant
condenser 3. Clogged at cooling fan and supply proper
amount of refrigerant.
• Air present in refrigeration system (Condition: Cooling system does not function.)

Pressure too high on both 1. Check compressor oil
low and high pressure 1. Air present in
to see if it is dirty or
sides Air entered in refrigeration refrigeration system
insufficient
The low pressure pipe system 2. Insufficient vacuum
2. Vacuumize and supply
overheated purging
new refrigerant
• Expansion valve trouble (Condition: Refrigerant functions insufficient.)

Pressure too high on both
low and high pressure 1. Excessive refrigerant
sides Trouble in expansion in low pressure pipe Check and replace
Frost or large amount of valve 2. Expansion valve expansion valve
dew on pipe of low opened too wide
pressure side
• Compressor failure (Condition: Refrigerant is not effective.)
61

Pressure too high on low 1. Compressor failure
pressure side Internal leakage in 2. Leakage from Repair or replace
Pressure too low on high compressor damaged valve or compressor
pressure side broken sliding parts
Gauge reading (Reference)
61
1 Blower LO Zone 2 Blower HI Zone
2. LEAKAGE DETECTION WITH SOAP SOLUTION.

(a) For a large amount of leakage on refrigerant pipe connection, leakage can be detected by spraying
soap liquid around the connection with a sprayer to check whether any bubble appears. This is a simple
and convenient method for leakage detection, but it is unable to detect minor leakage.
3. LEAKAGE DETECTION WITH NON-SELECTIVE DETECTOR.
(a) This detector can detect leakage of all kinds of liquid and gas regardless of chemical composition of the
detected material. It has advantages of easy using, stable performance and low cost, etc., but it cannot
be used for area detection of leakage.
4. LEAKAGE DETECTION WITH HALOGEN LEAKAGE DETECTOR.

(a) It equipped with special sensor which can detect air compounds containing a small amount of fluorine,
chlorine, bromine and iodine without interference of other materials. The great advantage of this
instrument is its high sensitivity which can reduce error. Its minimum detection limit is less than 5g per
year for area detection of leakage and 1.5g per year for leak-point detection (for leak-point, which leaks
1.5g per year).
5. LEAKAGE DETECTION WITH SPECIAL ELECTRONIC LEAKAGE DETECTOR.
(a) This instrument is complicated and expensive which can detect certain compounds without interference
of other materials. R-134a, a kind of special electronic leakage detector with high sensitivity and
selectivity, can not only detect leak-point correctly, but also can identify whether refrigerant is R-134a
type. Because it has high sensitivity, pay attention to pollution around the instrument when using it,
otherwise, it may cause error report.
6. LEAKAGE DETECTION WITH FLUORESCENT DYE.
(a) Fluorescent dye can produce fluorescence under the irradiation of ultraviolet light. Therefore, if add this
kind of dye to compressor oil or refrigerant, the leak-point can be detected through irradiating outer part
of the system when the system has a leakage.
REPLACEMENT
1. DISCHARGE REFRIGERANT FROM REFRIGERATION SYSTEM.
(a) Turn the A/C switch ON.
61
(b) Operate the compressor at the engine RPM 1000 for 5 to 6 minutes to circulate the refrigerant and
collect compressor oil remaining in each component into the compressor as many as possible.
(c) Stop the engine.
(d) Recover the refrigerant.

NOTE
Do not release the refrigerant into the air.
2. PUMP VACUUM.
(a) Connect high pressure and low pressure gauge hoses to
maintenance valve on compressor, and connect central
hose to vacuum pump.
(b) Open high and low pressure valves of manifold pressure
gauge, and then open the vacuum pump valve.
(c) Start the vacuum pump. Keep vacuumizing for at least 20
minutes to make vacuum value below -760 mmHg. Shut
manual valves at both high and low pressure sides and
stop vacuumizing to detect leakage.
3. INSPECT LEAKAGE OF REFRIGERANT. 61

(a) Shut valves, the gauge value shall not increase within 5 minutes. If the value increases, repair where
leaks, then pump vacuum again.
4. SUPPLY REFRIGERANT.
(a) If there is no leakage, connect central filling hose of manifold pressure gauge with refrigerant tank.
(b) Loosen the nut of manifold pressure gauge central hose, and retighten it until white gas refrigerant
flows out and a “fizz” sound is heard, which indicates that air in central hose is exhausted.
(c) Open high pressure manual valve, and turn refrigerant tank
upside down to fill liquid refrigerant into refrigeration system.
Do not start air conditioning system at this moment to avoid
back flow. Add at least 200g of refrigerant each time.
(d) Shut high pressure manual valve and open low pressure
manual valve to allow gas refrigerant to enter refrigeration
system. Start the engine. The refrigerant entering from low
pressure manual valve must be gasified because liquid
refrigerant will cause liquid impact in compressor and
damage the unit.
(e) Add refrigerant according to the specified amount of the

A/C system. If there is no specified amount, observe the
high and low pressure gauges and the peephole of the
refrigerant flow state (clear, sparkling, turbidity) to
estimate the adding time.
Specified value:
Front and rear A/C：1250 + 0/- 25 g
Front A/C：850 ± 25 g
When estimating refrigerant adding amount, set the
basic conditions:
• Radiator water temperature: maintain stable state
• A/C switch: ON
• Temperature regulator: adjust inner circulation air
temperature to 25 ~ 30 ℃
• Fan swtich: HI position
• Change inner and outer air: Inner circulation
• Door: full open
• Window: full open
• Estimate the adding amount
(f) After finishing the adding process, turn the HVAC switch
to OFF and wait to balance pressure condition, reopen
the A/C switch to ON and begin to judge.
Sparkling condition: gas and liquid refrigerant mixed
state with bubble.
Clear conditon: it is clear condition when all refrigerant is
liquid.
Turbidity condition: when the oil and refrigerant separae
with each other, it shows thin ivory.
Sparkling and turbidity condition: gas refrigerant and
separated oil mixing state, it shows thin ivory and
sparkling
Peephole Condition (After Turn

Refrigerant Adding Amount On The HVAC Switch About 1 High Side Pressure
Minute ) 61
Suitable 1.8 ~ 2.5 MPa
Excessive > 2.5 MPa
Insufficient 1.2 MPa
(g) Above peephole conditions are visible general condition. When it is hard to judge the peephole
condition due to the reasons such as external condition, it must be confirmed to inspect the pressure
variation of the high pressure side (excessive adding when pressure sharply up).
(h) When adding refrigerant, pay attention to refrigerant condition variation in peephole and high side
pressure variation in the pressure gauge.
(i) Shut low pressure manual valve and remove maintenance valve, then cap the valve quickly to avoid
gas leakage.
5. WARM UP ENGINE.
6. CHECK REFRIGERANT FOR LEAKAGE. （Refer to “Chapter 61 heater and air conditioning -
61
61-30 HEATER AND AIR CONDITIONING - COMPRESSOR OIL
COMPRESSOR OIL
INSPECTION
1. CORRELATION METHOD:
Take fresh compressor oil into test tube as the standard oil and also take old compressor oil into test
tube, then compare the two tubes. If the color of the old compressor oil is light yellow or orange, it can
be used. If it turns to bronzing turbid liquid, it can not be used.
2. PAPER METHOD:
Drip a drop of compressor oil on a clean white paper. After a while, check the color of the oil. If the color
is light and uniform, which shows it is no impurity and can be used. If the center of the oil has black
spot, which shows the oil is metamorphous and can not be used.
HEATER AND AIR CONDITIONING - COMPRESSOR OIL 61-31
REPLACEMENT
replacement”)
61
2. DRAIN OUT COMPRESSOR OIL.
(a) Remove the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
(b) Pour out the oil from the compressor.
3. FILL COMPRESSOR OIL.
(a) Install the compressor. (Refer to “Chapter 61 heater and air conditioning - compressor, overhaul”)
(b) Fill the oil into the compressor as the specified value.
Specified value: 180 mL
• Generally, it is no need to add oil to new A/C system, because new compressor has the whole amount
of the oil for the system (14% ~ 18% amount of the refrigerant ). If the A/C system has more than two
times repairment or other causes the lack of compressor oil, it is need to add compressor oil. After
replacing the A/C system, add compressor oil as necessary.
Part Name Amount of oil

Compressor -
Evaporator 10 ml
Reciever tank 5 ~ 10 ml
No leakage 5 ml
Condenser
Leakage 10 ml
No leakage -
Pipe
Leakage 5 ml
No leakage -
Gas leakage 61
Leakage 80 ml
Replace all pipes 40 ~ 60 ml
4. SUPPLY REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)
5. WARM UP ENGINE.
61-32 HEATER AND AIR CONDITIONING - A/C PIPE
A/C PIPE
REPLACEMENT
ment”)
replacement”)
3. REMOVE A/C PIPES.

(a) Loosen 2 mounting bolts attaching A/C pipes to reciever
tank.
(b) Loosen the A/C pipe mounting bolts and nuts around the
condenser.
HEATER AND AIR CONDITIONING - A/C PIPE 61-33
(c) Loosen 2 connecting bolts attaching high-pressure and

low-pressure pipes to evaporator.
61
(d) Loosen 2 bolts attaching A/C pipes to compressor.
(e) Loosen 2 A/C pipes connecting nuts leading to rear

evaporator and 1 clamp screw.
61
(f) Loosen A/C pipe clamp bolts leading to rear evaporator

and remove the clamps.
(g) Remove roof guard board assy. (Refer to “Chapter 88
exterior and interior trim - roof guard board assy,
replacement”)
(h) Remove 2 nuts attaching the A/C pipes to the rear

evaporator assy.
(i) Take out all A/C pipes with caution.
4. INSTALL A/C PIPES.

(a) Tighten 2 nuts attaching the A/C pipes to the rear
evaporator assy.
Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
NOTE
Use new O-ring.
(b) Tighten 2 A/C pipes connecting nuts leading to rear

evaporator and 1 clamp screw.
NOTE
Use new O-ring.
(c) Tighten A/C pipe clamp bolts leading to rear evaporator

and install the clamps.
(d) Tighten the A/C pipe mounting bolts and nuts around the
condenser.
NOTE
Use new O-ring.
HEATER AND AIR CONDITIONING - A/C PIPE 61-35
(e) Tighten 2 bolts attaching A/C pipes to compressor.

NOTE
Use new O-ring.
61
(f) Tighten 2 connecting bolts attaching high-pressure and

low-pressure pipes to evaporator.
NOTE
Use new O-ring.
(g) Tighten 2 mounting bolts attaching A/C pipes to reciever

tank.
NOTE
Use new O-ring. 61

replacement”)
6. WARM UP THE ENGINE.
8. INSTALL ROOF GUARD BOARD ASSY. (Refer to “Chapter 88 exterior and interior trim - roof
guard board assy, replacement”)
ment”)
HEATER AND AIR CONDITIONING - FRONT EVAPORATOR ASSY 61-37
FRONT EVAPORATOR ASSY

OVERHAUL
NOTE 61
Front evaporator is installed under the instrument panel with many parts (such as control wire
harness, control box, instrument cluster). When installing, be careful not to damage these parts.
ment”)
replacement”)

OUTLET HOSES.
(a) Loosen 2 hose clamps and remove 2 hoses.
61
6. LOOSEN 2 BOLTS ATTACHING HIGH-PRESSURE
61-38 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR ASSY
7. REMOVE FRONT BLOWER RESISTOR.

(b) Loosen 1 screw.

(c) Remove front blower resistor.
8. REMOVE FRONT EVAPORATOR ASSY AND HEATER

ASSY.
(a) Loosen 3 in-vehicle bolts.
(b) Loosen out-vehicle 9 nuts and 2 bolts.

(c) Take out front evaporator assy and front heater assy with
caution.
61
(d) Loosen the screw and separate the front heater assy and
front evaporator assy.
61
9. REMOVE FRONT EVAPORATOR.

(a) Loosen front evaporator pipe mounting screws.
(b) Remove clips and screws around the evaporator shell, then open the shell and take out the evaporator
core.
10. INSTALL FRONT EVAPORATOR.
(a) Position the evaporator core properly. Install the clips and screws around the shell.
(b) Tighten front evaporator pipe mounting screws.
11. INSTALL FRONT HEATER ASSY AND FRONT

EVAPORATOR ASSY.
(a) Tighten the screw to connect the front evaporator assy
and front heater assy.
61-40 HEATER AND AIR CONDITIONING - FRONT EVAPORATOR ASSY
(b) Position the front evaporaotr assy and front heater assy.
(c) Tighten 3 in-vehicle bolts.
(d) Tighten out-vehicle 9 nuts and 2 bolts.
12. INSTALL FRONT BLOWER RESISTOR.

(a) Tighten the mounting screw.
61
13. TIGHTEN 2 BOLTS ATTACHING HIGH-PRESSURE


OUTLET HOSES.
(a) Install 2 hoses and tighten 2 hose clamps.
61
ment”)
61-42 HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY
REAR EVAPORATOR ASSY

REPLACEMENT
replacement”)
2. REMOVE REAR EVAPORATOR COVER. (Refer to “Chapter 88 exterior and interior trim - rear
evaporator cover, replacement”)
3. REMOVE REAR EVAPORATOR.

(a) Remove 2 connecting nuts attaching A/C pipes to rear
evaporator assy.
(b) Disconnect the connector.
(c) Remove the dripping pipes and the vent ducts LH&RH.
(d) Loosen 4 bolts and remove rear evaporator assy.

HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY 61-43
4. REMOVE REAR EVAPORATOR BLOWER MOTOR.

(b) Loosen 8 screws.
(c) Remove rear evaporator blower motor. 61
5. INSTALL REAR EVAPORATOR BLOWER MOTOR.

(a) Position the rear evapotator blower motor properly.
(c) Connect the connector.
6. INSTSLL REAR EVAPORATOR ASSY.

(a) Position the rear evaporator assy properly and tighten 4
bolts.
61
(b) Install the dripping pipes and the vent ducts LH&RH.
61-44 HEATER AND AIR CONDITIONING - REAR EVAPORATOR ASSY
(c) Tighten 2 connecting nuts attaching the A/C pipes to rear

evaporator assy.
Torque: 12 ~ 15 N·m （Φ9）
Torque: 20 ~ 26 N·m （Φ12）
Torque: 30 ~ 35 N·m （Φ16）
NOTE
Use new O-ring.
(d) Connect the connector.
7. INSTALL REAR EVAPORATOR COVER. (Refer to “Chapter 88 exterior and interior trim - rear
evaporator cover, replacement”)
HEATER AND AIR CONDITIONING - COMPRESSOR 61-45
COMPRESSOR
COMPONENTS
61
61
1 Bolt 3 V Belt
2 Compressor
61-46 HEATER AND AIR CONDITIONING - COMPRESSOR
OVERHAUL
replacement”)
2. REMOVE COMPRESSOR.
(a) Remove engine accessory belt. (Refer to “Chapter 15A engine mechanical - engine accessory belt,
overhaul”)
(b) Loosen 2 bolts and remove the compressor pipes and O-

ring.
(c) Disconnect the connector.
(d) Loosen the retaining bolts and remove the compressor.
3. CHECK COMPRESSOR OIL.

(a) If replace the compressor with a new one, remove the refrigerant gas from the service valve, drain the
following amount of oil from the new compressor before installing.
Specified value:
Oil capacity inside new compressor － remaining oil amount in the removed compressor ＝ oil
amount to be drained out when replacing.
NOTE
• When checking the compressor oil level, observe the precautions on the compressor removal/
installation.
• Compressor oil will remain in the pipes of the vehicle. If a new compressor is installed without
draining out some oil inside, too much oil will affect heat exchange in the refrigerant cycle and
cause refrigerant failure.
• If the remaining oil in the removed compressor is too little in volume, oil leakage checking is
necessary.
• Be sure to use the right compressor oil.
HEATER AND AIR CONDITIONING - COMPRESSOR 61-47
4. INSTALL COMPRESSOR ASSY.

(a) Position the compressor properly. Tighten the retaining
bolts.
61
(b) Sufficiently apply compressor oil to the new O-ring and fit
surface of the compressor.
(c) Position A/C pipes properly. Tighten 2 retaining nuts.
(d) Connect the connector.
5. INSTALL ENGINE ACCESSORY BELT. (Refer to “Chapter 15A engine mechanical - engine acces-
sory belt, overhaul”)
61
7. WARM UP ENGINE.
61-48 HEATER AND AIR CONDITIONING - FRONT BLOWER
FRONT BLOWER
REPLACEMENT
1. REMOVE GLOVE BOX RH.
(a) Open the glove box RH and loosen 2 lower screws.
Remove the glove box RH as shown in the illustration.
2. REMOVE FRONT BLOWER MOTOR.

(b) Loosen 3 screws.

(c) Take out the front blower motor.
3. INSTALL FRONT BLOWER MOTOR.

(a) Position the front blower motor properly.
HEATER AND AIR CONDITIONING - FRONT BLOWER 61-49
(c) Connect the connector.
61
4. INSTALL GLOVE BOX RH.

(a) Tighten 2 lower screws and install glove box RH as
shown in the illustration.
61
61-50 HEATER AND AIR CONDITIONING - CONDENSER
CONDENSER
1. CHECK CONDENSER ASSY.
(a) If a fin of the condenser assy is dirty, clean it with water and dry it with compressing air.
NOTE
Do not damage the fin of the condenser assy.
(b) If a fin of the condenser assy is bent, use a screwdriver or plier to fixt.
2. CHECK CONDENSER ASSY FOR LEAKAGE OF REFRIGERANT.
(a) Using a halogen leak detector, check pipe joints for gas leakage.
(b) If gas leakage is detected in a joint, check the torque value of the joint.
HEATER AND AIR CONDITIONING - CONDENSER 61-51
OVERHAUL
NOTE
The condenser is a heat exchanger. It has many vulnerable parts (especially the heat sink) in structure
61
and material. When removing and installing, pay attention not to dropping, colliding or scraping.
replacement”)
3. REMOVE CONDENSER.
(a) Loosen the A/C pipe retaining bolts and nuts around the
condenser.
61
(b) Loosen the condenser retaining bolts and nuts.
(c) Take out the condenser with caution.
(d) Loosen the connecting nuts attaching the A/C pipes to

condenser.
61-52 HEATER AND AIR CONDITIONING - CONDENSER
(e) Disconnect the condenser fan connector.

(f) Loosen the condenser fan retaining nuts.
(g) Take out the condenser fan.
4. INSTALL CONDENSER.
(a) Position the condenser fan properly.
(b) Tighten the condenser fan retaining nuts.
(c) Connect the condenser fan connector.
(d) Tighten the connecting nuts attaching the A/C pipes to

condenser.
NOTE
Use new O-ring.
(e) Position the condenser properly.

(f) Tighten the condenser retaining bolts and nuts.
HEATER AND AIR CONDITIONING - CONDENSER 61-53
(g) Tighten the A/C pipes retaining bolts and nuts around the
condenser.
NOTE
Use new O-ring. 61
6. WARM UP ENGINE.
61
61-54 HEATER AND AIR CONDITIONING - RECIEVER TANK
RECIEVER TANK
REPLACEMENT
1. RECOVER REFRIGERANT. (Refer to “Chapter 61 heater and air conditioning - refrigerant, replacement”)
ment”)
3. REMOVE RECIEVER TANK.

(a) Loosen 2 mounting bolts attaching A/C pipes to reciever
tank.
(b) Loosen 2 bolts and remove the reciever tank.

HEATER AND AIR CONDITIONING - RECIEVER TANK 61-55
4. INSTALL RECIEVER TANK.

(a) Position the reciever tank properly and tighten 2 bolts.
NOTE
When installing, confirm that pipes can be connected on
61
the reciever tank.
(b) Tighten 2 mounting bolts attaching A/C pipes to reciever

tank.
NOTE
Use new O-ring.
61

replacement”)
6. WARM UP ENGINE.
ment”)
61-56 HEATER AND AIR CONDITIONING - A/C CONTROLLER
A/C CONTROLLER
REPLACEMENT
1. REMOVE INSTRUMENT CLUSTER PANEL. (Refer to “Chapter 83 instrument panel - dashboard,
replacement”)
2. REMOVE A/C CONTROLLER.

(a) Loosen 4 screws and take out the A/C controller.
(b) Loosen 2 screws and remove the cover.
(c) Pull out 2 control cables.
(d) Loosen the screw and remove the 3rd control cable.
HEATER AND AIR CONDITIONING - A/C CONTROLLER 61-57
(e) Rotate the A/C controller.

(f) Pull out the 4th control cable.
61
(g) Disconnect the A/C controller connector.
(h) Using a screwdriver, pry out the A/C switch.

(i) Disconnect the A/C switch connector.
61
3. INSTALL A/C CONTROLLER.

(a) Position the A/C switch properly.
(b) Connect the A/C switch connector.
(c) Connect the A/C controller connector.

61-58 HEATER AND AIR CONDITIONING - A/C CONTROLLER
(d) Install the 4th control cable.
(e) Rotate the A/C controller. Install the 3rd control cable and
tighten the screw .
(f) Install 2 control cable.
(g) Position the cover properly and tighten 2 screws.

HEATER AND AIR CONDITIONING - A/C CONTROLLER 61-59
(h) Position the A/C controller properly and tighten 4 screws.
61
4. INSTALL INSTRUMENT CLUSTER PANEL. (Refer to “Chapter 83 instrument panel - dashboard,

replacement”)
61
MEMO
SEAT BELT
63
SEAT BELT SYSTEM ........................................................................ 63-1
PRECAUTION.............................................................................. 63-1
DRIVER / ASSISTANT DRIVER SEAT BELT ................................... 63-2
COMPONENTS ........................................................................... 63-2 63
PASSENGER SEAT BELT ................................................................ 63-3
COMPONENTS ........................................................................... 63-3
BUCKLE ASSY .................................................................................. 63-7
REPLACEMENT .......................................................................... 63-7 63
RETRACTOR ASSY........................................................................... 63-8
OVERHAUL ................................................................................. 63-8
63
SEAT BELT - SEAT BELT SYSTEM 63-1
SEAT BELT SYSTEM

SEAT BELT
PRECAUTION
WARNING 63
• Once any fault is found in the system, be sure to replace the parts (including belt, retractor, lock
catch & latch, bolt and nut).
• The seat belt which is not used in a collision should also be inspected and replaced if found any
damage or working improperly.
63
63-2 SEAT BELT - DRIVER / ASSISTANT DRIVER SEAT BELT
DRIVER / ASSISTANT DRIVER SEAT BELT

COMPONENTS
1 Driver Seat Belt With Retractor Assy 3 Buckle Assy
2 Buckle Assy
SEAT BELT - PASSENGER SEAT BELT 63-3
PASSENGER SEAT BELT

COMPONENTS
SEATS (2+2+3) 63
1 Belt With Latch Plate Assy 3 Belt With Latch Plate And Buckle Assy 63
2 Dual Buckle Assy

63-4 SEAT BELT - PASSENGER SEAT BELT
SEATS (2+3+3)
1 Belt With Latch Plate Assy 3 Dual Buckle Assy
2 Buckle Assy 4 Belt With Latch Plate And Buckle Assy

SEAT BELT - PASSENGER SEAT BELT 63-5
SEATS (2+2+2+3)
63
1 Belt With Latch Plate Assy 3 Belt With Latch Plate With Buckle Assy
2 Dual Buckle Assy
63
63-6 SEAT BELT - PASSENGER SEAT BELT
SEATS (2+3+3+3)
1 Belt With Latch Plate Assy 3 Dual Buckle Assy
2 Buckle Assy 4 Belt With Latch Plate And Buckle Assy

SEAT BELT - BUCKLE ASSY 63-7
BUCKLE ASSY
REPLACEMENT
1. REMOVE BUCKLE ASSY. 63
(a) Remove the bolt.
(b) Remove the buckle by the sequence shown in the illus-

tration.
NOTE
Store buckle carefully and prevent it from deformed.
2. REMOVE ASSISTANT DRIVER BUCKLE ASSY.

NOTE
Remove the assistant driver buckle assy by the same procedures as the driver side.
(a) Position the buckle assy properly.
63
(b) Tighten the bolt.
4. INSTALL ASSISTANT DRIVER BUCKLE ASSY.

NOTE
Install the assistant driver buckle assy by the same procedures as the driver side.
63-8 SEAT BELT - RETRACTOR ASSY
RETRACTOR ASSY
OVERHAUL
1. REMOVE DRIVER SEAT BELT WITH RETRACTOR
ASSY.
(a) Remove the bolt completely.
(b) Remove the upper anchor trim cover.
(c) Remove the bolt completely.

SEAT BELT - RETRACTOR ASSY 63-9
(d) Slide down belt upper anchor.
63
(e) Remove the cover.
(f) Remove the screw. 63

(g) Remove the cover.
(h) Remove screws and B column cover.
(i) Remove the bolt.

(j) Remove the driver seat belt with retractor assy.

CAUTION
Never disassemble the retractor.
63
2. REMOVE ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY.

NOTE
Remove the assistant driver seat belt with retractor by the same procedures as the driver seat belt with
retractor assy.
3. INSPECT RETRACTOR.
(a) Check whether the belt is locked when tilting the retractor.
• Within 15° of tilt in all the directions, check that the belt
should not be locked.
• Over 45° of tilt in all the directions, check that the belt
should be locked.
If the operation is out of the specification, replace with a new
driver / assistant driver seat mesh belt with retractor assy. (Refer
to “Chapter 63 seat belt - retractor assy, overhaul”)
63
4. INSTALL DRIVER SEAT MESH BELT WITH RETRACTOR

ASSY.
(a) Position the retractor properly.
(b) Tighten the bolt.
(c) Install the cover of B column and tighten screws.

NOTE
Make sure the belt is neat without snarling.
(d) Install the cover.

NOTE
Make sure the belt is neat without snarling
(e) Install the cover and tighten the screw.

(f) Slide up the belt upper anchor.
63
(g) Install belt upper anchor and tighten the bolt.

(h) Install belt upper anchor trim cover. 63

(i) Tighten the bolt.

NOTE
Make sure the belt is neat without snarling.
5. INSTALL ASSISTANT DRIVER SEAT BELT WITH RETRACTOR ASSY.

NOTE
Install the assistant driver seat belt with retractor by the same procedures as the driver seat belt with
retractor assy.
6. Inspect driver / assistant driver seat belt with retractor assy.
(a) Check belt locking operation.
• The belt should be locked when being dragged quickly.
(b) Check children protection operation.
• After extracting the belt out of the retractor completely, the retractor enters LOCK mode. In this mode,
the belt only can be contracted.
• When the belt contracts fully, the retractor will recover to NORMAL mode from LOCK mode.
NOTE
This function is used for the children protector applied to the vehicle.
If the operation is out of the specification, replace with a new driver / assistant driver seat belt with retractor
assy. (Refer to “Chapter 63 seat belt - retractor assy, overhaul”)
LIGHTING
64
LIGHTING SYSTEM ........................................................................... 64-1
PRECAUTION.............................................................................. 64-1
COMPONENTS ........................................................................... 64-2
FRONT COMBINATION LAMP ASSY............................................... 64-4 64
REPLACEMENT .......................................................................... 64-4
ADJUSTMENT ........................................................................... 64-10
FRONT FOG LAMP ASSY............................................................... 64-11
REPLACEMENT ........................................................................ 64-11 64
REAR COMBINATION LAMP ASSY ............................................... 64-13
REPLACEMENT ........................................................................ 64-13
LICENCE LAMP ASSY .................................................................... 64-15
REPLACEMENT ........................................................................ 64-15
FRONT DOME LIGHT ASSY ........................................................... 64-17
REPLACEMENT ........................................................................ 64-17
REAR DOME LIGHT ASSY ............................................................. 64-19
REPLACEMENT ........................................................................ 64-19
COMBINATION SWITCH ASSY ...................................................... 64-21
REPLACEMENT ........................................................................ 64-21
FOG LAMP SWITCH........................................................................ 64-24
REPLAEMENT........................................................................... 64-24
REAR DOME LIGHT SWITCH ......................................................... 64-25
REPLACEMENT ........................................................................ 64-25
11B
64
LIGHTING - LIGHTING SYSTEM 64-1
LIGHTING SYSTEM
LIGHTING
PRECAUTION
1. LIGHTING SYSTEM PRECAUTION. 64
(a) Even if a thin film of oil is left on the surface of the halogen lamp, its service life will be shortened because
the lamp will be burned at a higher temperature.
(b) Handle any halogen lamp with great care. Dropping, hitting or damaging the bulb in any way may result
in exploding and scattering because the internal pressure is high.
(c) Always use a bulb of the same wattage for replacement. Be sure not to touch the bulb immediately.
(d) Reinstall the socket firmly after bulb replacement. The lens may become cloudy or the light cavity may
be filled with water through the gaps around the socket.
64
64-2 LIGHTING - LIGHTING SYSTEM
COMPONENTS
LIGHTING - LIGHTING SYSTEM 64-3
1 Rear Dome Light Assy 5 Front Combination Lamp Assy LH
2 Front Combination Lamp Assy RH 6 Rear Combination Lamp Assy LH
3 Front Fog Lamp Assy RH 7 Licence Lamp Assy 64
4 Front Fog Lamp Assy LH 8 Rear Combination Lamp Assy RH
64
64-4 LIGHTING - FRONT COMBINATION LAMP ASSY
FRONT COMBINATION LAMP ASSY

REPLACEMENT
2. REMOVE FRONT COMBINATION LAMP ASSY LH.
(a) Remove the front grille. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)
(b) Loosen the 2 bolts of front combination lamp assy LH.
(c) Loosen the 2 bolts by door side.
(d) Disconnect the 2 connectors and remove front combination

lamp assy LH.
3. REMOVE HEADLAMP BULB.

(a) Remove the cap as the hint shows on the back of the
cap.
LIGHTING - FRONT COMBINATION LAMP ASSY 64-5
(b) Remove the steel wire.
64
(c) Remove the headlamp bulb.
4. REMOVE FRONT TURN SIGNAL LAMP BULB.

(a) Remove the lamp socket.
(b) Remove the front turn signal lamp bulb.
64
5. REMOVE SIDE TURN SIGNAL LAMP BULB.

(b) Remove the side turn signal lamp bulb.
6. REMOVE TAIL LAMP BULB.

(b) Remove the tail lamp bulb.
7. REMOVE FRONT COMBINATION LAMP ASSY RH.

NOTE
8. INSTALL HEADLAMP BULB.

(a) Install the headlamp bulb.
(b) Install the steel wire.
(c) Install the cap as the hint shows on the back of the cap.
64
9. INSTALL FRONT TURN SIGNAL LAMP BULB.

(a) Install the front turn signal lamp bulb.
NOTE
Before turning, push the bulb slightly.
(b) Install the lamp socket.
10. INSTALL SIDE TURN SIGNAL LAMP BULB.

(a) Install the side turn signal lamp bulb.
64
(b) Install the lamp socket.

11. INSTALL TAIL LAMP BULB.

(a) Install the tail lamp bulb.
(b) Install the tail lamp socket.
12. INSTALL FRONT COMBINATION LAMP ASSY LH.

(a) Connect the 2 connectors to front combination lamp assy
LH.
(b) Install the front combination lamp LH and tighten the 2

blots.
(c) Tighten the 2 bolts by door side.
64
(d) Install the front grille. (Refer to “Chapter 88 exterior and

interior trim - front grille, replacement”)
13. INSTALL FRONT COMBINATION LAMP ASSY RH.

NOTE
64
ADJUSTMENT
1. ADJUST THE HEADLAMP AIMING.
(a) Park the vehicle in the following conditions.
• The area around the headlight is not deformed.
• The vehicle is parked on a level surface.
• Tire inflation pressure is in the specified value. (Refer to “Chapter 33 tire and wheel - tire and wheel
system, on-vehicle inspection,”)
• A driver is in the driver’s seat or let something weighs 73 Kg on the seat of the vehicle; the vehicle is
ready for driving. (with a tank full)
(b) Check the headlamp aiming.

• Park the vehicle at the flat field and make the lens surface
of the headlamps be 10 m away from the screen.The
curtain or flat wall can be used as the screen.
• Turn the headlamps on.
• Check that the headlamps properly strike the position
NOTE
A and B shows the position of the headlamps; H shows the
height of the headlamps; L1 and L2 shows the distance
between the center of headlamps and the center of the
vehicle.
• Adjust the headlamps if necessary.
(c) Adjust the adjusting screws to adjust the headlamp aiming

to be within the specified range.
LIGHTING - FRONT FOG LAMP ASSY 64-11
FRONT FOG LAMP ASSY

REPLACEMENT
1. DISCONNECT BATTERY NEGATIVE CABLE. 64
2. REMOVE FRONT FOG LAMP ASSY LH.
(a) Remove the front bumper assy. (Refer to “Chapter 88 exterior and interior trim - front bumper assy,
replacement”)
(b) Disconnect the connectors from the front fog lamp assy.
(c) Loosen the 3 nuts and remove the front fog lamp assy
LH.
3. REMOVE FRONT FOG LAMP BULB LH.

(a) Remove the steel wire.
(b) Remove the front fog lamp bulb.
64
4. REMOVE FRONT FOG LAMP ASSY RH.

NOTE
64-12 LIGHTING - FRONT FOG LAMP ASSY
5. INSTALL FRONT FOG LAMP BULB LH.

(a) Install the front fog lamp bulb.
(b) Install the steel wire.
6. INSTALL FRONT FOG LAMP ASSY LH.

(a) Install the front fog lamp assy and tighten the 3 nuts.
(b) Connect the connectors to front fog lamp assy.

(c) Install the front bumper assy. (Refer to “Chapter 88 exterior
and interior trim - front bumper assy, replacement”)
7. INSTALL FRONT FOG LAMP ASSY RH.

NOTE
LIGHTING - REAR COMBINATION LAMP ASSY 64-13
REAR COMBINATION LAMP ASSY

REPLACEMENT
2. OPEN THE REAR HATCH.
3. REMOVE REAR COMBINATION LAMP ASSY LH.

(a) Remove the 2 bolts.
(b) Disconnect the connector and remove rear combination

lamp assy LH.
4. REMOVE BULBS OF REAR COMBINATION LAMP ASSY

LH.
(a) Remove the lamp sockets.
64
(b) Remove the bulbs.
5. REMOVE REAR COMBINATION LAMP ASSY RH.

NOTE
64-14 LIGHTING - REAR COMBINATION LAMP ASSY
6. INSTALL BULBS OF REAR COMBINATION LAMP

ASSY LH.
(a) Install the bulbs.
(b) Install lamp sockets.
7. INSTALLE REAR COMBINATION LAMP ASSY LH.

(a) Connect the connector to rear combination lamp assy
LH.
(b) Install the rear combination lamp assy LH and tighten the
2 bolts.
8. CLOSE THE REAR HATCH.

9. INSTALL REAR COMBINATION LAMP ASSY RH.
NOTE
LIGHTING - LICENCE LAMP ASSY 64-15
LICENCE LAMP ASSY

REPLACEMENT
2. REMOVE LICENCE LAMP ASSY LH.

(a) Remove the 2 screws of licence lamp assy LH.
(b) Remove the lampshade.
(c) Remove the bulb of licence lamp.
64
3. REMOVE LICENCE LAMP ASSY RH.

NOTE
4. INSTALL LICENCE LAMP ASSY LH.

(a) Install the bulb of licence lamp.
64-16 LIGHTING - LICENCE LAMP ASSY
(b) Install the lampshade.
(c) Tighten the 2 screws.
5. INSTALL LICENCE LAMP ASSY RH.

NOTE
LIGHTING - FRONT DOME LIGHT ASSY 64-17
FRONT DOME LIGHT ASSY

REPLACEMENT
2. REMOVE FRONT DOME LIGHT ASSY.

(a) Remove the lampshade.
(b) Remove front dome light bulb.
(c) Loosen the 3 screws.
64
(d) Disconnect the connector and remove front dome light

assy.
64-18 LIGHTING - FRONT DOME LIGHT ASSY
3. INSTALL FRONT DOME LIGHT ASSY.

(a) Connect the connector to front dome light.
(b) Install the front dome light and tighten the 3 screws.
(c) Install the front dome light bulb.
(d) Install the lampshade of front dome light.

LIGHTING - REAR DOME LIGHT ASSY 64-19
REAR DOME LIGHT ASSY

REPLACEMENT
2. REMOVE REAR DOME LIGHT BULB.

(a) Remove the lampshade.
(b) Remove the rear dome light bulb.
3. REMOVE REAR DOME LIGHT ASSY.

(a) Remove vent line and reinforcement.
(b) Disconnect the connector from rear dome light assy.
64
(c) Loosen the 3 screws and remove the rear dome light
from reinforcement.
64-20 LIGHTING - REAR DOME LIGHT ASSY
4. INSTALL REAR DOME LIGHT ASSY.

(a) Install the rear dome light to the reinforcement and tighten
the 3 screws.
(b) Connect the connector to the rear dome light.

(c) Install the reinforcement.
5. INSTALL REAR DOME LIGHT BULB.

(a) Install rear dome light bulb.
(b) Install the lampshade.

LIGHTING - COMBINATION SWITCH ASSY 64-21
COMBINATION SWITCH ASSY

REPLACEMENT
2. REMOVE COMBINATION SWITCH ASSY.
(a) Remove the steering wheel assy. (Refer to “Chapter 51 steering column - steering wheel assy,
overhaul”)
(b) Loosen the 6 screws.
(c) Remove the upper and lower cover.
(d) Disconnect the connector from combination switch assy.
64
(e) Loosen the 4 screws.

64-22 LIGHTING - COMBINATION SWITCH ASSY
(f) Remove the combination switch assy.
3. INSTALL COMBINATION SWITCH ASSY.

(a) Install the combination switch and tighten the 4 screws.
(b) Connect the connector to combination switch.
(c) Install the upper and lower cover.

LIGHTING - COMBINATION SWITCH ASSY 64-23
(d) Tighten the 6 screws.
64
(e) Install the steering wheel assy. (Refer to “Chapter 51

steering column - steering wheel assy, overhaul”)
64
64-24 LIGHTING - FOG LAMP SWITCH
FOG LAMP SWITCH

REPLAEMENT
2. REMOVE FOG LAMP SWITCHES.

(a) Remove Instrument Cluster Cover. (Refer to “Chapter 83
instrument panel - dashboard, replacement”)
(b) Disconnect connectors from front and rear fog lamp
switch.
(c) Remove front and rear fog lamp switch.
3. INSTALL FOG LAMP SWITCHES.

(a) Install front and rear fog lamp switch to instrument cluster cover.
(b) Connect connectors to front and rear fog lamp switch.
(c) Install instrument cluster cover. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)

LIGHTING - REAR DOME LIGHT SWITCH 64-25
REAR DOME LIGHT SWITCH

REPLACEMENT
2. REMOVE REAR DOME LIGHT SWITCH.

(a) Remove instrument cluster cover. (Refer to “Chapter 83
instrument panel - dashboard, replacement”)
(b) Disconnect the connector from rear dome light switch.
(c) Remove the rear dome light switch.
3. INSTALL REAR DOME LIGHT SWITCH.

(a) Install the rear dome light switch to instrument cluster cover.
(b) Connect the connector to rear dome light switch.
(c) Install instrument cluster cover. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
64
MEMO
WIPER AND WASHER
65
WIPER AND WASHER SYSTEM....................................................... 65-1
PRECAUTION.............................................................................. 65-1
COMPONENTS ........................................................................... 65-4 65
WIPER ASSY ..................................................................................... 65-5
REPLACEMENT .......................................................................... 65-5
WIPER MOTOR ASSY ....................................................................... 65-9
REPLACEMENT .......................................................................... 65-9 65
WIPER LINK ASSY .......................................................................... 65-14
REPLACEMENT ........................................................................ 65-14
WIPER BLADE WITH BRACKET ASSY ......................................... 65-16
REPLACEMENT ........................................................................ 65-16
WASHER NOZZLE........................................................................... 65-17
INSPECTION ............................................................................. 65-17
ADJUSTMENT ........................................................................... 65-18
11B
12B
65
WIPER AND WASHER - WIPER AND WASHER SYSTEM 65-1
WIPER AND WASHER SYSTEM

WIPER AND WASHER
PRECAUTION
1. WIPER AND WASHER SYSTEM PRECAUTION. 65
(a) Usually use ordinary washer fluid for window glass.
(b) Sometimes use water instead of the washer fluid temporarily.
(c) Be sure to fill correct washer fluid in low temperature area.
(d) Never use the coolant of engine or other substitutes to prevent damage on body paint.
65
65-2 WIPER AND WASHER - WIPER AND WASHER SYSTEM

1. Fuse (Damaged) -

2. Wiper switches (Damaged) combination switch assy,
Wipers do not operate replacement

3. Wiper motor (Damaged) wiper motor assy, replacement
4. Wire harness (Open or short) -

1. Front wiper switch (Damaged) combination switch assy,
replacement
Front wipers do not operate in LO
or HI Chapter 65 wiper and washer -
2. Front wiper motor (Damaged) wiper motor assy, replacement

replacement
Front wipers do not operate in 2. Solid state timer (Damaged) -

INT
3. Front wiper motor (Damaged) wiper motor assy, replacement

1. Rear wiper and washer switch combination switch assy,
Rear wiper does not operate (Damaged) replacement

1. Wiper arms (Installed incorrectly) wiper assy, replacement
Wiper arms do not stop automati-
cally or not in correct position Chapter 65 wiper and washer -
2. Wiper motor (Damaged) wiper motor assy, replacement
(Wiper switch turned off)

1. Worm (Rusty or unlubricated) wiper motor assy, replacement

Abnormal noise 2. Wiper link (Worn or deformed) wiper link assy, replacement

3. Wiper blade assy (Aging or wiper blade with bracket assy,
cracked) replacement
WIPER AND WASHER - WIPER AND WASHER SYSTEM 65-3
1. Front and rear windshield (Be -

soiled by oil or wax)
65
2. Washer fluid (Poor quality) -
3. Wiper blade assy (Incorrect type) -

Wiper effect poor 4. Wiper blade assy (Aging or wiper blade with bracket assy,
cracked) replacement
5. Wiper arms (Deformed or Chapter 65 wiper and washer -

damaged) wiper assy, replacement
6. Wiper arms (Spring force Chapter 65 wiper and washer -

declined) wiper assy, replacement

replacement

2. Rear wiper and washer switch combination switch assy,
Washers do not operate (Damaged) replacement
3. Washer motor with pump assy -

(Damaged)
1. Washer fluid (Low) -
2. Washer fluid (Frozen) -
3. Washer fluid hose (Curving or -

Washer fluid does not spray or jam)
spray powerlessly
4. Washer nozzle (Blocking) washer nozzle, inspection
5. Washer motor with pump assy -

(Damaged)
65
Incorrect point where washer fluid 1. Washer nozzle (Adjustment Chapter 65 wiper and washer -
spray on front / rear windshield required) washer nozzle, adjustment
65-4 WIPER AND WASHER - WIPER AND WASHER SYSTEM
COMPONENTS
VEHICLE WITH REAR WIPER ASSY
1 Washer Nozzle 10 Wiper Link Assy
2 Washer House 11 Rod Shaft Washer
3 Nozzle Lock Plate 12 Right Wiper Assy
4 Washer Pipe Clip 13 Nut
5 Washer Pipeline Assy 1 14 Left Wiper Assy
6 Washer Pipeline Assy 2 15 Rear Wiper Motor With Link Assy
Washer Fluid Container And Washer 16 Bolt

7
Pump
17 Nut
8 Wiper Motor Assy
9 Screw And Plain Washer

WIPER AND WASHER - WIPER ASSY 65-5
WIPER ASSY
REPLACEMENT
1. REMOVE FRONT WIPER ASSY LH. 65
(a) Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.
CAUTION
Do not perform this operation when the windshield is dry to prevent scoring.
(b) Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop
position.
(c) Remove the front wiper arm cap.
(d) Remove the nut and spring washer.
(e) Remove the front wiper assy LH.

NOTE
• Disconnect the water line between wiper assy and
spray hose.
65
• Turn the front wiper arm LH up before performing
this operation.
2. REMOVE FRONT WIPER ASSY RH.

NOTE
65-6 WIPER AND WASHER - WIPER ASSY
3. REMOVE REAR WIPER ASSY.

(a) Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
Do not perform this operation when the rear window is dry to prevent scoring.
(b) Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
(c) Remove the rear wiper arm cap with hand.
(d) Remove the nut.
(e) Remove the rear wiper assy.

NOTE
• Disconnect the water line between wiper assy and
spray hose.
• Turn the rear wiper arm up before performing this
operation.
4. INSTALL FRONT WIPER ASSY LH.

(a) Scrape off the serration part of the wiper arm with a
round file or equivalent.
(b) Clean the wiper pivot serration with the wire brush.
WIPER AND WASHER - WIPER ASSY 65-7
(c) Position the front wiper assy LH properly.

NOTE
• The front wiper blade assy LH should be located
along lower edge of the windshield. 65
• Turn the front wiper arm LH up before performing
this operation.
• Connect the water spray hose.
(d) Install the spring washer and tighten the nut.

(e) Install the front wiper arm cap.

NOTE
• Turn the front wiper arm LH down after performing
this operation.
• Make sure the front wiper blade assy LH is located
along lower edge of the rear windshield.
(f) Check the automatic stop position of front wiper assy LH.
• Set the front wiper switch to the “INT / LO / HI” position to
activate the front wiper assy.
CAUTION
65
Do not perform this operation when the windshield is dry to
prevent scoring.
• Set the front wiper switch to the “OFF” position to stop
the front wiper assy at the automatic stop position.
• Check whether the front wiper blade assy LH is located
along lower edge of the windshield.
5. INSTALL FRONT WIPER ASSY RH.

NOTE
65-8 WIPER AND WASHER - WIPER ASSY
6. INSTALL REAR WIPER ASSY.

(a) Scrape off the serration part of the wiper arm with a
round file or equivalent.
(b) Clean the wiper pivot serration with the wire brush.
(c) Position the rear wiper assy properly.

NOTE
• The rear wiper blade assy should be located along
the lower edge of the rear window.
• Turn the rear wiper arm up before performing this
operation.
• Connect the water spray hose.
(d) Tighten the nut.

(e) Install the rear wiper arm cap.

NOTE
• Turn the rear wiper arm down after performing this
operation.
• Make sure the rear wiper blade assy is located along
lower edge of the rear window.
7. Check the automatic position of rear wiper assy.

(a) Set the rear wiper switch to the “INT/ON” position to activate the rear wiper assy.
CAUTION
(b) Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
(c) Check whether the rear wiper blade assy is located along lower edge of the rear window.
WIPER AND WASHER - WIPER MOTOR ASSY 65-9
WIPER MOTOR ASSY

REPLACEMENT
1. STOP WIPER ASSY AT AUTOMATIC STOP POSITION. 65
(a) Stop the front wiper assy at the automatic stop position.
• Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.
CAUTION
• Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop
position.
(b) Stop the rear wiper assy at the automatic stop position.
• Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
• Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
3. REMOVE DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
4. REMOVE VENT DUCT. (Refer to “Chapter 61 heater and air conditioning - vent duct, replace-
ment”)
5. REMOVE FRONT WIPER MOTOR ASSY.

(a) Disconnect the front wiper motor assy connector.
(b) Remove 4 bolts.

65
(c) Separate the front wiper motor assy from the front wiper
link assy.
(d) Remove the front wiper motor assy.
CAUTION
Store the front wiper motor assy carefully. Do not rotate the
rocker arm of front wiper motor assy.
65-10 WIPER AND WASHER - WIPER MOTOR ASSY
6. REMOVE REAR WIPER MOTOR WITH LINK ASSY.

(a) Remove the rear wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”)
(b) Remove the rear wiper arm shaft seal.
(c) Remove the nut.
(d) Remove the rear hatch lower inner guard board. (Refer
to “Chapter 88 exterior and interior trim - vehicle door
inner guard board, replacement”)
(e) Disconnect the rear wiper motor with link assy connector.
(f) Disconnect the ground point and remove the bolt.

(g) Remove 2 bolts.
65
(h) Remove rear wiper motor with link assy.

CAUTION
Store the rear wiper motor with link assy carefully. Do not
rotate the rocker arm of rear wiper motor with link assy.
7. INSTALL FRONT WIPER MOTOR ASSY.

(a) Connect the front wiper motor assy to the front wiper link assy.
NOTE
If hear a “click”, the front wiper motor assy is connected to the front wiper link assy completely.
65
(c) Connect the front wiper motor assy connector.
8. INSTALL VENT DUCT. (Refer to “Chapter 61 heater and air conditioning - vent duct, replace-
ment”)
9. INSTALL DASHBOARD. (Refer to “Chapter 83 instrument panel - dashboard, replacement”)
65-12 WIPER AND WASHER - WIPER MOTOR ASSY
replacement”)
11. INSTALL REAR WIPER MOTOR WITH LINK ASSY.

(a) Position the rear wiper motor with link assy properly.
NOTE
Align the rear wiper pivot with the mounting hole on rear
hatch.
(c) Tighten the bolt and connect the ground point..
(d) Connect the rear wiper motor with link assy connector.
(e) Install the rear hatch lower inner guard board. (Refer to
“Chapter 88 exterior and interior trim - vehicle door inner
guard board, replacement”)
(f) Tighten the nut.
65
(g) Install the rear wiper arm shaft seal.
(h) Install the rear wiper assy. (Refer to “Chapter 65 wiper

and washer - wiper assy, replacement”)
replacement”).
13. CHECK AUTOMATIC STOP POSITION OF WIPER ASSY.
(a) Check automatic stop position of the front wiper assy LH.
• Set the front wiper switch to the “INT / LO / HI” position to activate the front wiper assy.
CAUTION
• Set the front wiper switch to the “OFF” position to stop the front wiper assy at the automatic stop
position.
• Check whether the front wiper blade assy LH is located along lower edge of the windshield.
(b) Check the automatic position of rear wiper assy. 65
• Set the rear wiper switch to the “INT / ON” position to activate the rear wiper assy.
CAUTION
• Set the rear wiper switch to the “OFF” position to stop the rear wiper assy at the automatic stop
position.
• Check whether the rear wiper blade assy is located along lower edge of the rear window.
65-14 WIPER AND WASHER - WIPER LINK ASSY
WIPER LINK ASSY

REPLACEMENT
1. REMOVE FRONT WIPER LINK ASSY.
(a) Remove the front wiper assy. (Refer to “Chapter 65 wiper and washer - wiper assy, replacement”)
(b) Remove the rubber cover.

NOTE
Total 2 rubber covers. (Left and right)
(c) Remove the nut.

NOTE
Total 2 nuts. (Left and right)
(d) Remove the front wiper motor assy. (Refer to “Chapter

65 wiper and washer - wiper motor assy, replacement”)
(e) Remove the front wiper link assy.
2. REMOVE REAR WIPER LINK ASSY.

(a) Remove the rear wiper motor with link assy. (Refer to “Chapter 65 wiper and washer - wiper motor assy,
replacement”)
3. INSTALL FRONT WIPER LINK ASSY.
(a) Position the front wiper link assy properly.
(b) Install the front wiper motor assy. (Refer to “Chapter 65 wiper and washer - wiper motor assy,
replacement”)

NOTE
Total 2 nuts. (Left and right)
WIPER AND WASHER - WIPER LINK ASSY 65-15
(d) Install the rubber cover.

NOTE
Total 2 rubber covers. (Left and right)
65
(e) Install front wiper assy. (Refer to “Chapter 65 wiper and

washer - wiper assy, replacement”)
4. INSTALL REAR WIPER LINK ASSY.

(a) Install the rear wiper motor with link assy. (Refer to “Chapter 55 wiper and washer - wiper motor assy,
replacement”)
65
65-16 WIPER AND WASHER - WIPER BLADE WITH BRACKET ASSY
WIPER BLADE WITH BRACKET ASSY

REPLACEMENT
1. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY LH.
(a) Turn the front wiper blade bracket assy LH up.
(b) Press the latch plate, remove the front wiper blade with
bracket assy LH.
2. REMOVE FRONT WIPER BLADE WITH BRACKET ASSY RH.

NOTE
3. REMOVE REAR WIPER BLADE WITH BRACKET ASSY.
NOTE
Remove the rear by the same procedures as the front.
4. INSTALL FRONT WIPER BLADE WITH BRACKET

ASSY LH.
(a) Install the front wiper blade with bracket assy LH.
NOTE
If hear a “click”, the front wiper blade with bracket assy LH
is installed completely.
(b) Turn the front wiper blade bracket assy LH down.
5. INSTALL FRONT WIPER BLADE WITH BRACKET ASSY RH.

NOTE
6. INSTALL REAR WIPER BLADE WITH BRACKET ASSY.
NOTE
Install the rear by the same procedures as the front.
WIPER AND WASHER - WASHER NOZZLE 65-17
WASHER NOZZLE
INSPECTION
1. INSPECT WASHER NOZZLE. 65
(a) Set the front washer switch to the “ON” position. Check the point which the washer fluid sprays on
windshield is within the range shown in the illustration.
(b) Set the rear wiper and washer switch to the “WASH1 / WASH2” position. Check the point which the
washer fluid spray on rear window is within the range shown in the illustration.
65
65-18 WIPER AND WASHER - WASHER NOZZLE
ADJUSTMENT
1. ADJUST WASHER NOZZLE.
(a) Check the point which the washer fluid sprays on windshield and rear window. (Refer to “Chapter 65
wiper and washer - washer nozzle, inspection”)
(b) Insert a needle or equivalent into the nozzle to adjust until the point which the washer fluid sprays on
windshield and rear window is within the range specified.
AUDIO SYSTEM
66
AUDIO SYSTEM................................................................................. 66-1
COMPONENTS ........................................................................... 66-1
RADIO ASSY ..................................................................................... 66-2
REPLACEMENT .......................................................................... 66-2 66
FRONT SPEAKER ASSY .................................................................. 66-3
REPLACEMENT .......................................................................... 66-3
RADIO ANTENNA ASSY ................................................................... 66-6
REPLACEMENT .......................................................................... 66-6 66
11B
12B
14B
66
AUDIO SYSTEM - AUDIO SYSTEM 66-1
AUDIO SYSTEM
AUDIO SYSTEM
COMPONENTS
66
1 Front Speaker Assy RH 4 Radio Antenna Assy
2 Screw 5 Radio Assy
3 Bolt 6 Front Speaker Assy LH
66
66-2 AUDIO SYSTEM - RADIO ASSY
RADIO ASSY
REPLACEMENT
2. REMOVE INSTRUMENT CLUSTER COVER. (Refer to “Chapter 83 instrument panel - dashboard,
replacement”)
3. REMOVE RADIO ASSY.

(a) Loosen the 4 screws and take out the radio assy.
(b) Disconnect the connector from radio assy and remove

the radio assy.
4. INSTALL RADIO ASSY.

(a) Connect the connector to the radio assy.
(b) Install the radio assy and tighten the 4 screws.
5. INSTALL INSTRUMENT CLUSTER COVER. (Refer to “Chapter 83 instrument panel - dashboard,

replacement”)
7. CHECK RADIO ASSY AND RESET THE STATIONS.
AUDIO SYSTEM - FRONT SPEAKER ASSY 66-3
FRONT SPEAKER ASSY

REPLACEMENT
2. REMOVE FRONT SPEAKER ASSY LH.

(a) Open the glove compartment.
(b) Loosen the 4 screws.
(c) Remove the connector from front speaker assy LH.

66
66-4 AUDIO SYSTEM - FRONT SPEAKER ASSY
(d) Loosen the 2 screws and remove the front speaker assy
LH.
3. REMOVE FRONT SPEAKER ASSY RH.

NOTE
4. INSTALL FRONT SPEAKER ASSY LH.

(a) Install the front speaker assy LH on the board and tighten
the 2 screws.
(b) Connect the connector to the front speaker assy LH.
(c) Install the front speaker assy LH to the instrument panel

and tighten the 4 screws.
(d) Close the glove compartment.
AUDIO SYSTEM - FRONT SPEAKER ASSY 66-5

6. INSTALL FRONT SPEAKER ASSY RH.
NOTE
66
66
66-6 AUDIO SYSTEM - RADIO ANTENNA ASSY
RADIO ANTENNA ASSY

REPLACEMENT
2. REMOVE RADIO ASSY. (Refer to “Chapter 66 audio system - radio assy, replacement”)
3. REMOVE RADIO ANTENNA ASSY.
(a) Disconect the radio antenna from radio assy.

(c) Remove the radio antenna assy from vehicle body.
(d) Remove the radio antenna assy.
4. REMOVE RADIO ANTENNA ASSY.

(a) Install the radio antenna and tighten the 2 bolts.
(b) Connect the radio antenna to the radio assy.
5. INSTALL RADIO ASSY. (Refer to “Chapter 66 audio system - radio assy, replacement”)
WIRING
71
HOW TO USE THIS MANUAL ........................................................... 71-1
INTRODUCTION.......................................................................... 71-1
SYSTEM WIRING DIAGRAM SECTION EXAMPLE ................... 71-2
POWER SOURCE SECTION EXAMPLE .................................... 71-5 71
CONNECTOR VIEWS SECTION EXAMPLE .............................. 71-6
GLOSSARY OF TERMS AND SYMBOLS................................... 71-7
FUSE AND RELAY LOCATIONS ................................................ 71-9
WIRING DIAGRAM .......................................................................... 71-13 71
POWER SOURCE ..................................................................... 71-13
ENGINE CONTROL SYSTEM ................................................... 71-19
STARTING SYSTEM ................................................................. 71-44
CHARGING SYSTEM ................................................................ 71-48
BRAKE CONTROL SYSTEM..................................................... 71-52
HEATER AND AIR CONDITIONING CONTROL SYSTEM ....... 71-55
LIGHT SYSTEM......................................................................... 71-62
WIPER AND WASHER ............................................................ 71-105
RADIO...................................................................................... 71-108
POWER SOCKET.................................................................... 71-110
COMMUNICATION SYSTEM .................................................. 71-112
POWER MIRROR .................................................................... 71-119
REAR WINDOW DEFROSTER ............................................... 71-121
INSTRUMENT CLUSTER........................................................ 71-123
POWER DOOR LOCK SYSTEM ............................................. 71-135
POWER WINDOW CONTROL ................................................ 71-139
CONNECTOR VIEWS .................................................................... 71-142
A - ENGINE ROOM WIRE HARNESS..................................... 71-142
B - BATTERY POSITIVE CABLE WIRE HARNESS................ 71-150
C - INSTRUMENT PANEL WIRE HARNESS .......................... 71-151
D - Front Door LH Wire Harness.............................................. 71-174
11B
E - ENGINE CONTROL WIRE HARNESS .............................. 71-176
F - ROOF WIRE HARNESS..................................................... 71-183
G - BATTERY NEGATIVE CABLE WIRE HARNESS.............. 71-186
12B
H - FRONT DOOR RH WIRE HARNESS ................................ 71-187
J - REAR HATCH WIRE HARNESS ........................................ 71-188 14B
K - FRONT EVAPORATOR WIRE HARNESS ........................ 71-190
L - REAR EVAPORATOR WIRE HARNESS ........................... 71-193 14B
M - LEFT STEP WIRE HARNESS ........................................... 71-195
N - RIGHT STEP WIRE HARNESS ......................................... 71-196 71
P - FRONT SIDE REVERSE RADAR WIRE HARNESS ......... 71-197
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS ............ 71-199
R - REVERSE RADAR REAR BUMPER WIRE HARNESS .... 71-200
S - SIDE OF CHASSIS HARNESS ......................................... 71-201
T - CHASSIS HARNESS.......................................................... 71-202
U - FUEL TANK WIRE HARNESS........................................... 71-203
WIRE HARNESS & CONNECTOR LOCATION VIEWS................ 71-204
A - ENGINE ROOM WIRE HARNESS..................................... 71-204
B - BATTERY POSITIVE CABLE WIRE HARNESS................ 71-204
E - ENGINE CONTROL WIRE HARNESS .............................. 71-204
C - INSTRUMENT PANEL WIRE HARNESS .......................... 71-206
D - FRONT DOOR LH WIRE HARNESS................................. 71-211
F - ROOF WIRE HARNESS..................................................... 71-212
L - REAR EVAPORATOR WIRE HARNESS ........................... 71-212
U - FUEL TANK WIRE HARNESS........................................... 71-212
H - FRONT DOOR RH WIRE HARNESS ................................ 71-214
J - REAR HATCH WIRE HARNESS ....................................... 71-215
P - FRONT SIDE REVERSE RADAR WIRE HARNESS ......... 71-215
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS ............ 71-215
R - REVERSE RADAR REAR BUMPER WIRE HARNESS .... 71-215
S - SIDE OF CHASSIS HARNESS ......................................... 71-215
T - CHASSIS HARNESS.......................................................... 71-215
K - FRONT EVAPORATOR WIRE HARNESS ........................ 71-217
WIRING - HOW TO USE THIS MANUAL 71-1
HOW TO USE THIS MANUAL

WIRING
INTRODUCTION
This manual provides information on the electrical circuits installed on vehicles by dividing them into electrical 71
systems. The actual wiring of each system wiring diagram is shown from the point where the power source is
received from the battery to each ground point. (All wiring diagrams are shown with the switches in the OFF 71
position.)
When troubleshooting any problem, firstly, make sure you understand the operation of the circuit where the 71
problem was detected (see System Wiring Diagram Section). Secondly, understand the power source supply-
ing to that circuit (see Power Source Section). Finally, understand the direction of current flow (see System 71
Description).
When the circuit operation is understood, begin troubleshooting of the suspected circuit to find out the cause. 71
(Based on relays, controllers, accessory, inlines, sensors, actuators, switches, ground points, connection loca-
tion of each system wiring diagram and wire harness location.) 71
71
71
71
71
71
71
71
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71
71
71
71
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71-2 WIRING - HOW TO USE THIS MANUAL
SYSTEM WIRING DIAGRAM SECTION EXAMPLE
*The system wiring diagram shown here is an EXAMPLE ONLY. It is different to the actual circuit
shown in the SYSTEM WIRING DIAGRAM SECTION.
Note
No. Name Description

1 System Title Distinguish between different systems and functions, easy to query. 71
Wire colors are indicated by an alphabetical code.
B=Black O=Orange V=Violet BR=Brown 71
G=Green P=Pink W= White GR=Gray
L =Blue R=Red Y=Yellow LG=Light Green 71
Indicates the
2 The first letter indicates the basic wire color and the second letter indicates
wire color
the color of the stripe.
Example:
71
R (Red)
L-B (Blue and Black) 71
Indicates the Name of electrical component, easy to query.
3 71
component name An electrical component can only have one name.
Indicates the Number of electrical component, easy to query. 71

4
component number An electrical component has one or more numbers.
Female and male connectors have different numbering rules. 71

The two examples below are viewed from terminal side when connectors are
unplugged. 71
Female - Numbered in order from upper right to lower left.
71
Indicates the pin num-
5 ber of 71
connector
Male - Numbered in order from upper left to lower right.
71
71
This rules also applied to inline connector number. 71
The first letter of the code for each ground point(s) indicates the component’s
6 Indicates a ground point 71
location.
Indicates related Indicate that other system(s) associated with this system. 71
7
system
Indicates inline A group of inline has two connector numbers, one is the female and the other 71
8
connector number is the male.
71
Male:
71
Indicates inline 71
9
gender Female:
Note

10 System Description Describe the current flows and how the system works.
11 Service Hints Describe the component's value and principle. Refer in the service process.
12 Parts Location Indicate the wire harness showing the parts location on the vehicle.
13 Inline Indicate the inline two parts gender and the connected wire harness types.
14 Ground Points Indicate the ground location of each wire harness.

POWER SOURCE SECTION EXAMPLE

The “POWER SOURCE” section describes how the current flows and each part power feed conditions. In the
POWER SOURCE wiring diagram, the conditions when battery power is supplied to each system are explained.
Since all system wiring diagrams start from the power source, the power source system must be fully 71
understood.
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
CONNECTOR VIEWS SECTION EXAMPLE
*The connector views shown here is an EXAMPLE ONLY. It is different to the actual connector views
shown in the CONNECTOR VIEWS SECTION.
Note

1 Connector Face Indicate connector face and pin order.
Name of electrical component, easy to query.

2 Component Name
An electrical component can only have one name.
Number of electrical component, easy to query.

3 Component Number
An electrical component has one or more numbers.
4 Connector Information Indicate pin number, wire color and function.

GLOSSARY OF TERMS AND SYMBOLS

BATTERY
Stores chemical energy and converts it into electrical energy. 71
Provides DC current for the auto’s various electrical circuits.
71
GROUND
The point at which wiring attaches to the body, thereby providing a 71
return path for an electrical circuit. Without a ground, current cannot
flow.
71
FUSIBLE LINK FUSIBLE LINK
In high amperage circuits, a heavy gauge wire burns when it is over- 71
loaded to protect the connected components.
FUSE FUSE 71
A thin metal strip burns when too much current flows through it,
thereby it can stop current flow and protect a circuit from damage. 71
COIL 71
When the magnetic field engenders fluctuations, the coil circuit is
induced electromotive force. 71
SOLENOID
71
An electromagnetic coil which forms a magnetic field when current
flows, to move a plunger, etc.
71
SINGLE FILAMENT LAMPS
Current flow causes a headlight filament to heat up and emit light. A 71
headlight may have either a single filament or double filaments.
DOUBLE FILAMENT 71
71
INLINE
Indicate the connector joining wire harness and wire harness. 71
DIODE 71
A semiconductor which allows current flow in only one direction.
71
MOTOR MOTOR
A power unit which converts electrical energy into mechanical
energy, especially rotary motion. 71
SPEED MOTOR
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LED (LIGHT EMITTING DIODE)

Upon current flow, these diodes emit light without producing the
heat of a comparable light.
HORN
An electric device which sounds a loud audible signal.
SPEAKER
An electromechanical device which creates sound waves from
current flow.
TAPPED RESISTOR TAPPED RESISTOR

A resistor which supplies two or more different non-adjustable resistance
values.
SLIDE RHEOSTAT SLIDE RHEOSTAT

A controllable resistor with a variable rate of resistance. Also called
a potentiometer or rheostat.
THERMISTOR SENSOR
A resistor which varies its resistance with temperature.
POWER SOCKET (CIGARETTE LIGHTER)

An electric resistance heating element.
MANUAL SWITCH
Opens and closes circuits, stops or allows current flow.
IGNITION SWITCH
A key operated switch with several positions which allows various
circuits.
HEATER
An electric resistance heating element.
RELAY(3Pin) RELAY
Basically, an electrically operated switch which may be normally
closed or open. Current flow through a small coil to create a magnetic
field which either opens or closes an attached switch.
RELAY(4Pin)
RELAY(5Pin)
FUSE AND RELAY LOCATIONS

BODY JUNCTION BOX - 09 LATE PRODUCTION
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FUSIBLE LINK 71
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No. Amps Function No. Amps Function
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F1 50A AM1Fusible Link F4 30A Power Door/Window Fusible Link
F2 30A Headlamp Fusible Link F5 30A Rear Evaporator Fusible Link
F3 40A Front Heater Fusible Link

FUSE

F6 15A ABS Fuse F15 20A AM2 Fuse
F7 15A Headlamp Fuse (RH) F16 7.5A Instrument Cluster Fuse
F8 15A Headlamp Fuse (LH) F17 10A Turn Signal Fuse
F9 15A Rear Defroster Fuse F18 15A Radio & Cigarette Fuse
F10 15A Fog Lamp Fuse F19 15A Fuel Pump Fuse
F11 7.5A Dome Light Fuse F20 20A Wiper Fuse
F12 15A Rear Heater Fuse F21 15A A/C Fuse
F13 15A Stop Lamp Fuse F22 15A Tail Fuse
F14 15A Hazard & Horn Fuse F23 10A Engine (IG) Fuse
RELAY
No. Function No. Function

R1 EFI & A/C Relay (BJ491EQ) R6 Tail Light Relay
R1 Fan Relay (LO) (4GC1) R7 Rear Defroster Relay
R2 ABS Relay (BJ491EQ) R8 A/C Main Relay
R2 Fan Relay (HI) (4GC1) R9 Headlamp Relay
R3 Power Window Relay R10 Front Heater Relay
R4 Fog Lamp Relay R11 Front INT Wiper Relay
R5 Rear Heater Relay R12 Horn Relay

BODY JUNCTION BOX LOCATION - EARLY PRODUCTION
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FUSIBLE LINK 71
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F1 30A Front Heater Fusible Link F2 30A Rear Evaporator Fusible Link
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FUSE

F3 20A AM2 Fuse F15 25A Diesel Filter Heating Fuse (4D20)
F4 7.5A Dome Light Fuse F16 15A A/C Fuse
F5 15A Fog Lamp Fuse F17 20A Wiper Fuse
F6 15A Rear Heater Fuse F18 10A Turn Signal Fuse
F7 15A Stop Lamp Fuse F19 10A Engine Fuse (BJ491EQ)
F8 15A Tail Fuse F19 15A Fuel Cut-off Fuse (BJ493ZQ)
F9 15A ABS Fuse Fuel Supply Solenoid Fuse

F19 15A
(4D20)
F10 15A Headlamp Fuse (RH)
F20 7.5A Charge Fuse
F11 15A Headlamp Fuse (LH)
F21 15A ABS Fuse (BJ491EQ)
F12 15A Hazard & Horn Fuse
F21 20A EGR Fuse (BJ493ZQ)
F13 20A Radio & Cigarette Fuse
F21 7.5A Fuel Inlet Fuse (4D20)
F14 7.5A Fan Control Fuse
F22 7.5A A/C Cut-off Fuse (BJ491EQ)
F15 15A Fuel Pump Fuse (BJ491EQ)
F22 7.5A Starter Fuse (BJ493ZQ)
F15 15A Rear Defroster Fuse (BJ493ZQ)
RELAY
No. Function No. Function

R1 Tail Light Relay R6 Fan Relay (LO) (BJ491EQ)
R2 Horn Relay R6 Rear Defroster Relay (BJ493ZQ)
R3 Front INT Wiper Relay R6 Diesel Filter Heating Relay (4D20)
R4 EFI & A/C Relay (BJ491EQ) R7 Front Heater Relay
R4 ABS Relay (BJ493ZQ) R8 Rear Heater Relay
R4 Fuel Return Relay (4D20) R9 Headlamp Relay
R5 Fog Lamp Relay

WIRING - WIRING DIAGRAM 71-13
WIRING DIAGRAM
POWER SOURCE
POWER SOURCE - 09 LATE PRODUCTION 71
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71-14 WIRING - WIRING DIAGRAM
Service Hints
• C032 Ignition Switch 71
AM1 - ACC: Closed with the ignition switch at ACC/ON position.
AM1 - IG1: Closed with the ignition switch at ON/ST position.
AM2 - IG2: Closed with the ignition switch at ON/ST position. 71
AM2 - ST2: Closed with the ignition switch at ST position.
71
Parts Location
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Code Wire Harness Code Wire Harness
71
A021 Engine Room Wire Harness C051 Instrument Panel Wire Harness
A022 Engine Room Wire Harness C052 Instrument Panel Wire Harness 71
C032 Instrument Panel Wire Harness C053 Instrument Panel Wire Harness
71
C050 Instrument Panel Wire Harness
71
Connector Joining Wire Harness and Wire Harness
71
Code Code Wire Harness (Connector Location)
71
Instrument Panel Wire Harness & Engine Room Wire Harness
C102 A102
(Left Side of the Instrument Panel)
71
C103 A103
(Left Side of the Instrument Panel) 71
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POWER SOURCE - EARLY PRODUCTION

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Service Hints
• C032 Ignition Switch
AM1 - ACC: Closed with the ignition switch at ACC/ON position.
AM2 - ST1: Closed with the ignition switch at ST position.
Parts Location


ENGINE CONTROL SYSTEM - WITH ENGINE BJ491
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System Description
Engine control system of BJ491 engine is based on Engine Control Module (ECM) of Delphi MT20U2 as the
center system. The engine control system mainly consists of sensor signal input, engine control module (ECM) 71
and executive control.
71
• Sensor Signal Input
Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor
71
Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute
pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback
manifold absolute pressure and intake air temperature. 71
Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms
method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure 71
state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the
basis to adjust the basic fuel supply sprayed into the engine.
Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the 71
engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine
fuel supply. 71
Mounting Position: on the intake manifold pipe of the engine first-cylinder.
Coolant Temperature Sensor 71

Coolant temperature sensor is used for detecting engine operating temperature. The engine control module
(ECM) provides the optimum control solution for the engine according to different temperatures. Coolant 71
temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and resistance value
decreasing.
71
Mounting Position: on the engine coolant outlet.
Crankshaft Position Sensor 71

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects
the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output 71
signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine
control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft.
Mounting Position: on the flywheel housing perpendicular to the crankshaft position. 71
Knock Sensor 71
Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and
used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity
detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock, 71
so as to optimize engine power performance, fuel economy and reduce emissions.
Mounting Position: between Cylinders 2 and 3 of the engine block. 71
Throttle Position Sensor 71
Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the
throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also
varies. The control module determines real-time engine load and dynamic change condition based on the 71
sensor signal value and its rate of change.
Mounting Position: on the throttle body assembly, coaxial with the throttle lever and throttle. 71
Upstream Oxygen Sensor
Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment 71
and keeping the desired air-fuel ratio, the three-way catalytic converter can
achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for
activation. The sensor changes the output voltage according to the presence or absence of oxygen in the
exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased,
output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased,
thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually,
when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude,
helping the engine control module (ECM) to accurately determine the air-fuel ratio.
Mounting Position: The upstream oxygen sensor is mounted in front of three-way catalytic converter of the
engine exhaust pipe.
Vehicle Speed Sensor

Vehicle speed sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The
engine control module (ECM) measures digital voltage signal through the sensor. In order to determine the
current vehicle speed.
Mounting Position: On the transmission output shaft end.
• Executive Control
Fuel Injection Control
The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle
implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop
control and self-learning function.
Fuel pump is single-stage electric turbine pump, and its operation is controlled by the engine control module
(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the
crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is
detected, the fuel pump starts to work. Upon loss of crankshaft position signal, the pump will stop running.
Mounting Position: in the fuel tank.
Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled by the engine control
module (ECM) to produce magnetic force and pull up spool. The fuel is ejected from the pilot hole in the form
of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio, manifold absolute
pressure, intake air temperature, closed loop feedback correction, acceleration concentration, deceleration
cutoff, self-learning and correction.
Mounting Position: Fixed on the intake manifold through the fuel rail.
Ignition Control
The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition
energy for two cylinder spark plugs with 360-degree crankshaft angle difference.
Mounting Position: Above the timing belt casing.
Idle Control
The system uses the idle air control, achieving high-precision idle speed control.
The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the
engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the
stepping motor through the digital square wave signal.
Mounting Position: On the throttle body assembly.
Canister Solenoid Valve Control
The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister
through the canister solenoid valve control. The opening of canister solenoid valve is determined by the
engine control module (ECM) according to the duty cycle signal based on the state of engine.
Mounting Position: Between canister and intake manifold.
Fan Control
The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning
works properly to determine the operating state of each fan.
• Malfunction Diagnosis Function

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of
the system and conducts detection in real time. Once the system or parts have faults, the system will switch on
the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the
engine control module (ECM) will start backup emergency control program.
Service Hints
• E002 Fuel Injector 1, E003 Fuel Injector 2, E004 Fuel Injector 3, E005 Fuel Injector 4
1 - 2: Approx. 12 Ω
1 - Ground: Approx. 12 volts
• E007 Throttle Position Sensor
• E009 Idle Air Control

1 - 2: Approx. 53 Ω
3 - 4: Approx. 53 Ω
• E010 Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor 71
• E017 Upstream Oxygen Sensor, E015 Downstream Oxygen Sensor
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Parts Location 71
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A003 Engine Room Wire Harness E004 Engine Control Wire Harness
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A010 Engine Room Wire Harness E007 Engine Control Wire Harness 71
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C013 Instrument Panel Wire Harness E017 Engine Control Wire Harness 71
C035 Instrument Panel Wire Harness E021 Engine Control Wire Harness
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E001 Engine Control Wire Harness G002 Battery Negative Cable Wire Harness
E002 Engine Control Wire Harness K007 Front Evaporator Wire Harness 71
E003 Engine Control Wire Harness U002 Fuel Tank Wire Harness
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Engine Room Wire Harness & Instrument Panel Wire Harness
A101 C101
(Left Side of The Instrument Panel)
Engine Room Wire Harness & Engine Control Wire Harness

A106 E101
(After The Driver’s Seat, Right Side of The Intake Manifold)

A107 E100

C102 A102
Instrument Panel Wire Harness & Front Evaporator Wire Harness

C110 K100
(Inside of the Instrument Panel Center Console)
Roof Wire Harness & Fuel Tank Wire Harness

F104 U100
(At The Left Rear Wheel)
Battery Negative Cable Wire Harness & Engine Room Wire Harness
G100 A112
(Under the Driver’s Seat)
Ground Points
Code Ground Points Location Code Ground Points Location

A201 Under the Driver’s Seat F201 Under The Rear Window RH
E201 On The Engine Coolant Outlet

ENGINE CONTROL SYSTEM - WITH ENGINE 4GC1
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System Description
Engine control system of 4GC1 engine is based on Engine Control Module (ECM) of Delphi MT20U2 as the
center system. The engine control system mainly consists of sensor signal input, engine control module (ECM) 71
and executive control.
71
Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor
71
Manifold absolute pressure/intake air temperature (MAP/IAT) sensor integrates functions of manifold absolute
pressure sensor with those of intake air temperature sensor, while achieving the functions of feedback
manifold absolute pressure and intake air temperature. 71
Manifold absolute pressure sensor measures engine inhaled air volume, which is a critical element that forms
method of speed-density type air flow measurement. The sensor directly senses manifold absolute pressure 71
state inside the engine intake manifold. The engine control module (ECM) takes this reference signal as the
basis to adjust the basic fuel supply sprayed into the engine.
Intake air temperature sensor uses NTC (negative temperature coefficient) thermistor sensor, with which the 71
engine control module (ECM) measures the air temperature in the engine cylinder and modifies the engine
fuel supply. 71
Mounting Position: on the intake manifold pipe of the engine first-cylinder.
Coolant Temperature Sensor 71

Coolant temperature sensor is used for detecting engine operating temperature. The engine control module
(ECM) provides the optimum control solution for the engine according to different temperatures. Coolant 71
temperature sensor uses NTC thermistor sensor, with engine coolant temperature rising and resistance value
decreasing.
71
Mounting Position: on the engine coolant outlet.
Crankshaft Position Sensor 71

As magnetoelectric sensor, crankshaft position sensor works with gear ring of crankshaft. The sensor detects
the change of reluctance while the crankshaft rotates and alternating reluctance generates alternating output 71
signal. The notch positions on the gear ring correspond to top dead center (TDC) in the engine. The engine
control module (ECM) uses this signal to determine the rotation position and speed of the crankshaft.
Mounting Position: on the flywheel housing perpendicular to the crankshaft position. 71
Knock Sensor 71
Knock sensor is a vibration acceleration sensor, equipped at the engine knock induction-sensitive parts and
used for sensing the knock generated by the engine. The engine control module (ECM) uses knock intensity
detected by the knock sensor to modify ignition advance angle and achieve the effective control of the knock, 71
so as to optimize engine power performance, fuel economy and reduce emissions.
Mounting Position: between Cylinders 2 and 3 of the engine block. 71
Throttle position sensor consists of carbon film resistor and sliding pointer driven by throttle shaft. When the
throttle opening changes, the signal that the sensor feeds back to the engine control module (ECM) also
varies. The control module determines real-time engine load and dynamic change condition based on the 71
sensor signal value and its rate of change.
Mounting Position: on the throttle body assembly, coaxial with the throttle lever and throttle. 71
Upstream Oxygen Sensor
Oxygen sensor is an important symbolic component of closed loop fuel control system. With its adjustment 71
and keeping the desired air-fuel ratio, the three-way catalytic converter can
achieve the best conversion efficiency. The zirconium oxide in oxygen sensor is heated (> 300 ℃ ) for
activation. The sensor changes the output voltage according to the presence or absence of oxygen in the
exhaust and determines the oxygen content in the exhaust. If the oxygen content in the exhaust is increased,
output voltage of oxygen sensor will be decreased; on the other hand, the output voltage will be increased,
thus providing feedback of the actual air-fuel ratio conditions for the engine control module (ECM). Usually,
when the sensor has the theoretical air-fuel ratio (14.6:1), it will result in dramatic change of voltage amplitude,
helping the engine control module (ECM) to accurately determine the air-fuel ratio.
Mounting Position: The upstream oxygen sensor is mounted in front of three-way catalytic converter of the
engine exhaust pipe.
Vehicle Speed Sensor

Vehicle speed sensor is Hall effect sensor, working with signal wheel on the transmission output shaft. The
engine control module (ECM) measures digital voltage signal through the sensor. In order to determine the
current vehicle speed.
Mounting Position: On the transmission output shaft end.
Fuel Injection Control/CNG Injection Control
The system uses the speed density method to make multi-point sequential injection, i.e., each engine cycle
implements accurate fuel supply through main pulse width and amended pulse width, which has closed-loop
control and self-learning function.
Fuel pump is single-stage electric turbine pump, and its operation is controlled by the engine control module
(ECM) through the pump relay. When ignition switch is turned on, the pump will run for 1.5 seconds. If the
crankshaft position signal is not received, the pump will stop running. If the crankshaft position signal is
detected, the fuel pump starts to work. Upon loss of crankshaft position signal, the pump will stop running.
Mounting Position: in the fuel tank.
Fuel injector is a ball valve device with solenoid switch. The coil in injector is controlled grounded by the injec-
tor control unit to produce magnetic force and pull up spool. The fuel/CNG is ejected from the pilot hole in the
form of mist. The main factors affecting changes in fuel injection pulse width include air-fuel ratio, manifold
absolute pressure, intake air temperature, closed loop feedback correction, acceleration concentration,
deceleration cutoff, self-learning and correction.
Mounting Position: Fixed on the intake manifold through the fuel rail.
Ignition Control
The system uses grouping ignition. Ignition coil is divided into two groups, each group providing the ignition
energy for two cylinder spark plugs with 360-degree crankshaft angle difference.
Mounting Position: Above the timing belt casing.
Idle Control
The system uses the idle air control, achieving high-precision idle speed control.
The idle stepping motor controls circulation area of throttle body bypass air duct to adjust control volume in the
engine. The engine control module (ECM) controls the amount of movement (forward / backward) for the
stepping motor through the digital square wave signal.
Mounting Position: On the throttle body assembly.
Canister Solenoid Valve Control

The engine control module (ECM) controls volume of gasoline vapor in intake manifold flowing from canister
through the canister solenoid valve control. The opening of canister solenoid valve is determined by the
engine control module (ECM) according to the duty cycle signal based on the state of engine.
Mounting Position: Between canister and intake manifold.
Fan Control
The engine control module (ECM) monitors the level of coolant temperature and whether the air-conditioning
works properly to determine the operating state of each fan.

When the system comes into operation, the engine control module (ECM) controls the operation of all parts of
the system and conducts detection in real time. Once the system or parts have faults, the system will switch on
the malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the
engine control module (ECM) will start backup emergency control program.
Service Hints
• E002 Fuel Injector 1, E003 Fuel Injector 2, E004 Fuel Injector 3, E005 Fuel Injector 4
1 - 2: Approx. 12 Ω
• E007 Throttle Position Sensor
• E009 Idle Air Control

1 - 2: Approx. 53 Ω
3 - 4: Approx. 53 Ω 71
• E010 Manifold Absolute Pressure/Intake Air Temperature (MAP/IAT) Sensor
4 - Ground: Approx. 5 volts 71
• E017 Upstream Oxygen Sensor, E015 Downstream Oxygen Sensor
4 - Ground: Approx. 12 volts 71
Parts Location 71
Code Wire Harness Code Wire Harness 71

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E001 Instrument Panel Wire Harness E032 Engine Control Wire Harness 71
E002 Engine Control Wire Harness E033 Engine Control Wire Harness 71
E003 Engine Control Wire Harness G002 Battery Negative Cable Wire Harness
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E004 Engine Control Wire Harness K007 Front Evaporator Wire Harness
E005 Engine Control Wire Harness U002 Fuel Tank Wire Harness 71
E007 Engine Control Wire Harness 71


A101 C101
(Left Side of The Instrument Panel)

A106 E101

A107 E100

A108 E102

C102 A102

C110 K100

F104 U100
G100 A112
Ground Points

A201 Under the Driver’s Seat F201 Under The Rear Window RH
E201 On The Engine Coolant Outlet

EGR CONTROL SYSTEM - WITH ENGINE BJ493
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System Description
EGR Coolant Temperature Sensor
EGR coolant temperature sensor is used for detecting engine operating temperature. It uses NTC thermistor
sensor, with engine coolant temperature rising and resistance value decreasing.
Throttle Position Sensor

Throttle position sensor detects the position of accelerator pedal. When it detects the change of accelerator
pedal position, the change information will be transmitted instantaneously to the EGR valve control unit.
Speed Sensor
Speed sensor is a magnetoelectric sensor. When the fuel pump rotate, magnetic field generated by the perma-
nent magnet in the speed sensor generates AC voltage. EGR valve control unit uses this signal to determine
the rotation position and speed of the crankshaft.
EGR vacuum solenoid valve
EGR vacuum solenoid valve using the intake manifold and atmospheric pressure difference, the size of the
EGR control valve opening.

When the system comes into operation, the EGR control unit controls the operation of all parts of the system
and conducts detection in real time. Once the system or parts have faults, the system will switch on the
malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the EGR
control unit will start backup emergency control program.
Parts Location


Instrument Panel Wire Harness & Engine Control Wire Harness
C116 E110
Ground Points
Code Ground Points Location

C205 Under the Driver’s Seat
PREHEAT CONTROL - WITH ENGINE BJ493
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System Description
The current flows through fusible link 80A in fusible link box, to pin 10 of preheat control unit. System is then
powered.
When ignition switch is ON/ST, the current flows through fuel cut-off fuse in body junction box, to pin 6 of
preheat control unit and provide the ignition signal to preheat control unit.
Preheat Control
When ignition switch is ON/ST, the current flows through fuel cut-off fuse in body junction box， and through
coil of preheat relay to pin 3 of engine relay box, to pin 8 of preheat control unit, the power is ground at preheat
control unit. The coil of preheat relay creates a magnetic field, and switch is activated. The current flows
through fusible link 80A in fusible link box, to pin 7of engine relay box, through fusible link 60A in engine relay
box, to pin 1 of glow plugs, the power is ground at glow plugs shell. This enables glow plugs to operate.
Start Signal
When ignition switch is ST, the current flows through starter fuse, to pin 7 of preheat control unit and provide
the start signal to preheat control unit.
Coolant Temperature Signal
The current flows from pin 1 of preheat control unit, to pin 1 of preheat temperature sensor and through
preheat temperature sensor to ground. This checks the coolant temperature.
KSB Valve Control
The current flows from pin 9 of preheat control unit, to pin 1 of KSB valve and through preheat temperature
sensor to ground. This checks the KSB valve opening.
Service Hints
• C088 Engine Relay Box
4 - 7：Closed with the ignition switch at ON/ST position.
Parts Location


C116 E110

C117 E111
Ground Points

FAN CONTROL - WITH ENGINE BJ493
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System Description
The current flows through fusible link 80A in fusible link box, to pin 3 of fan control unit. System is then
powered.
When ignition switch is ON/ST, the current flows through fan control fuse, to pin 4 of fan control unit and
provide the ignition signal to fan control unit.
Signal Input
The current flows from pin 7 of fan control unit, to pin 1 coolant temperature sensor for fan, pin 2 of coolant
temperature sensor for fan, to pin 6 of fan control unit, and provide the coolant temperature signal to the fan
control unit.
Fan Control (LO)
When ignition switch is ON/ST, the current flows through fan control fuse, to pin 86 of fan relay (LO), and
through coil of fan relay (LO), from pin 85 of fan relay (LO), to pin 5 of fan control unit, the power is ground at
fan control unit. The coil of fan relay (LO) creates a magnetic field, and switch is activated.
The current flows through fusible link 80A in fusible link box, to pin 30 of fan relay (LO), and through switch
from pin 87 of fan relay (LO), to pin 2 of electronic fan. The power is ground at pin 1 of electronic fan. This
enable electronic fan to operate at low speed.
Fan Control (HI)
When ignition switch is ON/ST, the current flows through fan control fuse, to pin 85 of fan relay (HI), and
through coil of fan relay (HI), from pin 86 of fan relay (HI), to pin 1 of fan control unit, the power is ground at fan
control unit. The coil of fan relay (HI) creates a magnetic field, and switch is activated.
The current flows through fusible link 80A in fusible link box, to pin 30 of fan relay (HI), and through switch
from pin 87 of fan relay (HI), to pin 3 of electronic fan. The power is ground at pin 1 of electronic fan. This
enable electronic fan to operate at high speed.
Service Hints
• C085 Fan Relay (LO)
30 - 87：Closed with the relay at normal operation.
• C086 Fan Relay (HI)
30 - 87：Closed with the relay at normal operation.
Parts Location


C116 E110
Ground Points

EGR CONTROL SYSTEM - WITH ENGINE 4D20
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System Description
• Sensor Signal Input 71
EGR Coolant Temperature Sensor
EGR coolant temperature sensor is used for detecting engine operating temperature. It uses NTC thermistor
sensor, with engine coolant temperature rising and resistance value decreasing. 71

Throttle position sensor detects the position of accelerator pedal. When it detects the change of accelerator
pedal position, the change information will be transmitted instantaneously to the EGR valve control unit.
71
Speed Sensor
Speed sensor is a magnetoelectric sensor. When the fuel pump rotate, magnetic field generated by the perma- 71
nent magnet in the speed sensor generates AC voltage. EGR valve control unit uses this signal to determine
the rotation position and speed of the crankshaft. 71
• Executive Control 71
EGR vacuum solenoid valve
EGR vacuum solenoid valve using the intake manifold and atmospheric pressure difference, the size of the
EGR control valve opening. 71
• Malfunction Diagnosis Function 71

When the system comes into operation, the EGR control unit controls the operation of all parts of the system
and conducts detection in real time. Once the system or parts have faults, the system will switch on the
malfunction indicator light (MIL) to remind drivers of repair in time. When the system is in failure, the EGR 71
control unit will start backup emergency control program.
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Parts Location 71
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C045 Instrument Panel Wire Harness C072 Instrument Panel Wire Harness 71
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Ground Points

STARTING SYSTEM
STARTING SYSTEM - WITH ENGINE BJ491
System Description
When ignition switch is turned to ST, the current flows through fuse AM2 in body junction box, to pin AM2 of
ignition switch. The current flows from pin ST2 of ignition switch to pin 2 of starter relay, and through coil to 71
ground at pin 1 of starter relay. Coil then creates a magnetic field, and switch is activated.
The current flows through fusible link 100A in body junction box, through starter relay, to solenoid switch of 71
starter. Solenoid switch creates a magnetic field, and starter is activated.
The current flows through the “B” terminal of starter, to starter motor, and to crank the engine.
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Service Hints
• C032 Ignition Switch 71
AM2 – IG2: Closed with the ignition switch at ON/ST position.
AM2 – ST2: Closed with the ignition switch at ST position. 71
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Parts Location
A007 Engine Room Wire Harness B003 Battery Positive Cable Wire Harness 71
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B002 Battery Positive Cable Wire Harness C035 Instrument Panel Wire Harness
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Engine Room Wire Harness & Battery Positive Cable Wire Harness 71
A115 B100
(Left Side of the Battery)
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C102 A102
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Ground Points 71
Code Ground Points Location 71
A201 Under the Driver’s Seat
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STARTING SYSTEM - WITH ENGINE BJ493

System Description
The current flows through fusible link 50A in fusible link box, to pin AM1 of ignition switch. When ignition switch
is ST, the current flows output from pin ST1 of ignition switch, and through starter fuse in body junction box, to 71
pin 10 of engine relay box, and through coil of starter relay in the engine relay box. The power is ground at pin
1 of engine relay box. The coil of starter relay in the engine relay box creates a magnetic field, and switch is 71
activated.
The current flows through fusible link 80A in fusible link box, to pin 9 of engine relay box, and through switch of
starter relay, output from pin 2 of engine relay box, to solenoid switch of starter. Solenoid switch creates a
71
magnetic field, and starter is activated.
The current flows through the “B” terminal of starter, to starter motor, and to crank the engine. 71
71
Service Hints 71
• C032 Ignition Switch
AM1 – IG1: Closed with the ignition switch at ON/ST position. 71
AM1 – ST1: Closed with the ignition switch at ST position.
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Parts Location
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B002 Battery Positive Cable Wire Harness C081 Instrument Panel Wire Harness 71
B003 Battery Positive Cable Wire Harness C082 Instrument Panel Wire Harness 71
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Instrument Panel Wire Harness & Battery Positive Cable Wire Harness 71
C119 B100
(Next to the Battery)
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Ground Points
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CHARGING SYSTEM
CHARGING SYSTEM - WITH ENGINE BJ491
System Description
When ignition switch is ON/ST, the current flows output from ignition switch, to pin 3 of junction connector, from
pin 10 of junction connector, to pin C2 of instrument cluster. The current flows through charging warning light 71
of instrument cluster, from pin C6 of instrument cluster, to pin 1 of generator connector A002, to field winding
of generator. Field winding creates a magnetic field. 71
Rotation of the excited field coil generates AC voltage in the stator. The alternation current is rectified through
diodes to DC voltage, to pin B of generator connector A001, to fusible link 100A in fusible link box. This charge
a battery, and supply electrical energy to other electrical devices.
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Service Hints
• A002 Generator 71
1 - Ground：12 volts with the ignition switch at ON position and engine not running.
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Parts Location
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A002 Engine Room Wire Harness C052 Instrument Panel Wire Harness 71
A021 Engine Room Wire Harness 71
Connector Joining Wire Harness and Wire Harness 71
Code Code Wire Harness (Connector Location) 71

C102 A102 71
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CHARGING SYSTEM - WITH ENGINE BJ493

System Description
When ignition switch is ON/ST, the current flows output from ignition switch, and then pass fuel cut-off fuse in
the body junction box, to pin 1(“IG” terminal) of generator connector C075 (voltage regulator). 71
When ignition switch is ON/ST, the current flows output from ignition switch, and then pass charge fuse in the
body junction box, to pin A9 of instrument cluster. The current flows through charging warning light of 71
instrument cluster, from pin A8 of instrument cluster, to pin 3 (“L” terminal) of generator connector C075, to
field winding of generator. Field winding creates a magnetic field. Rotation of the excited field coil generates
AC voltage in the stator. The alternation current is rectified through diodes to DC voltage, to pin B of generator
71
connector A001, to fusible link 80A in fusible link box. This charge a battery, and supply electrical energy to
other electrical devices. 71
The electrical energy pass through pin 2 (“S” terminal) of generator connector C075 (voltage regulator). This
regulates differential voltage between output voltage of generator and voltage regulator. 71
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Service Hints
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• C075 Generator
1 - Ground：12 volts with the ignition switch at ON position and engine not running.
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Parts Location 71
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C075 Instrument Panel Wire Harness 71
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BRAKE CONTROL SYSTEM

BRAKE CONTROL SYSTEM
System Description
Brake control system uses vehicle speed sensor to detect vehicle speed and transmits the speed signal to the
control module. The control module controls wheel slipping rate by repeatedly increasing or decreasing the 71
wheel brake pressure according to the input vehicle speed, keep the wheels rotating. The system enables the
vehicle in braking state to prevent the wheels locking and have the steering capability, guaranteeing stability in 71
the braking direction and preventing side-slipping and deviation.
71
• Signal Input
The current flows through ABS fuse in body junction box, and through switch from pin 3 of ABS relay, to pin 10
When ignition switch is ON/ST, the current flows through fuel pump fuse in body junction box, to pin 2 of ABS relay, and through coil of ABS relay in the body junction box. The power is ground at pin 1 of ABS relay. The coil of ABS relay in junction box creates a magnetic field, and switch is activated.
of ABS module. System is then powered. 71
Speed Signal 71
Speed sensor provide the alternating signal to the ABS module.
71
Brake Signal
The current flows through stop lamp fuse in the body junction box, to pin 1 of stop lamp switch. When the
brake pedal is depressed, the current flows from pin 2 of stop lamp switch, to pin 7 of ABS module, and 71
provide the brake signal to the ABS module.
71
ABS Warning Light
When ignition switch is ON/ST, the current flows through instrument cluster fuse in body junction box, to pin 12 71
of junction connector, and then pass from pin 5 of junction connector, to pin B9 of instrument cluster. The
current flows through ABS warning light of instrument cluster, from pin A9 of instrument cluster, to pin 15 of
ABS module. The ABS warning light is controlled by ABS module. 71
• Malfunction Diagnosis Function 71

When the system comes into operation, ABS module detects the operation of all parts of the system. Once the
system or parts have faults, the system will switch on the ABS warning light to remind drivers of repair in time.
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Service Hints
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• C044 Stop Lamp Switch
• 1 - 2：Closed with the brake pedal depressed.
71
Parts Location 71

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C012 Instrument Panel Wire Harness S001 Side of Chassis Harness 71
C035 Instrument Panel Wire Harness T001 Chassis Harness 71

C039 Instrument Panel Wire Harness T002 Chassis Harness


Engine Room Wire Harness & Side of Chassis Harness
A110 S100

C102 A102

C103 A103
Side of Chassis Harness & Chassis Harness

S101 T100
(Within the Chassis Frame)
Ground Points

A201 Under the Driver’s Seat C202 Right Side of the Instrument Panel
C201 Left Side of the Instrument Panel

HEATER AND AIR CONDITIONING CONTROL SYSTEM

HEATER AND AIR CONDITIONING CONTROL SYSTEM
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System Description
Front Blower Control
When ignition switch is ON/ST, the current flows output from ignition switch, through A/C fuse in body junction
box, to pin 5 of junction connector C051, and pass then from pin 6 of junction connector C051, and through
coil of front heater relay, to pin 2 of junction connector C052, from pin 8 of junction connector C052, to pin 5 of
blow switch. System is then powered.
a.When the blower switch is in Ⅰ position, the current flows input from pin 5 of blower switch, the power is
ground at pin 8 of blower switch. The coil of front heater relay creates a magnetic field, and switch is activated.
The current flows through front heater fusible link in body junction box, and through switch of front heater relay,
to pin 1 of front blower motor, from pin 2 to blower motor, to pin 1 of front blower motor resistor, through
resistor, the current then flows from pin 2 of front blower motor resistor, to pin 2 of blower switch. The power is
ground at pin 8 of blower switch. This enables in Ⅰ position of front blower switch to operate.
b.When the blower switch is in Ⅱ position, the current flows input from pin 5 of blower switch, the power is
to pin 1 of front blower motor, from pin 2 to blower motor, to pin 1 of front blower motor resistor, through
resistor, the current then flows from pin 3 of front blower motor resistor, to pin 1 of blower switch. The power is
ground at pin 8 of blower switch. This enables in Ⅱ position of front blower switch to operate.
c.When the blower switch is in HI position, the current flows input from pin 5 of blower switch, the power is
to pin 1 of front blower motor, from pin 2 to blower motor, to pin 6 of blower switch, the power is ground at pin
8 of blower switch. This enables in HI position of front blower switch to operate.
Front A/C Control

When ignition switch is ON/ST, the current flows through ignition switch, to pin 1 of A/C cut off relay, and
through coil of A/C cut off relay, the power is ground at pin 2 of A/C cut off relay. The coil of A/C cut off relay
creates a magnetic field, and switch is open. A/C system is then out of power, and ensure starting system
operates in normal.
a.Front A/C switch:When the front A/C switch is ON and the blower switch is OFF/LO position, the current
flows output from ignition switch, through A/C fuse in body junction box, to pin 5 of junction connector C051,
and pass then from pin 6 of junction connector C051, and through coil of front heater relay, to pin 2 of junction
connector C052, from pin 1 of junction connector C052, to pin 6 of front A/C switch, from pin 1 of front A/C
switch, to pin 5 of junction connector C055, the power is ground at pin 1 of junction connector C055. The coil
of front heater relay creates a magnetic field, and switch is activated. The current flows through font heater
fusible link in body junction box, and pass then switch of front heater relay, to pin 1 of front blower motor, from
pin 2 to blower motor, to pin 1 of front blower motor resistor, the power is ground at pin 4 of front blower motor
resistor. This enables in OFF/LO position of front blower switch to operate.
b.Signal Input:
When ignition switch is ON/ST, the current flows through A/C fuse in body junction box, to pin 5 of junction
connector C051, from pin 12 of junction connector, to pin 4 of A/C cut off relay, from pin 3 of A/C cut off relay,
to pin 4 of A/C amplifier, system is then powered.
When ignition switch is ON/ST, the current flows through A/C fuse in body junction box, to pin 5 of junction
connector C051, from pin 12 of junction connector, to pin 4 of A/C cut off relay, from pin 3 of A/C cut off relay,
to pin 1 of A/C pressure switch, and through hi-low pressure switch in A/C pressure switch, from pin 2 of A/C
pressure switch, to pin 3 of A/C amplifier, this provide pressure signal to A/C amplifier.
When the front A/C switch is closed, the current flows input pin 4 of front A/C switch, from pin 5 of front A/C
switch, to pin 11 of A/C amplifier. This provide A/C working signal to A/C amplifier.
Temperature Control
a.The current flows from pin 13 of A/C amplifier to pin 2 of front inlet air sensor. The current then flows from pin
1 of front inlet air sensor to pin 1 and pin 2 of A/C amplifier. This emits the front intake signal to A/C amplifier.
b.The current flows from pin 13 of A/C amplifier to pin 2 of rear intake sensor. The current then flows from pin
1 of rear intake sensor to pin 10 of A/C amplifier. This emits the rear intake signal to A/C amplifier.
c.The current flows from pin 1 of rear intake sensor to pin 2 of rear temperature control switch. The current
then flows from pin 1 of rear temperature control switch to pin 9 of A/C amplifier. This emits the rear intake
adjust signal to A/C amplifier.
A/C Amplifier and Engine Control System

a.The data communication transmits from pin 16 of A/C amplifier to pin 45 of engine control module. This emits
A/C operation signal.
b.When ignition switch is ON/ST, the current flows through A/C fuse in body junction box, to pin 5 of junction 71
connector C051, from pin 12 of junction connector C051, to pin 4 of A/C cut off relay, from pin 3 of A/C cut off
relay, to pin 1 of A/C pressure switch, and through hi-low pressure switch in A/C pressure switch, from pin 2 of
A/C pressure switch, to pin 1 of A/C request relay, and through coil of A/C request relay, to pin 7 of A/C 71
amplifier. The power is ground at A/C amplifier. The coil of A/C request relay creates a magnetic field, and
switch is activated. The current flows through switch of A/C request relay, to pin 39 of engine control module, 71
this provide request signal to engine control module.
71
A/C clutch Control
When ignition switch is ON/ST, the current flows through ignition switch, to pin 3 of junction connector C052,
from pin 4 of junction connector, to pin 2 and pin 5 of EFI & A/C relay, and through coil of EFI & A/C relay, to 71
pin 46 of engine control module, the power is ground at engine control module. The coil of EFI & A/C relay
creates a magnetic field, and switch is activated. The current flows through switch of EFI & A/C relay, to pin 1 71
of A/C clutch. The power is ground by A/C clutch. This enables A/C clutch to operate.
Condenser Fan Motor Control 71

a.When ignition switch is ON/ST, the current flows through A/C fuse in body junction box, to pin 2 of A/C main
relay and through coil of A/C main relay in body junction box, the power is ground at pin 1 of A/C main relay. 71
The coil of A/C main relay creates a magnetic field, and switch is activated. The current flows through switch of
A/C main relay, to pin 1 of condenser fan motor fusible link, and pass then fusible link, to pin 4 of condenser 71
fan motor, from pin 3 of condenser fan motor, to pin 5 of condenser fan motor high speed relay, the power is
ground at pin 4 of condenser fan motor high speed relay. This enables high speed of condenser fan motor to
operate. 71
b.When ignition switch is ON/ST, the current flows through ignition switch, to pin 3 of junction connector C052,
from pin 4 of junction connector, to pin 2 and pin 5 of EFI & A/C relay, and through coil of EFI & A/C relay, to 71
pin 46 of engine control module, the power is ground at engine control module. The coil of EFI & A/C relay
creates a magnetic field, and switch is activated. The current flows through switch of EFI & A/C relay, to pin 1
of condenser fan motor low speed relay, and through coil of condenserfan motor low speed relay, the power is 71
ground at pin 2 of condenser fan motor low speed relay. The coil of condenser fan motor low speed relay cre-
ates a magnetic field, and switch is activated.When ignition switch is ON/ST, the current flows through A/C 71
fuse in body junction box, to pin 5 of junction connector C051, from pin 12 to junction connector C051, to
condenser fan motor high speed relay, through coil of condenser fan motor high speed relay, to pin 4 of A/C 71
pressure switch, and through mid pressure of A/C pressure switch, from pin 3 of A/C pressure switch, to pin 6
of A/C amplifier. The power is ground at A/C amplifier. The coil of condenser fan motor high speed relay
creates a magnetic field, and switch is activated. When ignition switch is ON/ST, the current flows through A/C 71
fuse in body junction box, to pin 2 of A/C main relay, and through coil of A/C main relay, the power is ground at
pin 1 of A/C main relay. The coil of A/C main relay creates a magnetic field, and switch is activated. The cur- 71
rent flows through switch of A/C main relay, to pin 1 of condenser fan motor fusible link, and through fusible
link, from pin 2 of condenser fan motor fusible link, to pin 4 of condenser fan motor, from pin 3 of condenser
fan motor, to pin 5 of condenser fan motor high speed relay, and through switch of condenser fan motor high 71
speed relay, to pin 4 of condenser fan motor low speed relay, and through switch of condenser fan motor low
speed relay, to pin 1 of condenser fan motor, and through resister in the condenser fan motor, the power is 71
ground at pin 2 of condenser fan motor. This enables low speed of condenser fan motor to operate.
71
Rear A/C Control
When ignition switch is ON/ST, the current flows through A/C fuse in body junction, to pin 5 of junction
connector C051, from pin 12 of junction connector C051, to pin 4 of A/C cut off relay, from pin 3 of A/C cut off 71
relay, to pin 2 of rear evaporator motor relay, through coil of rear evaporator motor relay, to pin 7 of rear A/ C
switch. The current flows from pin 8 of rear A/C switch, to pin 3 of rear evaporator blower switch. The power is
ground at pin 4 of rear evaporator blower switch. The coil of rear evaporator motor relay creates a magnetic
field, and switch is activated. The current flows through rear evaporator fusible link in body junction box, to pin
3 of rear evaporator motor relay, and then to two fuses. The current flows from pin 2 of rear evaporator motor
LH and pin 2 of rear evaporator motor RH, through motor, to pin 1 of rear evaporator blower switch and pin 1
of rear evaporator resistor:
When rear evaporator motor operation in LO, the current flows from pin 1 of rear evaporator motor LH and pin
1 of rear evaporator motor RH, to pin 1 of rear evaporator resistor. The power is ground at pin 2 of rear
evaporator resistor.
When rear evaporator motor operation in Ⅰ , the current flows from pin 1 of rear evaporator motor LH and pin
1 of rear evaporator motor RH, to pin 1 of rear evaporator resistor. Through resistor, the current flows from pin
3 of rear evaporator resistor to pin 2 of rear evaporator blower switch. The power is ground at pin 4 of rear
evaporator blower switch.
When rear evaporator motor operation in HI, the current flows from pin 1 of rear evaporator motor LH and pin
1 of rear evaporator motor RH, to pin 1 of rear evaporator blower switch. The power is ground at pin 4 of rear
evaporator blower switch.
Service Hints
• K003 A/C Cut Off Relay
3 - 4：Open with the ignition switch at ST position.
• K005 Condenser Fan Motor Low Speed Relay
2 - 4：Closed witch the ignition switch at ON/ST position.
• K006 Rear Evaporator Motor Relay
• K007 A/C Request Relay
• K008 Condenser Fan Motor High Speed Relay
Parts Location

A023 Engine Room Wire Harness K003 Front Evaporator Wire Harness
C016 Instrument Panel Wire Harness K004 Front Evaporator Wire Harness
C034 Instrument Panel Wire Harness L001 Rear Evaporator Wire Harness
E001 Engine Control Wire Harness L006 Rear Evaporator Wire Harness
E022 Engine Control Wire Harness L007 Rear Evaporator Wire Harness
K001 Front Evaporator Wire Harness L008 Rear Evaporator Wire Harness
K002 Front Evaporator Wire Harness


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A101 C101
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A107 E100
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C102 A102
C110 K100 71
Instrument Panel Wire Harness & Front Evaporator Wire Harness 71

C111 K101
F100 A109 Roof Wire Harness & Engine Room Wire Harness (Left Side of the B Pillar) 71
F101 A108 Roof Wire Harness & Engine Room Wire Harness (Left Side of the B Pillar)
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F105 L100 Roof Wire Harness & Rear Evaporator Wire Harness (Left Side of the B Pillar)
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Ground Points
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C201 Left Side of the Instrument Panel C204 Right Side of the Instrument Panel
C202 Right Side of the Instrument Panel F201 Under The Rear Window RH 71
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LIGHT SYSTEM
HEADLAMP - 09 LATE PRODUCTION
System Description
Headlamp (Low Beam)
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The current flows through headlamp fusible link in body junction box, to pin 2 and pin 5 of headlamp relay,
through coil of headlamp relay, and then to pin A13 of combination switch. When the combination switch is set
headlamp (Low Beam) position, the current output from pin A11 of combination switch, to pin 2 of junction 71
connector, the power is ground at pin 1 of junction connector. The coil of headlamp relay creates a magnetic
field, and switch is activated. The current flows through switch of headlamp relay, to headlamp fuse (LH) and 71
headlamp fuse (RH) in body junction box, and pass then to pin 3 of front combination lamp LH and pin 3 of
front combination lamp RH, and through light of headlamp (Low Beam), to pin A3 of combination switch, from
pin A9 of combination switch, to pin 2 of junction connector. The power is ground at pin 1 of junction connector. 71
This enables headlamp (Low Beam) to operate.
71
Headlamp (High Beam)
The current flows through headlamp fusible link in body junction box, to pin 2 and pin 5 of headlamp relay, 71
headlamp (High Beam) position, the current output from pin A11 of combination switch, to pin 2 of junction
connector, the power is ground at pin 1 of junction connector. The coil of headlamp relay creates a magnetic 71
field, and switch is activated. The current flows through switch of headlamp relay, to headlamp fuse (LH) and
headlamp fuse (RH) in body junction box, and pass then to pin 3 of front combination lamp LH and pin 3 of 71
front combination lamp RH, and through light of headlamp (High Beam), to pin A12 of combination switch,
from pin A9 of combination switch, to pin 2 of junction connector. The power is ground at pin 1 of junction
connector. This enables headlamp (High Beam) to operate. 71
High Beam Indicator 71

When the combination switch is set headlamp (Low Beam) position, power is ground at pin A3 of combination
switch. So the both ends of high beam indicator at the same potential, the indicator is inoperable. When the 71
combination switch is set headlamp (High Beam) position, pin A3 of combination switch is open, and pin A3 of
combination switch is in high potential. So the current flows through pin C9 of instrument cluster, and through
high beam indicator, from pin C11 of instrument cluster, to pin 3 of junction connector, and ground at pin 1 of 71
junction connector. This enables high beam indicator to operate.
71
Flash to Pass
The current flows through headlamp fusible link in body junction box, to pin 2 and pin 5 of headlamp relay,
71
flash to pass position, the current output from pin A9 of combination switch, to pin 2 of junction connector, the
power is ground at pin 1 of junction connector. The coil of headlamp relay creates a magnetic field, and switch 71
is activated. The current flows through switch of headlamp relay, to headlamp fuse (LH) and headlamp fuse
(RH) in body junction box, and pass then to pin 3 of front combination lamp LH and pin 3 of front combination 71
lamp RH, and through light of headlamp (High Beam), to pin A12 of combination switch, from pin A9 of
combination switch, to pin 2 of junction connector. The power is ground at pin 1 of junction connector. This
enables flash to pass to operate. 71
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Service Hints
• C008 Combination Switch (Light Control) 71
A11 - A13：Closed with the combination switch at Headlamp position (High Beam and Low Beam).
A3 - A9： Closed with the combination switch at Headlamp position (Low Beam).
A9 - A14：Closed with the combination switch at Flash to Pass position.
• C055 Junction Connector.
1 - 2 - 3：Conduction
Parts Location


C102 A102
Ground Points

HEADLAMP - EARLY PRODUCTION
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System Description
Headlamp (Low Beam)
The current flows through pin 2 and pin 5 of headlamp relay, through coil of headlamp relay, and then to pin
A13 of combination switch. When the combination switch is set headlamp (Low Beam) position, the current
output from pin A11 of combination switch, to pin 2 of junction connector C067, the power is ground at pin 1 of
junction connector C067. The coil of headlamp relay creates a magnetic field, and switch is activated. The cur-
rent flows through switch of headlamp relay, to headlamp fuse (LH) and headlamp fuse (RH) in body junction
box, and pass then to pin 3 of front combination lamp LH and pin 3 of front combination lamp RH, and through
light of headlamp (Low Beam), to pin A3 of combination switch, from pin A9 of combination switch, to pin 3 of
junction connector C068. The power is ground at pin 1 of junction connector C068. This enables headlamp
(Low Beam) to operate.
Headlamp (High Beam)

A13 of combination switch. When the combination switch is set headlamp (High Beam) position, the current
output from pin A11 of combination switch, to pin 2 of junction connector C067, the power is ground at pin 1 of
junction connector C067. The coil of headlamp relay creates a magnetic field, and switch is activated. The cur-
rent flows through switch of headlamp relay, to headlamp fuse (LH) and headlamp fuse (RH) in body junction
box, and pass then to pin 3 of front combination lamp LH and pin 3 of front combination lamp RH, and through
light of headlamp (High Beam), to pin A12 of combination switch, from pin A9 of combination switch, to pin 3 of
junction connector C068. The power is ground at pin 1 of junction connector C068. This enables headlamp
(High Beam) to operate.
High Beam Indicator

When the combination switch is set headlamp (Low Beam) position, power is ground at pin A3 of combination
switch. So the both ends of high beam indicator at the same potential, the indicator is inoperable. When the
combination switch is set headlamp (High Beam) position, pin A3 of combination switch is open, and pin A3 of
combination switch is in high potential. So the current flows through pin B9 of instrument cluster, and through
high beam indicator, from pin B7 of instrument cluster, to pin 6 of junction connector C067, and ground at pin 1
of junction connector C067. This enables high beam indicator to operate.
Flash to Pass
A14 of combination switch. When the combination switch is set flash to pass position, the current output from
pin A9 of combination switch, to pin 3 of junction connector C068, the power is ground at pin 1 of junction
connector C068. The coil of headlamp relay creates a magnetic field, and switch is activated. The current
flows through switch of headlamp relay, to headlamp fuse (LH) and headlamp fuse (RH) in body junction box,
and pass then to pin 3 of front combination lamp LH and pin 3 of front combination lamp RH, and through light
of headlamp (High Beam), to pin A12 of combination switch, from pin A9 of combination switch, to pin 3 of
junction connector C068. The power is ground at pin 1 of junction connector C068. This enables flash to pass
to operate.
Service Hints
• C008 Combination Switch (Light Control)
A3 - A9： Closed with the combination switch at Headlamp position (Low Beam).
A9 - A14：Closed with the combination switch at Flash to Pass position.
1 - 2 - 6：Conduction
1 - 3：Conduction
Parts Location

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Ground Points 71

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PARKING, LICENSE AND TAIL LAMPS - 09 LATE PRODUCTION

System Description
Parking Light
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The current flows through the coil of tail light relay in body junction box, and then to pin A2 of combination
switch. When the combination switch is set tail light or headlamp (Low Beam/High Beam) position, the current
flows output pin A11 of combination switch, to pin 2 of junction connector C055, the power is ground at pin 1 of 71
junction connector C055. The coil of tail light relay creates a magnetic field, and switch is activated. The
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 1 of junction 71
connector C053, and from pin 2 and pin 5 of junction connector C053, to pin 2 of front combination lamp LH
and pin 2 of front combination lamp RH. The power is ground at pin 5 of front combination lamp LH and pin 5
of front combination lamp RH. This enables parking light to operate. 71
Tail Light 71
switch. When the combination switch is set tail light or headlamp (Low Beam/High Beam) position, the current 71
flows output pin A11 of combination switch, to pin 2 of junction connector C055, the power is ground at pin 1 of
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 1 of junction 71
connector C053, and from pin 2 of junction connector C053, to pin 2 of rear combination lamp LH and pin 2 of
rear combination lamp RH. The power is ground at pin 4 of rear combination lamp LH and pin 4 of rear 71
combination lamp RH. This enables tail light to operate.
License Light 71
junction connector C055. The coil of tail light relay creates a magnetic field, and switch is activated. The 71
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 1 of junction
connector C053, and from pin 2 of junction connector C053, to pin 2 of license lamp, and through th license
light, the power is ground at pin 1 of license lamp. This enables license light to operate. 71
71
Service Hints 71
A2 - A11：Closed with the combination switch at Headlamp position (High Beam and Low Beam). 71
• C053 Junction Connector
1 - 2 - 5：Conduction 71
1 - 2：Conduction
71
Parts Location 71

71
C005 Instrument Panel Wire Harness F001 Roof Wire Harness
C035 Instrument Panel Wire Harness J003 Rear Hatch Wire Harness


C103 A103
Roof Wire Harness & Engine Room Wire Harness

F100 A109
(Left Side of the B Pillar)
Rear Hatch Wire Harness & Roof Wire Harness

J101 F102
(Left Side of the Rear Combination Lamps)
Ground Points

C201 Left Side of the Instrument Panel F201 Under The Rear Window RH
C202 Right Side of the Instrument Panel

PARKING, LICENSE AND TAIL LAMPS - EARLY PRODUCTION
71
71
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System Description
Parking Light
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 2 of front
combination lamp LH and pin 2 of front combination lamp RH. The power is ground at pin 5 of front
combination lamp LH and pin 5 of front combination lamp RH. This enables parking light to operate.
Tail Light
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 5 of rear
combination lamp LH and pin 5 of rear combination lamp RH. The power is ground at pin 6 of rear combination
lamp LH and pin 6 of rear combination lamp RH. This enables tail light to operate.
License Light
current flows through switch of tail light relay, and through the tail fuse in body junction box, to pin 2 of license
lamp, and through th license light, the power is ground at pin 1 of license lamp. This enables license light to
operate.
Service Hints
1 - 2：Conduction
Parts Location


71
Roof Wire Harness & Instrument Panel Wire Harness
F100 C100
71
J101 F102
71
Ground Points 71
Code Ground Points Location Code Ground Points Location 71

71
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71
71
71
STOP LAMP - 09 LATE PRODUCTION

System Description
The current flows through stop lamp fuse in body junction box, to pin 1 of stop lamp switch. The stop lamp
switch is closed with the brake pedal depressed. The current then flows from pin 2 of stop lamp switch to pin 3 71
of rear combination lamp LH, pin 3 of rear combination lamp RH and pin 1 of high-mounted stop lamp. The
power is ground at pin 4 of rear combination lamp LH, pin 4 of rear combination lamp RH and pin 2 of high- 71
mounted stop lamp. This enables stop lamp and high-mounted stop lamp to operate.
71
Service Hints
71
71
1 - 2：Closed with the brake pedal depressed.
71
Parts Location
71
C035 Instrument Panel Wire Harness F002 Roof Wire Harness 71
C044 Instrument Panel Wire Harness J006 Rear Hatch Wire Harness 71
F001 Roof Wire Harness
71

71
C103 A103
F100 A109
(Left Side of the B Pillar) 71
J101 F102 71
71
Ground Points
71
F201 Under The Rear Window RH 71
71
71
STOP LAMP - EARLY PRODUCTION

System Description
The current flows through stop lamp fuse in body junction box, to pin 1 of stop lamp switch. The stop lamp
switch closed with the brake pedal depressed. The current then flows from pin 2 of stop lamp switch to pin 3 of 71
rear combination lamp LH, pin 3 of rear combination lamp RH and pin 1 of high-mounted stop lamp. The
power is ground at pin 6 of rear combination lamp LH, pin 6 of rear combination lamp RH and pin 2 of high- 71
mounted stop lamp. This enables stop lamp and high-mounted stop lamp to operate.
71
Service Hints
71
71
1 - 2：Closed with the brake pedal depressed.
71
Parts Location
71
71

71
F100 C100
(Left Side of the B Pillar) 71
J101 F102
(Left Side of the Rear Combination Lamps) 71
71
Ground Points
F201 Under The Rear Window RH 71
71
71
71
BACK-UP LAMP - 09 LATE PRODUCTION

System Description
When ignition switch is ON/ST, the current flows through instrument cluster fuse in body junction box, to pin 12
of junction connector, from pin 13 of junction connector, to pin 2 of back-up lamp switch. The current flows 71
from pin 1 of back-up lamp switch, and then to the circuit as follows:
a. The current pass through pin 2 of rear combination lamp LH, and ground at pin 1 of rear combination lamp 71
LH. This enables rear back-up lamp LH to operate.
b. The current pass through pin 2 of rear combination lamp RH, and ground at pin 1 of rear combination lamp
RH. This enables rear back-up lamp RH to operate.
71
c. The current pass through the reverse radar control unit. Reverse radar control unit is then powered.
71
71
Service Hints
• G001 Back-up Lamp Switch 71
1 – 2: Closed with the shift lever in “R” position.
71
Parts Location
71
71
G001 Battery Negative Cable Wire Harness
71

C102 A102
F100 A109 71
Battery Negative Cable Wire Harness & Engine Room Wire Harness 71
G100 A112
Rear Hatch Wire Harness & Roof Wire Harness 71

J101 F102
71
J102 F106
71
Ground Points 71
F201 Under The Rear Window RH
BACK-UP LAMP - EARLY PRODUCTION

System Description
of junction connector, from pin 6 of junction connector, to pin 2 of back-up lamp switch. The current flows from 71
pin 1 of back-up lamp switch, and then to the circuit as follows:
a. The current pass through pin 1 of rear combination lamp LH, and ground at pin 6 of rear combination lamp 71
LH. This enables rear back-up lamp LH to operate.
b. The current pass through pin 1 of rear combination lamp RH, and ground at pin 6 of rear combination lamp
RH. This enables rear back-up lamp RH to operate.
71
71
Service Hints 71
• G001 Back-up Lamp Switch
1 – 2: Closed with the shift lever in “R” position. 71
71
Parts Location

C069 Instrument Panel Wire Harness G001 Battery Negative Cable Wire Harness
71
71
71
Roof Wire Harness & Instrument Panel Wire Harness 71
F100 C100
71
Battery Negative Cable Wire Harness & Instrument Panel Wire Harness
G100 C118
71
Ground Points 71

F201 Under The Rear Window RH
71
71
71
TURN SIGNAL AND HAZARD WARNING LAMPS - 09 LATE PRODUCTION

System Description
When ignition switch is ON/ST, the current flows through turn signal fuse in body junction box, to pin 2 of
junction connector C051, from pin 8 of junction connector C051, to pin 10 of hazard switch, When hazard 71
switch is OFF position, the current flow output from pin 7 of hazard switch, to pin 2 of turn signal flasher relay,
and pass then output from pin 3 of turn signal flasher relay, to pin 6 of junction connector C055, the power is 71
ground at pin 1 of junction connector C055. Turn signal flasher relay is working condition.
71
Turn Signal Lamp LH
When the combination switch is in Left Turn position, the current flows output from pin 1 of turn signal flasher
relay, to pin A1 of combination switch. The current then flows from pin A5 of combination switch, to the circuit 71
as follows:
a. The current flows through pin 3 of front combination lamp LH, and ground at pin 6 of front combination lamp 71
LH. This enables front turn signal lamp LH to operate.
b. The current flows through pin 1 of front combination lamp LH, and ground at pin 4 of front combination lamp
LH. This enables left side of front turn signal lamp to operate. 71
c. The current flows through pin 5 of junction connector C054, to pin 12 of junction connector C054, to pin 1 of
rear combination lamp LH, and ground at pin 6 of rear combination lamp LH.This enables rear turn signal lamp 71
LH to operate.
d. The current flows through pin 5 of junction connector C054, to pin 6 of junction connector C054, to pin A7 of
71
instrument cluster, and through the left turn signal/hazard indicator in instrument cluster, from pin C11 of
instrument cluster, to pin 3 of junction connector C055 and ground at pin 1 of junction connector C055. This
enables left turn signal/hazard indicator to operate. 71
Turn Signal Lamp RH 71

When the combination switch is in Right Turn position, the current flows output from pin 1 of turn signal flasher
relay, to pin A1 of combination switch. The current then flows from pin A8 of combination switch, to the circuit
as follows: 71
a. The current flows through pin 7 of junction connector C054, from pin 13 of junction connector C054, to pin 3
of front combination lamp RH, and ground at pin 6 of front combination lamp RH. This enables front turn signal 71
lamp RH to operate.
b. The current flows through pin 7 of junction connector C054, from pin 13 of junction connector C054, to pin 1 71
of front combination lamp RH, and ground at pin 4 of front combination lamp RH. This enables right side of
front turn signal lamp to operate.
c. The current flows through pin 7 of junction connector C054, from pin 13 of junction connector C054, to pin 1 71
of rear combination lamp RH, and ground at pin 4 of rear combination lamp RH. This enables rear turn signal
lamp RH to operate. 71
d. The current flows through pin 7 of junction connector C054, from pin 14 of junction connector C054, to pin
C10 of instrument cluster, and through the right left turn signal/hazard indicator in instrument cluster, from pin
C11 of instrument cluster, to pin 3 of junction connector C055, and ground at pin 1 of junction connector C055. 71
This enables right turn signal/hazard indicator to operate.
71
Hazard Lamp
When hazard switch is pressed, the current flows through hazard & horn fuse in body junction box, to pin 14 of 71
junction connector C051, from pin 7 of junction connector C051, to pin 8 of hazard switch, from pin 7 of hazard
switch, to pin 2 of turn signal flasher relay, from pin 3 of turn signal flasher relay, to pin 6 of junction connector
C055, and ground at pin 1 of junction connector C055. Turn signal flasher relay is working condition. The 71
current flows output from pin 1 of turn signal flasher relay, to pin 9 of hazard switch, and through hazard
switch, the current flows output from pin 5 and pin 6 of hazard switch. 71
a.The current flows output from pin 5 of hazard switch, to pin 6 of junction connector C054, from pin 5 of
junction connector C054, to pin 3 of front combination lamp LH and ground at pin 6 of front combination lamp
b.The current flows output from pin 5 of hazard switch, to pin 6 of junction connector C054, from pin 5 of
junction connector C054, to pin 1 of front combination lamp LH and ground at pin 4 of front combination lamp
LH. This enables left side of front turn signal lamp to operate.
c.The current flows output from pin 5 of hazard switch, to pin 6 of junction connector C054, from pin 12 of
junction connector C054, to pin 1 of rear combination lamp LH and ground at pin 4 of rear combination lamp
LH. This enables rear turn signal lamp LH to operate.
d. The current flows output from pin 5 of hazard switch, to pin A7 of instrument cluster, and through the left turn
signal/hazard indicator in instrument cluster, from pin C11 of instrument cluster, to pin 3 of junction connector
C055 and ground at pin 1 of junction connector C055. This enables left turn signal/hazard indicator to operate.
e.The current flow output from pin 6 of hazard switch, to pin 14 of junction connector C054, from pin 13 of
junction connector C054, to pin 3 of front combination lamp RH and ground at pin 6 of front combination lamp
RH. This enables front turn signal lamp RH to operate.
f.The current flow output from pin 6 of hazard switch, to pin 14 of junction connector C054, from pin 13 of
junction connector C054, to pin 1 of front combination lamp RH and ground at pin 4 of front combination lamp
RH. This enables right side of front turn signal lamp to operate.
g.The current flow output from pin 6 of hazard switch, to pin 14 of junction connector C054, from pin 13 of
junction connector C054, to pin 1 of rear combination lamp RH and ground at pin 4 of rear combination lamp
RH. This enables rear turn signal lamp RH to operate.
h.The current flow output from pin 6 of hazard switch, to pin C10 of instrument cluster, and through the right
left turn signal/hazard indicator in instrument cluster, from pin C11 of instrument cluster, to pin 3 of junction
connector C055, and ground at pin 1 of junction connector C055. This enables right turn signal/hazard
indicator to operate.
Service Hints
• C015 Hazard Switch
7 - 10：Closed with the hazard switch released.
7 - 8：Closed with the hazard switch pressed.
9 - 5 - 6：Closed with the hazard switch pressed.
• C008 Combination Switch
A1 - A5：Closed with the combination switch at Left Turn position.
A1 - A8：Closed with the combination switch at Right Turn position.
Parts Location


A101 C101

F100 A109
Ground Points

71
C202 Right Side of the Instrument Panel 71
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TURN SIGNAL AND HAZARD WARNING LAMPS - EARLY PRODUCTION

System Description
When ignition switch is ON/ST, the current flows through turn signal fuse in body junction box, to pin 5 of
junction connector C069, from pin 12 of junction connector C069, to pin 10 of hazard switch, When hazard 71
switch is OFF position, the current flow output from pin 7 of hazard switch, to pin 2 of turn signal flasher relay,
and pass then output from pin 3 of turn signal flasher relay, to pin 10 of junction connector C067, the power is 71
ground at pin 1 of junction connector C067. Turn signal flasher relay is working condition.
71
Turn Signal Lamp LH
When the combination switch is in Left Turn position, the current flows output from pin 1 of turn signal flasher
as follows:
a. The current flows through pin 3 of front combination lamp LH, and ground at pin 6 of front combination lamp 71
b. The current flows through pin 1 of front combination lamp LH, and ground at pin 4 of front combination lamp
LH. This enables left side of front turn signal lamp to operate. 71
c. The current flows through pin 4 of rear combination lamp LH, and ground at pin 6 of rear combination lamp
LH. This enables rear turn signal lamp LH to operate. 71
d. The current flows through pin B8 of instrument cluster, and through the left turn signal/hazard indicator in
instrument cluster, from pin B7 of instrument cluster, to pin 6 of junction connector C067 and ground at pin 1 of
71
junction connector C067. This enables left turn signal indicator to operate.
Turn Signal Lamp RH 71

When the combination switch is in Right Turn position, the current flows output from pin 1 of turn signal flasher
as follows:
a. The current flows through pin 3 of front combination lamp RH, and ground at pin 6 of front combination lamp
RH. This enables front turn signal lamp RH to operate. 71
b. The current flows through pin 1 of front combination lamp RH, and ground at pin 4 of front combination
lamp RH. This enables right side of front turn signal lamp to operate. 71
c. The current flows pin 4 of rear combination lamp RH, and ground at pin 6 of rear combination lamp RH.
This enables rear turn signal lamp RH to operate. 71
d. The current flows through pin B10 of instrument cluster, and through the right left turn signal/hazard indica-
tor in instrument cluster, from pin B7 of instrument cluster, to pin 6 of junction connector C067, and ground at
pin 1 of junction connector C067. This enables right turn signal indicator to operate. 71
Hazard Lamp 71
When hazard switch is pressed, the current flows through hazard & horn fuse in body junction box, to pin 8 of
hazard switch, from pin 7 of hazard switch, to pin 2 of turn signal flasher relay, from pin 3 of turn signal flasher
71
relay, to pin 10 of junction connector C067, and ground at pin 1 of junction connector C067. Turn signal flasher
relay is working condition. The current flows output from pin 1 of turn signal flasher relay, to pin 9 of hazard
switch, and through hazard switch, the current flows output from pin 5 and pin 6 of hazard switch. 71
a. The current flows output from pin 5 of hazard switch, to pin 3 of front combination lamp LH, and ground at
pin 6 of front combination lamp LH. This enables front turn signal lamp LH to operate. 71
b. The current flows output from pin 5 of hazard switch, to pin 1 of front combination lamp LH, and ground at
pin 4 of front combination lamp LH. This enables left side of front turn signal lamp to operate.
c. The current flows output from pin 5 of hazard switch, to pin 4 of rear combination lamp LH, and ground at 71
pin 6 of rear combination lamp LH. This enables rear turn signal lamp LH to operate.
d. The current flows output from pin 5 of hazard switch, to pin B8 of instrument cluster, and through the left turn 71
signal/hazard indicator in instrument cluster, from pin B7 of instrument cluster, to pin 6 of junction connector
C067 and ground at pin 1 of junction connector C067. This enables left hazard indicator to operate.
e. The current flows output from pin 6 of hazard switch, to pin 3 of front combination lamp RH, and ground at
pin 6 of front combination lamp RH. This enables front turn signal lamp RH to operate.
f. The current flows output from pin 6 of hazard switch, to pin 1 of front combination lamp RH, and ground at
pin 4 of front combination lamp RH. This enables right side of front turn signal lamp to operate.
g. The current flows output from pin 6 of hazard switch, to pin 4 of rear combination lamp RH, and ground at
pin 6 of rear combination lamp RH. This enables rear turn signal lamp RH to operate.
h. The current flows output from pin 6 of hazard switch, to pin B10 of instrument cluster, and through the right
left turn signal/hazard indicator in instrument cluster, from pin B7 of instrument cluster, to pin 6 of junction con-
nector C067, and ground at pin 1 of junction connector C067. This enables right hazard indicator to operate.
Service Hints
• C015 Hazard Switch
7 - 10：Closed with the hazard switch released.
7 - 8：Closed with the hazard switch pressed.
9 - 5 - 6：Closed with the hazard switch pressed.
A1 - A5：Closed with the combination switch at Left Turn position.
A1 - A8：Closed with the combination switch at Right Turn position.
Parts Location


F100 C100
Ground Points


FOG LAMP - 09 LATE PRODUCTION
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System Description
Front Fog Lamp
Operation requirement: Always turn on parking lamp.
current flows through switch of tail light relay and through the tail fuse in body junction box, to pin 2 of fog lamp
relay, and through the coil of fog lamp relay, to pin 1 of front fog lamp switch. When front fog lamp switch is
closed, the current flows output from pin 4 of front fog lamp switch, to pin 6 of junction connector C055, and
ground at pin 1 of junction connector C055. The coil of fog lamp relay creates a magnetic field, and switch is
activated. The current flows through fog lamp fuse in body junction box, to pin 5 of fog lamp relay, and through
switch of fog lamp relay, to pin 1 of front fog lamp LH and pin 1 of front fog lamp RH, the power is ground at pin
2 of front fog lamp LH and pin 2 of front fog lamp RH. This enables front fog lamp LH and front fog lamp RH to
operate.
Rear Fog Lamp

Operation requirement: Always turn on front fog lamp.
The current flows through fog lamp fuse in body junction box, to pin 5 of fog lamp relay, and through switch of
fog lamp relay, to pin 1 of rear fog lamp switch. When rear fog lamp switch is closed, the current flows output
from pin 4 of rear fog lamp switch, to pin 2 of rear fog lamp LH and pin 2 of rear fog lamp RH, the power is
ground at pin 1 of front fog lamp LH and pin 1 of front fog lamp RH. This enables rear fog lamp LH and rear fog
lamp RH to operate.
Service Hints
Parts Location



71
A101 C101
71
F100 A109
71
J101 F102
Ground Points 71

71
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71
FOG LAMP - EARLY PRODUCTION

System Description
Front Fog Lamp
71
Operation requirement: Always turn on parking lamp.
junction connector C067. The coil of tail light relay creates a magnetic field, and switch is activated. The 71
current flows through switch of tail light relay and through the tail fuse in body junction box, to pin 2 of fog lamp
relay, and through the coil of fog lamp relay, to pin 1 of front fog lamp switch. When front fog lamp switch is
closed, the current flows output from pin 4 of front fog lamp switch, to pin 5 of junction connector C067, and 71
ground at pin 1 of junction connector C067. The coil of fog lamp relay creates a magnetic field, and switch is
activated. The current flows through fog lamp fuse in body junction box, to pin 5 of fog lamp relay, and through 71
switch of fog lamp relay, to the circuit as follows:
a. The current flows through switch of fog lamp relay, to pin 1 of front fog lamp LH, and ground at pin 2 of front
fog lamp LH. This enables front fog lamp LH to operate. 71
b. The current flows through switch of fog lamp relay, to pin 1 of front fog lamp RH, and ground at pin 2 of front
fog lamp RH. This enables front fog lamp RH to operate. 71
Rear Fog Lamp
Operation requirement: Always turn on front fog lamp. 71
The current flows through fog lamp fuse in body junction box, to pin 5 of fog lamp relay, and through switch of
fog lamp relay, to pin 1 of rear fog lamp switch. When rear fog lamp switch is closed, the current flows output
from pin 4 of rear fog lamp switch, to pin 2 of rear fog lamp LH and pin 2 of rear fog lamp RH, the power is 71
ground at pin 6 of front fog lamp LH and pin 6 of front fog lamp RH. This enables rear fog lamp LH and rear fog
lamp RH to operate. 71
71
Service Hints
• C008 Combination Switch (Light Control) 71
71
Parts Location
71
71
71
C035 Instrument Panel Wire Harness F010 Rear Hatch Wire Harness
71
C036 Instrument Panel Wire Harness F011 Rear Hatch Wire Harness
71

F100 C100 Roof Wire Harness & Instrument Panel Wire Harness (Left Side of the B Pillar)
Ground Points

INTERIOR LAMPS - 09 LATE PRODUCTION

System Description
Front Dome Light
71
The current flows through dome light fuse in body junction box, to pin 1 of front dome light. Press front dome
light switch, and the power is ground by the switch. This enables front dome light to operate.
If any front door is not closed, the front door ajar switch will turn to ON. The current flows from pin 2 of front 71
dome lamp, to pin D3 of instrument cluster, and output from pin D4 and pin D5 of instrument cluster, to front
door ajar switch. The power is ground by ajar the switch. This enables front dome light to operate. 71
Rear Dome Light
The current flows through dome light fuse in body junction box, to pin 1 of rear dome light, and from pin 2 of 71
rear dome light, to pin D10 of instrument cluster, and from pin D9 to instrument cluster, to pin 1 of rear dome
light switch. Press rear dome light switch, and the power is ground at pin 4 of rear dome light switch. This 71
enables rear dome light to operate.
If any sliding door is not closed, the door ajar switch will turn to ON. The current flows from pin 2 of rear dome 71
lamp, to pin D10 of instrument cluster and through the diode in the instrument cluster, and from pin D7 and D8
of instrument cluster, and the power is ground by the ajar switch. This enables rear indoor lamp to operate.
71
Step Lamp LH/RH
The current flows through dome light fuse in body junction box, to pin 1 of step lamp LH/RH, and from pin 2 of 71
step lamp LH/RH, to D10 of instrument cluster, and from pin D9 to instrument cluster, to rear dome light switch.
Press rear dome light switch, and the power is ground at pin 4 of rear dome light switch. This enables step
lamp LH/RH to operate.
71
If any sliding door is not closed, the door ajar switch will turn to ON. The current flows from pin 2 of step lamp
LH/RH, to pin D10 of instrument cluster and through the diode in the instrument cluster, and from pin D7 and 71
D8 of instrument cluster, and the power is ground by the ajar switch. This enables step lamp LH/RH to
operate. 71
Parts Location 71

A004 Engine Room Wire Harness F004 Roof Wire Harness
71
A008 Engine Room Wire Harness F005 Roof Wire Harness
C033 Instrument Panel Wire Harness M001 Left Step Wire Harness 71
C035 Instrument Panel Wire Harness N001 Right Step Wire Harness 71
71
71
71
71

Engine Room Wire Harness & Left Step Wire Harness
A113 M100
Engine Room Wire Harness & Right Step Wire Harness

A114 N100
(Right Side of the B Pillar)

C102 A102

C103 A103

F100 A109

J102 F106
Ground Points

INTERIOR LAMPS - EARLY PRODUCTION
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System Description
Front Dome Light
The current flows through dome light fuse in body junction box, to pin 1 of junction connector C069, from pin 9
of junction connector C069, to pin 1 of front dome light. Press front dome light switch, and the power is ground
by the switch. This enables front dome light to operate.
If any front door is not closed, the front door ajar switch will turn to ON. The current flows from pin 2 of front
dome lamp, to front door ajar switch. The power is ground by ajar the switch. This enables front dome light to
operate.
Rear Dome Light

The current flows through dome light fuse in body junction box, to pin 1 of junction connector C069, and from
pin 9 of junction connector C069, to pin 1 of rear dome light, and from pin 2 of rear dome light, to pin 1 of rear
dome light switch. Press rear dome light switch, and from pin 4 of rear dome light switch, to pin 5 of junction
connector C067, and ground at pin 1 of junction connector C067. This enables rear dome light to operate.
If any sliding door is not closed, the door ajar switch will turn to ON. The current flows from pin 2 of rear dome
lamp, and the power is ground by the ajar switch. This enables rear dome lamp to operate.
Step Lamp LH/RH

The current flows through dome light fuse in body junction box, to pin 1 of junction connector C069, and from
pin 9 of junction connector C069, to pin 1 of step lamp LH/RH, and from pin 2 of step lamp LH/RH, to pin 1 of
rear dome light switch. Press rear dome light switch, and from pin 4 of rear dome light switch, to pin 5 of
junction connector C067, and ground at pin 1 of junction connector C067. This enables step lamp LH/RH to
operate.
If any sliding door is not closed, the door ajar switch will turn to ON. The current flows from pin 2 of step lamp
LH/RH, and the power is ground by the ajar switch. This enables step lamp LH/RH to operate.
Parts Location

C067 Instrument Panel Wire Harness N001 Right Step Wire Harness

Instrument Panel Wire Harness & Right Step Wire Harness
C121 N100

F100 C100
Ground Points

ILLUMINATION - 09 LATE PRODUCTION
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System Description
current flows through switch of tail light relay and through the tail fuse in body junction box, to pin 1 of junction
connector C053, illumination is then powered.
Instrument Cluster Illumination

When the combination switch is set tail light or headlamp (Low Beam/High Beam) position, the current flows
output pin 6 of junction connector C053, to pin D1 of instrument cluster, and output from pin D2 of instrument
cluster, to pin 3 of junction connector C055, the power is ground at pin 1 of junction connector C055. This
enables instrument cluster illumination to operate.
Hazard Switch Illumination

output pin 5 of junction connector C053, to pin 2 of hazard switch, from pin 3 of hazard switch, to pin 4 of
junction connector C055, the power is ground at pin 1 of junction connector C055. This enables hazard switch
illumination to operate.
Cigarette Lighter Illumination

output pin 6 of junction connector C053, to pin 2 of cigarette lighter, from pin 1 of cigarette lighter, to pin 5 of
junction connector C055, the power is ground at pin 1 of junction connector C055. This enables cigarette
lighter illumination to operate.
Front A/C Controller Illumination

output pin 3 of junction connector C053, to pin 3 of front A/C switch, and from pin 1 of front A/C switch, to pin 5
of junction connector C055, and ground at pin 1 of junction connector C055. This enables front A/C switch
Radio Illumination
from pin 4 of connector C053, to pin 10 of radio, the power is ground at pin 7 of radio. This enables radio
Blower Switch Illumination

from pin 3 of junction connector C053, to pin 4 of blower switch, and from pin 3 of blower switch, to pin 5 of
junction connector C055, the power is ground at pin 1 of junction connector C055. This enables blower switch
Combined Display Illumination

from pin 2 of junction connector C053, to pin 11 of combined display, the power is ground at pin 10 of
combined display. This enables combined display illumination to operate.
Service Hints
Parts Location

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C017 Instrument Panel Wire Harness P002 Front Side Reverse Radar Wire Harness

Instrument Panel Wire Harness & Front Side Reverse Radar Wire Harness
C112 P100 71
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Ground Points
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C201 Left Side of the Instrument Panel C203 Left Side of the Instrument Panel 71
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ILLUMINATION - EARLY PRODUCTION

System Description
flow output pin A11 of combination switch, to pin 2 of junction connector, the power is ground at pin 1 of
junction connector. The coil of tail light relay creates a magnetic field, and switch is activated. The current 71
flows through switch of tail light relay and through the tail fuse in body junction box, system is then powered.
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Instrument Cluster Illumination
from tail fuse in body junction, to pin B1 of instrument cluster, and output from pin B1 of instrument cluster, to 71
pin 6 of junction connector, the power is ground at pin 1 of junction connector. This enables instrument cluster
illumination to operate. 71
Front A/C Controller Illumination 71

from tail fuse in body junction, to pin 3 of front A/C switch, and output from pin 1 of front A/C switch, to pin 7 of
junction connector, and ground at pin 1 of junction connector. This enables front A/C switch illumination to 71
operate.
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Radio Illumination
When the combination switch is set tail light or headlamp (Low Beam/High Beam) position, the current flows 71
output from tail fuse in body junction connector, to pin 10 of radio, and output from pin 7 of radio, to pin 4 of
junction connector, the power is ground at pin 1 of junction connector. This enables radio illumination to
operate. 71
Blower Switch Illumination 71

output from tail fuse in body junction connector, to pin 4 of blower switch, and output from pin 3 of blower 71
switch, to pin 9 of junction connector, the power is ground at pin 1 of junction connector. This enables blower
switch illumination to operate.
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Combined Display Illumination
When the combination switch is set tail light or headlamp (Low Beam/High Beam) position, the current flows 71
output from tail fuse in body junction, to pin 11 of combined display, and output from pin 10 of combined
display, to pin 10 of junction, connector, the power is ground at pin 1 of junction connector. This enables
combined display illumination to operate. 71
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Service Hints 71
A2 - A11：Closed with the combination switch at Headlamp position (High Beam and Low Beam). 71
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Parts Location
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C112 P100
Ground Points

WIPER AND WASHER
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System Description
When ignition switch is ON/ST, the current flows through wiper fuse in body junction box, to pin 5 of junction
connector C052. System is then powered.
Front Wiper Switch LO

When the front wiper switch of combination switch is in LO position, the current flows from pin 12 to junction
connector C052, to pin B18 of combination switch, and output from pin B7 of combination switch, to pin 2 of
front wiper motor, and through wiper motor to ground at pin 2 of front wiper motor. This enables front wiper to
operate at low speed.
Front Wiper Switch HI

When the front wiper switch of combination switch is in HI position, the current flows from pin 12 of junction
connector C052, to pin B18 of combination switch, and output from pin B13 of instrument cluster, to pin 1 of
front wiper motor, and through wiper motor, the power is ground at pin 5 of front wiper motor. This enables
front wiper to operate at high speed.
Front Wiper Switch INT

When the front wiper switch of combination switch is set INT, the current flows from pin 12 of junction
connector C052, to pin 3 of front INT wiper relay, and output from pin 2 of front INT wiper relay, to pin B12 of
combination switch, and output from pin B16 of combination switch, to pin 6 of junction connector C055, the
power is ground at pin 1 of junction connector C055.
The current flows output from pin 1 of front INT wiper relay, to pin B4 of combination switch, and output from
pin B7 of combination switch, to pin 2 of front wiper motor, and through wiper motor, the power is ground at pin
5 of front wiper motor. This enables front wiper to operate in the intermittent mode.
Front Washer switch ON

When the front washer switch is in ON position, the current flows output from pin 13 of junction connector
C052, to pin 2 of front washer pump, and through the front washer pump, output from pin 1 of front washer
pump, to pin B8 of combination switch, and then from pin B16 of combination switch, to pin 6 of junction
connector C055, and ground at pin 1 of junction connector C055. This enables front washer to function.
Rear Wiper Switch ON

When the rear washer switch of combination switch is set ON, the current flows output from pin 7 of junction
connector C052, to pin 3 of rear wiper relay, and then output from pin 6 of rear wiper relay, to B1 of
combination switch, and then output from pin B16 of combination switch, to connector C055, and then to
ground at pin 1 of junction connector C055.
The current flows output from pin 4 of rear wiper relay, to pin 4 of rear wiper motor, and through the rear wiper
motor, to ground at pin 2 of rear wiper motor. This enables rear wiper to function.
Rear Washer Switch INT

When the rear washer switch of combination switch is set INT, the current flows from pin 7 of junction
connector C052, to pin 3 of rear wiper relay, and output from pin 2 of rear wiper relay, to pin B10 of
combination switch, and output from pin B16 of combination switch, to pin 6 of junction connector C055, and to
ground at pin 1 of junction connector C055.
motor, to ground at pin 2 of rear wiper motor. This enables rear wiper to operate in intermittent mode.
Rear Washer Switch WASH1

When the rear wiper switch is in WASH1 position, the current flows output from pin 7 of junction connector
C052, to pin 2 of rear washer pump, and output from pin 1 of rear washer pump, to pin B2 of combination
switch, and output from pin B16 of combination switch, to pin 6 of junction connector C055, and to ground at
pin 1 of junction connector C055. This enables rear washer to function.
Rear Washer Switch WASH2

When the rear wiper switch is in WASH2 position, the current flows output from pin 7 of junction connector
C052, to pin 2 of rear washer pump, and output from pin 1 of rear washer pump, to pin B2 of combination
switch, and output from pin B16 of combination switch, to pin 6 of junction connector C055, and to ground at
pin 1 of junction connector C055. This enables rear washer to function.
The current flows output from pin 7 of junction connector C052, to pin 3 of rear wiper relay, and then output
from pin 6 of rear wiper relay, to B1 of combination switch, and then output from pin B16 of combination switch,
to connector C055, and then to ground at pin 1 of junction connector C055.
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motor, to ground at pin 2 of rear wiper motor. This enables rear wiper to function.
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Parts Location
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Engine Room Wire Harness & Instrument Panel Wire Harness 71

A101 C101
Instrument Panel Wire Harness & Engine Room Wire Harness 71

C102 A102
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F100 A109
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J101 F102
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J102 F106
Ground Points 71

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RADIO
Service Hints
• C021 Radio
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3 - Ground Points：Approx.12 V with the ignition switch at ACC/ON position.
4 - Ground Points：Approx. 12 V
• C040 Front Speaker LH 71
1 - 2：Approx. 4 Ω
• C041 Front Speaker RH 71
1 - 2：Approx. 4 Ω
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Parts Location
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Ground Points 71

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POWER SOCKET
System Description
Power Point Socket (Cigarette Lighter) 71
When ignition switch is ACC/ON, the current flows through radio & cigarette fuse in body junction box, pin 2 of
power point socket (cigarette lighter). When pressing the cigarette lighter, the current flows output from pin 1 of
power point socket (cigarette lighter), to pin 4 of junction connector, and ground at pin 1 of junction connector.
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This enables cigarette lighter to operate.
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Parts Location 71
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Ground Points
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C201 Left Side of the Instrument Panel C202 Right Side of the Instrument Panel 71
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COMMUNICATION SYSTEM
HORN
System Description
The current flows through hazard & horn fuse in body junction box, to pin 14 of junction connector, and output
from pin 13 of junction connector, to pin 2 of horn relay, and through the coil of horn relay, to pin 10 of 71
combination switch, when pressing the horn switch, the power is ground by combination switch. The coil of
horn relay creates a magnetic field, and switch is activated. The current then flows through switch of horn 71
relay, to pin 1 of horn, and to ground at pin 2 of horn. This enables horn to operate.
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Service Hints
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13 - 14：Conduction
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Parts Location
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Ground Points 71

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System Description
of junction connector, and output from pin 13 of junction connector, to pin 2 of back-up lamp switch. When shift
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lever in “R” position, the current flows from pin 1 of back-up lamp switch to pin 1 of reverse radar control unit.
The reverse radar control system is then powered.
The current flows from pin 4 of reverse radar control unit, to pin 1 of reverse radar sensor LH, pin 1 of reverse 71
radar sensor MID and pin 1 of reverse radar sensor RH.This emits the reverse signal to reverse radar control
unit. 71
a. The current outputs from pin 8 of reverse radar control unit, to pin 3 of reverse radar sensor LH, and through
the sensor, output from pin 2 of reverse radar sensor LH, to pin 10 of reverse radar control unit, this detects the
obstacle in left side. 71
b. The current outputs from pin 5 of reverse radar control unit, to pin 3 of reverse radar sensor MID, and
through the sensor, output from pin 2 of reverse radar sensor MID, to pin 16 of reverse radar control unit, this 71
detects the obstacle in middle.
c. The current outputs from pin 6 of reverse radar control unit, to pin 3 of reverse radar sensor RH, and
through the sensor, output from pin 2 of reverse radar sensor RH, to pin 11 of reverse radar control unit, this 71
detects the obstacle in right side.
The data communication transmits from pin 12 and pin 13 of reverse radar control unit to pin 3 and pin 11 of 71
combined display. This will display the information of reverse radar control unit on the combined display.
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Service Hints 71
• G001 Back-up Lamp Switch
1 - 2：Closed with the shift lever in “R” position. 71
Parts Location 71

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C050 Instrument Panel Wire Harness R001 Reverse Radar Rear Bumper Wire Harness
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G001 Battery Negative Cable Wire Harness R002 Reverse Radar Rear Bumper Wire Harness
P001 Front Side Reverse Radar Wire Harness R003 Reverse Radar Rear Bumper Wire Harness 71
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Instrument Panel Wire Harness & Engine Room Wire Harness 71

C102 A102
Instrument Panel Wire Harness & Front Side Reverse Radar Wire Harness 71
C112 P100
Battery Negative Cable Wire Harness & Engine Room Wire Harness 71
G100 A112
Front Side Reverse Radar Wire Harness & Left Side Reverse Radar Wire Harness
P101 Q100
(Left Side of Chassis)
Left Side Reverse Radar Wire Harness & Reverse Radar Rear Bumper Wire Harness
Q101 R100
(Rear Bumper)
Ground Points

COMBINED DISPLAY
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System Description
When ignition switch is ACC/ON, the current flows through radio & cigarette fuse in body junction box, to pin 1
of combined display. The combined display is then powered.
The current flows through pin 6 of combined display, to pin 1 of interior temperature sensor, and output from
pin 3 of interior temperature sensor, to pin 14 of combined display. This emits the vehicle speed signal to
combined display.
The current flows through pin 5 of combined display, to pin 2 of outside mirror LH, and through the ambient
sensor in outside mirror LH, and output from pin 1 of outside mirror LH, to pin 13 of combined display. This
emits the ambient temperature signal to combined display.
The data communication transmits from pin 2 and pin 11 of combined display to pin 12 and pin 13 of reverse
radar control unit. This will display the information of reverse radar control unit on the combined display.
Parts Location

D005 Front Door LH Wire Harness P003 Front Side Reverse Radar Wire Harness
P001 Front Side Reverse Radar Wire Harness

C112 P100
Front Door LH Wire Harness & Instrument Panel Wire Harness

D102 C108
Ground Points

POWER MIRROR
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System Description
When ignition switch is ACC/ON, the current flows through radio & cigarette fuse in body junction box, pin 10
of outside mirror remote control switch. System is then powered.
Outside Mirror LH (Up/Down)
The current flows from pin 10 to pin 5 of outside mirror remote control switch, to pin 2 of outside mirror LH,
through motor, the current flows from pin 3 of outside mirror LH, to pin 6 of outside mirror remote control
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror LH to go up.
through motor, the current flows from pin 2 of outside mirror LH, to pin 5 of outside mirror remote control
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror LH to go down.
Outside Mirror RH (Up/Down)
The current flows from pin 10 to pin 8 of outside mirror remote control switch, to pin 2 of outside mirror RH,
through motor, the current then flows from pin 3 of outside mirror RH, to pin 6 of outside mirror remote control
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror RH to go up.
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror RH to go down.
Outside Mirror LH (Left/Right)
through motor, the current then flows from pin 4 of outside mirror LH, to pin 1 of outside mirror remote control
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror LH to turn left.
through motor, the current then flows from pin 3 of outside mirror LH, to pin 6 of outside mirror remote control
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror LH to turn right.
Outside Mirror RH (Left/Right)
switch, and ground at pin 9 of outside mirror remote control switch. This enables outside mirror RH to turn left.
switch, and ground at pin 9 outside mirror remote control switch. This enables outside mirror RH to turn right.
Parts Location

C020 Instrument Panel Wire Harness D005 Front Door LH Wire Harness
C035 Instrument Panel Wire Harness H005 Front Door RH Wire Harness

Instrument Panel Wire Harness & Front Door LH Wire Harness
C106 D100
Instrument Panel Wire Harness & Front Door RH Wire Harness

C109 H100
(Right Side of the Instrument Panel)
Ground Points

REAR WINDOW DEFROSTER
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System Description
of junction connector, and output from pin 6 of junction connector, to pin 2 of rear defroster relay, through the
coil in rear defroster relay, and output from pin 1 of rear defroster relay, to pin 6 of rear window defrost switch.
When pressing the rear window defrost switch, and ground at pin 3 of rear window defrost switch. The coil of
rear defroster relay creates a magnetic field, and switch is activated. The current flows through rear defroster
fuse in body junction box, to pin 5 of rear defroster relay, and through the switch of rear defroster relay, to pin
1 of rear window defrost grid J010, and ground at pin 1 of rear window defrost grid J011. This enables rear
window defroster to operate.
Service Hints
• C019 Rear Window Defrost Switch
3 - 6：Closed with the rear window defrost switch in operation.
Parts Location


C102 A102

F100 A109

J101 F102

J102 F106
Ground Points


INSTRUMENT CLUSTER
INSTRUMENT CLUSTER - FOUR CONNECTORS
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System Description
of junction connector C050, and output from pin 5 of junction connector C050, to pin B9 of instrument cluster 71
C012. System is then powered.
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Coolant Fluid Level Warning Light
The current flows through coolant fluid level warning light in instrument cluster, and output from pin A8 of 71
instrument cluster C011, to pin 3 of coolant level sensor, and ground at pin 2 of coolant level sensor. This
enables coolant fluid level warning light to operate.
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ABS Warning Light
The current flows through ABS warning light in instrument cluster, and output from pin A9 of instrument cluster 71
C011, to 15 of ABS module. This enables ABS warning light to operate.
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Engine Oil Pressure Warning Light
The current flows through engine oil pressure warning light in instrument cluster, and output from pin A11 of
instrument cluster C011, to pin 1 of engine oil pressure switch, and then to ground. This enables engine oil 71
pressure warning light to operate.
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Malfunction Indicator
The current flows through malfunction indicator in instrument cluster, and output from pin C4 of instrument 71
cluster C013, to pin 31 of engine control module. This enables malfunction indicator to operate.
Low Fuel Warning Light 71

The current flows through low fuel warning light in instrument cluster, and output from pin B10 of instrument
cluster C012, to pin 2 of fuel level sensor. This checks the fuel pressure. 71
Brake Warning Light 71

The current flows through brake warning light in instrument cluster, and output pin C1 of instrument cluster
C013, to pin 1 of brake fluid level sensor, and output from pin 2 of brake fluid level sensor, to pin 6 of junction
connector C055, and ground at pin 1 of junction connector C055. This checks the brake fluid level. 71
The current flows through brake warning light in instrument cluster, and output pin C1 of instrument cluster, to
pin 1 of parking brake switch, and then to ground. This checks if the parking brake is applied or not. 71
Door Ajar Warning Light 71
The current flows through dome light fuse in body junction box, to pin 8 of junction connector C050, and output
from pin 1 of junction connector C050, to pin C7 of instrument cluster C013, and through door ajar warning
light in instrument cluster, to door ajar switch of all. If one of door is not fully closed, door ajar switch will be 71
closed. The current flows output from pin D4, pin D5, pin D7 and pin D8 of instrument cluster C014, to door
ajar switch, and then to ground. This enables door ajar warning light to operate. 71
Charging Warning Light
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When ignition switch is ON/ST, the current outputs from ignition switch, to pin 3 of junction connector C052,
and outputs from pin 10 to junction connector C052, to pin C2 of instrument cluster C013, and through
charging warning light in instrument cluster, and outputs from pin C6 of instrument cluster C013, to pin 1 of 71
generator. This identifies if the generator operates or not.
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Illumination
from the switch of tail light relay, to tail fuse in body junction box, to pin 1 of junction connector C053, and
output of pin 6 of junction connector C053, to pin D1 of instrument cluster C014, and through illumination in
instrument cluster, output from pin D2 of instrument cluster C014, to pin 3 of junction connector C055, and to
ground at pin 1 of junction connector C055. This enables illumination to operate.
Parts Location

C038 Instrument Panel Wire Harness M001 Left Step Wire Harness
C039 Instrument Panel Wire Harness N001 Right Step Wire Harness
C043 Instrument Panel Wire Harness S001 Side of Chassis Harness
C050 Instrument Panel Wire Harness U001 Fuel Tank Wire Harness

A101 C101

A107 E100
Engine Room Wire Harness & Side of Chassis Harness

A110 S100
Engine Room Wire Harness & Left Step Wire Harness

A113 M100
Engine Room Wire Harness & Right Step Wire Harness

A114 N100

C102 A102

C103 A103

F100 A109

F101 A108

F104 U100
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G100 A112
(Under the Driver’s Seat) 71
Ground Points 71

A201 Under the Driver’s Seat C204 Right Side of the Instrument Panel
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INSTRUMENT CLUSTER - THREE CONNECTORS

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System Description
of junction connector C069, and output from pin 7 of junction connector C069, to pin C2 of instrument cluster 71
C063. System is then powered.
Coolant Fluid Level Warning Light 71

The current flows through coolant fluid level warning light in instrument cluster, and output from pin C4 of
instrument cluster C063, to pin 3 of coolant level sensor, and output from pin 2 of coolant level sensor, to pin 8 71
of junction connector C065, and to ground at pin 1of junction connector C055. This enables coolant fluid level
warning light to operate. 71
ABS Warning Light
The current flows through ABS warning light in instrument cluster, and output from pin C1 of instrument cluster 71
C063, to 15 of ABS module. This enables ABS warning light to operate.
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Engine Oil Pressure Warning Light
The current flows through engine oil pressure warning light in instrument cluster, and output from pin A11 of 71
instrument cluster C061, to pin 1 of engine oil pressure switch, and then to ground. This enables engine oil
pressure warning light to operate.
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Low Fuel Warning Light
The current flows through low fuel warning light in instrument cluster, and output from pin A5 of instrument 71
cluster C061, to pin 2 of fuel level sensor. This checks the fuel pressure.
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Illumination
from the switch of tail light relay, to tail fuse in body junction box, to pin B1 of instrument cluster C062, and 71
through illumination in instrument cluster, output from pin B2 of instrument cluster C062, to pin 6 of junction
connector C067, and to ground at pin 1 of junction connector C067. This enables illumination to operate. 71
Brake Warning Light 71

The current flows through brake warning light in instrument cluster, and output pin A7 of instrument cluster
C061, to pin 1 of brake fluid level sensor, and output from pin 2 of brake fluid level sensor, to pin 5 of junction
connector C067, and ground at pin 1 of junction connector C055. This checks the brake fluid level. 71
The current flows through brake warning light in instrument cluster, and output pin A7 of instrument cluster
C061, to pin 1 of parking brake switch, and then to ground. This checks if the parking brake is applied or not. 71
Charging Warning Light 71
When ignition switch is ON/ST, the current flow output from ignition switch, to pin A9 of instrument cluster
C061, and through charging warning light in instrument cluster, and output from pin A8 of instrument cluster
C061, to pin 1 of generator. This identifies if the generator operates or not. 71
Preheat Indicator 71
The current flows through preheat indicator in instrument cluster, and output from pin A11 of instrument cluster
C061, to pin 5 of preheat control unit. This enables preheat indicator to operate.
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Fuel Water Separator Warning Light
The current flows through fuel water separator warning light in instrument cluster, and output from A12 of 71
instrument cluster C061, to pin 1 of fuel water separator. This enables fuel water separator warning light to
operate.
Low Pressure Alarm Light

The current flows through low pressure alarm light in instrument cluster, and output from pin A1 of instrument
cluster C061, to pin 1 of vacuum alarm. This enables low pressure alarm light to operate.
Parts Location

C067 Instrument Panel Wire Harness S001 Side of Chassis Harness
C069 Instrument Panel Wire Harness U001 Fuel Tank Wire Harness

Instrument Panel Wire Harness & Side of Chassis Harness
C005 S100

C116 E110

F101 C117

F104 U100
G100 C118
Ground Points


POWER DOOR LOCK SYSTEM
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System Description
The current flows through power door/window fusible link in body junction box, to pin 1 of power door lock
control unit. System is then powered. 71
Key Lock Signal 71

When key lock switch is LOCK position, the current flows output from pin 6 of power door lock control unit, to
pin 1 of front door lock actuator assembly LH D002, and through the key lock switch, to ground at pin 2 of front 71
door lock actuator assembly LH D002. This enables closed with door of all with mechanical operate.
When key lock switch is OPEN position, the current flows output from pin 5 of power door lock control unit, to
pin 3 of front door lock actuator assembly LH D002, and through the key lock switch, to ground at pin 1 of front 71
door lock actuator assembly LH D002. This enables opened with door of all with mechanical operate.
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Door Actuator Control
a. The current flows output from pin 8 of power door lock control unit, to pin 1 of junction connector C054, and
from pin 2 of junction C054, to pin 2 of front door lock actuator assembly LH D001, and through the motor in 71
front door lock actuator assembly LH, output from pin 3 of front door lock actuator assembly LH D001, to pin 4
of junction connector C054, and from pin 3 of junction connector C054, to pin 7 of power door lock control unit. 71
This enables front door LH open. On the contrary, the front door LH is closed.
b. The current flows output from pin 8 of power door lock control unit, to pin 1 of junction connector C054, and
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from pin 8 of junction C054, to pin 2 of front door actuator RH, and through the motor in front door actuator RH,
output from pin 3 of front door actuator RH, to pin 10 of junction connector C054, and from pin 3 of junction
connector C054, to pin 7 of power door lock control unit. This enables front door RH open. On the contrary, the 71
front door RH is closed.
c. The current flows output from pin 8 of power door lock control unit, to pin 1 of junction connector C054, and 71
from pin 9 of junction C054, to pin 2 of sliding door lock actuator RH, and through the motor in sliding door lock
actuator RH, output from pin 3 of sliding door lock actuator RH, to pin 11 of junction connector C054, and from
pin 3 of junction connector C054, to pin 7 of power door lock control unit. This enables sliding door RH open. 71
On the contrary, the sliding door RH is closed.
d. The current flows output from pin 8 of power door lock control unit, to pin 1 of junction connector C054, and 71
from pin 9 of junction C054, to pin 3 of rear hatch lock actuator, and through the motor in rear hatch lock
actuator, output from pin 2 of rear hatch lock actuator, to pin 11 of junction connector C054, and from pin 3 of
junction connector C054, to pin 7 of power door lock control unit. This enables rear hatch open. On the 71
contrary, the rear hatch is closed.
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Remote keyless entry
The current flows through dome light fuse in body junction box, to pin 8 of remote keyless entry receiver. 71
System is then powered.
a. The current flows output from pin 5 of power door lock control unit, to pin 15 of remote keyless entry
receiver, and output from pin 1 of remote keyless entry receiver, to pin 2 of junction connector C055 and 71
ground at pin 1 of junction connector C055. This enables door of all closed.
b. The current flows output from pin 6 of power door lock control unit, to pin 7 of remote keyless entry receiver, 71
and output from pin 14 of remote keyless entry receiver, to pin C8 of instrument cluster, through the instrument
cluster, and output from pin D4, pin D5, pin D7 and pin D8 of instrument cluster, to door ajar switches. If one of
door is not fully closed, door ajar switch will turn to ON and door lock actuator still open. 71
If all the doors are closed, the current flows output from pin 1 of remote keyless entry receiver, to pin 2 of
junction connector C055 and ground at pin 1 of junction connector C055. This enables all the doors closed. 71
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Parts Location

A008 Engine Room Wire Harness D001 Front Door LH Wire Harness
A011 Engine Room Wire Harness D002 Front Door LH Wire Harness

C103 A103

C109 H100

D101 C017

D102 C108

F100 A109

J102 F106
Ground Points


POWER WINDOW CONTROL
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System Description
of power window relay, and through the coil in power window relay, and to ground at pin 1 of power window
relay. The coil of power window relay creates a magnetic field, and switch is activated. The current flows
through the switch in power window relay, to pin 2 of power window control unit, pin 3 of main power window
lock/unlock switch and pin 3 of front power window switch RH. System is then powered.
Power Window Control LH

a. The current flows output from pin 8 of main power window lock/unlock switch, to pin 4 of power window
control unit. This enables front power window LH to go up.
b. The current flows output from pin 7 of main power window lock/unlock switch, to pin 8 of power window
control unit. This enables front power window LH to go down.
c. The current flows output pin 6 and pin 7 of main power window lock/unlock switch, to pin 7 and pin 8 of
power window control unit. This enables front power window LH to auto down.
d. The current flows output from pin 1 of power window control unit, to pin 2 of front power window motor LH,
and through the motor, output from pin 1 of front power window motor LH, to pin 3 of power window control
unit. This enables front power window motor to go up.
e. The current flows output from pin 3 of power window control unit, to pin 1 of front power window motor LH,
and through the motor, output from pin 2 of front power window motor LH, to pin 1 of power window control
unit. This enables front power window motor to go down.
Power Window Control RH

a. The current flows output from pin 5 of front power window switch RH, to pin 1 of front power window motor
RH, and through motor, output front pin 2 of front power window motor RH, to pin 1 of front power window
switch RH, and output from pin 2 of front power window switch, to pin 4 of main power window lock/unlock
switch, and to ground at pin 2 of main power window lock/unlock switch. This enables front power window RH
to go up.
b. The current flows output from pin 1 of front power window switch RH, to pin 2 of front power window motor
RH, and through motor, output front pin 1 of front power window motor RH, to pin 5 of front power window
switch RH, and output from pin 4 of front power window switch, to pin 1 of main power window lock/unlock
switch, and to ground at pin 2 of main power window lock/unlock switch. This enables front power window RH
to go down.
c. The current flows output from pin 1 of main power window lock/unlock switch, pin 4 of power window switch
RH, and output from pin 5 of power window switch RH, to pin 1 of front power window motor RH, and through
motor, output front pin 2 of front power window motor RH, to pin 1 of front power window switch RH, and
output from pin 2 of front power window switch, to pin 4 of main power window lock/unlock switch, and to
ground at pin 2 of main power window lock/unlock switch. This enables front power window RH to go up (Main
power window lock/unlock switch controls front power window motor RH.)
d. The current flows output from pin 4 of main power window lock/unlock switch, pin 2 of power window switch
RH, and output from pin 1 of power window switch RH, to pin 2 of front power window motor RH, and through
motor, output front pin 1 of front power window motor RH, to pin 5 of front power window switch RH, and
output from pin 4 of front power window switch, to pin 1 of main power window lock/unlock switch, and to
ground at pin 2 of main power window lock/unlock switch. This enables front power window RH to go down
(Main power window lock/unlock switch controls front power window motor RH.)
Parts Location

C026 Instrument Panel Wire Harness D004 Front Door LH Wire Harness
D003 Front Door LH Wire Harness H004 Front Door RH Wire Harness

71
Instrument Panel Wire Harness & Front Door LH Wire Harness
C106 D100
71
C109 H100
71
D101 C107
Ground Points 71

71
71
(Connector Location)
71
71
71
71
71
71
71
71
71
71
71
71
71-142 WIRING - CONNECTOR VIEWS
CONNECTOR VIEWS
A - ENGINE ROOM WIRE HARNESS
A001 Generator A004 Front Door Ajar Switch RH

Code Color Function Qualifier Code Color Function Qualifier
B W Output 1 B Ajar Signal
A002 Generator (Voltage Regulator) A008 Front Door Ajar Switch LH

1 Y Voltage Regulator 1 L Ajar Signal
A003 Electronic Fan A005 Sliding Door Lock Actuator RH

1 W-B Ground 1 - -
2 R-W HI 2 L-Y Unlock
3 R-W LO 3 L-B Lock
4 - -
A006 Coolant Level Sensor

Code Color Function Qualifier A009 Electronic Fan Fusible Link Box
1 - - Code Color Function Qualifier
2 W-B Ground 1 W Input
3 V-W Input 2 R-B Output

WIRING - CONNECTOR VIEWS 71-143
71
A007 Starter Relay A011 Sliding Door Lock Actuator LH 71
Code Color Function Qualifier Code Color Function Qualifier 71

1 W-B Ground 1 - -
71
2 B-R Start 2 L-Y Unlock
71
3 B Output 3 L-B Lock
4 W Input 4 - - 71
71
71
71
71
A010 Data Link Connector A013 Fan Relay (HI)
71
1 L-B Diagnosis 1 R-L Control 71
2 - - 2 BR Input
71
3 - - 3 R-L Output
71
4 W-B Ground 4 - -
5 W-B Ground 5 R-B Power Supply 71

6 - -
71
7 BR-Y D-Link
71
8 - -
9 - - 71
10 - - A014 Fan Relay (LO)
71
71
12 - - 1 R-W Control
13 - - 2 BR-W Input
14 - - 3 R-W Output
15 - - 4 - -
16 R Powe Supply 5 R-B Power Supply

A015 Fuel Pump A016 EFI Relay

1 W-L Control 1 B Control
2 L-W Input 2 B-R Input
3 L-Y Output 3 B-G Output
4 - - 4 - -
5 L-W Power Supply 5 W-R Power Supply
A021 Fusible Link Box

Code Color Function Qualifier
A026 Fuel Selection Relay
1 W Output
1 L-W Input
2 G Control
3 L-W Power Supply
4 L-Y Switch
A022 Fusible Link Box
5 L-Y Output
1 - -
2 - -
3 W Output
A027 High-pressure Solenoid Valve Relay

A025 CNG Pressure Gauge 1 L-W Input
Code Color Function Qualifier 2 O Control
1 L Ignition 3 L-W Power Supply
2 L-R Signal 4 - -
3 W-B Ground 5 L-B Output

71
71
A028 EFI & A/C Relay
71
1 B-R Input 3 Y-B Output 71
2 B-W Control 5 B-R Power Supply
71
71
71
71
71
A101 to Instrument Panel Wire Harness
71
1 Y-B - 11 BR-W - 71
2 B-R - 12 R-B -
71
3 B-R - 13 GR -
71
4 Y-G - 14 V-W -
5 L-R - 15 W - 71
6 L-W - 16 Y-G -
71
7 W-G - 17 L -
71
8 R-Y - 18 W-G -
9 G-R - 19 W-R - 71
10 G-Y - 20 B-O -
71
71
71

1 G - 11 R -
2 R - 12 Y-B -
3 Y-R - 13 GR -
4 Y-R - 14 Y -
5 R-W - 15 V -
6 B - 16 L-W -
7 B-R - 17 - -
8 R-L - 18 - -
9 L-W - 19 W-B -
10 W-B - 20 L -

1 - - 11 G-W -
2 Y - 12 Y-G -
3 L - 13 - -
4 B - 14 L-Y -
5 W-B - 15 L-B -
6 - - 16 R-Y -
7 - - 17 L -
8 R-L - 18 G -
9 B - 19 Y-R -
10 W-L - 20 W -
71
71
A106 to Engine Control Wire Harness
1 R - 6 W-L - 71
2 B-R - 7 B -
71
3 B-G - 8 BR-Y -
4 B-G - 9 L-B - 71
5 Y - 10 - - 71
71
71
71
A107 to Engine Control Wire Harness
71
71
1 B-O - 7 Y-R -
2 R-B - 8 B-R - 71
3 V - 9 B-W - 71
4 Y-G - 10 - -
71
5 Y-B - 11 - -
6 R-W - 12 R-L - 71
71
71
71
A108 to Roof Wire Harness 71

1 - - 6 - -
2 - - 7 Y-R -
3 W - 8 Y-G -
4 Y-G - 9 W-G -
5 - - 10 W-R -
A109 to Roof Wire Harness

1 L - 12 L-Y -
2 R-Y - 13 L-B -
3 G - 14 R-L -
4 R - 15 L-W -
5 L-R - 16 - -
6 R - 17 W-B -
7 L - 18 L-Y -
8 W - 19 R-Y -
9 Y - 20 G-W -
10 W-G - 21 G-Y -
11 L-W - 22 G-R -
A110 to Side of Chassis Harness A112 to Battery Negative Cable Wire Harness
1 W-B - 1 R-L -
2 R-B - 2 R -
3 - - 3 BR-W -
4 B - 4 W-B -
5 Y-R - 5 - -
6 G-W - 6 R-B -
71
A113 to Left Step Wire Harness A114 to Right Step Wire Harness 71
71
1 R-Y - 1 R -
71
2 R - 2 R-Y -
71
71
71
A115 to Battery Positive Cable Wire Harness
71
1 B - 71
71
71
71
71
71
71
71
71
71
71
71
B - BATTERY POSITIVE CABLE WIRE HARNESS
B001 Battery B003 Starter

B B-R Output 1 B-R Start
B002 Starter B100 to Engine Room Wire Harness

B B-R Power Supply 1 B-R -
C - INSTRUMENT PANEL WIRE HARNESS
71
C001 Front Fog Lamp RH C004Front Fog Lamp LH 71

1 LG Power Supply 1 LG Power Supply
71
2 W-B Ground 2 W-B Ground
71
71
71
C002 Front Combination Lamp RH C005 Front Combination Lamp LH 71

71
1 G-Y Left Side Turn Signal 1 G-B Left Side Turn Signal
71
2 G Tail 2 G Tail
3 G-Y Front Turn Signal 3 G-B Front Turn Signal 71

71
71
71
71
71
C003 Front Combination Lamp RH C006 Front Combination Lamp LH
71
1 R-G Low Beam 1 R-G Low Beam 71
2 R-Y High Beam 2 R-Y High Beam 71

3 R Power Supply 3 R-B Power Supply
71
C007 Front Washer Pump C010 Horn

1 L-Y Power Supply 1 B Power Supply
2 L Output 2 W-B Ground

C008 Combination Switch (Light Control)

A1 G-W Power Supply A8 G-Y Output RH
A2 G-L Tail Light Relay A9 W-B Ground
A3 R-G Low Beam A10 LG Power Supply
A4 - - A11 W-B Ground
A5 G-B Output LH A12 R-Y High Beam
A6 - - A13 R-W Headlamp Relay
A7 - - A14 R-W High Beam
C009 Combination Switch (Wiper and Washer Control)

B1 LG Rear Wiper B11 - -
B2 W-G Rear Washer B12 L-R Front INT Wiper
B3 - - B13 L-O High Control
B4 W-L Limit Switch B14 - -
B5 - - B15 - -
B6 - - B16 W-B Ground
B7 L-B Front Wiper B17 - -
B8 L-Y Front Washer B18 L Power supply
B9 - - B19 - -
B10 G-Y Rear Wiper B20 - -

71
71
C011 Instrument Cluster 71

71
A1 Y-R Fuel Gauge A9 R-L ABS Indicator
71
A2 P Temperature Gauge A10 - -
A3 W-B Ground A11 P-L Oil Pressure 71

A4 W-B Ground A12 - -
71
A5 - - A13 - -
71
A6 - - A14 - -
A7 G-B Left Turn Signal A15 - - 71

A8 V-W Coolant Indicator A16 - -
71
71
71
71
C012 Instrument Cluster C013 Instrument Cluster 71

B1 - - C1 B Brake Indicator
71
B2 - - C2 B-R Power Supply
B3 - - C3 - -
71
B4 - - C4 V Malfunction Indicator 71
B5 - - C5 - -
71
B6 BR-W Sensor Power C6 Y Charging Indicator
B7 R-B Vehicle Speed C7 R Power Supply

71
B8 - - C8 Y-G Door Ajar Indicator
B9 R-L Power Supply C9 R-G High Beam Indicator
B10 Y-G Low Fuel Indicator C10 G-Y Right Turn Signal
C11 W-B Ground
C12 B-Y RPM
C13 - -
C014Instrument Cluster
D1 G Illumination D8 Y Sliding Door RH
D2 W-B Ground D9 R-G Rear Dome light
D3 W Front Dome Light D10 R-Y Illumination
D4 L-R Front Door RH D11 - -
D5 L-W Front Door LH D12 - -
D6 - - D13 - -
D7 R-L Rear Hatch
C015 Hazard Switch C016 Blower Switch

1 - - 1 L-O II Signal
2 G Illumination 2 L-Y I Signal
4 - - 4 G Illumination
5 G-B Left Turn Signal 5 Y-B Front Heater Relay
6 G-Y Right Turn Signal 6 L-R HI Signal
7 LG Output 7 - -
8 G-O Power Supply 8 W-B Ground
9 G-W Flasher
10 R-Y Power Supply

71
C017 Front A/C Switch C019 Rear Window Defrost Switch
71
71
1 W-B Ground 1 - -
2 - - 2 R-L Working Indicator 71
3 G Illumination 3 W-B Ground 71

4 LG Request 4 - -
71
5 Y A/CSignal 5 - -
6 Y-B Blower Signal 6 L Rear Defroster Relay 71
71
71
71
C020 Outside Mirror RemoteControl Switch C021 Radio
71
1 R-G - 1 LG Speaker FR+ 71
2 - - 2 P Speaker FL+ 71
3 - - 3 BR Power Supply
71
4 - - 4 R Power Supply
5 LG - 5 L Speaker FR- 71
6 GR-R - 6 V Speaker FL- 71

7 R-Y - 7 W-B Ground
71
8 BR-W - 8 - -
9 W-B - 9 - - 71
10 GR - 10 G Illumination 71
71
C023 Power Point Socket (Cigarette Light) C024 Power Point Socket (Cigarette Light)
2 BR Power Supply 2 G Illumination

C022 Fuel Selection Switch C025 Condenser Fan Motor

1 - - 1 R-B Resistor
2 R-L Working Indicator 2 W-B Ground
3 W-B Ground 3 B-R Fan Control
4 - - 4 L-W Power Supply
5 - -
6 L-Y Selection
C027 Front Blower Motor Resistor

C026 Power Window Control Unit 1 L-R Power Supply
Code Color Function Qualifier 2 L-Y I Signal
1 L-B Up 3 L-O II Signal
2 L Power Supply 4 W-B Ground
3 L-W Down
4 R-B Up
5 - -
6 W-B Ground Points
7 L Auto Donwn C029 Front Wiper Motor

8 R-Y Down
Qualifie
Code Color Function
r
1 L-O HI Signal
2 L-B INT/LO Signal
3 L-W Limit Switch
C028 Front Blower Motor 4 L Power Supply

1 L-B Power Supply
2 L-R Ground
71
C030 Power Door Lock Control Unit C031 Rear Wiper Relay 71
71
1 W-L Power Supply 1 - -
71
2 - - 2 G-Y INT
3 - - 3 L Power Supply 71
4 - - 4 L-R Power Supply
71
5 G-W Open 5 L-W Limit Switch
71
6 G-B Lock 6 LG Rear Wiper
7 L-B Open 71
8 L-Y Lock
71
9 - -
71
10 W-B Ground
C033 Rear Dome Light Switch
71
1 R-G Dome Light 71
2 - - 71
3 - -
C032 Ignition 71
4 W-B Ground
71
AM1 W -
71
AM2 W-R -
ACC L-R - 71
IG1 B-Y -
71
C034 A/C Pressure Switch
IG2 B-R -
Code Color Function Qualifier 71
ST1 B-W -
1 Y-B Power Supply 71
ST2 B -
2 R-L Hi-low Pressure
3 R-Y Power Supply
4 R-W Mid Pressure
5 - -
6 W-B Ground
C036 Front Fog Lamp Switch C037 Rear Fog Lamp Switch
1 R-Y Input 1 LG Input
2 - - 2 - -
3 - - 3 - -
4 W-B Ground 4 R-Y Output
C038 Remote Keyless Entry Receiver

1 W-B Ground Points 9 - -
2 - - 10 - -
3 - - 11 - -
4 - - 12 - -
5 - - 13 - -
6 - - 14 Y-G Ajar Door
7 G-B Lock 15 G-W Unlock
8 R Power Supply
C039 Brake Fluid Level Sensor C040 Front Speaker LH

1 B Input 1 P Speaker LH+
2 W-B Ground 2 V Speaker LH-

71
C043 Parking Brake Switch
C041 Front Speaker RH 71
1 B - 71
1 LG Speaker RH+
71
2 L Speaker RH-
71
C047 Return Fuel Solenoid Valve 71

1 BR-B Input
C042 Turn Signal Flasher Relay 71
71
1 G-W Signal
71
2 G-R Power Supply
C045 Fuel Inlet Solenoid Valve
3 W-B Ground 71
71
1 W-R Input
71
71
C044 Stop Lamp Switch
C048 Fuel Supply Solenoid Valve 71
1 G-R Power Supply
1 R Input
2 G-W Output 71
71
71
71
C046 Clutch Switch C049 Fuel Supply Solenoid Valve Relay
1 - - 1 W-B -
2 - - 2 R-B -
3 W - 3 R -
4 G-O - 5 R-B -
C050 Junction Connector C051 Junction Connector

1 R - 1 R-Y -
2 R - 2 R-Y -
3 - - 3 - -
4 - - 4 - -
5 R-L - 5 GR -
6 R-L - 6 G-R -
7 - - 7 G-O -
8 R - 8 R-Y -
9 - - 9 R-Y -
10 - - 10 - -
11 - - 11 - -
12 R-L - 12 GR -
13 R-L - 13 G-O -
14 R-L - 14 G-O -
C052 Junction Connector

1 Y-B - 8 Y-B -
2 Y-B - 9 - -
3 B-R - 10 B-R -
4 B-R - 11 Y -
5 L - 12 L -
6 L - 13 L -
7 L - 14 - -
71
71
71
1 G - 1 W-B -
2 G - 2 W-B - 71
3 G - 3 W-B - 71
4 G - 4 W-B -
71
5 G - 5 W-B -
6 G - 6 W-B - 71
71
71
71
71
71
1 L-Y - 8 L-Y -
2 L-Y - 9 L-Y - 71
3 L-B - 10 L-B - 71
4 L-B - 11 L-B -
71
5 G-B - 12 G-B -
6 G-B - 13 G-Y - 71
7 G-Y - 14 G-Y - 71
71
71
71
C056 Preheat Relay C058 Idle Speed Control Relay

30 B-R - 1 G-L -
85 W-B - 2 W-B -
86 R-L - 3 W-B -
87 B-Y - 5 LG -
C057 Glow Plugs C059 Idle Speed Control Valve

1 W-Y - 1 GR -
2 LG -
C061 Instrument Cluster

A1 Y-O Low Pressure A7 B Brake Indicator
A2 Y-R Fuel Gauge A8 Y-W Chargning Indicator
A3 W-B Ground A9 B-R Power Supply
A4 Y-G Temperature Indicator A10 Y-B Oil Pressure
A5 Y-G Low Fuel A11 L-W Preheat Indicator
A6 - - A12 Y-G fuel water separator
C062 Instrument Cluster C063 Instrument Cluster
B1 G Illumination C1 Y-R ABS Indicator
B2 W-B Ground C2 R-L Power Supply
B3 - - C3 - -
B4 - - C4 L-Y Coolant Indicator
B5 - - C5 - -
B6 - - C6 R Sensor Power
B7 W-B Ground C7 R-B Vehicle Speed
B8 G-B Left Turn Signal C8 W-B Ground
B9 R-G High Beam C9 - -
B10 G-Y Right Turn Signal C10 - -

71
C065 Junction Connector C067 Junction Connector 71

1 W-B - 1 W-B -
71
2 W-B - 2 W-B -
71
3 W-B - 3 W-B -
4 W-B - 4 W-B - 71
5 W-B - 5 W-B -
71
6 W-B - 6 W-B -
71
7 - - 7 W-B -
8 W-B - 8 W-B - 71
9 - - 9 W-B -
71
10 W-B - 10 W-B -
71
11 - - 11 - -
71
71
71
C066 Junction Connector C068 Junction Connector 71

1 W-B - 1 W-B -
71
2 W-B - 2 W-B -
71
3 W-B - 3 W-B -
4 W-B - 4 W-B - 71
5 W-B - 5 W-B -
71
6 W-B - 6 W-B -

1 L-Y - 8 - -
2 P - 9 L-Y -
3 GR - 10 GR -
4 GR - 11 GR -
5 R-L - 12 R-L -
6 R-L - 13 R-L -
7 R-L - 14 - -
C070 Preheat Control Unit C072 Throttle Position Sensor (4D20)

5 L-W Preheat Indicator 1 W-B Ground
6 B-Y Ignition 2 GR TPS Signal
7 B-W Start 3 W-L Power Supply
8 Y Preheat Relay
9 G-W Start
10 W Power Supply
C073 Fuel Water Separator

1 Y-G -
C071 Preheat Control Unit

1 L Temperature
2 - -
C074 Vacuum Alarm
4 W-B Ground 1 Y-O -

71
C075 Generator C078 Data Link Connector
71
71
1 B-Y IG 1 Y-B -
2 W-R S 2 Y-L - 71
3 Y-W L 3 R - 71
4 B -
71
71
71
71
C076 EGR Valve Control Unit
71
1 Y - 10 BR-W - 71
2 Y-L - 11 G-R - 71
3 - - 12 GR-G -
71
4 Y-B - 13 G -
5 P - 14 GR - 71
6 W-P - 15 W -
71
7 BR-G - 16 B-Y -
71
8 W-B - 17 B -
9 B-G - 18 R - 71
71
71
71
C077 Fan Control Unit

1 BR Hi Speed 5 BR-L Low Speed
2 W-B Ground 6 L-O Temperature+
3 W-G Power Supply 7 O Temperature-
4 Y Ignitin 8 - -
C079 EGR Valve Lift Sensor C080 EGR Vacuum Solenoid Valve
1 W-P - 1 B-G -
2 P - 2 BR-G -
3 W -
C082 Fusible Link Box

C081 Fusible Link Box Code Color Function Qualifier
Code Color Function Qualifier 1 W-R -
1 W - 2 W-L -
C083 Fusible Link Box C084 Electronic Fan Fusible Link Box
1 W - 1 W -
2 W-G -
C085 Fan Relay (LO) C086 Fan Relay (HI)

30 W-G - 30 W-G -
85 Y - 85 BR-L -
86 BR - 86 Y -
87 Y-R - 87 G-W -
71
C087 Electronic Fan C088 Engine Relay Box 71

71
1 W-B Ground 1 W-B -
2 G-W Low Speed 2 B -

71
3 Y-R Hi Speed 3 Y - 71
4 W -
71
5 - -
6 - -
71
C089 Generator 7 W-R - 71
Code Color Function Qualifier 8 B-Y -

71
B W Output 9 W -
10 W -
71
71
71
71
C091 EGR Valve Electronic Control Module 71

1 B-L Timing Solenoid Valve 14 Y-W Timing Signal
71
2 R-B Power Supply 15 R Fuel Supply Solenoid
3 B-Y Sensor Power 16 LG Temperautre Input 71
4 W-O Lift Signal 17 GR Tp Sensor 71

5 W-L Output 18 W Clutch Signal
71
6 GR RXD 19 W-B Ground
7 W-G TXD 20 B-W ST Signal 71
8 L-W Preheat Indicator 21 BR-B Fuel Return Relay
9 V Speed Input 22 L-R Output
10 R-B Output 23 LG Idle Speed Control
11 B-Y Glow Plugs 24 BR-B Fuel Return Solenoid
12 G-L Control 25 G-O Ignition
13 R-L Output
C092 EGR Valve Lift Sensor C096 Preheat Fusible Link Box
1 W-L +5V Power 1 W -
2 W-B Ground 2 B-R -
3 W-O Output
C097 EGR Vacuum Solenoid Valve
C093 EGR Coolant Temperature Sensor Code Color Function Qualifier

1 W-B Ground
2 - -
1 W-B Ground
3 - -
2 B-L Output
4 L-R Input
C094 Timing Solenoid Valve

C098 Speed Sensor
1 W-B Ground Points
1 B-Y +5V Power
2 B-L Input
2 W-B Ground
3 V Input
C095 Timing Stroke Sensor

1 Y-W Input
2 W-B Ground
3 W-L +5V Power

71
71
C100 to Roof Wire Harness 71

1 L - 12 - -
71
2 R-Y - 13 L-B -
71
3 G - 14 - -
4 R - 15 L-W - 71
5 L-R - 16 - -
71
6 R - 17 W-B -
71
7 L - 18 L-Y -
8 W - 19 R-Y - 71
9 Y - 20 G-W -
71
10 W-G - 21 G-Y -
71
11 L-W - 22 G-R -
71
71
71
71
C101 to Engine Room Wire Harness
71
1 Y-B - 11 BR-W - 71
2 B-R - 12 R-B -
71
3 Y - 13 B-O -
71
4 P - 14 V-W -
5 L-R - 15 W -
6 L-W - 16 Y-G -
7 W-G - 17 L -
8 R-Y - 18 W-G -
9 G-R - 19 W-R -
10 G-R - 20 B-Y -

1 G - 11 R -
2 R - 12 P-L -
3 Y-R - 13 R-Y -
4 R-L - 14 Y -
5 R-W - 15 V -
6 B - 16 L-W -
7 B-R - 17 R-G -
8 R-L - 18 R -
9 L-W - 19 W-B -
10 W-B - 20 L -

1 R - 11 G-W -
2 Y - 12 Y-G -
3 L-W - 13 Y -
4 B - 14 L-Y -
5 W-B - 15 L-B -
6 B - 16 R-Y -
7 W - 17 L -
8 R-L - 18 G -
9 L-R - 19 Y-R -
10 W - 20 W -
71
C106 to Front Door LH Wire Harness C108 to Front Door LH Wire Harness 71

1 L-B - 1 G-R -
71
2 L-W - 2 L-Y -
71
3 R-Y - 3 R-B -
4 R-B - 4 L-B - 71
5 L -
71
6 LG -
71
7 BR-R -
8 R-G - 71
C109 to Front Door RH Wire Harness 71

71
1 R-L -
71
2 G-R -
C107 to Front Door LH Wire Harness 3 L - 71
Code Color Function Qualifier 4 L-Y -
71
1 G-B - 5 BR-W -
71
2 R-L - 6 GR-R -
3 G-R - 7 R-Y - 71
4 G-W - 8 L-B -
71
5 L -
71
6 W-B -
71
71
C110 to Front Evaporator Wire Harness

1 Y - 11 B-O -
2 - - 12 L -
3 B-Y - 13 - -
4 W-L - 14 LG -
5 Y-G - 15 GR -
6 W - 16 W-B -
7 W-R - 17 W-L -
8 W-R - 18 Y-B -
9 W-G - 19 B-R -
10 B -
C111 to Front Evaporator Wire Harness C112 to Front Side Reverse Radar Wire Harness
1 L-W - 1 W-B -
2 R-W - 2 R-B -
3 R-L - 3 G-B -
4 B-R - 4 G-R -
5 R-B - 5 R -
6 Y-B - 6 G -
7 R-Y -
8 - -
71
71
71
C116 to Engine Control Wire Harness (BJ493ZQ)
71
1 G-W - 9 Y-G - 71
2 GR - 10 Y-B -
71
3 G - 11 B-Y -
71
4 GR-G - 12 Y -
5 G-R - 13 - - 71
6 BR-W - 14 - -
71
7 O - 15 B-Y -
71
8 L-O - 16 L -
71
71
71
C117 to Roof Wire Harness C118 to Battery Negative Cable Wire Harness 71

1 - - 1 R-L -
71
2 - - 2 R-Y -
3 W 3 R
71
4 Y-L - 4 W-B - 71
5 - - 5 - -
71
6 - - 6 R-B -
7 Y-R -
71
8 Y-G -
9 W-G -
10 W-R -
C119 to Battery Positive Cable Wire Harness
1 B -
D - Front Door LH Wire Harness
D001 Front Door Lock Actuator Assembly LH D002 Front Door Lock Actuator Assembly LH
1 W-B Ground 1 G-B Lock
2 L-Y Open 2 W-B Ground
3 L-B Lock 3 G-W Open
4 - -
D005 Outside Mirror LH

1 Y Temperature
D003 Front Power Window Motor LH 2 LG Mirror (MH)
Code Color Function Qualifier 3 GR Mirror (M+)
1 L-W Down 4 R-G Mirror (MV)
2 L-G Up 5 G-R Temperautre
D004 Main Power Window Lock/Unlock Switch D100 to Instrument Panel Wire Harness
1 G-R Window RH 1 L-G -
2 W-B Ground 2 L-W -
3 L Power Supply 3 R -
4 R-L Window RH 4 R-B -
5 - - 5 R-W -
6 R-W Auto Down 6 LG -
7 R Down 7 GR -
8 R-B Up 8 R-G -
71
71
D101 to Instrument Panel Wire Harness D102 to Instrument Panel Wire Harness
71
71
1 G-B - 1 G-R -
2 G-R - 2 L-Y - 71
3 R-L - 3 L-B -
71
4 G-W - 4 Y -
71
5 L -
6 W-B - 71
71
71
71
71
71
71
71
71
71
71
71
71
E - ENGINE CONTROL WIRE HARNESS
E001 Engine Control Module

1 BR Ignition 38 - -
2 - - 39 B-W ACI
3 W-B Vehicle Speed 40 - -
4 GR-B Sensor Ground 41 - -
5 GR Sensor Ground 42 G Signal - MAP Sensor
6 L-G Ground - O2 Sensor 43 R-L Signal - ECT Sensor
7 - - 44 - -
8 - - 45 B-Y Signal -CKP Sensor
9 - - 46 B-R ACT
10 - - 47 L-W Fuel Pump Control
11 BR-Y Diagnostic K Line 48 - -
12 L CKP Sensor(Hi) 49 - -
13 - - 50 BR Fan Control (Hi)
14 - - 51 - -
15 - - 52 BR-G Ignition Control (2,3)
16 - - 53 W-Y Idle Air Control Coil B
17 R Power Supply 54 Y-L Idle Air Control Coil A
18 R Power Supply 55 G-Y Fuel Injector 1
19 - - 56 BR-R Fuel Injector 3
20 R-W 5V Power 57 - -
21 L-BR 5V Power 58 B Main Relay
22 - - 59 - -
23 - - 60 - -
24 L-Y TP Sensor 61 R-Y Heat - Upstream O2S

E001 Engine Control Module

25 - - 62 Y-R Upstream O2S (Hi ) 71
26 - - 63 B-L Canister Valve
71
27 G-BR IAT Sensor 64 - -
71
28 GR CKP (Low Voltage) 65 - -
29 - - 66 - - 71
30 L-B Diagnosis 67 BR-W Fan Control (Low)
71
31 V Malfunction Indicator 68 - -
71
32 Y Ignition Control (1,4) 69 - -
33 V-G Idle Air Control Coil C 70 G-R Fuel Injector 2 71

34 Y-B Idle Air Control Coil D 71 GR-R Fuel Injector 4
71
35 - - 72 - -
71
36 G-W Power Steering 73 W-B Ground
37 - - 71
71
71
71
E002 Fuel Injector 1 E004 Fuel Injector 3 71
71
1 B-G Fuel Injector 1 (Hi) 1 B-G Fuel Injector 1 (Hi)
2 G-Y Fuel Injector 1 (Lo) 2 BR-R Fuel Injector 1 (Lo) 71
71
71
71
E003 Fuel Injector 2 E005 Fuel Injector 4 71

1 B-G Fuel Injector 1 (Hi) 1 B-G Fuel Injector 1 (Hi)
2 G-R Fuel Injector 1 (Lo) 2 GR-R Fuel Injector 1 (Lo)

E007 Throttle Position Sensor E010 MAP/IAT Sensor

A R-W +5V Power A G Pressure
B GR Ground B GR-B Ground
C L-Y TP Signal C G-BR Temperature
D L-BR 5V Power
E008 Canister Solenoid Valve

E013 Crankshaft Position Sensor
A B-L Solenoid Valve
A L High Voltage
B L-W Power Supply
B GR Low Voltage
C W-B Ground
E009 Idle Air Control Valve

Code Color Function Qualifier E017 Upstream Oxygen Sensor
A Y-B Idle Air Control Coil D Code Color Function Qualifier
B V-G Idle Air Control Coil C 1 L-G Low Voltage
C W-Y Idle Air Control Coil B 2 Y-R High Voltage
D Y-L Idle Air Control Coil A 3 R-Y Heat Control
4 L-W Power Supply
E020 Ignition Coil

Code Color Function Qualifier E021 Coolant Temperature Sensor
A Y Ignition Control (2,3) Code Color Function Qualifier
B BR Ignition A GR Ground
C BR-G Ignition Control (2,3) B R-G Temperature

71
E022 A/C Clutch E025 Coolant Temperature Sensor
71
1 Y-R Input 1 Y-G Input 71
71
71
71
E024 Engine Oil Pressure Switch E027 Pressure Regulator
71
1 Y-B Input 1 V Input 71
2 W-B Ground 71
71
71
71
71
71
E026 Injector Control Unit
71
1 GR-R - 9 V -
71
2 BR-R - 10 L - 71
3 G-R - 11 - -
71
4 G-Y - 12 W-B -
5 B - 13 GR-R -
71
6 V - 14 BR-R - 71
7 W - 15 G-R -
8 GR - 16 G-Y -
E028 Filter Pressure/Intake Air E034 CNG Injector 4

Temperature Sensor
Code Color Function Qualifier 1 B Output
A Y Pressure 2 R Input
B GR-B Ground
C B Temperature
D L-BR +5V Power
E035 Speed Sensor

E030 CNG Injector 1 1 B-Y -
Code Color Function Qualifier 2 Y -
1 GR Output
2 R Input
E036 EGR coolant temperature sensor

E031 CNG Injector 2 1 BR-W -
Code Color Function Qualifier 2 G-R -
1 W Output
2 R Input
E037 Throttle Position Sensor

E033 CNG Injector 3 Code Color Function Qualifier
Code Color Function Qualifier 1 GR-G -
1 V Output 2 G -
2 R Input 3 GR -
71
E038 Temperature Sensor E040 Preheat Temperature Sensor
71
1 L Preheat Temperature 71
1 O Temperature+
2 L-O Temperature- 71
71
71
E041 Fuel Cut-off Solenoid Valve
71
E039 KSB Valve Code Color Function Qualifier
1 B-Y Input 71
1 G-W Input 71
71
71
E042 Glow Plug
71
1 W Input
71
71
71
71
E100 to Engine Room Wire Harness 71

1 B-Y - 7 Y-R -
71
2 R-B - 8 B-W -
71
3 V - 9 B-R -
4 Y-G - 10 - -
5 Y-B - 11 - -
6 BR-W - 12 BR -
E101 to Engine Room Wire Harness

1 R - 6 L-W -
2 BR - 7 B -
3 L-W - 8 BR-Y -
4 B-G - 9 L-B -
5 - - 10 - -
E110 to Engine Control Wire Harness

1 G-W - 9 Y-G -
2 GR - 10 Y-B -
3 G - 11 B-Y -
4 GR-G - 12 Y -
5 G-R - 13 - -
6 BR-W - 14 - -
7 O - 15 B-Y -
8 L-O - 16 L -
F - ROOF WIRE HARNESS
71
71
F001 Rear Combination Lamp RH F002 Rear Combination Lamp LH 71

71
1 G-Y Turn Signal 1 G-B Turn Signal
71
2 G Tail Light 2 G Tail Light
3 G-W Stop Lamp 3 G-W Stop Lamp 71

71
71
71
71
F003 Front Dome Light F004 Rear Dome Light
71
1 R Power Supply 1 R Power Supply
71
2 W Output 2 R-Y Output 71
71
71
71
F005 Sliding Door Ajar Switch LH F009 Rear Washer Pump 71
71
1 Y Input 1 W-G Output
2 L Power Supply 71
71
F010 Rear Combination Lamp RH F011 Rear Combination Lamp LH

1 R-Y Back-up Lamp 1 R Back-up Lamp
2 L-W Fog Lamp 2 L-W Fog Lamp
3 G-W Stop Lamp 3 G-W Stop Lamp
4 G-Y Turn Signal 4 G-B Turn Signal
5 G Tail Light 5 G Tail Light
F100 to Instrument Panel Wire Harness

1 L - 12 L-Y -
2 R-Y - 13 L-B -
3 G - 14 R-L -
4 R - 15 L-W -
5 L-R - 16 R -
6 R - 17 W-B -
7 L - 18 L-Y -
8 W - 19 R-Y -
9 Y - 20 G-W -
10 W-G - 21 G-Y -
11 L-W - 22 G-R -
71
F101 to Instrument Panel Wire Harness 71

1 - - 6 - -
71
2 - - 7 Y-R -
3 W - 8 Y-G - 71
4 Y-G - 9 W-G - 71
5 - - 10 W-R -
71
71
71
F102 to Rear Hatch Wire Harness F105 to Rear Evaporator Wire Harness 71

1 G - 1 Y-G -
71
2 L-Y - 2 W -
3 W-B - 3 W-R - 71
4 R-Y - 4 W-G - 71
5 G-W - 5 W-B -
71
6 L-B - 6 L -
71
71
71
F104 to Fuel Tank Wire Harness F106 to Rear Hatch Wire Harness 71

1 W-B - 1 L -
2 W-B - 2 L-R -
3 Y-R - 3 L-W -
4 Y-G - 4 L-W -
5 - - 5 R-L -
6 L-Y - 6 R -
G - BATTERY NEGATIVE CABLE WIRE HARNESS
G001 Back-up Lamp Switch G100 to Engine Room Wire Harness

1 R-Y Output 1 R-L -
2 R-L Power Supply 2 R-Y -
3 R -
4 W-B -
5 - -
6 R-B -
G002 Vehicle Speed Sensor
1 R-B Output
2 W-B Ground
3 R Power Supply
H - FRONT DOOR RH WIRE HARNESS
71
71
H001 Front Door Lock Actuator RH H005 Outside Mirror RH 71

71
1 - - 1 - -
71
2 L-Y Unlock 2 BR-W Mirror (MH)
3 L-B Lock 3 GR-R Mirror (M+) 71

4 - - 4 R-Y Mirror (MV)
71
5 - -
71
71
71
H003 Front Power Window Motor RH
71
H100 to Instrument Panel Wire Harness 71
1 L-W Up
2 L-R Down 71
1 G-R -
71
2 R-L -
3 - - 71
4 L-Y -
71
5 BR-W -
H004 Front Power Window Switch RH 71
6 GR-R -
7 R-Y - 71
1 L-R -
8 L-B -
2 R-L - 71
3 L - 71
4 G-R -
5 L-W -
J - REAR HATCH WIRE HARNESS
J001 Rear Combination Lamp RH J002 Rear Combination Lamp LH

2 L-W Fog Lamp 2 L-W Fog Lamp
3 - - 3 - -
4 - - 4 - -
J003 License Lamp J004 Rear Combination Lamp RH

2 G Signal 2 R Back-up Lamp
J005 Rear Combination Lamp LH J006 High-mounted Stop Lamp

1 W-B Ground 1 G-W Signal
2 R Back-up Lamp 2 W-B Ground
J007 Rear Hatch Lock Actuator J009 Rear Wiper Motor

1 - - 1 L Power Supply
2 L-B Lock 2 W-B Ground
3 L-Y Unlock 3 L-W Limit Switch
4 - - 4 L-R Rrar Wiper

71
J010 Rear Window Defrost Grid J011 Rear Window Defrost Grid 71

1 L-W Input 1 W-B Ground
71
71
71
71
J101 to Roof Wire Harness J102 to Roof Wire Harness
71
71
1 G - 1 L -
2 L-Y - 2 L-R - 71
3 W-B - 3 L-W -
71
4 L-W - 4 G-W -
71
5 G-W - 5 - -
6 L-B - 6 R - 71
71
71
71
71
71
71
71
K - FRONT EVAPORATOR WIRE HARNESS
K001 A/C Amplifier

1 W-O Front Temperature 10 W-R Rear Temperautre
2 W-O Front Temperautre 11 L Front A/C Signal
3 R Power Supply 12 Y-L Rear A/C Signal
4 Y-B Power Supply 13 W-G Ground
5 - - 14 - -
6 R-Y Hi-low Pressure 15 W-B Ground
7 BR-L ACI 16 B Speed Signal
8 G Idle Signal 17 - -
9 W Rear Temperautre
K002 Front Inlet Air Sensor K004 CondenserFan Motor Fusible Link
1 W-O Temperature 1 W-R -
2 W-G Temperature 2 L-W -
K003 A/C Cut Off Relay K005 Condenser Fan Motor Low Speed Relay
1 B-W - 1 B-Y -
2 W-B - 2 R-B -
3 Y-B - 3 W-B -
4 GR - 4 Y -
71
71
K006 Rear Evaporator Motor Relay K008 Condenser Fan Motor High Speed Relay
1 Y-L - 1 B-W - 71
2 Y-B - 2 GR -
71
3 W-L - 3 Y -
4 W-B - 4 W-B - 71
5 L-B - 5 B-R 71
71
71
71
K007 A/C Request Relay K101 to Instrument Panel Wire Harness
71
1 R - 1 L-W - 71
2 Y-B - 2 B-W - 71
3 BR-L - 3 R -
71
4 O-W - 4 B-R -
5 R-B - 71
6 Y-B - 71
7 R-Y -
71
8 - -
71
71
71
K100 to Instrument Panel Wire Harness

1 L - 11 B-Y -
2 - - 12 L-B -
3 B - 13 - -
4 G - 14 R -
5 Y-L - 15 GR -
6 W - 16 W-B -
7 W-R - 17 W-L -
8 W-R - 18 B-Y -
9 W-G - 19 O-W -
10 B-W -
L - REAR EVAPORATOR WIRE HARNESS
71
71
L001 Rear A/C Switch L002 Rear Evaporator Blower Switch
71
71
1 - - 1 R-B HI Signal
2 - - 2 L-W I Signal 71
3 - - 3 Y-B LO Signal
71
4 - - 4 W-B Ground
71
5 - -
6 - - 71
7 Y-L Input
71
8 Y-B Output
L003 Rear Temperature Control Switch
71
9 - -
10 - - 71
1 W-Y Temperature
2 W-R Input 71
71
71
L005 Rear Evaporator Motor LH 71

L004 Rear Intake Sensor
1 W-R Output 1 R-B -

71
2 W-G Ground 2 R -
71
71
71
L006 Rear Evaporator Motor RH L007 Rear Evaporator Resistor
1 R-B - 1 R-B Power Supply
2 R-W - 2 W-B Output
3 L-W Ground
L100 to Roof Wire Harness

1 Y-L -
2 W-Y -
3 W-R -
4 W-G -
5 W-B -
6 L-B -
M - LEFT STEP WIRE HARNESS
71
71
M001 Step Lamp LH M101 to Engine Room Wire Harness 71

71
1 Y - 1 Y -
71
2 R-L - 2 R-L -
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
N - RIGHT STEP WIRE HARNESS
N001 Step Lamp RH N100 to Engine Room Wire Harness

1 Y - 1 Y -
2 R-L - 2 R-L -
P - FRONT SIDE REVERSE RADAR WIRE HARNESS
71
71
71
P001 Reverse Radar Control Unit
71
71
1 R Back-up Signal 9 W-B Ground
2 - - 10 Y LH Signal Input 71
3 - - 11 GR RH Signal Input
71
4 BR Sensor Power 12 P Data
71
5 W-R MID Signal Output 13 O Clock
6 GR-R RH Signal Output 14 - - 71

7 W-B Ground 15 - -
71
8 Y-R LH Signal Output 16 W MID Signal Input
71
71
71
71
P002 Combined Display 71

1 R-B Power Supply 9 G Illumination
71
2 W-B Ground 10 W-B Ground Points
3 P Data 11 O Clock 71
4 - - 12 - - 71
5 G-R Temperature+ 13 G-B Temperature-
71
6 L-R Temperature+ 14 L-B Temperature-
7 - - 15 - -
8 - - 16 - -
P003 In-vehicle Sensor P100 to Instrument Panel Wire Harness

1 L-R Temperature+ 1 W-B -
2 - - 2 R-B -
3 L-B Temperature- 3 G-B -
4 G-R -
5 R -
6 G -
P101 to Left Side Reverse Radar Wire Harness

1 BR - 9 W-B -
2 - - 10 - -
3 - - 11 - -
4 GR-R - 12 GR -
5 - - 13 - -
6 W-R - 14 W -
7 - - 15 - -
8 Y-R - 16 Y -
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS
71
71
71
Q100 to Front Side Reverse Radar Wire Harness
71
71
1 BR - 9 W-B -
2 - - 10 - - 71
3 - - 11 - -
71
4 GR-R - 12 GR -
71
5 - - 13 - -
6 W-R - 14 W - 71
7 - - 15 - -
71
8 Y-R - 16 Y -
71
71
71
71
Q101 to Reverse Radar Rear Bumper Wire Harness 71

1 BR - 9 W-B -
71
2 - - 10 - -
3 - - 11 - - 71
4 GR-R - 12 GR - 71
5 - - 13 - -
71
6 W-R - 14 W -
7 - - 15 - -
8 Y-R - 16 Y -
R - REVERSE RADAR REAR BUMPER WIRE HARNESS
R001 Reverse Radar Sensor LH R100 to Left Side Reverse Radar Wire Harness
1 BR Sensor Power 1 BR -
2 Y Output 2 - -
3 Y-R Input 3 - -
4 W-B Ground 4 GR-R -
5 - -
6 W-R -
7 - -
8 Y-R -
R002 Reverse Radar Sensor MID 9 W-B -
10 - -
11 - -
1 BR Sensor Power
12 GR -
2 W Output
13 - -
3 W-R Input
14 W -
4 W-B Ground
15 - -
16 Y -
R003 Reverse Radar Sensor RH

1 BR Sensor Power
2 GR Output
3 GR-R Input
4 W-B Ground
S - SIDE OF CHASSIS HARNESS
71
71
71
S001 ABS Module
71
71
1 Y-G Speed Signal 7 G-W Brake Signal
2 L-W Ground 8 B Parking Brake 71

3 P Limit Switch 9 - -
71
4 - - 10 R-B Power Supply
71
5 W-B Ground 11 Y-R ABS Indicator
6 G Pressure Relief Valve 12 LG Stop Valve 71
71
71
71
71
S100 to Engine Room Wire Harness S101 to Chassis Harness
1 W-B - 1 P - 71
2 R-B - 2 LG -
71
3 - - 3 Y-G -
4 B - 4 L-W - 71
5 Y-R - 5 W-B - 71
6 G-W - 6 G -
71
71
T - CHASSIS HARNESS
T001 Hydraulic Regulator Assembly T100 to Side of Chassis Harness

1 LG - 1 P -
2 P - 2 LG -
3 W-B - 3 Y-G -
4 G - 4 L-W -
5 W-B -
6 G -
T002 Vehicle Speed Sensor

1 Y-G -
2 L-W -
U - FUEL TANK WIRE HARNESS
71
71
71
U001 Fuel Level Sensor U100 to Roof Wire Harness
71
1 Y-R Sensor Power 1 W-B - 71
2 Y-G Fuel Level 2 W-B -
71
3 W-B Ground 3 Y-R -
71
4 Y-G -
5 - - 71
6 L-Y -
71
71
U002 Fuel Pump
71
1 L-Y Power Supply 71
2 W-B Ground
71
71
71
71
71
71
71
71
71-204 WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS
WIRE HARNESS & CONNECTOR LOCATION VIEWS

A - ENGINE ROOM WIRE HARNESS
B - BATTERY POSITIVE CABLE WIRE HARNESS
Engine Room Wire Harness - Connector

A001 Generator A011 Sliding Door Lock Actuator LH
A002 Generator (Voltage Regulator) A013 Fan Relay (HI)
A003 Electronic Fan A014 Fan Relay (LO)
A004 Front Door Ajar Switch RH A015 Fuel Pump Relay
A005 Sliding Door Lock Actuator RH A016 EFI Relay
A006 Coolant Level Sensor A017 Engine Control Fuse box
A007 Starter Relay A021 Fusible Link Box
A008 Front Door Ajar Switch LH A022 Fusible Link Box
A009 Electronic Fan Fusible Link Box A023 Body Junction Box
A010 Data Link Connector

WIRING - WIRE HARNESS & CONNECTOR LOCATION VIEWS 71-205
Engine Room Wire Harness - Inline

A101 to Instrument Panel Wire Harness A109 to Roof Wire Harness
A102 to Instrument Panel Wire Harness A110 to Side of Chassis Harness

71
A103 to Instrument Panel Wire Harness A112 to Battery Negative Cable Wire Harness
71
A106 to Engine Control Wire Harness A114 to Right Step Wire Harness
A107 to Engine Control Wire Harness A115 to Battery Positive Cable Wire Harness 71
A108 to Roof Wire Harness 71
Battery Positive Cable Wire Harness - Connector 71
B001 Battery B003 Starter 71

B002 Starter
71
Battery Positive Cable Wire Harness - Inline 71

B100 to Engine Room Wire Harness
71
Engine Control Wire Harness - Connector 71

00
E001 ECM (Engine Control Module) Manifold Absolute Pressure/Intake Air

E010
Temperature Sensor 71
E002 Fuel Injector 1
E013 Crankshaft Position Sensor
E003 Fuel Injector 2 71
E017 Upstream Oxygen Sensor
E004 Fuel Injector 3 71
E020 Ignition Coil
E005 Fuel Injector 4
E021 Coolant Temperature Sensor 71
E007 Throttle Position Sensor
E022 A/C Clutch
E008 Canister Solenoid Valve 71
E024 Engine Oil Pressure Switch
E009 Idle Air Control Valve 71
E025 Coolant Temperature Sensor
71
Engine Control Wire Harness - Inline 71
E100 to Engine Room Wire Harness E101 to Engine Room Wire Harness
71
71
Instrument Panel Wire Harness - Connector

C001 Front Fog Lamp RH C006 Front Combination Lamp LH
C002 Front Combination Lamp RH C007 Front Washer Pump
C003 Front Combination Lamp RH C010 Horn
C004 Front Fog Lamp LH C025 Condenser Fan Motor
C005 Front Combination Lamp LH C034 A/C Pressure Switch
Instrument Panel Wire Harness - Inline

C106 to Front Door LH Wire Harness C108 to Front Door LH Wire Harness
C107 to Front Door LH Wire Harness C109 to Front Door RH Wire Harness
71
71
71
71
71
71
71
71
71
71
71
71
71
71
Instrument Panel Wire Harness - Connector 71
C008 Combination Switch (Light Control) C022 Fuel Selection Switch 71

Combination Switch C023 Power Point Socket (Cigarette Lighter)
C009 71
(Wiper and Washer Control)
C024 Power Point Socket (Cigarette Lighter)
C026 Power Window Control Unit
C027 Front Blower Motor Resistor 71
C028 Front Blower Motor
C029 Front Wiper Motor
C015 Hazard Switch
C030 Power Door Lock Control Unit
C016 Blower Switch
C031 Rear Wiper Relay
C017 Front A/C Switch
C032 Ignition Switch
C019 Rear Window Defrost Switch
C033 Rear Dome Light Switch
C020 Outside Mirror Remote Control Switch
C035 Body Junction Box
C021 Radio
C036 Front Fog Lamp Switch
C037 Rear Fog Lamp Switch C053 Junction Connector
C038 Remote Keyless Entry Receiver C054 Junction Connector
C039 Brake Fluid Level Sensor C055 Junction Connector
C040 Front Speaker LH C061 Instrument Cluster
C041 Front Speaker RH C062 Instrument Cluster
C042 Turn Signal Flasher Relay C063 Instrument Cluster
C043 Parking Brake Switch C065 Junction Connector
C044 Stop Lamp Switch C066 Junction Connector

C101 to Engine Room Wire Harness C110 to Front Evaporator Wire Harness
C102 to Engine Room Wire Harness C111 to Front Evaporator Wire Harness
C103 to Engine Room Wire Harness C112 to Front Side Reverse Radar Wire Harness
71
71
71
71
71
71
71
71
71
71
71
71
71
71
Instrument Panel Wire Harness - Connector 71
C064 Coolant Level Sensor C082 Fusible Link Box

71
C070 Preheat Control Unit C083 Fusible Link Box
71
C071 Preheat Control Unit C084 Electronic Fan Fusible Link Box
C075 Generator C085 Fan Relay (LO) 71
C076 EGR Valve Control Unit C086 Fan Relay (HI)

71
C077 Fan Control Unit C087 Electronic Fan
71
C078 Data Link Connector C088 Engine Relay Box
C079 EGR Valve Lift Sensor C089 Generator
C080 EGR Vacuum Solenoid Valve C090 Sliding Door Ajar Switch RH
C081 Fusible Link Box


C116 to Engine Control Wire Harness C119 to Battery Positive Cable Wire Harness
C117 to Roof Wire Harness C121 to Right Step Wire Harness
C118 to Battery Negative Cable Wire Harness
Engine Control Wire Harness - Connector

E024 Engine Oil Pressure Switch E038 Coolant Temperature Sensor For Fan
E025 Coolant Temperature Sensor E039 KSB Valve
E035 Speed Sensor E040 Preheat Temperature Sensor
E036 EGR Coolant Temperature Sensor E041 Fuel Cut-off Solenoid Valve
E037 Throttle Position Sensor E042 Glow Plug
Engine Control Wire Harness - Inline

E110 to Instrument Panel Wire Harness
Battery Negative Cable Wire Harness - Connector

G001 Back-up Lamp Switch G002 Vehicle Speed Sensor
Battery Negative Cable Wire Harness - Inline

G100 to Engine Room Wire Harness
D - FRONT DOOR LH WIRE HARNESS
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
Front Door LH Wire Harness - Connector
71
D001 Front Door Lock Actuator Assembly LH D004 Main Power Window Lock/Unlock Switch
71
D002 Front Door Lock Actuator Assembly LH D005 Outside Mirror LH
D003 Front Power Window Motor LH 71
71
Front Door LH Wire Harness - Inline
D100 to Instrument Panel Wire Harness D102 to Instrument Panel Wire Harness 71
D101 to Instrument Panel Wire Harness

F - ROOF WIRE HARNESS

U - FUEL TANK WIRE HARNESS
Roof Wire Harness - Connector

F001 Rear Combination Lamp RH (4 pins) F005 Sliding Door Ajar Switch LH
F002 Rear Combination Lamp LH (4 pins) F009 Rear Washer Pump
F003 Front Dome Light F010 Rear Combination Lamp RH (6 pins)
F004 Rear Dome Light F011 Rear Combination Lamp LH (6 pins)
Roof Wire Harness - Inline

F100 to Instrument Panel Wire Harness F104 to Fuel Tank Wire Harness
F101 to Instrument Panel Wire Harness F105 to Rear Evaporator Wire Harness
F102 to Rear Hatch Wire Harness F106 to Rear Hatch Wire Harness
Rear Evaporator Wire Harness - Connector

L001 Rear A/C Switch L005 Rear Evaporator Motor LH
L002 Rear Evaporator Blower Switch L006 Rear Evaporator Motor RH 71

L003 Rear Temperature Control Switch L007 Rear Evaporator Resistor
71
L004 Rear Intake Sensor L008 Fuse Box
71
71
Rear Evaporator Wire Harness - Inline
L100 to Roof Wire Harness 71
Fuel Tank Wire Harness - Connector 71

U001 Fuel Level Sensor U002 Fuel Pump
71
71
Fuel Tank Wire Harness - Inline
71
U100 to Roof Wire Harness
71
71
71
71
71
71
71
71
71
71
71
H - FRONT DOOR RH WIRE HARNESS
Front Door RH Wire Harness - Connector

H001 Front Door Lock Actuator RH H004 Front Power Window Switch RH
H003 Front Power Window Motor RH H005 Outside Mirror RH
Front Door RH Wire Harness - Inline

H100 to Instrument Panel Wire Harness
J - REAR HATCH WIRE HARNESS

P - FRONT SIDE REVERSE RADAR WIRE HARNESS
71
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS
R - REVERSE RADAR REAR BUMPER WIRE HARNESS 71
S - SIDE OF CHASSIS HARNESS 71
T - CHASSIS HARNESS 71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
Rear Hatch Wire Harness - Connector 71

J001 Rear Combination Lamp RH (Fog Lamp) J007 Rear Hatch Lock Actuator
J002 Rear Combination Lamp LH (Fog Lamp) J008 Rear Hatch Ajar Switch
J003 License Lamp J009 Rear Wiper Motor
J004 Rear Combination Lamp RH (Back-up Lamp) J010 Rear Window Defrost Grid
J005 Rear Combination Lamp LH (Back-up Lamp) J011 Rear Window Defrost Grid
J006 High-mounted Stop Lamp

Rear Hatch Wire Harness - Inline

J101 to Roof Wire Harness J102 to Roof Wire Harness
Front Side Reverse Radar Wire Harness - Connector

P001 Reverse Radar Control Unit P003 In-vehicle Sensor
P002 Combined Display
Front Side Reverse Radar Wire Harness - Inline

P100 to Instrument Panel Wire Harness P101 to Left Side Reverse Radar Wire Harness
Front Side Reverse Radar Wire Harness - Inline

Q100 to Front Side Reverse Radar Wire Harness Q101 to Reverse Radar Rear Bumper Wire Harness
Reverse Radar Rear Bumper Wire Harness - Connector

R001 Reverse Radar Sensor LH R003 Reverse Radar Sensor RH
R002 Reverse Radar Sensor MID
Reverse Radar Rear Bumper Wire Harness - Inline

R100 to Left Side Reverse Radar Wire Harness
Side of Chassis Harness - Connector

S001 ABS Module
Side of Chassis Harness - Inline

S100 to Engine Room Wire Harness S101 to Chassis Harness
Chassis Harness - Connector

T001 Hydraulic Regulator Assembly T002 Vehicle Speed Sensor
Chassis Harness - Inline

T100 to Side of Chassis Harness
71
71
71
71
71
71
71
71
71
71
71
71
71
71
71
Front Evaporator Wire Harness - Connector 71

K001 A/C Amplifier K005 Condenser Fan Motor Low Speed Relay
71
K002 Front Inlet Air Sensor K006 Rear Evaporator Motor Relay
K003 A/C Cut Off Relay K007 A/C Request Relay 71
K004 Condenser Fan Motor Fusible Link K008 Condenser Fan Motor High Speed Relay
71
Front Evaporator Wire Harness - Inline 71
K100 to Instrument Panel Wire Harness K101 to Instrument Panel Wire Harness
MEMO
81
HORN ................................................................................................. 81-1
COMPONENTS ........................................................................... 81-2
REPLACEMENT .......................................................................... 81-3 81
81
11B
12B
14B
81
COMMUNICATION SYSTEM - HORN 81-1
HORN


Chapter 81 communication system - horn,
1. Horn (Damaged) replacement

2. Combination switch assy (Damaged) switch assy, replacement
Horn is inoperative
3. Horn switch (Damaged) assy, overhaul
4. Harness (Damaged) -

1. Combination switch assy (Damaged) switch assy, replacement
Horn is always on Chapter 51 steering column - steering wheel

2. Horn switch (Damaged) assy, overhaul
3. Harness (Damaged) -
81
81-2 COMMUNICATION SYSTEM - HORN
COMPONENTS
1 M8 Bolt 2 Horn
COMMUNICATION SYSTEM - HORN 81-3
REPLACEMENT
2. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replace-
81
memt”)
3. REMOVE HORN.
(a) Disconnect the horn connector.
(b) Remove the horn retaining bolt, then take out the horn.
4. INSTALL HORN.
(a) Tighten the horn retaining bolt.
(b) Connect the horn connector.
81
5. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replace-
memt”)
6. CHECK HORN OPERATION AFTER INSTALLATION. (Refer to “ Chapter 04 diagnostics - horn
system, check”)
MEMO
WINDSHIELD / WINDOWGLASS / REAR
VIEW MIRROR 82
POWER WINDOW.............................................................................. 82-1
COMPONENTS ........................................................................... 82-1
INSPECTION ............................................................................... 82-2
REPLACEMENT .......................................................................... 82-3 82
WINDSHIELD ..................................................................................... 82-6
COMPONENTS ........................................................................... 82-6
REPLACEMENT .......................................................................... 82-7
REAR WINDOW GLASS.................................................................. 82-10 82
COMPONENTS ......................................................................... 82-10
REPLACEMENT ........................................................................ 82-11
SIDE WINDOW GLASS ................................................................... 82-13
COMPONENTS ......................................................................... 82-13
REPLACEMENT ........................................................................ 82-14
REAR VIEW MIRROR ...................................................................... 82-15
COMPONENTS ......................................................................... 82-15
REPLACEMENT ........................................................................ 82-16
11B
12B
14B
14B
82
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - POWER WINDOW 82-1
POWER WINDOW
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR
COMPONENTS
82
1 Bolt 3 Front Power Window Motor LH
2 Front Power Window Motor RH
82
82-2 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - POWER WINDOW
INSPECTION
NOTE
Inspect the RH side by the same procedures as the LH side.
1. CHECK POWER WINDOW MOTOR FOR DEFORMATION.
(a) If there is any deformation, replace it with a new one.
2. CHECK ROLLER FOR WEAR AND DEFORMATION.
(a) Check roller for wear and deformation.
(b) If there are any wear and deformation, replace the power window motor with a new one.
3. CHECK ROCKER ARM RATCHET (MANUAL OPERATION).
(a) If the fit clearance between the rocker arm ratchet and rocker arm is excessive or malposition, replace
it with a new window regulator.
4. CHECK ROCKER ARM SHAFT (MANUAL OPERATION).
(a) Rotate rocker arm, it should be smooth and no “click”. Otherwise, replace it with a new window regula-
tor.
5. CHECK BASIC FUNCTION (AUTO OPERATION).
(a) Turn on the ignition switch and check when turning the window switch UP or DOWN, the glass will
move UP or DOWN automatically.
REPLACEMENT
NOTE
Replace the RH side by the same procedures as the LH side
82
2. REMOVE FRONT DOOR INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and interior
reim - vehicle door inner guard board, replacement”)

NOTE
• When disconnecting or connecting the battery cables,
please first turn off the ignition switch and lighting
switch and completely loosen the cable nut. Do not
pry up the cable when peforming these operation.
• For the vehicle equipped with the power door locks,
before disconnecting the battery negative cable, do
not leave the key in the vehicle to avoid the door
being locked.
4. REMOVE FRONT POWER WINDOW MOTOR LH.

(a) Remove front door water-proof film.
(b) Turn the ignition switch ON and connect the front door
controller connectors. Lower the glass to a proper position,
and loosen 2 retaining bolts of the power window motor
LH.
(c) Carefully take out the glass.
(d) Turn the ignition switch OFF and disconnect the front
door controller connector.
82
(e) Disconnect the connector of the front power window
motor LH.
82-4 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - POWER WINDOW
(f) Loosen 6 front power window motor LH retaining bolts.

(g) Carefully take out front power window motor LH.
5. INSTALL FRONT POWER WINDOW MOTOR LH.

(a) Position the front power window motor LH properly.
(b) Tighten 6 front power window motor LH retaining bolts.
(c) Connect the connector of the front power window motor

LH.
(d) Position the glass properly.

(e) Tighten 2 power window motor LH retaining bolts.
(f) Install front door water-proof film.

6. INSTALL FRONT DOOR INNER GUARD BOARD LH. (Refer to “Chapter 88 exterior and interior
reim - vehicle door inner guard board, replacement”)
8. REMOVE FRONT POWER WINDOW MOTOR RH. 82
NOTE
82
82-6 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - WINDSHIELD
WINDSHIELD
COMPONENTS
1 Windshield Glass 2 Windshield Weatherstrip

WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - WINDSHIELD 82-7
REPLACEMENT
1. REMOVE SUN VISOR ASSY. (Refer to “Chapter 88 exterior and interior trim - sun visor assy,
replacement”)
82
2. REMOVE REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,
replacement”)
3. REMOVE FRONT WINDSHIELD WEATHERSTRIP.

(a) Remove front wiper arm.
(b) Insert a screwdriver between the weatherstrip and joint

cover to pry it out.
NOTE
Tape the screwdriver tip before using.
(c) Remove the windshield weatherstrip from the end with

the screwdriver or similar tool.
(d) Pull the windshield weatherstrip with your hand.

(e) Remove the front windshield glass.
82
NOTE
Front windshield weatherstrip, one end fixes the galss, the
other fixes the frame. When removing the weatherstrip, the
windshield will be also removed.
82-8 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - WINDSHIELD
4. INSTALL WINDSHIELD.
(a) Install the windshield with double-stick tape as shown in
the illustration.
(b) Install the windshield glass weatherstrip as shown in the
illustration.
NOTE
Do not touch the glass surface after cleaning it.
5. INSTALL GLASS.
NOTE
Confirm that the windshield is attached body panel as
(a) Position the glass so that the reference marks are lined
up, and press in gently along the edge.
6. INSTALL FRONT WINDSHIELD WEATHERSTRIP.

(a) Insert the edge of the windshield onto the weatherstrip.
(b) Using a rubber hammer, tap the weatherstrip to make it
in position.
NOTE
Tape the screwdriver tip before using.
7. INSPECT FOR WATER LEAKAGE.

(a) Take the leakage test after the hardening period.
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - WINDSHIELD 82-9
8. INSTALL SUN VISOR ASSY. (Refer to “Chapter 88 exterior and interior trim - sun visor assy,
replacement”)
9. INSTALL REAR VIEW MIRROR ASSY. (Refer to “Chapter 82 windshield - rear view mirror,
replacement”) 82
82
82-10 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR WINDOW GLASS
REAR WINDOW GLASS

COMPONENTS
1 Rear Window Weatherstrip 2 Rear Window Glass

WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR WINDOW GLASS 82-11
REPLACEMENT
1. REMOVE REAR WIPER ARM ASSY IF EQUIPPED. (Refer to “Chapter 65 wiper and washer -
wiper assy, replacement”)
82
2. REMOVE REAR HATCH LOWER INNER GUARD BOARD ASSY. (Refer to “Chapter 88 exterior
and interiror trim - vehicle door inner guard board, replacement”)
3. DISCONNECT REAR WINDOW DEFROST GRID CONNECTOR.
4. REMOVE REAR WINDOW GLASS BY THE SAME PROCEDURES AS FRONT WINDSHIELD.
5. POSITION GLASS.
(a) Using a suction rubber, place the glass in the correct
position as shown in the illustration.
(b) Check that all connecting parts of the glass edge are per-
fectly even.
(c) Place reference marks between the glass and body.
(d) Remove the glass.
6. CLEAN GLASS CONTACT SURFACE.

(a) Clean the window frame black contact area with cleaning
solvent.
NOTE
Do not touch the glass after cleaning it.
7. INSTALL WINDSHIELD.
(a) Install the windshield with double-stick tape as shown in
the illustration.
(b) Install the windshield glass weatherstrip as shown in the
illustration.
NOTE
Do not touch the glass face after cleaning it.
82
8. INSTALL GLASS.
NOTE
Confirm that the windshield is attached body panel as
82-12 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR WINDOW GLASS
(a) Position the glass so that the reference marks are lined
up, and press in gently along the edge.
9. INSTALL FRONT WINDSHIELD WEATHERSTRIP.

(a) Insert the edge of the windshield onto the weatherstrip.
(b) Using a rubber hammer, tap the weatherstrip to make it
in position.
10. INSPECT FOR WATER LEAKAGE.

(a) Take the leakage test after the hardening period.
11. CONNECT REAR WINDOW DEFROST GRID CONNECTOR.

12. INSTALL REAR HATCH LOWER INNER GUARD BOARD ASSY. (Refer to “Chapter 88 exterior
and interiror trim - vehicle door inner guard board, replacement”)
13. INSTALL REAR WIPER ARM ASSY IF EQUIPPED. (Refer to “Chapter 65 wiper and washer - wiper
assy, replacement”)
NOTE
• After installing rear window glass, park the vehicle on a flat ground for more than four hours. If
run the car at this moment, slowly drive the car in eight hours.
• When all the windows are closed, do not close the door rudely.
• After installing rear window glass, do not be over-load in two to three days. (As drive in irregular,
uneven road.)
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - SIDE WINDOW GLASS 82-13
SIDE WINDOW GLASS

COMPONENTS
82
1 Rear Side Window Assy RH 3 Rear Side Window Assy LH
2 Front Side Window Assy LH
82
82-14 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - SIDE WINDOW GLASS
REPLACEMENT
1. REMOVE SIDE WINDOW GLASS.
(a) Using a screwdriver, pry up the glass weatherstrip.
(b) Push out the lip of the weatherstrip from the room side.
(c) Push on the glass with your hands from the room side to remove it.
(d) Remove the glass stop.
(e) Lightly tap the window frame with your hand, then remove the frame with the center sash.
(f) Pull apart the sash and remove the glass.
2. INSTALL SIDE WINDOW GLASS.
(a) Before installing, check rubber surface for leafing, crazing, bubble, pit, concave-convex and so on
flaws.
(b) Take out the glass from the package. Pick up the glass and weatherstrip together by one hand and the
glass bottom by the other hand, then put the glass on the bracket.
(c) Insert the cord to the side window glass slot.
(d) Install the side window glass to window frame. Pull the cord and tap it with rubber hammer, and confirm
that embed rubber strip in vehicle body seals.
(e) In room, tensioning two sides of the cord and pull it out from the weatherstrip at a uniform speed, and
tap the glass with rubber hammer to make the weatherstrip encase the window stop.
NOTE
• When all the windows are closed, do not close the door furiously.
• After installing side window glass, park the vehicle on a flat ground for more than four hours. If
run the car at this moment, slowly drive the car in eight hours.
• After installing side window glass, do not be over-load in two to three days. (As drive in irregular,
uneven road.)
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR VIEW MIRROR 82-15
REAR VIEW MIRROR

COMPONENTS
82
1 Screw 4 Inside Rear View Mirror
2 Bush 5 Screw
3 Outside Rear View Mirror RH 6 Outside Rear View Mirror LH

82
82-16 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR VIEW MIRROR
REPLACEMENT
trim - vehicle door inner guard board, replacement”)
2. REMOVE OUTSIDE REAR VIEW MIRROR LH.

(a) Disconnect outside rear view mirror LH connector.
(b) Loosen 3 retaining bolts.

(c) Remove outside rear view mirror LH.
3. INSTALL OUTSIDE REAR VIEW MIRROR LH.

(a) Tighten 3 retaining bolts.
(b) Connect outside rear view mirror LH connector.
5. CHECK IF ELECTRIC REAR VIEW MIRROR FUNCTION IS NORMAL.
WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR VIEW MIRROR 82-17
6. REMOVE OUTSIDE REAR VIEW MIRROR RH.

NOTE
82
7. REMOVE INSIDE REAR VIEW MIRROR.
(a) Using a screwdriver, remove inside rear view mirror cover.
(b) Loosen 3 screws and remove inside rear view mirror.
(c) Disconnect the connector.
8. INSTALL INSIDE REAR VIEW MIRROR.

(a) Connect the connector.
82
82-18 WINDSHIELD/WINDOWGLASS/REAR VIEW MIRROR - REAR VIEW MIRROR
(b) Position inside rear view mirror properly and tighten 3

screws.
(c) Install inside rear view mirror cover.
9. CHECK IF INSIDE REAR VIEW MIRROR FUNCTION IS NORMAL.

INSTRUMENT PANEL
83
DASHBOARD..................................................................................... 83-1
PRECAUTION.............................................................................. 83-1
COMPONENTS ........................................................................... 83-2
REPLACEMENT .......................................................................... 83-4 83
INSTRUMENT CLUSTER ................................................................ 83-12
PRECAUTION............................................................................ 83-12
COMPONENTS ......................................................................... 83-13
REPLACEMENT ........................................................................ 83-14 83
11B
12B
14B
83
INSTRUMENT PANEL - DASHBOARD 83-1
DASHBOARD
INSTRUMENT PANEL
PRECAUTION
1. WHEN REMOVING INSTRUMENT PANEL, MEMORY OF THE AUDIO SYSTEM WILL BE LOST. 83
NOTE
When work is finished, reset the audio systems as they were before. (Refer to “OWNER’S MANUAL”)
2. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to
(b) Make sure ingition switch is OFF if no specific instructions.
83
83-2 INSTRUMENT PANEL - DASHBOARD
COMPONENTS
LHD
1 Bolt 4 Dashboard Assy
2 Nut 5 Dashboard Bracket RH
3 Dashboard Beam Assy 6 Dashboard Beam Bracket

RHD
83
1 Bolt 4 Dashboard Assy
2 Nut 5 Dashboard Bracket RH
3 Dashboard Beam Assy 6 Dashboard Beam Bracket

83
REPLACEMENT
NOTE
Remove the RHD dashboard by the same procedures as the LHD.
1. PLACE VEHICLE ON LEVEL OR LIFTER AND FACE TIRES STRAIGHT AHEAD.

NOTE
please turn off the ignition switch first and lighting switch
and loosen the cable nut completely. Do not pry up the
cable when peforming these operations。
overhaul”)
6. REMOVE STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column - steering
column assy, overhaul”)
7. REMOVE DASHBOARD ASSY.
(a) Loosen 6 screws and remove the instrument cluster

cover.
83
(b) Pry up the instrument cluster cover and disconnect 6

connectors.
(c) Take out the instrument cluster cover.
(d) Loosen instrument cluster 4 screws.
(e) Take out the instrument cluster and disconnect 4 connec-

tors.
83
(f) Loosen the vent duct LH 2 screws and remove the vent
duct LH.
(g) Loosen the dashboard bracket 1 screw.
(h) Open the glove box RH and loosen 2 lower screws.

(i) Remove the glove box RH as the illustration shows.
(j) Loosen 4 screws.

(k) Disconnect the speaker connector.
(l) Remove the speaker cover.
(m) Loosen 3 screws and remove the evaporator lower guard

board.
(n) Loosen 2 screws and remove the dashboard vent duct

MID.
83
(o) Remove the A/C controller. (Refer to “Chapter 61 heater

and air conditioning - air controller, replacement”)
(p) Remove the radio assy. (Refer to “Chapter 66 audio
system - radio assy, replacement”)
(q) Loosen 5 bolts and 1 screws and take out the dashboard
carefully.
83
NOTE
Because there are many harnesses in the instrument panel,
when removing the instrument panel, be careful not to hook
the harness, so as not to damage the harness.
8. INSTALL DASHBOARD ASSY.
(a) Position the dashboard body properly.

(b) Put the inside harness in order and wait for using when
installing dashboard accessories.
(c) Tighten 5 bolts and 1 screw.
(d) Install the radio assy. (Refer to “Chapter 66 audio system
- radio assy, replacement”)
(e) Install the A/C controller. (Refer to “Chapter 61 heater
and air conditioning - air controller, replacement”)
(f) Install the dashboard vent duct MID and tighten 2 screws.
(g) Install the evaporator lower guard board and tighten 3 screws.
(h) Connect the speaker connector.

(i) Install the speaker cover.
(j) Tighten 4 screws.
83
(k) Install the glove box RH and tighten 2 lower screws.
(l) Tighten the dashboard bracket screw.
(m) Install the vent duct LH and tighten 2 screws.
83
(n) Connect the instrument cluster 4 connectors and turn on

the ignition switch to check if the functions are normal.
(o) Install the instrument cluster assy and tighten 4 screws.
(p) Connect 6 connectors and install the instrument cluster

cover to right position.
83
(q) Tighten instrument cluster cover 6 screws.

overhaul”)
(a) Inspect the dashboard switch function and combination switch function.
83
83-12 INSTRUMENT PANEL - INSTRUMENT CLUSTER
INSTRUMENT CLUSTER
PRECAUTION
1. POWER OFF.
(a) Before removing or installing any electrical devices, please disconnect the battery negative cable to
(b) Make sure ingition switch is OFF if no specific instructions.
INSTRUMENT PANEL - INSTRUMENT CLUSTER 83-13
COMPONENTS
83
1 Instrument Cluster Assy 4 Screw
2 Screw 5 Washer
3 Odometer Sensor 6 Fuel Level Sensor

83
REPLACEMENT

NOTE
please turn off the ignition switch first and lighting switch
and loosen the cable nut completely. Do not pry up the
cable when peforming these operations。
overhaul”)
6. REMOVE INSTRUMENT CLUSTER.
(a) Loosen 6 screws and remove the instrument cluster

cover.
83
(b) Pry up the instrument cluster cover and disconnect 6

connectors.
(c) Take out the instrument cluster cover.
(d) Loosen instrument cluster 4 screws.
(e) Take out the instrument cluster and disconnect 4 connec-

tors.
83
7. INSTALL INSTRUMENT CLUSTER.

(a) Connect the instrument cluster 4 connectors and turn on
the ignition switch to check if the functions are normal.
(b) Install the instrument cluster assy and tighten 4 screws.
(c) Connect 6 connectors and install the instrument cluster

cover to right position.
83
(d) Tighten instrument cluster cover 6 screws.

overhaul”)
83
MEMO
SEAT
84
SEAT .................................................................................................. 84-1
PRECAUTION.............................................................................. 84-1
DRIVER / ASSISTANT DRIVER SEAT.............................................. 84-2
COMPONENTS ........................................................................... 84-2 84
ADJUSTMENT ............................................................................. 84-3
REMOVAL & INSTALLATION AND
DISASSEMBLY & ASSEMLBY .................................................... 84-8
PASSENGER SEAT......................................................................... 84-15 84
COMPONENTS ......................................................................... 84-15
REMOVAL & INSTALLATION.................................................... 84-17
11B
12B
84
SEAT - SEAT 84-1
SEAT
SEAT
PRECAUTION
WARNING 84
• Never adjust the seat when vehicle is moving.
• After adjusting the seat position fore-and-aft, be sure to attempt to slide the seat with track
handle released and make sure the seat is locked completely.
• After adjusting the angle of backrest, be sure to attempt to recline the backrest backward and
make sure the backrest is locked completely.
• Never move the vehicle before all pasengers sitting down properly.
• When vehicle is moving, make sure the backrest is locked completely. Be sure to wear seat belt
correctly and lean the backrest. Never sit on a folding seat or in the trunk.
• Do not stand and ambulate when vehicle is moving.
• Never place objects under the seat. Otherwise it will affect the performance of seat adjuster,
even cause the seat slide unexpectedly.
84
84-2 SEAT - DRIVER / ASSISTANT DRIVER SEAT
DRIVER / ASSISTANT DRIVER SEAT

COMPONENTS
1 Driver Seat Assy 2 Assistant Driver Seat Assy

SEAT - DRIVER / ASSISTANT DRIVER SEAT 84-3
ADJUSTMENT
1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”)
2. PRECAUTION ON DRIVER SEAT ADJUSTMENT.
84
(a) Slide the driver seat backward as much as possible on the premise that the driver can push the pedal
comfortably.
(b) If necessary, adjust the angle of driver seat backrest to keep the distance between steering wheel and
your chest above 250 mm.
3. ADJUST HEADREST HEIGHT.

(a) Press the lock button and hold it.
(b) Move the headrest up or down to the comfortable posi-

tion.
(c) Release the lock button.
84
(d) Attempt to move the headrest up and down to make sure

the headrest is locked completely.
NOTE
If hear a “click”, the headrest is locked completely.
4. ADJUST FORE-AND-AFT POSITION.

(a) Pull the handle up and hold it.
(b) Slide the seat forward or rearward to the comfortable

position.
(c) Release the handle.
84
(d) Attempt to slide the seat forward and rearward to make

sure the seat is locked completely.
NOTE
If hear a “click”, the seat is locked completely.
84
5. ADJUST BACKREST RECLINING.

(a) Pull the reclining adjuster handle up.
(b) Recline the backrest forward or rearward to the comfort-

able position.
(c) Release the reclining adjuster handle.
84
(d) Attempt to recline the backrest rearward to make sure

the backrest is locked completely.
NOTE
The backrest can not be moved, if it locked completely.
84
REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMLBY

WARNING
Be sure to wear gloves when performing operations below.
NOTE
Tape the screwdriver tip before removing parts.
1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”)
2. REMOVE DRIVER SEAT ASSY.

(a) Remove 2 screws and extinguisher bracket.
(b) Release the lock catch of drive seat side.

NOTE
Total two locks exist.
(c) Rotate the drive seat and support it with braket rod.
(d) Remove the driver seat assy.

(e) Remove nuts and separate the driver seat and engine
cover.
WARNING 84
Care must be taken because the driver seat assy is quite
heavy.
NOTE
• Do not score surfaces of parts around.
• Do not move the tracks when storing to prevent mal-
position.
3. REMOVE ASSISTANT DRIVER SEAT ASSY.

(a) Remove the bolts of assistant driver seat at rear side.
(b) Remove the bolts of assistant driver seat at front side.

NOTE
Make sure the seat will be removed carefullt. At the same
time, another operator is needed to support the assistant
drive seat with hands temporarily.
84
(c) Remove the assistant driver seat assy.

WARNING
Care must be taken because the seat assy is quite heavy.
NOTE
• Do not move the tracks when storing to prevent mal-
position.
4. DISASSEMBLE DRIVER SEAT ASSY.

(a) Remove the screw.
NOTE
Do not move the tracks when performing operations to
prevent malposition.
(b) Pull out the reclining adjuster handle cover.
(c) Remove screws.
(d) Press the lock button and hold it.
(e) Pull out the headrest.

(f) Remove the backrest.
5. DISASSEMBLE ASSISTANT DRIVER SEAT ASSY.

NOTE
Disassemble the assistant driver seat assy by the same procedures as the driver seat assy.
84
6. ASSEMBLE DRIVER SEAT ASSY.
(a) Press the lock button and hold it.
(b) Insert the headrest.
(c) Install the reclining adjuster trim cover.
(d) Install the reclining adjuster handle cover. 84

(e) Tighten the screw.
7. ASSEMBLE ASSISTANT DRIVER SEAT ASSY.

NOTE
Assemble the assistant driver seat assy by the same procedures as the driver seat assy.
8. INSTALL DRIVER SEAT ASSY.

WARNING
Care must be taken because the driver seat assy is quite heavy.
CAUTION
• Do not move the tracks to prevent malposition.
(a) Make sure the driver seat moving track for both sides is
aligned.
(b) Turn over the engine cover and support it with braket rod.
(c) Tighten 4 nuts.

NOTE
• Make sure the seat moving track for both sides are at
the same position.
• Do not move the moving track to prevent malposition.
(d) Lower the driver seat and lock the lock catch.
NOTE
Total two locks exist.
(e) Position the extinguisher bracket properly and tighten

screws.
84
9. INSTALL ASSISTANT DRIVER SEAT ASSY.

WARNING
NOTE
Do not score surfaces of parts around.
(a) Install the bolts of assistant driver seat at rear side.

NOTE
Do not tighten bolts.
84
(b) Install the bolts of assistant driver seat at front side.

NOTE
Tighten bolts including in step (a).
10. ADJUST DRIVER / ASSISTANT DRIVER SEAT ASSY. (Refer to “Chapter 84 seat - driver /
assistant driver seat, adjustment”)
SEAT - PASSENGER SEAT 84-15
PASSENGER SEAT
COMPONENTS
FIXED 84
1 Bolt 6 Second Row Seat Assy
2 Nut 7 Single Seat Assy
3 Bolt 8 Third Row Seat Assy

84
4 Folding Seat Assy 9 Three Seats Assy
5 First Row Seat Assy

84-16 SEAT - PASSENGER SEAT
ROTARY
1 First Row Rotary Seat Assy 4 Nut
2 Second Row Rotary Seat Assy 5 Rotary Seat Hook Assy
3 Bolt
SEAT - PASSENGER SEAT 84-17
REMOVAL & INSTALLATION

1. PRECAUTION. (Refer to “Chapter 84 seat - seat, precaution”))
2. REMOVE PASSENGER SEAT ASSY. 84

(a) Rotary passenger seat:
• Pull the handle up, disconnect the seat and seat hook
and turn over the seat.
• Remove bolts.
(b) Remove the rotary passenger seat.

WARNING
NOTE
(c) Fixed passenger seat:

• Remove bolts.
• Remove the fixed passenger seat.
WARNING
Care must be taken because the seat assy is quite heavy. 84
NOTE
3. INSTALL PASSENGER SEAT ASSY.

WARNING
NOTE
84-18 SEAT - PASSENGER SEAT
(a) Rotary passenger seat:

• Position the seat properly.
• Tighten bolts.
• Turn over the seat and connect the seat and seat hook.
NOTE
If hear a “click”, the seat is installed completely.
(b) Fixed passenger seat:

• Position the seat properly.
• Tighten Bolts.
DOOR LOCKS
85
FRONT DOOR LOCKS ...................................................................... 85-1
COMPONENTS ........................................................................... 85-1
REPLACEMENT .......................................................................... 85-2
SLIDING DOOR LOCKS .................................................................... 85-7 85
COMPONENTS ........................................................................... 85-7
REPLACEMENT .......................................................................... 85-8
REAR HATCH LOCK ....................................................................... 85-13
COMPONENTS ......................................................................... 85-13 85
REPLACEMENT ........................................................................ 85-14
11B
85
DOOR LOCKS - FRONT DOOR LOCKS 85-1
FRONT DOOR LOCKS

DOOR LOCKS
COMPONENTS
85
1 Inside Handle Assy RH 9 Inside Handle Assy LH
2 Front Door Inside Handle Bezel RH 10 Front Door Inside Handle Bezel LH
3 Guiding Buckle 11 Lock Assy LH

85
4 Lock Assy RH 12 Lock Cylinder LH
5 Key Cylinder RH 13 Outside Handle Assy LH
6 Outside Handle Assy RH 14 Front Door Inside Lock Rod LH
7 Door Lock Rod RH 15 Door Lock Rod LH
8 Guiding Buckle 16 Door Striker Assy

85-2 DOOR LOCKS - FRONT DOOR LOCKS
REPLACEMENT
NOTE

NOTE
• When disconnecting or connecting the battery cable,
first turn off the ignition switch and lighting switch
and completely loosen the cable nut. Do not pry up
the cable when peforming these operation.
being locked.
4. REMOVE FRONT DOOR LOCK ASSY LH.

(a) Remove the front door water-proof film.
(b) Disconnect the front door lock actuator LH connectors.

(c) Disconnect the front door lock connecting rods.

NOTE
Do not damage the connecting rod plastic clamp.
(d) Loosen 3 front door actuator LH retaining screws.
85
(e) Remove the front door actuator LH.
5. INSPECT FRONT DOOR ACTUATOR ASSY LH. (Refer to “Chapter 04 diagnostics - power door
locks”)
6. REMOVE INSIDE HANDLE LH.

(a) Disconnect the inside handle LH connecting rod.
(b) Loosen 2 bolts and remove the inside handle LH.
85
7. REMOVE OUTSIDE HANDLE LH.

(a) Disconnect the outside handle LH connecting rod.
(b) Loosen the retaining screw and remove the inside han-
dle LH.
(c) Remove the outside handle LH.
NOTE
Do not damage the connecting rod plastic clamp.
8. INSTALL OUTSIDE HANDLE LH.

(a) Position the outside handle LH properly.
(b) Tighten the outside handle LH retaining screw.
(c) Connect the outside handle LH connecting rod.
9. INSTALL INSIDE HANDLE LH.

(a) Tighten 2 bolts and install inside handle LH.
(b) Connect the inside handle LH connecting rod.
85
10. INSTALL FRONT DOOR LOCK ASSY LH.

(a) Position the front door lock actuator properly.
(b) Tighten 3 front door actuator LH retaining screws.
(c) Connect the front door lock connecting rods.
85
(d) Connect the front door lock actuator LH connectors.
(e) Install the front door water-proof film.
13. INSPECT FRONT DOOR LOCK/UNLOCK WITH KEY.
NOTE
• For the vehicle equipped with the power door locks, before disconnecting the battery negative
cable, do not leave the key in the vehicle to avoid the door being locked.
• For the vehicle equipped with the power door locks, when inspecting front door LH lock and
unlock, both the slidind door and the front door RH should be activated simultaneously.
DOOR LOCKS - SLIDING DOOR LOCKS 85-7
SLIDING DOOR LOCKS

COMPONENTS
85
85
1 Sliding Door Inside Handle Assy 4 Sliding Door Lock Cylinder Assy
2 Sliding Door Lock Actuator Assy 5 Sliding Door Lock And Control Rod Assy
3 Sliding Door Outside Handle Assy 6 Lock Rod Assy

85-8 DOOR LOCKS - SLIDING DOOR LOCKS
REPLACEMENT
NOTE

NOTE
being locked.
3. REMOVE SLIDING DOOR LOWER INNER GUARD BOARD ASSY RH. (Refer to “Chapter 88 exte-
rior and interior trim - vehicle door inner guard board, replacement”)
4. REMOVE SLIDING DOOR INSIDE HANDLE RH.

(a) Using a screwdriver, pry up the sliding door inside handle
screw cover.
(b) Loosen the sliding door inside handle RH screws.

(c) Disconnect the sliding door inside handle connecting rod
RH.
(d) Remove sliding door inside handle RH.
5. REMOVE SLIDING DOOR LOCK ACTUATOR RH.

(a) Remove the water-proof film.
(b) Disconnect the sliding door lock actuator RH connector.
85
(c) Disconnect the sliding door lock actuator RH connecting

rods.
(d) Loosen 4 sliding door lock actuator RH retaining bolts.
(e) Remove the sliding door lock actuator RH.
85
6. INSPECT SLIDING DOOR LOCK ACTUATOR RH. (Refer to “Chapter 04 diagnostics - power door
locks”)
7. REMOVE SLIDING DOOR LOCK RH.

(a) Disconnect the sliding door lock RH connecting rods .
(b) Remove 3 sliding door lock RH retaining bolts.
(c) Remove the sliding door lock RH.
8. INSTALL SLIDING DOOR LOCK RH.

(a) Position the sliding door lock RH properly.
(b) Tighten 3 sliding door lock RH retaining bolts.
(c) Connect the sliding door lock RH connecting rods.
9. INSTALL SLIDING DOOR LOCK ACTUATOR RH.

(a) Position the sliding door lock actuator RH properly.
(b) Tighten 4 sliding door lock actuator RH retaining bolts.
(c) Connect the sliding door lock actuator RH connecting
rods.
(d) Connect the sliding door lock actuator RH connector.
85
(e) Install the water-proof film.
10. INSTALL SLIDING DOOR INSIDE HANDLE RH.

(a) Connect the sliding door inside handle connecting rod
RH. 85
(b) Tighten the sliding door inside handle RH screws.
(c) Install the sliding door inside handle screw cover.

11. INSTALL SLIDING DOOR LOWER INNER GUARD BOARD ASSY RH. (Refer to “Chapter 88 exte-
rior and interior trim - vehicle door inner guard board, replacement”)
13. INSPECT SLIDING DOOR LOCK/UNLOCK WITH KEY.
NOTE
• For the vehicle equipped with the power door locks, before disconnecting the battery negative
cable, do not leave the key in the vehicle to avoid the door being locked.
• For the vehicle equipped with the power door locks, when inspecting sliding door LH lock and
unlock, the front doors should be activated simultaneously.
DOOR LOCKS - REAR HATCH LOCK 85-13
REAR HATCH LOCK

COMPONENTS
85
1 Rear Hatch Door Lock Cylinder Assy 3 Door Striker Assy
2 Rear Hatch Door Lock Actuator Assy 4 Rear Hatch Door Lock Assy
85
85-14 DOOR LOCKS - REAR HATCH LOCK
REPLACEMENT

NOTE
being locked.
3. REMOVE REAR HATCH LOWER INNER GUARD

BOARD ASSY.
(a) Loosen 10 screws and remove the rear hatch lower inner
guard board.
4. REMOVE REAR HATCH LOCK ACTUATOR ASSY.

(a) Disconnect the rear hatch lock actuator connector.
(b) Disconnect the rear hatch lock actuator connecting rods.

DOOR LOCKS - REAR HATCH LOCK 85-15
(c) Loosen the rear hatch lock actuator 3 retaining bolts.

(d) Remove the rear hatch lock actuator.
85
5. INSPECT REAR HATCH LOCK ACTUATOR. (Refer to “Chapter 04 diagnostics - power door
locks”)
6. REMOVE REAR HATCH LOCK ASSY.

(a) Disconnect the rear hatch lock connecting rod.
(b) Loosen 3 rear hatch lock retaining bolts.
(c) Remove the rear hatch lock assy.
7. INSTALL REAR HATCH LOCK ASSY.

(a) Connect the rear hatch lock connecting rod.
(b) Position the rear hatch lock assy properly.
(c) Tighten 3 rear hatch lock retaining bolts.
85
8. INSTALL REAR HATCH LOCK ACTUATOR ASSY.
(a) Position the rear hatch lock actuator assy properly.
(b) Tighten 3 rear hatch lock actuator retaining bolts.
85-16 DOOR LOCKS - REAR HATCH LOCK
(c) Connect the rear hatch lock actuator connecting rods.
(d) Connect the rear hatch lock actuator connector.
9. INSTALL REAR HATCH LOWER INNER GUARD BOARD

ASSY.
(a) Install the rear hatch lower inner guard board.

11. INSPECT REAR HATCH LOCK/UNLOCK WITH KEY.
NOTE
For the vehicle equipped with the power door locks, before disconnecting the battery negative cable,
do not leave the key in the vehicle to avoid the door being locked.
DOORS
87
FRONT DOOR.................................................................................... 87-1
COMPONENTS ........................................................................... 87-1
ADJUSTMENT ............................................................................. 87-2
REPLACEMENT .......................................................................... 87-3 87
SLIDING DOOR.................................................................................. 87-7
COMPONENTS ........................................................................... 87-7
ADJUSTMENT ............................................................................. 87-8
REPLACEMENT ........................................................................ 87-10 87
REAR HATCH .................................................................................. 87-11
COMPONENTS ......................................................................... 87-11
ADJUSTMENT ........................................................................... 87-12
REPLACEMENT ........................................................................ 87-13
87
DOORS - FRONT DOOR 87-1
FRONT DOOR
DOORS
COMPONENTS
87
87
1 Front Door Outer Weatherstrip RH 13 Front Door Limit Assy
2 Front Door Glass RH 14 Front Door Glass RH Guide Slot Gasket
3 Front Door Inner Weatherstrip RH 15 Front Door Glass RH Guide Slot
4 Front Door Glass Front Bracket 16 Front Door Glass Outer Weatherstrip LH
5 Front Door Glass Rear Bracket 17 Front Door Glass LH
6 Front Door Handle Bezel 18 Front Door Glass Inner Weatherstrip LH
7 Front Door Guard Board Assy RH 19 Front Door Inner Weatherstrip LH
8 Front Door Lower Weatherstrip 20 Front Door Vice-weatherstrip LH
9 Front Door Weatherstrip RH 21 Front Door Guard Board Assy LH
10 Front Door Vice-weatherstrip RH 22 Front Door Glass LH Guide Slot Gasket
11 Front Door Upper Damping Block 23 Front Door Glass LH Guide Slot
12 Front Door Lower Damping Block

87-2 DOORS - FRONT DOOR
ADJUSTMENT
NOTE
Adjust the RH side by the same procedures as the LH side.
1. ADJUST FRONT DOOR LH.

(a) Adjust the door vertically and horizontally by loosening
the body side hinge bolts.
(b) After adjusting, tighten the body hinge bolts.
(c) Adjust the door vertically and horizontally by loosening

the body side hinge bolts.
(d) After adjusting, tighten the body hinge bolts.
(e) Adjust the striker position by slightly loosening the striker

mounting screws and hitting the striker with a plastic
hammer.
(f) After adjusting, tighten the striker mounting screws.
REPLACEMENT
1. DISCONNECT FRONT DOOR CONNECTOR.
87
2. REMOVE FRONT DOOR LIMIT LH.
87
3. REMOVE FRONT DOOR HINGE LH.

(a) Loosen 4 front door hinge LH retaining bolts.
(b) Remove the front door assy.
4. REMOVE FRONT DOOR WEATHERSTRIP.

(a) Pry out the front door weatherstrip clips and then remove
the weatherstrip.
NOTE
Discard the removed clips.
5. INSTALL FRONT DOOR HINGE LH.

(a) Position the front door LH properly. After adjusting the
front door clearance, tighten 4 front door hinge LH retain-
ing bolts.
6. INSTALL FRONT DOOR LIMIT LH.
87
7. CONNECT FRONT DOOR LH CONNECTOR.
87
8. INSTALL FRONT DOOR WEATHERSTRIP LH.

(a) Position the weatherstrip properly with new clips.
NOTE
Use new parts when installing.
9. ADJUST FRONT DOOR LH. (Refer to “Chapter 87 engine hood and doors - front door,
adjustment)
10. REMOVE FRONT DOOR RH.
NOTE
DOORS - SLIDING DOOR 87-7
SLIDING DOOR
COMPONENTS
87
87
1 Sliding Door Inner Guard Board Clip 11 Bearing Bush
2 Sliding Door Inner Guard Board 12 Lower Bracket Guide Assy
3 Sliding Door Weatherstrip Assy 13 Limit Block Assy
4 No.2 Sliding Door Weatherstrip Assy 14 Upper Slideway Assy
5 Sliding Door Glass Assy 15 Rear Damping Block
6 Concave Limiting Device 16 Middle Slideway Assy
7 Front Damping Block 17 Convex Limiting Device
8 Middle Slideway Bracket Assy 18 Convex Limiting Device Assy
9 Sliding Door Upper Bracket Assy 19 Wire Convex Limiting Device
10 Sliding Door Lower Bracket Assy

87-8 DOORS - SLIDING DOOR
ADJUSTMENT
1. ADJUST SLIDING DOOR.
(a) Open the sliding door, adjust the door vertically by loos-
ening 3 lower bracket bolts.
(b) Adjust the door horizontally by loosening 3 upper and

lower brackets bolts.
(c) Ensure that the clearance between the upper roller or
lower roller and tail is as shown in the illustration through-
out the stroke.
Clearance:
A：3.2 mm
B：4.6 mm
C：5.4 mm
D：4.5 mm
(d) After adjusting, tighten the sliding door hinge bolts.
(e) Adjust the lock catch vertically and horizontally by slightly

loosening the lock catch mounting bolts and hitting the
lock catch with a plastic hammer.
DOORS - SLIDING DOOR 87-9
(f) Loosen the door side convex limit retaining bolts.

(g) With the door closed, adjust the convex limit so it may be
placed 3 mm above the face.
(h) After adjusting, tighten the bolts. 87
87
87-10 DOORS - SLIDING DOOR
REPLACEMENT
1. REMOVE SLIDING DOOR RH.
(a) Loosen sliding door RH upper and lower brackets 5
bolts.
(b) Move forward the sliding door and separate it from the
middle rail.
(c) Remove the sliding door RH.
2. INSTALL SLIDING DOOR RH.

(a) Position the sliding door middle rail into the guide slot.
(b) Tighten sliding door RH upper and lower brackets 5
bolts.
3. ADJUST SLIDING DOOR RH. （Refer to “Chapter 87 engine hood and doors - sliding door,
adjustment”）
4. REMOVE SLIDING DOOR LH (IF EQUIPPED).
NOTE
DOORS - REAR HATCH 87-11
REAR HATCH
COMPONENTS
87
87
1 Rear Window Weatherstrip 7 Hatch Bar Assy RH
2 Rear Window Glass 8 Hatch Bar Assy LH
3 Rear Hatch Convex Limit Assy (Side) 9 Bolt
4 Rear Hatch Concave Limit Assy (Side) 10 Rear Hatch Concave Limit Assy (Middle)
5 Rear Hatch Weatherstrip 11 Rear Hatch Convex Limit Assy (Middle)
6 Bolt 12 Damping Block

87-12 DOORS - REAR HATCH
ADJUSTMENT
1. ADJUST REAR HATCH.
(a) Adjust the convex limit by slightly loosening the convex
limit mounting bolts and hitting the convex limit with a
plastic hammer.
(b) After adjusting, tighten the convex limit mounting bolts.
(c) Loosen the rear hatch hinge mounting bolts to adjust the
rear hatch position.
(d) After adjusting, tighten the rear hatch hinge mounting
bolts.
(e) Adjust the concave limit by slightly loosening the con-

cave limit mounting bolts and hitting the concave limit
with a plastic hammer.
REPLACEMENT
1. DISCONNECT REAR HATCH CONNECTOR.
(a) Unwrap a rubber case and disconnect the rear hatch wir- 87
ing harness connector.
(b) If rear wiper is equipped, disconnect the rear washer hose.
2. REMOVE HATCH BAR ASSY RH.

(a) Remove 2 hatch bar assy RH upper mounting bolts.
(b) Remove 2 hatch bar assy RH lower mounting bolts.
87
3. REMOVE HATCH BAR RH BODY.

(a) Remove the hatch bar RH body upper snap ring.
(b) Remove the hatch bar RH body lower snap ring.

(c) Remove the hatch bar RH body.
WARNING
• Do not disassemble it or throw it into fire.
• Using a drill, make a hole in the hatch bar to discharge
the gas inside.
4. REMOVE HATCH BAR LH.

NOTE
5. REMOVE REAR HATCH HINGE.

(a) Hold the rear hatch and remove 4 rear hatch hinge
mounting bolts.
6. INSTALL REAR HATCH.

(a) Tighten 4 rear hatch hinge mounting bolts.
87
(b) Position the hatch bar properly and tighten the upper
snap ring.
(c) Position the hatch bar properly and install the lower snap 87
ring.
(d) Hold the rear hatch and tighten 4 hatch bar LH and RH
mounting bolts.
(e) Connect the rear hatch connector.

(f) Connect the rear washer hose if the rear wiper is equipped.
7. ADJUST REAR HATCH. (Refer to “Chapter 87 engine hood and doors - rear hatch, adjustment”)
88
FRONT GRILLE ................................................................................. 88-1
COMPONENTS ........................................................................... 88-1
REPLACEMENT .......................................................................... 88-2
FRONT BUMPER ASSY .................................................................... 88-4 88
COMPONENTS ........................................................................... 88-4
REPLACEMENT .......................................................................... 88-5
WHEEL FENDER ............................................................................... 88-9
REPLACEMENT .......................................................................... 88-9 88
REAR BUMPER ASSY .................................................................... 88-11
COMPONENTS ......................................................................... 88-11
REPLACEMENT ........................................................................ 88-12
SUN VISOR ASSY ........................................................................... 88-14
COMPONENTS ......................................................................... 88-14
REPLACEMENT ........................................................................ 88-15
STEP BOARD .................................................................................. 88-17
COMPONENTS ......................................................................... 88-17
REPLACEMENT ........................................................................ 88-18
VEHICLE DOOR INNER GUARD BOARD ...................................... 88-19
REPLACEMENT ........................................................................ 88-19
SIDE WALL GUARD BOARD.......................................................... 88-25
REPLACEMENT ........................................................................ 88-25
FLOOR DECORATIVE PARTS........................................................ 88-26
COMPONENTS ......................................................................... 88-26
REPLACEMENT ........................................................................ 88-27
ROOF PANEL .................................................................................. 88-29
COMPONENTS ......................................................................... 88-29
REPLACEMENT ........................................................................ 88-30 88
EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 88-1
FRONT GRILLE
COMPONENTS
88
88
1 Bolt 3 Front Grille
2 Front Bumper Assy 4 Clip

88-2 EXTERIOR AND INTERIOR TRIM - FRONT GRILLE
REPLACEMENT
1. REMOVE FRONT GRILLE.
(b) Remove 7 clips.
(c) Remove the front grille.

EXTERIOR AND INTERIOR TRIM - FRONT GRILLE 88-3
2. INSTALL FRONT GRILLE.

(a) Install 7 clips and front grille.
88
(b) Install 4 screws.
88
88-4 EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY
FRONT BUMPER ASSY

COMPONENTS
1 Bolt 3 Front Grille
2 Front Bumper Assy 4 Clip

EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY 88-5
REPLACEMENT
2. REMOVE FRONT GRILLE. (Refer to “Chapter 88 exterior and interior - front grille, replacement”) 88
3. REMOVE FRONT BUMPER ASSY.
(a) Remove 2 bolts from front bumper assy.
(b) Loosen the screw from front bumper assy by front door
LH side.
88
(c) Loosen the screw from front bumper assy by front step
board cover LH side.
(d) Loosen the screw from front bumper assy by front door
RH side.
(e) Loosen the screw from front bumper assy by front step
board cover RH side.
(f) Remove 2 bolts from front bumper assy by downside.
(g) Disconnect the connectors from front fog lamps.

(h) Remove the front bumper assy.
EXTERIOR AND INTERIOR TRIM - FRONT BUMPER ASSY 88-7
4. INSTALL FRONT BUMPER ASSY.

(a) Connect the connectors to front fog lamps and install the
front bumper assy.
(b) Install 2 bolts to front bumper assy. 88
(c) Install the screw to front bumper assy by front door LH

side.
88
(d) Install the screw to front bumper assy by front step board
cover LH side.
(e) Install the screw to front bumper assy by front door RH

side.
(f) Install the screw to front bumper assy by front step board
cover RH side.
(g) Install 2 bolts to front bumper assy by downside.
5. INSTALL FRONT GRILLE. (Refer to “Chapter 88 exterior and interior trim - front grille, replacement”)
EXTERIOR AND INTERIOR TRIM - WHEEL FENDER 88-9
WHEEL FENDER
REPLACEMENT
88
1. REMOVE FRONT WHEEL FENDER LH.
(a) Remove 5 bolts and front wheel fender LH.
2. REMOVE FRONT WHEEL FENDER RH.

NOTE
3. REMOVE REAR WHEEL FENDER LH.

(a) Remove 3 bolts and rear wheel fender LH.
88
4. REMOVE REAR WHEEL FENDER RH.

NOTE
88-10 EXTERIOR AND INTERIOR TRIM - WHEEL FENDER
5. INSTALL FRONT WHEEL FENDER LH.

(a) Install the front wheel fender LH and install 5 bolts.
6. INSTALL FRONT WHEEL FENDER RH.

NOTE
Intsall the RH side by the same procedures as the LH side.
7. INSTALL REAR WHEEL FENDER LH.

(a) Install the rear wheel fender LH and install 3 bolts.
8. INSTALL REAR WHEEL FENDER RH.

NOTE
EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY 88-11
REAR BUMPER ASSY

COMPONENTS
88
88
1 Rear Bumper Left Weather Strip 4 Rear Bumper Assy
2 Rear Bumper Bracket Weldment Assy 5 Bolt
3 Rear Bumper Right Weather Strip

88-12 EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY
REPLACEMENT
1. REMOVE REAR BUMPER ASSY.
(a) Remove 2 bolts from rear bumper assy.
(b) Remove 3 bolts from rear bumper assy by downside.
(c) Remove the rear bumper assy.

EXTERIOR AND INTERIOR TRIM - REAR BUMPER ASSY 88-13
2. INSTALL REAR BUMPER ASSY.

(a) Install the rear wheel bumper and install 3 bolts.
88
(b) Install 2 bolts to rear bumper assy.
88
88-14 EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY
SUN VISOR ASSY

COMPONENTS
1 Bolt 3 Hook
2 Sun Visor Assy RH 4 Sun Visor Assy LH

EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY 88-15
REPLACEMENT
1. REMOVE SUN VISOR ASSY LH.
(a) Remove 2 bolts from sun visor assy. 88
(b) Remove the bolt from the hook.
(c) Remove the sun visor assy.
88
2. REMOVE SUN VISOR ASSY RH.

NOTE
3. INSTALL SUN VISOR ASSY LH.

(a) Install the sun visor assy LH and tighten the bolt to the
hook.
88-16 EXTERIOR AND INTERIOR TRIM - SUN VISOR ASSY
(b) Install 2 bolts to sun visor assy.
4. INSTALL SUN VISOR ASSY RH.

NOTE
EXTERIOR AND INTERIOR TRIM - STEP BOARD 88-17
STEP BOARD
COMPONENTS
88
1 Clip 3 Step Board RH
2 Clip 4 Step Board LH
88
88-18 EXTERIOR AND INTERIOR TRIM - STEP BOARD
REPLACEMENT
1. REMOVE FRONT STEP BOARD COVER ASSY LH.
(a) Remove 2 clips from the step board LH.
(b) Remove the step board LH.
2. REMOVE STEP BOARD COVER RH.

NOTE
3. INSTALL STEP BOARD LH.

(a) Install the step board LH.
(b) Install 2 clips to step board LH.
4. INSTALL FRONT STEP BOARD COVER ASSY RH.

NOTE
EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD 88-19
VEHICLE DOOR INNER GUARD BOARD

REPLACEMENT
2. REMOVE FRONT DOOR INNER GUARD PLATE ASSY

LH.
(a) Remove the clip from front door inner guard plate assy
LH.
(b) Remove 2 screw covers from front door inner guard plate
assy LH.
88
(c) Loosen 2 screws.

88-20 EXTERIOR AND INTERIOR TRIM - VEHICLE DOOR INNER GUARD BOARD
(d) Loosen the screw and remove front door lock inner
handle assy LH.
(e) Loosen the screw and remove the glove box.
(f) Disengage 9 clips.

(g) Disconnect the connector from power door locks.
88
(h) Remove the front door inner guard plate assy LH.
3. REMOVE FRONT DOOR INNER GUARD PLATE ASSY RH.

NOTE
4. REMOVE SLIDING DOOR INNER GUARD BOARD.

(a) Remove the sliding door limiter.
88
(b) Disengage 13 clips and remove the sliding door inner

guard board.
5. INSTALL FRONT DOOR INNER GUARD PLATE ASSY

LH.
(a) Connect the connector to power door locks.
(b) Install the front door inner guard plate assy LH with 9
clips.
(c) Install the glove box with the screw.

(d) Install the front door lock inner handle assy LH with the
screw.
88
(e) Tighten 2 screws.
88
(f) Install 2 screw covers to front door inner guard plate assy
LH.
(g) Install the clip to front door inner guard plate assy LH.
6. INSTALL FRONT DOOR INNER GUARD PLATE ASSY RH.

NOTE
7. INSTALL SLIDING DOOR INNER GUARD BOARD.

(a) Install the sliding door inner guard board with 9 clips.
(b) Install the sliding door limiter.

EXTERIOR AND INTERIOR TRIM - SIDE WALL GUARD BOARD 88-25
SIDE WALL GUARD BOARD

REPLACEMENT
88
1. REMOVE SIDE WALL GUARD BOARD LH.
(a) Disengage 11 clips and remove the side wall guard
board LH.
2. REMOVE SIDE WALL GUARD BOARD RH.

NOTE
3. INSTALL SIDE WALL GUARD BOARD LH.

(a) Install the side wall guard board properly with 11 clips.
4. INSTALL SIDE WALL GUARD BOARD RH. 88

NOTE
88-26 EXTERIOR AND INTERIOR TRIM - FLOOR DECORATIVE PARTS
FLOOR DECORATIVE PARTS

COMPONENTS
1 Assistant Driver Step Board Trim Strip 8 Front Floor Covering
2 Assistant Driver Lower Covering 9 Driver Step Board Trim Strip
3 Sliding Door Upper Trim Strip 10 Engine Service Hole Covering
4 Sliding Door Lower Trim Strip 11 Engine Rear Stop Plate Covering
5 Passenger Step Board Covering 12 Rear Floor Covering
6 Wheel Casing Carpet RH 13 Wheel Casing Carpet LH
7 Rear Door Floor Trim Strip

EXTERIOR AND INTERIOR TRIM - FLOOR DECORATIVE PARTS 88-27
REPLACEMENT
1. REMOVE DRIVER SEAT AND ASSISTANT DRIVER SEAT.
2. REMOVE THE ENGINE SERVICE HOLE COVERING, ASSISTANT DRIVER LOWER COVERING, 88
FRONT FLOOR COVERING AND ENGINE REAR STOP PLATE COVERING.
3. REMOVE REAR FLOOR COVERING.

(a) Loosen 5 screws and remove the rear door floor trim
strip.
(b) Loosen 7 screws and remove the sliding door upper trim
strip LH.
88
(c) Remove the sliding door upper trim strip RH.

NOTE
Remove the RH side by the same procedures as the LH
side.
(d) Remove wheel casing carpet LH, wheel casing carpet

RH and rear floor covering.
88-28 EXTERIOR AND INTERIOR TRIM - FLOOR DECORATIVE PARTS
4. INSTALL REAR FLOOR COVERING.

(a) Install wheel casing carpet LH, wheel casing carpet RH
and rear floor covering.
(b) Install the sliding door upper trim strip LH and tighten 7
screws.
(c) Install the sliding door upper trim strip RH.

NOTE
(d) Install the rear door floor trim strip and tighten 5 screws
5. INSTALL THE ENGINE SERVICE HOLE COVERING, ASSISTANT DRIVER LOWER COVERING,
FRONT FLOOR COVERING AND ENGINE REAR STOP PLATE COVERING.
6. INSTALL DRIVER SEAT AND ASSISTANT DRIVER SEAT.
EXTERIOR AND INTERIOR TRIM - ROOF PANEL 88-29
ROOF PANEL
COMPONENTS
88
88
1 Rear Trim Cover 8 Roof Cover Peripheral Trim Strip No.2
2 Front Trim Cover 9 Roof Cover Peripheral Trim Strip No.3
3 Rubber Sheet 10 Rear Vent Line RH
4 Front Vent Line LH 11 Front Vent Line RH
5 Rear Vent Line LH 12 Roof Reinforcement
6 Roof Panel 13 Roof Reinforcement Covering
7 Roof Cover Peripheral Trim Strip No.1

88-30 EXTERIOR AND INTERIOR TRIM - ROOF PANEL
REPLACEMENT
2. REMOVE REAR EVAPORATOR COVER.

(a) Disconnect the connector and remove the rear control
panel.
(b) Disconnect the connector and remove the A/C switch.
(c) Remove 2 air inlet grilles and 2 air outlet grilles.
(d) Remove 5 bolts.

(e) Remove the rear evaporator cover.
88
3. REMOVE REAR EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - rear
evaporator assy, replacement”)
4. REMOVE VENT LINE LH.

(a) Remove 2 air outlet grilles by left side.
(b) Loosen 2 screws and remove 2 vent lines LH.
88
5. REMOVE VENT LINE RH.

NOTE
6. REMOVE REAR DOME LIGHT ASSY. (Refer to “Chapter 64 lighting - rear dome light assy,
replacement”)
7. REMOVE 3 CLIPS AND REAR TRIM COVER.

8. REMOVE FRONT TRIM COVER.
9. REMOVE 5 REINFORCEMENTS AND ROOF PANEL.

10. INSTALL ROOF PANEL AND 5 REINFORCEMENTS.
11. INSTALL FRONT TRIM COVER.
12. INSTALL REAR TRIM COVER AND 3 CLIPS.
13. INSTALL REAR DOME LIGHT ASSY. (Refer to “Chapter 64 lighting - rear dome light assy,
replacement”)
14. INSTALL VENT LINE LH.

(a) Install 2 vent lines LH and tighten 2 screws
(b) Install 2 air outlet grilles by left side.
88
15. INSTALL VENT LINE RH.

NOTE
16. INSTALL REAR EVAPORATOR ASSY. (Refer to “Chapter 61 heater and air conditioning - rear
evaporator assy, replacement”)
17. INSTALL REAR EVAPORATOR COVER.

(a) Install the rear evaporator cover.
88
(c) Install 2 air inlet grilles and 2 air outlet grilles.

(d) Connect the connector and install the A/C switch.
(e) Connect the connector and install the rear control panel.
91
IGNITION SWITCH ASSY .................................................................. 91-1
INSPECTION ............................................................................... 91-1
REMOVAL & INSTALLATION AND
DISASSEMBLY & ASSEMBLY .................................................... 91-2 91
91
91
VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY 91-1
IGNITION SWITCH ASSY

INSPECTION
91
1. INSPECT IGNITION SWITCH ASSY.
(a) Check the resistance.
Standard:
Switch position Terminal Specified condition

LOCK AM1 - ACC - IG1 - ST1 - AM2 - IG2 - ST2 ≥ 1 MΩ
ACC AM1 - ACC ＜2Ω
ON AM1 - ACC - IG1， AM2 - IG2 ＜2Ω
START AM1 - IG1 - ST1， AM2 - IG2 - ST2 ＜2Ω
If the resistance is out of the specification, replace the ignition

switch assy. (Refer to “Chapter 91 vehicle control system -
ignition switch assy, removal & installation and disassembly &
assembly”) 91
91-2 VEHICLE CONTROL SYSTEM - IGNITION SWITCH ASSY
REMOVAL & INSTALLATION AND DISASSEMBLY & ASSEMBLY

1. PRECAUTION. (Refer to “Chapter 51 steering column - steering system, precaution”)
overhaul”)
overhaul”)
8. REMOVE IGNITION SWITCH ASSY.

(a) Remove the harness tie.
(b) Using an allen wrench, loosen 2 bolts.

(c) Remove the ignition switch assy.

CAUTION
• During this procedure, the ignition switch assy connector
is not disconnected. 91
• Do not drag the wire harness.
• Make sure there is no interference between wire harness
and parts around.
NOTE
Store the ignition switch assy carefully.
(d) Disconnect 1 connector:

NOTE
Store the ignition switch assy carefully.
9. DISASSEMBLE IGNITION SWITCH ASSY.

(a) Remove the screw.
91
(b) Remove the ignition switch cover.
(c) Insert the ignition key, then turn the ignition switch to the
“ACC” position.
(d) Using a stick, press the lock latch of ignition switch.
(e) Pull out the ignition switch.
(f) Remove the screw.
(g) Remove the ignition switch connector.
10. ASSEMBLE IGNITION SWITCH ASSY.

(a) Install the ignition switch connector.
NOTE
Insert and turn it to align the key sets.
(b) Tighten the screw.

(c) Insert the ignition key, then turn the ignition switch to the
“ACC” position.
(d) Install the ignition switch.
NOTE 91
If hear a “click”, the ignition switch is installed properly.
(e) Install the ignition switch cover.
(f) Tighten the screw.
91
11. INSTALL IGNITION SWITCH ASSY.

(a) Connect 1 connector.
CAUTION
• Make sure the wire harness does not interfere with
parts around.
(b) Align the lock slot on the steering column assy and the latch
block on the ignition switch assy.
NOTE
The ignition switch lock latch will extrude only when the
ignition key is pulled out.
(c) Position the ignition switch assy properly.

CAUTION
• Make sure the wire harness does not interfere with
parts around.
(d) Using an allen wrench , tighten 2 bolts.
(e) Install the harness tie.

NOTE
Always replace with a new harness tie.
12. INSTALL STEERING COLUMN LOWER COVER. (Refer to “Chapter 51 steering column - steering
13. INSTALL COMBINATION SWITCH ASSY. (Refer to “Chapter 51 steering column - combination
overhaul”)
overhaul”)
16. CONNECT BATTERY CABLE.(Refer to “Chapter 20 starting and charging-battery, replacement”)
INDEX
(ORGNIZED ALPHABETICALLY)
A B
A - ENGINE ROOM WIRE HARNESS B - BATTERY POSITIVE CABLE WIRE HARNESS
(CONNECTOR VIEWS) .............................................................71-142 (CONNECTOR VIEWS) ............................................................ 71-150
A - ENGINE ROOM WIRE HARNESS B - BATTERY POSITIVE CABLE WIRE HARNESS
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-204 (WIRE HARNESS & CONNECTOR LOCATION VIEWS)......... 71-204
A SINGLE MIRROR IS INOPERATIVE(OUTSIDE MIRROR) ...04-826 BACK-UP LAMP IS INOPERATIVE(LIGHTING SYSTEM) ....... 04-633
ABBREVIATIONS USED IN THIS MANUAL(TERMS) ................01-35 BACK-UP LAMP IS INOPERATIVE(ONE SIDE)
ABS IS INOPERATIVE(ANTI-LOCK BRAKE SYSTEM)............04-399 (LIGHTING SYSTEM) ............................................................... 04-516
ABS MODULE CONNECTOR BACK-UP LAMPS ARE INOPERATIVE (BOTH SIDES)
(ANTI-LOCK BRAKE SYSTEM).................................................04-371 (LIGHTING SYSTEM) .................................................. 04-518, 04-635
ABS WARNING LIGHT IS ALWAYS ON BASIC IDLE SPEED ADJUSTMENT
(ANTI-LOCK BRAKE SYSTEM).................................................04-388 (THROTTLE BODY) .................................................... 11A-26, 11D-33
ABS WARNING LIGHT IS INOPERATIVE BASIC INSPECTION(AUDIO SYSTEM) ................................... 04-714
(ANTI-LOCK BRAKE SYSTEM).................................................04-390 BASIC INSPECTION(COMINED DISPLAY) ............................. 04-737
ABS WARNING LIGHT IS INTERMITTENT ON BASIC INSPECTION
(ABS MODULE CHECK FAULT INTERMITTENTLY) (HEATER AND AIR CONDITIONING SYSTEM)....................... 04-409
(ANTI-LOCK BRAKE SYSTEM).................................................04-394 BASIC INSPECTION(INSTRUMENT CLUSTER) ........ 04-850, 04-890
ACCUMULATOR .........................................................................61-54 BASIC INSPECTION(LIGHTING SYSTEM).............................. 04-444
ADJUSTMENT(BRAKE PEDAL)....................................................35-6 BASIC INSPECTION(OUTSIDE MIRROR)............................... 04-821
ADJUSTMENT(CLUTCH PEDAL) .................................................42-4 BASIC INSPECTION(POWER DOOR LOCKS)........................ 04-920
ADJUSTMENT(DRIVER / ASSISTANT DRIVER SEAT) ...............84-3 BASIC INSPECTION(POWER WINDOWS).............................. 04-780
ADJUSTMENT(FRONT DOOR) ....................................................87-2 BASIC INSPECTION
ADJUSTMENT(FRONT WHEEL ALIGNMENT) ............................31-8 (REAR WINDOW DEFROSTER SYSTEM) .............................. 04-835
ADJUSTMENT(LIGHTING SYSTEM)..........................................64-10 BASIC INSPECTION(WIPER AND WASHER) ......................... 04-674
ADJUSTMENT(LOAD SENSING PROPORTIONING BASIC PRINCIPLE(CNG ENGINE CONTROL SYSTEM) ........11D-12
AND BY- PASS VALVE(LSP&BV))..............................................35-43 BASIC PRINCIPLE(DIESEL ENGINE CONTROL SYSTEM) .....11C-6
ADJUSTMENT(PARKING BRAKE SYSTEM) ...............................36-2 BASIC PRINCIPLE
ADJUSTMENT(REAR HATCH) ...................................................87-12 (GASOLINE ENGINE CONTROL SYSTEM)...............................11A-8
ADJUSTMENT(SLIDING DOOR) ..................................................87-8 BASIC SERVICE PROCEDURE
ADJUSTMENT(TIRE AND WHEEL SYSTEM) ..............................33-7 (CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-252
ADJUSTMENT(WASHER NOZZLE)............................................65-18 BASIC SERVICE PROCEDURE
AIR FILTER ASSY ...............................................14A-6, 14B-6, 14C-7 (DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ))................ 04-140
AIR STRAINING BOX ASSY ...........................14A-10, 14B-11, 14C-4 BASIC SERVICE PROCEDURE
ALL FOG LAMPS ARE INOPERATIVE (DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-177
(LIGHTING SYSTEM) ................................................................04-480 BASIC SERVICE PROCEDURE
ALL HEADLAMPS ARE INOPERATIVE (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-11
(LIGHTING SYSTEM) .................................................. 04-464, 04-582 BATTERY ...................................................... 20A-22, 20B-23, 20C-23
ALL POWER WINDOWS ARE INOPERATIVE BATTERY COMMON PROBLEMS, THE CAUSES ANALYSIS
(POWER WINDOWS) ................................................................04-783 AND TROUBLESHOOTING(BATTERY)..................... 20B-27, 20C-27
AMBIENT TEMPERATURE DOES NOT DISPLAY OR BLEEDING AND PURIFYING(STEERING FLUID) ..................... 52-17
DISPLAY INCORRECTLY(COMINED DISPLAY)......................04-744 BLEEDING(CLUTCH FLUID) ........................................................ 42-3
ANALYSIS OF DATA BLOWER SWITCH ILLUMINATION IS INOPERATIVE
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-263 (LIGHT SYSTEM)...................................................................... 04-546
ANTI-LOCK BRAKE SYSTEM ...................................................04-368 BLOWER SWITCH ILLUMINATION IS INOPERATIVE
AUDIO ILLUMINATION IS INOPERATIVE(LIGHT SYSTEM) ...04-548 (LIGHTING SYSTEM) ............................................................... 04-657
AUDIO ILLUMINATION IS INOPERATIVE BRAKE ............................................................................. 02-19, 03-32
(LIGHTING SYSTEM) ................................................................04-659 BRAKE ACTUATOR LEVER SUB-ASSY...................................... 36-9
AUDIO SYSTEM .............................................................. 04-711, 66-1 BRAKE CONTROL SYSTEM(WIRING DIAGRAM) .................... 71-52
AXLE AND PROPELLER SHAFT .................................... 02-16, 03-29 BRAKE MASTER CYLINDER ASSY........................................... 35-10
AXLE HUB ...................................................................................34-23 BRAKE SYSTEM........................................................................... 35-1
AXLE HUB AND STEERING KNUCKLE .....................................34-19 BRAKE WARNING LIGHT NEVER / ALWAYS ON
AXLE SHAFT ASSY.....................................................................34-58 (INSTRUMENT CLUSTER).......................................... 04-864, 04-903
A/C CONTROLLER......................................................................61-56 BUCKLE ASSY.............................................................................. 63-7
A/C PIPE ......................................................................................61-32 BUZZER IS INOPERATIVE OR OPERATIVE INCORRECTLY
A/C SYSTEM IS INOPERATIVE WITHIN SPECIFIED DISTANCE
(HEATER AND AIR CONDITIONING SYSTEM) .......................04-414 (REVERSE RADAR SYSTEM).................................................. 04-770
C COMPONENTS
(ELECTRONIC CONTROL VE DISPENSING PUMP ASSY)... 12C-17
COMPONENTS
(CONNECTOR VIEWS) ............................................................ 71-151 (ENGINE ACCESSORY BELT) ..................... 15A-19, 15B-18, 15C-27
COMPONENTS(ENGINE BLOCK)..............................15B-54, 15C-63
COMPONENTS(ENGINE TIMING BELT) ................................ 15B-30
(WIRE HARNESS & CONNECTOR LOCATION VIEWS)......... 71-206
CAMSHAFT................................................... 15A-47, 15B-51, 15C-60 COMPONENTS(ENGINE TIMING CHAIN) .............................. 15A-31
COMPONENTS(ENGINE TIMING GEAR) ............................... 15C-39
CANISTER SOLENOID VALVE ................................................11A-56
COMPONENTS
CAPTURING DATA
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-262 (EXHAUST PIPE) .........................16A-1, 16B-1, 16B-6, 16C-1, 16C-7
COMPONENTS(FINAL DRIVE)...................................................34-51
CAPTURING DATA
COMPONENTS(FLOOR DECORATIVE PARTS) .......................88-26
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-22
CAUTIONS FOR CIRCUIT TROUBLESHOOTING COMPONENTS(FRONT BRAKE) ...............................................35-19
COMPONENTS(FRONT BUMPER ASSY) ...................................88-4
(DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ))................ 04-136
COMPONENTS(FRONT DOOR LOCKS) .....................................85-1
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-173 COMPONENTS(FRONT DOOR)...................................................87-1
COMPONENTS(FRONT GRILLE).................................................88-1
CENTER SUPPORT BEARING .................................................. 34-14
COMPONENTS(FRONT SUSPENSION)......................................31-5
CHARCOAL CANISTER .............................................................13A-2
CHARCOAL CANISTER SOLENOID VALVE .............................13A-4 COMPONENTS(FUEL STRAINER ASSY)............................... 12B-17
COMPONENTS(FUEL SYSTEM)....................................12A-4, 12D-5
CHARGING SYSTEM(WIRING DIAGRAM)................................ 71-48
COMPONENTS(FUEL TANK ASSY) ..............................12B-5, 12C-5
CIGARETTE LIGHTER ILLUMINATION IS INOPERATIVE
(LIGHT SYSTEM)...................................................................... 04-542 COMPONENTS(FUEL TANK CAP)............................................ 13C-2
COMPONENTS(GENERATOR) ................................................. 20A-4
CKP SENSOR ............................................................. 11A-44, 11D-51
COMPONENTS(HEATER AND AIR CONDITIONING) .................61-3
CLUTCH ........................................................................... 02-23, 03-37
CLUTCH FLUID............................................................................. 42-3 COMPONENTS(INSTRUMENT CLUSTER) ...............................83-13
COMPONENTS(INTAKE AIR SYSTEM) ............. 14A-2, 14B-2, 14C-2
CLUTCH MASTER CYLINDER ASSY .......................................... 42-7
COMPONENTS(INTAKE MANIFOLD) ..................................... 14A-13
CLUTCH PEDAL ........................................................................... 42-4
CLUTCH SLAVE CYLINDER ...................................................... 42-12 COMPONENTS(LIGHTING SYSTEM) ..........................................64-2
COMPONENTS(LOAD SENSING PROPORTIONING
CLUTCH SUB - ASSY................................................................. 42-15
AND BY- PASS VALVE(LSP&BV))..............................................35-42
CLUTCH SYSTEM ........................................................................ 42-1
COMPONENTS(LUBRICATION SYSTEM).....................18B-2, 18C-2
CNG ENGINE CONTROL SYSTEM ...........................................11D-1
CNG ENGINE CONTROL SYSTEM (4GC1)............................. 04-242 COMPONENTS(OIL PAN).......................................................... 18B-8
COMPONENTS(OUTPUT SHAFT ASSY)...................................41-42
CNG SUPPLY SYSTEM............................................................12D-19
COMPONENTS(PASSENGER SEAT BELT) ................................63-3
COMBINATION SWITCH ASSY ...................................... 51-11, 64-21
COMBINED DISPLAY ............................................................... 04-734 COMPONENTS(PASSENGER SEAT) ........................................84-15
COMPONENTS
(PISTON AND CONNECTING ROD ASSY)................15B-63, 15C-71
(LIGHT SYSTEM)...................................................................... 04-540
COMBINED DISPLAY ILLUMINATION IS INOPERATIVE COMPONENTS(PISTON AND CONNECTING RODS) ........... 15A-64
COMPONENTS(POWER STEERING SYSTEM) ..........................52-5
(LIGHTING SYSTEM) ............................................................... 04-653
COMPONENTS(POWER WINDOW) ............................................82-1
COMBINED DISPLAY IS INOPERATIVE WITHIN
SPECIFIED DISTANCE(REVERSE RADAR SYSTEM) ........... 04-773 COMPONENTS(PROPELLER SHAFT ASSY)..............................34-3
COMPONENTS(RADIATOR) ............................ 17A-10, 17B-9, 17C-8
COMBINED DISPLAY IS INOPERATIVE
COMPONENTS(REAR BRAKE)..................................................35-30
(COMINED DISPLAY) ............................................................... 04-739
COMMUNICATION SYSTEM(WIRING DIAGRAM) .................. 71-112 COMPONENTS(REAR BUMPER ASSY)....................................88-11
COMPONENTS(REAR HATCH LOCK).......................................85-13
COMPONENTS (ROTARY)(PASSENGER SEAT) ..................... 84-16
COMPONENTS(REAR HATCH) .................................................87-11
COMPONENTS(AUDIO SYSTEM) ............................................... 66-1
COMPONENTS(AXLE HUB)....................................................... 34-23 COMPONENTS(REAR SUSPENSION .........................................32-2
COMPONENTS(REAR VIEW MIRROR) .....................................82-15
COMPONENTS(BRAKE ACTUATOR LEVER SUB-ASSY) ......... 36-9
COMPONENTS(REAR WINDOW GLASS) .................................82-10
COMPONENTS(BRAKE MASTER CYLINDER ASSY) .............. 35-10
COMPONENTS(ROOF PANEL)..................................................88-29
COMPONENTS(CENTER SUPPORT BEARING) ...................... 34-14
COMPONENTS(SIDE WINDOW GLASS)...................................82-13
COMPONENTS(CLUTCH MASTER CYLINDER ASSY) .............. 42-7
COMPONENTS(SLIDING DOOR LOCKS) ...................................85-7
COMPONENTS(CLUTCH SLAVE CYLINDER) .......................... 42-12
COMPONENTS(SLIDING DOOR).................................................87-7
COMPONENTS(CLUTCH SUB - ASSY)..................................... 42-15
COMPONENTS(STARTER) ........................................20A-12, 20B-13
COMPONENTS(CNG SUPPLY SYSTEM) ...............................12D-19
COMPONENTS(STEERING KNUCKLE) ....................................34-35
COMPONENTS(COMBINATION SWITCH ASSY) ..................... 51-11
COMPONENTS(STEERING SYSTEM).........................................51-5
COMPONENTS(COMPRESSOR) .............................................. 61-45
COMPONENTS(STEP BOARD)..................................................88-17
COMPONENTS(COUNTER SHAFT ASSY AND
COMPONENTS(SUN VISOR ASSY) ..........................................88-14
REVERSE IDLER GEAR SHAFT)............................................... 41-57
COMPONENTS(TIRE AND WHEEL SYSTEM) ............................33-2
COMPONENTS
COMPONENTS
(CRANKSHAFT/ENGINE BLOCK/FLYWHEEL) .......................15A-75
(TRANSMISSION OPERATION MECHANISM ASSY) .................41-1
COMPONENTS(CYLINDER HEAD AND VALVE) ....................15C-43
COMPONENTS(TURBOCHARGER ASSY)............................. 14B-14
COMPONENTS(CYLINDER HEAD ASSY)...............................15B-35
COMPONENTS(VENT DUCT) ....................................................61-10
COMPONENTS(DASHBOARD).................................................... 83-2
COMPONENTS(WINDSHIELD) ....................................................82-6
COMPONENTS(DIFFERENTIAL ASSY) .................................... 34-65
COMPONENTS(U-JOINT).............................................................34-9
COMPONENTS(DRIVE PINION) ................................................ 34-80
COMPONENTS(WIPER AND WASHER SYSTEM)......................65-4
COMPONENTS
COMPOSITION(BATTERY) ........................................20A-22, 20C-23
(DRIVER / ASSISTANT DRIVER SEAT BELT)............................. 63-2
COMPRESSOR ...........................................................................61-45
COMPONENTS(DRIVER / ASSISTANT DRIVER SEAT)............. 84-2
COMPRESSOR OIL ....................................................................61-30
COMPONENTS(ELECTRONIC CONTROL EGR VALVE) .........13B-2
COMPULSORY DIAGNOSIS FUNCTION DIAGNOSTICS TROUBLE CODE (DTC) CHECK
(ACCESSIBILITY FOR THE DIAGNOSIS OF (DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-189
LOW-TEMPERATURE HOT VEHICLE) DIAGNOSTICS TROUBLE CODE (DTC) CHECK
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-185 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-37
CONDENSER ..............................................................................61-50 DIESEL ENGINE CONTROL SYSTEM........................... 11B-1, 11C-1
CONNECTOR VIEWS ...............................................................71-142 DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ) .................. 04-128
CONNECTOR VIEWS SECTION EXAMPLE DIESEL ENGINE CONTROL SYSTEM (4D20)......................... 04-166
(HOW TO USE THIS MANUAL) ....................................................71-6 DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS
CONSIDERATIONS (DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ))................ 04-148
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-185 DIESEL ENGINE SYMPTOM DIAGNOSIS AND TESTS
COOLANT............................................................17A-5, 17B-5, 17C-5 (DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-227
COOLANT FLUID LEVEL WARNING LIGHT DOOR AJAR WAINING LIGHT NEVER / ALWAYS ON
NEVER / ALWAYS ON(INSTRUMENT CLUSTER)..... 04-873, 04-912 (INSTRUMENT CLUSTER)....................................................... 04-876
COOLANT PUMP ..........................................17A-22, 17B-23, 17C-24 DOOR DOES NOT OPEN (USING THE REMOTE KEY)
COOLANT TEMPERATURE SENSOR FOR FAN.................... 11B-25 (POWER DOOR LOCKS).......................................................... 04-931
COOLING......................................................................... 02-10, 03-21 DOOR LOCKS............................................................................. 02-33
COOLING FAN ......................................................................... 17B-15 DOORS ....................................................................................... 02-34
COOLING SYSTEM.............................................17A-1, 17B-1, 17C-1 DOORS DO NOT CLOSE (USING THE REMOTE KEY)
COUNTER SHAFT ASSY AND REVERSE IDLER (POWER DOOR LOCKS).......................................................... 04-939
GEAR SHAFT ..............................................................................41-57 DOWNSTREAM OXYGEN SENSOR.......................... 11A-52, 11D-59
CRANKSHAFT/ENGINE BLOCK/FLYWHEEL ......................... 15A-75 DRIVE PINION ............................................................................ 34-80
CYLINDER HEAD ..................................................................... 15A-52 DRIVER / ASSISTANT DRIVER SEAT ......................................... 84-2
CYLINDER HEAD AND VALVE................................................ 15C-43 DRIVER / ASSISTANT DRIVER SEAT BELT ............................... 63-2
CYLINDER HEAD ASSY .......................................................... 15B-35
E
D
D - Front Door LH Wire Harness(CONNECTOR VIEWS)..........71-174 (CONNECTOR VIEWS) ............................................................ 71-176
D - FRONT DOOR LH WIRE HARNESS E - ENGINE CONTROL WIRE HARNESS
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-211 (WIRE HARNESS & CONNECTOR LOCATION VIEWS)......... 71-204
DASHBOARD ................................................................................83-1 ECM TERMINAL DIAGRAM (ECM SIDE)
DATA STREAM LISTACTIVE TEST (CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-253
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-25 EGR COOLANT TEMPERATURE SENSOR .............. 11B-20, 11C-13
DATA STREAM LIST/ACTIVE TEST EGR VACUUM REGULATOR...................................................11B-39
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-266 EGR VACUUM SOLENOID VALVE ..........................................11C-35
DEFROST ER SYSTEM IS INOPERATIVE EGR VALVE CONTROL UNIT ..................................................11B-16
(REAR WINDOW DEFROSTER SYSTEM) ...............................04-837 EGR VALVE ELECTRONIC CONTROL MODULE .....................11C-9
DIAGNOSTIC HELP - INTERMITTENT FAULT EGR VALVE ELECTRONIC CONTROL MODULE TERMINAL
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-250 DIAGRAM(DIESEL ENGINE CONTROL SYSTEM (4D20) ) .... 04-179
DIAGNOSTIC HELP - INTERMITTENT FAULT EGR VALVE LIFT SENSOR........................................ 11B-34, 11C-22
(DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)) ................04-138 ELECTRONIC CIRCUIT INSPECTION PROCEDURE
DIAGNOSTIC HELP - INTERMITTENT FAULT (HOW TO TROUBLESHOOT)..................................................... 01-31
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-175 ELECTRONIC CONTROL EGR VALVE ......................... 13B-2, 13C-2
DIAGNOSTIC HELP - INTERMITTENT FAULT ELECTRONIC CONTROL VE DISPENSING PUMP ASSY......12C-17
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ..............04-9 EMISSION CONTROL ......................................................... 02-4, 03-7
DIAGNOSTIC SCAN TOOL MAIN FUNCTION ENGINE ACCESSORY BELT ....................... 15A-19, 15B-18, 15C-27
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-184 ENGINE ASSY .................................................... 15A-4, 15B-5, 15C-6
DIAGNOSTIC SYSTEM ENGINE BLOCK.......................................................... 15B-54, 15C-63
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-258 ENGINE CONTROL MODULE (ECM) ........................ 11A-15, 11D-18
DIAGNOSTIC SYSTEM ENGINE CONTROL SYSTEM ............................................. 02-2, 03-2
(DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)) ................04-143 ENGINE CONTROL SYSTEM(WIRING DIAGRAM)................... 71-19
DIAGNOSTIC SYSTEM ENGINE COOLANT TEMPERATURE SENSOR ........ 11A-19, 11D-26
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-181 ENGINE MAINTENANCE AND CHECKLIST
DIAGNOSTIC SYSTEM (ENGINE MECHANICAL PART) .................................................15C-4
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-18 ENGINE MECHANICAL ....................................................... 02-6, 03-8
DIAGNOSTIC TROUBLE CODE CHART ENGINE MECHANICAL PART............................ 15A-1, 15B-1, 15C-1
(ANTI-LOCK BRAKE SYSTEM).................................................04-372 ENGINE OIL ........................................................ 18A-2, 18B-3, 18C-3
DIAGNOSTIC TROUBLE CODE CHART ENGINE OIL PRESSURE WARNING LIGHT
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-270 NEVER / ALWAYS ON(INSTRUMENT CLUSTER) ..... 04-870, 04-909
DIAGNOSTIC TROUBLE CODE CHART ENGINE RELAY BOX ...............................................................11B-56
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-186 ENGINE SYMPTOM DIAGNOSTIC
DIAGNOSTIC TROUBLE CODE CHART (CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-325
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-29 ENGINE SYMPTOM DIAGNOSTIC
DIAGNOSTICS ..............................................................................02-1 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-85
DIAGNOSTICS GASOLINE ENGINE CONTROL SYSTEM ENGINE TECHNICAL PARAMETERS
(BJ491EQ) ....................................................................................04-1 (ENGINE MECHANICAL PART) ......................... 15A-3, 15B-4, 15C-5
DIAGNOSTICS TROUBLE CODE (DTC) CHECK ENGINE TIMING CHAIN COVER .............................................15A-27
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-276 ENGINE TIMING GEAR .............................................. 15B-30, 15C-39
ENGINE TIMING GEAR COVER ................................ 15B-25, 15C-35
EXHAUST............................................................... 02-9, 03-20, 16B-1 FUEL PRECIPITATOR ASSY......................................12B-11, 12C-11
EXHAUST PIPE .............................................................. 16A-1, 16C-1 FUEL PUMP ASSY......................................................12A-12, 12D-13
EXTERIOR AND INTERIOR TRIM.............................................. 03-47 FUEL STRAINER ASSY ..............................................12B-16, 12C-16
FUEL SYSTEM ........................................ 12A-1, 12B-1, 12C-1, 12D-1
F FUEL TANK ASSY................................... 12A-5, 12B-5, 12C-5, 12D-6
FUEL TANK CAP..................................... 13A-1, 13B-1, 13C-1, 13D-1
F - ROOF WIRE HARNESS(CONNECTOR VIEWS)................ 71-183 FUSE AND RELAY LOCATIONS
F - ROOF WIRE HARNESS (HOW TO USE THIS MANUAL) ....................................................71-9
FAIL-SAFE CHART G
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-264
FAIL-SAFE CHART G - BATTERY NEGATIVE CABLE WIRE HARNESS
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-23 (CONNECTOR VIEWS).............................................................71-186
FAN CONTROL - WITH ENGINE BJ493 GASOLINE ENGINE CONTROL SYSTEM ................................ 11A-1
(WIRING DIAGRAM) ................................................................... 71-39 GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ).................04-1
FINAL DRIVE .............................................................................. 34-48 GENERAL INFORMATION(HOW TO TROUBLESHOOT)..........01-20
FINAL DRIVE OIL........................................................................ 34-55 GENERAL INFORMATION(HOW TO USE THIS MANUAL).........01-1
FLOOR DECORATIVE PARTS................................................... 88-26 GENERATOR ...................................................... 20A-4, 20B-4, 20C-4
FOG LAMP SWITCH................................................................... 64-24 GLOSSARY OF TERMS AND SYMBOLS
FRONT A/C SWITCH ILLUMINATION IS INOPERATIVE (HOW TO USE THIS MANUAL) ....................................................71-7
(LIGHT SYSTEM)...................................................................... 04-544 GLOW PLUG ............................................................................ 11C-32
(LIGHTING SYSTEM) ............................................................... 04-655 H
FRONT BLOWER........................................................................ 61-48
FRONT BRAKE ........................................................................... 35-19 H - FRONT DOOR RH WIRE HARNESS
FRONT BUMPER ASSY ............................................................... 88-4 (CONNECTOR VIEWS).............................................................71-187
FRONT DOME LIGHT ASSY ...................................................... 64-17 H - FRONT DOOR RH WIRE HARNESS
FRONT DOME LIGHT IS INOPERATIVE(LIGHT SYSTEM) .... 04-523 (WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-214
FRONT DOME LIGHT IS INOPERATIVE HAZARD SWITCH ILLUMINATION IS INOPERATIVE
(LIGHTING SYSTEM) ............................................................... 04-640 (LIGHT SYSTEM) ......................................................................04-550
FRONT DOOR .............................................................................. 87-1 HAZARD WARNING AND TURN SIGNAL LAMPS ARE
FRONT DOOR LOCKS ................................................................. 85-1 INOPERATIVE(LIGHTING SYSTEM)...........................04-498, 04-615
FRONT EVAPORATOR ASSY.................................................... 61-37 HAZARD WARNING LAMPS ARE ALWAYS ON
FRONT FOG LAMPS ARE ALWAYS ON (LIGHTING SYSTEM)...................................................04-506, 04-623
(LIGHTING SYSTEM) .................................................. 04-473, 04-591 HAZARD WARNING LAMPS ARE INOPERATIVE (TURN SIGNAL
FRONT FOG LAMPS ARE INOPERATIVE LAMPS ARE NORMAL)(LIGHTING SYSTEM)............04-486, 04-605
(LIGHTING SYSTEM) .................................................. 04-469, 04-587 HEATER AND AIR CONDITIONING ...................... 02-26, 03-41, 61-1
FRONT GRILLE ............................................................................ 88-1 HEATER AND AIR CONDITIONING SYSTEM .........................04-408
FRONT HEATER ASSY .............................................................. 61-16 HEATER AND CONDITIONING CONTROL SYSTEM
FRONT PARKING LAMPS ARE INOPERATIVE (WIRING DIAGRAM) ...................................................................71-55
(LIGHT SYSTEM)...................................................................... 04-552 HEATER PIPE .............................................................................61-13
FRONT PARKING LAMPS ARE INOPERATIVE HI-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)
(LIGHTING SYSTEM) ............................................................... 04-661 (LIGHTING SYSTEM)...................................................04-456, 04-573
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE HI-BEAM HEADLAMPS ARE INOPERATIVE (BOTH SIDES)
LAMP ARE INOPERATIVE(LIGHT SYSTEM) .......................... 04-558 (LIGHTING SYSTEM)...................................................04-458, 04-575
FRONT PARKING LAMPS, TAIL LAMPS AND LICENSE HIGH-MOUNTED STOP LAMP IS INOPERATIVE
LAMP ARE INOPERATIVE(LIGHTING SYSTEM) .................... 04-667 (LIGHTING SYSTEM)...................................................04-514, 04-631
FRONT POWER WINDOW IS INOPERATIVE HORN IS ALWAYS ON(HORN SYSTEM).................................04-732
(POWER WINDOWS) ............................................................... 04-788 HORN IS INOPERATIVE(HORN SYSTEM) ..............................04-728
FRONT POWER WINDOW LH DOES NOT CLOSE HORN SYSTEM.........................................................................04-726
(POWER WINDOWS) ............................................................... 04-794 HOW TO PERFORM DIAGNOSTICS ANALYSIS
FRONT POWER WINDOW LH DOES NOT OPEN (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-247
FRONT POWER WINDOW RH IS INOPERATIVE (DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)) ................04-134
FRONT SHOCK ABSORBER ..................................................... 31-10 (DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-171
FRONT SPEAKER ASSY.............................................................. 66-3 HOW TO PERFORM DIAGNOSTICS ANALYSIS
FRONT SUSPENSION............................................02-13, 03-26, 31-1 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ..............04-6
FRONT TIRE AND WHEEL........................................................... 33-8 HOW TO PROCEED WITH TROUBLESHOOTING
FRONT WHEEL ALIGNMENT ...................................................... 31-8 (HOW TO TROUBLESHOOT) .....................................................01-22
FRONT WINDOW RH IS INOPERATIVE (USING THE FRONT HOW TO TROUBLESHOOT .......................................................01-20
POWER WINDOW SWITCH RH)(POWER WINDOWS) .......... 04-813 HOW TO USE THIS MANUAL..............................................01-1, 71-1
FUEL .................................................................................... 02-3, 03-5 HYDRAULIC ADJUSTER / VALVE PUSH ROD....................... 15A-42
FUEL FILLING DOOR ................................... 12A-18, 12B-25, 12C-26 HYDRAULIC PRESSURE REGULATOR ....................................35-48
FUEL FILLING DOOR(CNG SUPPLY SYSTEM)........12D-20, 12D-26
FUEL FILTER ASSY ................................................... 12A-10, 12D-11
FUEL INJECTOR ASSY................................ 12B-23, 12C-23, 12D-15
FUEL INLET SOLENOID VALVE ..............................................11C-27
FUEL LEVEL SENSOR ASSY .........12A-11, 12B-15, 12C-15, 12D-12
J LIGHT SYSTEM(WIRING DIAGRAM)......................................... 71-62
LIGHTING.................................................................................... 03-43
LIGHTING SYSTEM......................................................... 04-443, 64-1
J - REAR HATCH WIRE HARNESS(CONNECTOR VIEWS)....71-188
J - REAR HATCH WIRE HARNESS LIST OF SYMPTOM OF FAILURE
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-223
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-215
LOAD SENSING PROPORTIONING AND
IDENTIFICATION INFORMATION ................................................01-7
IDLE AIR CONTROL MOTOR .................................... 11A-30, 11D-37 BY- PASS VALVE(LSP&BV) ....................................................... 35-42
LO-BEAM AND HI-BEAM HEADLAMPS ARE INOPERATIVE
IGNITION .....................................................................................03-23
(ONE SIDE)(LIGHTING SYSTEM)............................... 04-460, 04-578
IGNITION CONTROL MODULE ................................. 11A-67, 11D-74
IGNITION SWITCH ASSY .............................................................91-1 LO-BEAM HEADLAMP IS INOPERATIVE (ONE SIDE)
(LIGHTING SYSTEM) .................................................. 04-452, 04-568
(LIGHT SYSTEM) ......................................................................04-533
ILLUMINATED SYSTEM IS NOT INOPERATIVE (LIGHTING SYSTEM) .................................................. 04-454, 04-570
LOCATION (3 CONNECTORS)(INSTRUMENT CLUSTER) .... 04-885
(LIGHTING SYSTEM) ................................................................04-647
LOCATION (4 CONNECTORS)(INSTRUMENT CLUSTER) .... 04-844
INJECTOR CONTROL UNIT TERMINAL DIAGRAM
(CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-257 LOCATION(ANTI-LOCK BRAKE SYSTEM).............................. 04-369
LOCATION(AUDIO SYSTEM)................................................... 04-712
INJECTOR DRIVER.................................................................. 11D-22
LOCATION(CNG ENGINE CONTROL SYSTEM (4GC1))........ 04-245
INPUT SHAFT ASSY(INPUT SHAFT ASSY) ..............................41-59
INSPECTION AND ADJUSTMENT(DIFFERENTIAL ASSY).......34-66 LOCATION(COMBINED DISPLAY) .......................................... 04-735
LOCATION(DIESEL ENGINE CONTROL SYSTEM
INSPECTION ON VEHICLE
(BJ493ZQ))................................................................................ 04-131
(THROTTLE POSITION SENSOR) .......................................... 11C-18
INSPECTION(BATTERY) ..............................20A-25, 20B-26, 20C-26 LOCATION
INSPECTION(COMPRESSOR OIL) ............................................61-30
LOCATION
INSPECTION(DRIVE PINION) ....................................................34-81
INSPECTION(FUEL TANK CAP).........................13A-1, 13B-1, 13C-1 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)).............. 04-4
LOCATION(HEATER AND AIR CONDITIONING SYSTEM) .... 04-410
INSPECTION(IGNITION SWITCH ASSY) .....................................91-1
LOCATION(HORN SYSTEM) ................................................... 04-726
INSPECTION(POWER WINDOW) ................................................82-2
LOCATION(LIGHTING SYSTEM) ............................................. 04-445
INSPECTION(PROPELLER SHAFT ASSY)..................................34-4
LOCATION(OUTSIDE MIRROR) .............................................. 04-819
INSPECTION(SEAT BELT WARNING SYSTEM) .........................63-2
LOCATION(POWER DOOR LOCKS) ....................................... 04-917
INSPECTION(WASHER NOZZLE)..............................................65-17
LOCATION(POWER WINDOWS) ............................................. 04-776
INSTRUMENT CLUSTER.............................................. 04-843, 83-12
LOCATION(REAR WINDOW DEFROSTER SYSTEM) ............ 04-833
LOCATION(REVERSE RADAR SYSTEM) ............................... 04-749
(LIGHT SYSTEM) ......................................................................04-538
LOCATION(WIPER AND WASHER)......................................... 04-671
LOWER CONTROL ARM............................................................ 31-17
(LIGHTING SYSTEM) ................................................................04-651
LUBRICATION ................................................................. 02-11, 03-22
LUBRICATION SYSTEM..................................... 18A-1, 18B-1, 18C-1
(INSTRUMENT CLUSTER) ......................................... 04-845, 04-886
INSTRUMENT CLUSTER(WIRING DIAGRAM) ........................71-123
INSTRUMENT PANEL.................................................................02-31 M
INTAKE AIR ....................................................................... 02-5, 03-18
INTAKE AIR CONNECT PIPE .................................................. 14B-22 M - LEFT STEP WIRE HARNESS
INTAKE AIR HOSE ............................................14A-3, 14B-3, 14C-12 (CONNECTOR VIEWS) ............................................................ 71-195
INTAKE AIR SYSTEM ............................. 14A-1, 14B-1, 14C-1, 14D-1 MAIFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT
INTAKE MANIFOLD.......................................14A-13, 14B-26, 14C-24 NEVER OR ALWAYS ON(INSTRUMENT CLUSTER).............. 04-896
INTRODUCTION OF SYSTEM FUNCTION MAIN COMPONENTS
(CNG ENGINE CONTROL SYSTEM)....................................... 11D-10 (GASOLINE ENGINE CONTROL SYSTEM).............................11A-13
INTRODUCTION TO SYSTEM FUNCTION MAINTENANCE OF TURBOCHARGER
(GASOLINE ENGINE CONTROL SYSTEM) .............................. 11A-6 (TURBOCHARGER ASSY) ......................................... 14B-15, 14C-17
INTRODUCTION(HOW TO USE THIS MANUAL).........................71-1 MALFUCTION IN ENGINE COOLANT TEMPERATURE GAUGE
IN-VEHICLE TEMPERATURE DOES NOT DISPLAY OR (INSTRUMENT CLUSTER).......................................... 04-861, 04-900
DISPLAY INCORRECTLY(COMINED DISPLAY)......................04-742 MALFUCTION IN FUEL GAUGE / LOW FUEL WARNING LIGHT
NEVER OR ALWAYS ON(INSTRUMENT CLUSTER).............. 04-858
K MALFUCTION IN SPEEDOMETER
(INSTRUMENT CLUSTER)....................................................... 04-894
MALFUNCTION IN SPEEDOMETER
(CONNECTOR VIEWS) .............................................................71-190
K - FRONT EVAPORATOR WIRE HARNESS MALFUNCTION IN TACHOMETER
L TEMPERATURE SENSOR .......................................................11D-47
MIRROR ADJUSTMENT LEFT/RIGHT IS INOPERATIVE
(OUTSIDE MIRROR)................................................................. 04-831
MIRROR ADJUSTMENT UP/DOWN IS INOPERATIVE
(CONNECTOR VIEWS) .............................................................71-193
(OUTSIDE MIRROR)................................................................. 04-829
MIRRORS ARE INOPERATIVE (BOTH SIDES)
(OUTSIDE MIRROR)................................................................. 04-823
LICENCE LAMP ASSY ................................................................64-15
LICENSE LAMP IS INOPERATIVE(LIGHT SYSTEM)...............04-556
LICENSE LAMP IS INOPERATIVE(LIGHTING SYSTEM) ........04-665
N OVERHAUL(COMPRESSOR).....................................................61-46
OVERHAUL(CONDENSER)........................................................61-51
OVERHAUL(COOLANT FAN) .................................................. 17B-15
N - RIGHT STEP WIRE HARNESS
(CONNECTOR VIEWS) ............................................................ 71-196 OVERHAUL(COOLANT PUMP) .................... 17A-22, 17B-23, 17C-24
OVERHAUL
O (COOLANT TEMPERATURE SENSOR FOR FAN) ................. 11B-26
OVERHAUL(CRANKSHAFT/ENGINE BLOCK/FLYWHEEL) ... 15A-77
OVERHAUL(CYLINDER HEAD AND VALVE) ......................... 15C-44
OIL FILTER ......................................................... 18A-4, 18B-5, 18C-5
OVERHAUL(CYLINDER HEAD)..................................15A-52, 15A-60
OIL FILTER BRACKET ............................................... 18B-14, 18C-12
OVERHAUL(DIFFERENTIAL ASSY)...........................................34-70
OIL PAN .......................................................................... 18B-8, 18C-8 OVERHAUL(DOWNSTREAM OXYGEN SENSOR)....11A-54, 11D-61
OIL PUMP ....................................................... 18A-9, 18B-12, 18C-10
OVERHAUL(DRIVE PINION) ......................................................34-84
OLING SYSTEM..........................................................................17B-1
OVERHAUL(EGR COOLANT TEMPERATURE SENSOR) ..... 11B-21
ON VEHICLE INSPECTION OVERHAUL(EGR VACUUM REGULATOR) ............................ 11B-40
(CANISTER SOLENOID VALVE)..............................................11D-64
OVERHAUL(EGR VACUUM SOLENOID VALVE) ................... 11C-35
ON VEHICLE INSPECTION
OVERHAUL(EGR VALVE LIFT SENSOR)..................11B-35, 11C-23
(DOWNSTREAM OXYGEN SENSOR) .....................................11D-60 OVERHAUL(ELECTRONIC CONTROL EGR VALVE)............... 13C-5
ON VEHICLE INSPECTION(IDLE AIR CONTROL MOTOR) ...11A-31
OVERHAUL
(ENGINE ACCESSORY BELT) ..................... 15A-22, 15B-21, 15C-30
(THROTTLE POSITION SENSOR (TPS)) ................................11A-36 OVERHAUL(ENGINE BLOCK)....................................15B-56, 15C-65
OVERHAUL
(UPSTREAM OXYGEN SENSOR)............................................11D-56
(ENGINE COOLANT TEMPERATURE SENSOR) ......11A-20, 11D-27
ON VEHICLE INSPECT(COOLANT) ..........................................17A-9 OVERHAUL(ENGINE TIMING CHAIN) .................................... 15A-32
ON VEHICLE INSPECT
OVERHAUL(ENGINE TIMING GEAR) ........................15B-31, 15C-40
(COOLING SYSTEM)...............................17A-3, 17B-3, 17C-3, 17C-9
OVERHAUL(FRONT BRAKE) .....................................................35-20
ONE DOOR IS INOPERATIVE OVERHAUL(FRONT EVAPORATOR ASSY)..............................61-37
(USING THE KEY)(POWER DOOR LOCKS) ........................... 04-929
OVERHAUL(FRONT SHOCK ABSORBER)................................31-10
OVERHAUL
(AXLE HUB AND STEERING KNUCKLE) .................................. 34-21 (FUEL INJECTOR ASSY)................ 12A-14, 12B-23, 12C-23, 12D-15
OVERHAUL(FUEL INLET SOLENOID VALVE) ....................... 11C-28
(BRAKE VACUUM BOOSTER ASSY) ........................................ 35-15
OVERHAUL(FUEL PUMP ASSY)................................12A-12, 12D-13
OVERHAUL(GENERATOR) ................................ 20A-5, 20B-4, 20C-5
(CANISTER SOLENOID VALVE)..............................................11A-57 OVERHAUL(GLOW PLUG) ...................................................... 11C-32
ON-VEHICLE INSPECTION(CONDENSER) .............................. 61-50
OVERHAUL
(HYDRAULIC ADJUSTER / VALVE PUSH ROD) .................... 15A-42
(DOWNSTREAM OXYGEN SENSOR) .....................................11A-53 OVERHAUL(IDLE AIR CONTROL MOTOR)...............11A-32, 11D-39
ON-VEHICLE INSPECTION OVERHAUL(IGNITION CONTROL MODULE)............11A-69, 11D-76
(ENGINE ACCESSORY BELT)..................... 15A-20, 15B-19, 15C-28 OVERHAUL(INPUT SHAFT ASSY).............................................41-60
ON-VEHICLE INSPECTION(FINAL DRIVE) ............................... 34-52 OVERHAUL(MANIFOLD ABSOLUTE PRESSURE/INTAKE
ON-VEHICLE INSPECTION(FRONT SUSPENSION) .................. 31-7 TEMPERATURE SENSOR) ........................................11A-42, 11D-49
ON-VEHICLE INSPECTION OVERHAUL(OIL PUMP).................................. 18A-9, 18B-12, 18C-10
(HEATER AND AIR CONDITIONING) .......................................... 61-9 OVERHAUL
ON-VEHICLE INSPECTION(IDLE AIR CONTROL MOTOR) ...11D-38 (PISTON AND CONNECTING ROD ASSY)................15B-65, 15C-73
OVERHAUL(PISTON AND CONNECTING RODS) ................. 15A-65
(IGNITION CONTROL MODULE) ............................... 11A-68, 11D-75 OVERHAUL(POSITIVE CRANKCASE VENTILATION
ON-VEHICLE INSPECTION(MANIFOLD ABSOLUTE
VALVE (PCV VALVE))................................................................ 13A-5
PRESSURE/INTAKE TEMPERATURE SENSOR) ..... 11A-41, 11D-48
OVERHAUL(PREHEAT TEMPERATURE SENSOR) .............. 11B-30
ON-VEHICLE INSPECTION(POWER STEERING SYSTEM) ...... 52-7 OVERHAUL(PROPELLER SHAFT ASSY)....................................34-5
ON-VEHICLE INSPECTION(REAR BRAKE) .............................. 35-31
OVERHAUL(REAR AXLE HOUSING WELDING ASSEMBLY)...34-60
ON-VEHICLE INSPECTION(REAR SUSPENSION...................... 32-3
OVERHAUL(REAR BRAKE)........................................................35-32
ON-VEHICLE INSPECTION(REFRIGERANT) ........................... 61-21 OVERHAUL(REAR LEAF SPRING ASSY) ...................................32-6
ON-VEHICLE INSPECTION(STEERING SYSTEM) ..................... 51-6
OVERHAUL(REAR SHOCK ABSORBER) ....................................32-4
OVERHAUL(RETRACTOR ASSY)................................................63-8
(THROTTLE POSITION SENSOR (TPS) ) ...............................11D-43 OVERHAUL(ROCKER ARM/ROCKER SHAFT) ...................... 15A-37
ON-VEHICLE INSPECTION(TIRE AND WHEEL SYSTEM)......... 33-4
OVERHAUL(STARTER) ................................ 20A-13, 20B-14, 20C-14
OVERHAUL(STEERING BOX)....................................................52-30
(VEHICLE SPEED SENSOR) ..........11A-64, 11B-45, 11C-39, 11D-71 OVERHAUL(STEERING COLUMN ASSY) .................................51-15
OVERHAUL(STEERING KNUCKLE) ..........................................34-36
(UPSTREAM OXYGEN SENSOR)............................................11A-49
OVERHAUL(STEERING PROPELLER SHAFT ASSY) ..............51-20
ON-VEHICLE INSPECT(COOLANT) ..........................................17B-8 OVERHAUL(THERMOSTAT) ........................ 17A-20, 17B-20, 17C-21
OVERHAUL(ADJUSTMENT(STEERING WHEEL ASSY)) ........... 51-7
OVERHAUL(THROTTLE BODY ASSY) ................................... 14A-17
OVERHAUL(BRAKE MASTER CYLINDER ASSY) .................... 35-11
OVERHAUL(THROTTLE BODY).................................11A-27, 11D-34
OVERHAUL(CAMSHAFT)............................. 15A-47, 15B-51, 15C-60 OVERHAUL(THROTTLE POSITION SENSOR (TPS) ) ........... 11D-44
OVERHAUL(CANISTER SOLENOID VALVE) ............ 11A-58, 11D-65
OVERHAUL(THROTTLE POSITION SENSOR (TPS)) ............ 11A-37
OVERHAUL(CENTER SUPPORT BEARING) ............................ 34-15
OVERHAUL(TURBOCHARGER ASSY)................................... 14B-16
OVERHAUL(CHARCOAL CANISTER SOLENOID VALVE) .......13A-4 OVERHAUL(VACUUM REGULATOR)....................................... 13B-6
OVERHAUL(CHARCOAL CANISTER) .......................................13A-2
OVERHAUL(VALVE / VALVE SPRING)................................... 15B-45
OVERHAUL(CKP SENSOR)....................................... 11A-45, 11D-52
OVERHAUL(VALVE/VALVE SPRING)..................................... 15C-55
OVERHAUL(CLUTCH SLAVE CYLINDER) ................................ 42-13
OVERHAUL(CLUTCH SUB - ASSY)........................................... 42-16
OVERHAUL PRECAUTION(POWER WINDOWS)........................................ 04-775
(VEHICLE SPEED SENSOR) .......... 11A-65, 11B-46, 11C-40, 11D-72 PRECAUTION(PROPELLER SHAFT ASSY)................................ 34-1
OVERHAUL(U-JOINT).................................................................34-10 PRECAUTION(REPAIR INSTRUCTION).................................... 01-10
OVERHAUL(UPSTREAM OXYGEN SENSOR) ......... 11A-50, 11D-57 PRECAUTION(REVERSE RADAR SYSTEM) .......................... 04-748
OVERHAUL((CYLINDER HEAD ASSY)).................................. 15B-36 PRECAUTION(SEAT BELT SYSTEM) ......................................... 63-1
OUTPUT SHAFT ASSY ...............................................................41-42 PRECAUTION(SEAT) ................................................................... 84-1
OUTSIDE MIRROR....................................................................04-819 PRECAUTION
(STARTING AND CHARGING SYSTEM) ....................... 20A-1, 20B-1
P PRECAUTION(TIRE AND WHEEL SYSTEM) .............................. 33-1
PRECAUTION(WIPER AND WASHER SYSTEM)........................ 65-1
P - FRONT SIDE REVERSE RADAR WIRE HARNESS PRECAUTION(WIPER AND WASHER) ................................... 04-670
(CONNECTOR VIEWS) .............................................................71-197 PREHEAT CONTROL UNIT......................................................11B-52
P - FRONT SIDE REVERSE RADAR WIRE HARNESS PREHEAT TEMPERATURE SENSOR .....................................11B-29
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-215 PREPARATION(AXLE AND PROPELLER SHAFT) ................... 02-16
PARKING BRAKE............................................................ 02-20, 03-33 PREPARATION(BRAKE) ............................................................ 02-19
PARKING BRAKE SYSTEM ..........................................................36-1 PREPARATION(CLUTCH).......................................................... 02-23
PASSENGER SEAT ....................................................................84-15 PREPARATION(COOLING)........................................................ 02-10
PASSENGER SEAT BELT ............................................................63-3 PREPARATION(DIAGNOSTICS).................................................. 02-1
PISTON AND CONNECTING ROD ASSY ................. 15B-63, 15C-71 PREPARATION(DOOR LOCKS) ................................................ 02-33
PISTON AND CONNECTING RODS........................................ 15A-64 PREPARATION(DOORS) ........................................................... 02-34
POOR SOUND QUALITY(AUDIO SYSTEM).............................04-722 PREPARATION(EMISSION CONTROL) ...................................... 02-4
POSITIVE CRANKCASE VENTILATION VALVE PREPARATION(ENGINE CONTROL SYSTEM) .......................... 02-2
(PCV VALVE).............................................................................. 13A-5 PREPARATION(ENGINE MECHANICAL) .................................... 02-6
POWER DOOR LOCK SYSTEM(WIRING DIAGRAM)..............71-135 PREPARATION(EXHAUST) ......................................................... 02-9
POWER DOOR LOCKS.............................................................04-916 PREPARATION(FRONT SUSPENSION) ................................... 02-13
POWER MIRROR(WIRING DIAGRAM) ....................................71-119 PREPARATION(FUEL) ................................................................. 02-3
POWER SOCKET(WIRING DIAGRAM) ....................................71-110 PREPARATION(HEATER AND AIR CONDITIONING)............... 02-26
POWER SOURCE SECTION EXAMPLE PREPARATION(INSTRUMENT PANEL) .................................... 02-31
(HOW TO USE THIS MANUAL) ....................................................71-5 PREPARATION(INTAKE AIR) ...................................................... 02-5
POWER SOURCE(WIRING DIAGRAM)......................................71-13 PREPARATION(LUBRICATION) ................................................ 02-11
POWER STEERING ........................................................ 02-25, 03-39 PREPARATION(PARKING BRAKE) ........................................... 02-20
POWER STEERING LINE ASSY.................................................52-27 PREPARATION(POWER STEERING) ....................................... 02-25
POWER STEERING SYSTEM ......................................................52-1 PREPARATION(REAR SUSPENSION)...................................... 02-14
POWER WINDOW.........................................................................82-1 PREPARATION(SEAT BELT) ..................................................... 02-28
POWER WINDOW CONTROL(WIRING DIAGRAM).................71-139 PREPARATION(SEAT) ............................................................... 02-32
POWER WINDOWS ..................................................................04-775 PREPARATION(STARTING AND CHARGING) ......................... 02-12
PRE - CHECK(ANTI-LOCK BRAKE SYSTEM) .........................04-375 PREPARATION(STEERING COLUMN) ..................................... 02-24
PRECAUTION(ANTI-LOCK BRAKE SYSTEM) .........................04-368 PREPARATION(TIRE AND WHEEL).......................................... 02-15
PRECAUTION(AUDIO SYSTEM) ..............................................04-711 PREPARATION(TRANSMISSION) ............................................. 02-21
PRECAUTION(BRAKE SYSTEM) .................................................35-1 PREPARATION(VEHICLE CONTROL SYSTEM)....................... 02-35
PRECAUTION(CLUTCH SYSTEM)...............................................42-1 PREPARATION(WINDSHIELD).................................................. 02-30
PRECAUTION(CNG ENGINE CONTROL SYSTEM (4GC1)) ...04-242 PREPARATION(WIPER AND WASHER) ................................... 02-29
PRECAUTION(CNG ENGINE CONTROL SYSTEM) ................. 11D-1 PRINCIPLE(CANISTER SOLENOID VALVE)............. 11A-56, 11D-63
PRECAUTION(COMBINED DISPLAY)......................................04-734 PRINCIPLE(CKP SENSOR)........................................ 11A-44, 11D-51
PRECAUTION(COOLING SYSTEM)...................17A-1, 17B-1, 17C-1 PRINCIPLE
PRECAUTION(DASHBOARD) ......................................................83-1 (COOLANT TEMPERATURE SENSOR FOR FAN)..................11B-25
PRECAUTION PRINCIPLE(DOWNSTREAM OXYGEN SENSOR) .... 11A-52, 11D-59
(DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)) ................04-128 PRINCIPLE
PRECAUTION (EGR COOLANT TEMPERATURE SENSOR)............ 11B-20, 11C-13
(DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-166 PRINCIPLE(EGR VACUUM REGULATOR) .............................11B-39
PRECAUTION PRINCIPLE(EGR VALVE CONTROL UNIT).............................11B-16
(DIESEL ENGINE CONTROL SYSTEM)........................ 11B-1, 11C-1 PRINCIPLE
PRECAUTION (EGR VALVE ELECTRONIC CONTROL MODULE)...................11C-9
(ENGINE MECHANICAL PART)..........................15A-1, 15B-1, 15C-1 PRINCIPLE(EGR VALVE LIFT SENSOR) .................. 11B-34, 11C-22
PRECAUTION(FINAL DRIVE) .....................................................34-48 PRINCIPLE(ENGINE CONTROL MODULE (ECM)) ... 11A-15, 11D-18
PRECAUTION(FRONT SUSPENSION) ........................................31-1 PRINCIPLE
PRECAUTION(FUEL SYSTEM) .............. 12A-1, 12B-1, 12C-1, 12D-1 (ENGINE COOLANT TEMPERATURE SENSOR)...... 11A-19, 11D-26
PRECAUTION PRINCIPLE(ENGINE RELAY BOX) ..........................................11B-56
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ..............04-1 PRINCIPLE(FUEL INLET SOLENOID VALVE).........................11C-27
PRECAUTION(GASOLINE ENGINE CONTROL SYSTEM)....... 11A-1 PRINCIPLE(IDLE AIR CONTROL MOTOR) ............... 11A-30, 11D-37
PRECAUTION PRINCIPLE(IGNITION CONTROL MODULE) ............ 11A-67, 11D-74
(HEATER AND AIR CONDITIONING SYSTEM) .......................04-408 PRINCIPLE(INJECTOR DRIVER).............................................11D-22
PRECAUTION(HEATER AND AIR CONDITIONING) ...................61-5 PRINCIPLE(MANIFOLD ABSOLUTE PRESSURE/INTAKE
PRECAUTION(INSTRUMENT CLUSTER).................... 04-843, 83-12 TEMPERATURE SENSOR) ........................................ 11A-40, 11D-47
PRECAUTION(INTAKE AIR SYSTEM) ...............14A-1, 14B-1, 14C-1 PRINCIPLE(PREHEAT CONTROL UNIT) ................................11B-52
PRECAUTION(LIGHTING SYSTEM) .............................. 04-443, 64-1 PRINCIPLE(PREHEAT TEMPERATURE SENSOR)................11B-29
PRECAUTION(LUBRICATION SYSTEM) ...........18A-1, 18B-1, 18C-1 PRINCIPLE(THROTTLE POSITION SENSOR (TPS) ) ............11D-42
PRECAUTION(POWER DOOR LOCKS)...................................04-916 PRINCIPLE(THROTTLE POSITION SENSOR (TPS)) .............11A-35
PRECAUTION(POWER STEERING SYSTEM) ............................52-1 PRINCIPLE(THROTTLE POSITION SENSOR).......... 11B-48, 11C-17
PRINCIPLE P0113 - IAT CIRCUIT HIGH VOLTAGE
(VEHICLE SPEED SENSOR) ..........11A-63, 11B-44, 11C-38, 11D-70 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-48
PRINCIPLE(UPSTREAM OXYGEN SENSOR)........... 11A-48, 11D-55 P0115-1 - ECT TOO LOW
PROBLEM SYMPTOMS TABLE - EARLY PRODUCTION (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-276
(LIGHT SYSTEM)...................................................................... 04-563 P0115-2 - ECT TOO HIGH
PROBLEM SYMPTOMS TABLE - 09 LATE PRODUCTION (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-276
(LIGHTING SYSTEM) ............................................................... 04-447 P0117 - ECT CIRCUIT LOW VOLTAGE
PROBLEM SYMPTOMS TABLE (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-37
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-324 P0118 - ECT CIRCUIT HIGH VOLTAGE
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-84 P0120-1 - THROTTLE POSITION TOO HIGH
PROBLEM SYMPTOMS TABLE (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-290
(ANTI-LOCK BRAKE SYSTEM) ................................................ 04-373 P0120-2 - THROTTLE POSITION TOO LOW
PROBLEM SYMPTOMS TABLE(AUDIO SYSTEM) ................. 04-715 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-290
PROBLEM SYMPTOMS TABLE P0122 - TPS CIRCUIT LOW VOLTAGE OR OPEN
(AXLE HUB AND STEERING KNUCKLE) .................................. 34-19 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-52
PROBLEM SYMPTOMS TABLE(BRAKE SYSTEM)..................... 35-2 P0123 - TPS CIRCUIT HIGH VOLTAGE
PROBLEM SYMPTOMS TABLE(CLUTCH SYSTEM) .................. 42-2 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-52
PROBLEM SYMPTOMS TABLE(COMINED DISPLAY) ........... 04-738 P0130-4 - OXYGEN SENSOR NO SIGNAL
(COOLING SYSTEM).......................................... 17A-2, 17B-2, 17C-2 P0131 - O2S 1 CIRCUIT LOW VOLTAGE
(ENGINE MECHANICAL PART) ......................... 15A-2, 15B-2, 15C-2 P0132 - O2S 1 CIRCUIT HIGH VOLTAGE
PROBLEM SYMPTOMS TABLE(FINAL DRIVE) ........................ 34-50 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-58
PROBLEM SYMPTOMS TABLE(FRONT SUSPENSION)............ 31-2 P0134 - O2S 1 CIRCUIT INSUFFICIENT ACTIVITY OR OPEN
(FUEL SYSTEM) ......................................12A-3, 12B-3, 12C-3, 12D-3 P0170-1 - OXYGEN SENSOR SIGNAL RICH FOR A
PROBLEM SYMPTOMS TABLE LONG TIME(CNG ENGINE CONTROL SYSTEM (4GC1)).......04-295
(HEATER AND AIR CONDITIONING SYSTEM)....................... 04-412 P0170-2 - OXYGEN SENSOR SIGNAL LEAN FOR A
PROBLEM SYMPTOMS TABLE LONG TIME(CNG ENGINE CONTROL SYSTEM (4GC1)).......04-295
(HEATER AND AIR CONDITIONING) .......................................... 61-5 P0201 - INJECTOR 1 CIRCUIT MALFUNCTION
PROBLEM SYMPTOMS TABLE(HORN SYSTEM) .................. 04-727 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-65
PROBLEM SYMPTOMS TABLE P0335-0 - NO 58X CKP SENSOR SIGNAL
(INSTRUMENT CLUSTER).......................................... 04-851, 04-891 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-302
PROBLEM SYMPTOMS TABLE(OUTSIDE MIRROR) ............. 04-822 P0335-8 - 58X CKP SENSOR CIRCUIT FAULT
PROBLEM SYMPTOMS TABLE(PARKING BRAKE SYSTEM) ... 36-1 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-302
PROBLEM SYMPTOMS TABLE(POWER DOOR LOCKS) ...... 04-921 P0336 - CKP SENSOR CIRCUIT PERFORMANCE
(POWER STEERING SYSTEM) ................................................... 52-2 P0337 - CKP SENSOR CIRCUIT MALFUNCTION
PROBLEM SYMPTOMS TABLE(POWER WINDOWS)............ 04-781 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-72
PROBLEM SYMPTOMS TABLE(PROPELLER SHAFT ASSY).... 34-2 P0480 - FAN 1 FAULT
PROBLEM SYMPTOMS TABLE(REAR SUSPENSION ............... 32-1 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-77
PROBLEM SYMPTOMS TABLE P0480-1 - FAN RELAY SHORT TO THE BATTERY
(REAR WINDOW DEFROSTER SYSTEM) .............................. 04-836 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-307
PROBLEM SYMPTOMS TABLE P0480-2 - FAN RELAY SHORT TO GROUND OR OPEN
(REVERSE RADAR SYSTEM).................................................. 04-753 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-307
PROBLEM SYMPTOMS TABLE P0481 - FAN 2 FAULT
(STARTING AND CHARGING SYSTEM) ........... 20A-2, 20B-2, 20C-2 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-77
PROBLEM SYMPTOMS TABLE(STEERING SYSTEM) ..... 51-1, 51-2 P0481-1 - FAN RELAY SHORT TO THE BATTERY
(TIRE AND WHEEL SYSTEM)...................................................... 33-3 P0481-2 - FAN RELAY SHORT TO GROUND OR OPEN
(WIPER AND WASHER SYSTEM) ............................................... 65-2 P1106 - MAP CIRCUIT HIGH INTERMITTENT
PROBLEM SYMPTOMS TABLE(WIPER AND WASHER) ....... 04-675 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-42
P0105-1 - MAP PRESSURE TOO HIGH P1107 - MAP CIRCUIT LOW INTERMITTENT
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-281 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-42
P0105-2 - MAP PRESSURE TOO LOW P1121 - TPS CIRCUIT HIGH INTERMITTENT
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-281 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-52
P0107 - MAP CIRCUIT LOW VOLTAGE OR OPEN P1122 - TPS CIRCUIT LOW INTERMITTENT
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-42 (GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ)) ............04-52
P0108 - MAP CIRCUIT HIGH VOLTAGE P1297 - HIGH PRESSURE SOLENOID VALVE RELAY FAULT
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-42 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-314
P0110-1 - INLET AIR TEMPERATURE TOO LOW P1299 - FUEL SELECTION RELAY FAULT
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-286 (CNG ENGINE CONTROL SYSTEM (4GC1))...........................04-319
P0110-2 - INLET AIR TEMPERATURE TOO HIGH
(CNG ENGINE CONTROL SYSTEM (4GC1)) .......................... 04-286
P0112 - IAT CIRCUIT LOW VOLTAGE OR OPEN
(GASOLINE ENGINE CONTROL SYSTEM (BJ491EQ))............ 04-48
Q REPLACEMENT(BUCKLE ASSY) ................................................ 63-7
REPLACEMENT(CLUTCH MASTER CYLINDER ASSY)............. 42-8
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS REPLACEMENT(CLUTCH PEDAL).............................................. 42-5
(CONNECTOR VIEWS) .............................................................71-199 REPLACEMENT(CNG SUPPLY SYSTEM) ..............................12D-21
Q - LEFT SIDE REVERSE RADAR WIRE HARNESS REPLACEMENT(COMBINATION SWITCH ASSY) ......... 51-12, 64-21
(WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-215 REPLACEMENT(COMPRESSOR OIL) ...................................... 61-31
REPLACEMENT(COOLANT).............................. 17A-5, 17B-5, 17C-5
R REPLACEMENT(COUNTER SHAFT ASSY AND
REVERSE IDLER GEAR SHAFT)............................................... 41-58
REPLACEMENT(DASHBOARD) .................................................. 83-3
R - REVERSE RADAR REAR BUMPER WIRE HARNESS
REPLACEMENT(EGR VALVE CONTROL UNIT).....................11B-17
REPLACEMENT
RADIATOR.........................................................17A-10, 17B-9, 17C-8
(EGR VALVE ELECTRONIC CONTROL MODULE).................11C-10
RADIO ANTENNA ASSY ...............................................................66-6
REPLACEMENT
RADIO ASSY .................................................................................66-2
(ELECTRONIC CONTROL EGR VALVE) ....................... 13B-3, 13C-3
RADIO DOES NOT WORK(AUDIO SYSTEM) ..........................04-716
REPLACEMENT
RADIO RECEPTION IS POOR(AUDIO SYSTEM) ....................04-721
(ELECTRONIC CONTROL VE DISPENSING PUMP ASSY) ...12C-18
RADIO(WIRING DIAGRAM) ......................................................71-108
REPLACEMENT(ENGINE ASSY)....................... 15A-4, 15B-5, 15C-6
REPLACEMENT
CODE (DTC)(CNG ENGINE CONTROL SYSTEM (4GC1))......04-260
(ENGINE CONTROL MODULE (ECM)) ...................... 11A-16, 11D-19
REPLACEMENT(ENGINE OIL)................18A-2, 18B-3, 18B-5, 18C-3
CODE (DTC)(DIESEL ENGINE CONTROL SYSTEM (4D20) ).04-183
REPLACEMENT(ENGINE RELAY BOX) ..................................11B-57
REPLACEMENT(ENGINE TIMING GEAR COVER)... 15B-25, 15C-35
CODE (DTC)(GASOLINE ENGINE CONTROL SYSTEM
REPLACEMENT(EXHAUST MANIFOLD)........... 16A-7, 16B-7, 16C-8
(BJ491EQ)) ..................................................................................04-20
REPLACEMENT(EXHAUST PIPE) ..................... 16A-2, 16B-2, 16C-2
REAR .........................................................................................04-475
REPLACEMENT(FINAL DRIVE OIL) .......................................... 34-55
REAR AXLE HOUSING WELDING ASSEMBLY .........................34-60
REPLACEMENT(FLOOR DECORATIVE PARTS) ..................... 88-27
REAR BRAKE ..............................................................................35-30
REPLACEMENT(FRONT BLOWER) .......................................... 61-48
REAR BUMPER ASSY ................................................................88-11
REPLACEMENT(FRONT BUMPER ASSY).................................. 88-5
REAR COMBINATION LAMP ASSY ...........................................64-13
REPLACEMENT(FRONT DOME LIGHT ASSY)......................... 64-17
REAR DOME LIGHT ASSY .........................................................64-19
REPLACEMENT(FRONT DOOR LOCKS).................................... 85-2
REAR DOME LIGHT IS INOPERATIVE(LIGHT SYSTEM) .......04-526
REPLACEMENT(FRONT DOOR) ................................................. 87-3
REPLACEMENT(FRONT GRILLE) ............................................... 88-2
(LIGHTING SYSTEM) ................................................................04-642
REPLACEMENT(FRONT HEATER ASSY)................................. 61-16
REAR DOME LIGHT SWITCH.....................................................64-25
REPLACEMENT(FRONT SPEAKER ASSY) ................................ 66-3
REAR EVAPORATOR ASSY.......................................................61-42
REPLACEMENT(FRONT TIRE AND WHEEL) ............................. 33-8
REPLACEMENT
(LIGHTING SYSTEM) .................................................. 04-478, 04-596
(FUEL FILLING DOOR)....................12A-18, 12B-25, 12C-26, 12D-26
REPLACEMENT(FUEL LEVEL SENSOR ASSY) ....... 12B-15, 12C-15
(LIGHTING SYSTEM) .................................................. 04-475, 04-593
REPLACEMENT(FUEL PRECIPITATOR ASSY)........ 12B-11, 12C-11
REAR HATCH..............................................................................87-11
REPLACEMENT(FUEL STRAINER ASSY) .. 12B-16, 12B-18, 12C-16
REAR HATCH LOCK ...................................................................85-13 REPLACEMENT(FUEL TANK ASSY)......12A-5, 12B-6, 12C-6, 12D-6
REAR LEAF SPRING ASSY..........................................................32-6 REPLACEMENT(HEATER PIPE) ............................................... 61-13
REAR SHOCK ABSORBER ..........................................................32-4 REPLACEMENT(HYDRAULIC PRESSURE REGULATOR) ...... 35-48
REAR SUSPENSION....................................................... 02-14, 03-27 REPLACEMENT(INJECTOR DRIVER).....................................11D-23
REAR SUSPENSION REAR SUSPENSION .................................32-1 REPLACEMENT(INSTRUMENT CLUSTER).............................. 83-14
REAR TIRE AND WHEEL..............................................................33-9 REPLACEMENT(INTAKE AIR CONNECT PIPE) .....................14B-22
REAR VIEW MIRROR .................................................................82-15 REPLACEMENT(INTAKE AIR HOSE) .............. 14A-3, 14B-3, 14C-12
REAR WINDOW DEFROSTER SYSTEM .................................04-833 REPLACEMENT(INTAKE MANIFOLD)......... 14A-14, 14B-26, 14C-24
REAR WINDOW DEFROSTER(WIRING DIAGRAM)................71-121 REPLACEMENT(LICENCE LAMP ASSY) .................................. 64-15
REAR WINDOW GLASS .............................................................82-10 REPLACEMENT(LOAD SENSING PROPORTIONING
REFRIGERANT ...........................................................................61-21
AND BY- PASS VALVE(LSP&BV)) ............................................. 35-44
REMOVAL & INSTALLATION AND DISASSEMBLY &
REPLACEMENT(LOWER CONTROL ARM) .............................. 31-17
REASSEMBLY(IGNITION SWITCH ASSY)...................................91-2 REPLACEMENT(OIL FILTER BRACKET) .................. 18B-14, 18C-12
REMOVAL & INSTALLATION AND DISASSEMBLY &
REPLACEMENT(OIL FILTER) ........................................ 18A-4, 18C-5
REASSEMLBY((DRIVER / ASSISTANT DRIVER SEAT)) ............84-8
REPLACEMENT(OIL PAN) ............................................. 18B-9, 18C-8
REMOVAL & INSTALLATION(PASSENGER SEAT) ..................84-17 REPLACEMENT(POWER STEERING FLUID RESERVIOR)..... 52-19
REPAIR INSTRUCTION ..............................................................01-10
REPLACEMENT(POWER STEERING LINE ASSY)................... 52-27
REPLACEMENT(ACCUMULATOR) ............................................61-54
REPLACEMENT(POWER WINDOW)........................................... 82-3
REPLACEMENT(AIR FILTER ASSY)..................14A-6, 14B-6, 14C-7 REPLACEMENT(PREHEAT CONTROL UNIT) ........................11B-53
REPLACEMENT
REPLACEMENT(RADIATOR)....................... 17A-11, 17B-10, 17C-10
(AIR STRAINING BOX ASSY) .........................14A-10, 14B-11, 14C-4
REPLACEMENT(RADIO ANTENNA ASSY) ................................. 66-6
REPLACEMENT(AXLE HUB) ......................................................34-25 REPLACEMENT(RADIO ASSY) ................................................... 66-2
REPLACEMENT(AXLE SHAFT ASSY) .......................................34-58
REPLACEMENT(REAR BUMPER ASSY) .................................. 88-12
REPLACEMENT(A/C CONTROLLER) ........................................61-56
REPLACEMENT(REAR COMBINATION LAMP ASSY) ............. 64-13
REPLACEMENT(A/C PIPE).........................................................61-32 REPLACEMENT(REAR DOME LIGHT ASSY) ........................... 64-19
REPLACEMENT(BATTERY) .........................20A-27, 20B-28, 20C-28
REPLACEMENT(REAR DOME LIGHT SWITCH)....................... 64-25
REPLACEMENT(BRAKE ACTUATOR LEVER SUB-ASSY).......36-10
REPLACEMENT(REAR EVAPORATOR ASSY)......................... 61-42
REPLACEMENT(BRAKE PEDAL).................................................35-8 REPLACEMENT(REAR HATCH LOCK) ..................................... 85-14
REPLACEMENT(BRAKE VACUUM BOOSTER ASSY)..............35-16
REPLACEMENT(REAR HATCH)................................................ 87-13 SERVICE DATA(EMISSION CONTROL) ......................................03-8
REPLACEMENT(REAR TIRE AND WHEEL)................................ 33-9 SERVICE DATA(ENGINE CONTROL SYSTEM) ..........................03-2
REPLACEMENT(REAR VIEW MIRROR) ................................... 82-16 SERVICE DATA(EXHAUST) .......................................................03-20
REPLACEMENT(REFRIGERANT) ............................................. 61-27 SERVICE DATA(FRONT SUSPENSION) ...................................03-26
REPLACEMENT(ROOF PANEL) ................................................ 88-30 SERVICE DATA(FUEL) .................................................................03-5
REPLACEMENT(SIDE WALL GUARD BOARD) ........................ 88-25 SERVICE DATA(HEATER AND AIR CONDITIONING) ..............03-41
REPLACEMENT(SIDE WINDOW GLASS) ................................. 82-14 SERVICE DATA(IGNITION) ........................................................03-23
REPLACEMENT(SILICONE OIL FAN AND FAN COWL).........17C-17 SERVICE DATA(INTAKE AIR) ....................................................03-18
REPLACEMENT(SLIDING DOOR LOCKS).................................. 85-8 SERVICE DATA(POWER STEERING) .......................................03-39
REPLACEMENT(SLIDING DOOR) ............................................. 87-10 SERVICE DATA(STARTING AND CHARGING) .........................03-24
REPLACEMENT(STABILIZER BAR) .......................................... 31-21 SERVICE DATA(STEERING COLUMN) .....................................03-38
REPLACEMENT(STEERING FLUID) ......................................... 52-15 SERVICE DATA(TIRE AND WHEEL)..........................................03-28
REPLACEMENT(STEP BOARD) ................................................ 88-18 SERVICE DATA(TRANSMISSION).............................................03-34
REPLACEMENT(STRUT ROD) .................................................. 31-25 SIDE WALL GUARD BOARD ......................................................88-25
REPLACEMENT(SUN VISOR ASSY)......................................... 88-15 SIDE WINDOW GLASS...............................................................82-13
REPLACEMENT SILICONE OIL FAN AND FAN COWL...................................... 17C-17
(THROTTLE POSITION SENSOR)............................. 11B-49, 11C-19 SLIDING DOOR.............................................................................87-7
REPLACEMENT(TORSION BAR SPRING)................................ 31-13 SLIDING DOOR LOCKS................................................................85-7
REPLACEMENT SPEAKER DOES NOT WORK(AUDIO SYSTEM) ....................04-723
(TRANSMISSION OPERATION MECHANISM ASSY) ................. 41-4 SPECIFIED TORQUE FOR SPECIFICATION BOLTS..................03-1
REPLACEMENT(TURBOCHARGER ASSY) ............................14C-18 STABILIZER BAR ........................................................................31-21
REPLACEMENT(VEHICLE DOOR INNER GUARD BOARD) .... 88-19 STARTER ...................................................... 20A-12, 20B-13, 20C-13
REPLACEMENT(VEHICLE SPEED SENSOR) .......................... 35-50 STARTING AND CHARGING...........................................02-12, 03-24
REPLACEMENT(VENT DUCT)................................................... 61-11 STARTING AND CHARGING SYSTEM .. 20A-1, 20B-1, 20C-1, 20D-1
REPLACEMENT(WHEEL FENDER)............................................. 88-9 STARTING SYSTEM(WIRING DIAGRAM) .................................71-44
REPLACEMENT(WINDSHIELD)................................................... 82-7 STEERING BOX ..........................................................................52-30
REPLACEMENT(WIPER ASSY)................................................... 65-5 STEERING COLUMN .......................................................02-24, 03-38
REPLACEMENT(WIPER BLADE WITH BRACKET ASSY)........ 65-16 STEERING COLUMN ASSY .......................................................51-15
REPLACEMENT(WIPER MOTOR ASSY) .................................... 65-9 STEERING KNUCKLE.................................................................34-35
REPLACEMENT(UPPER CONTROL ARM) ............................... 31-15 STEERING PROPELLER SHAFT ASSY.....................................51-20
REPLACENEMT(ENGINE TIMING CHAIN COVER)................15A-27 STEERING WHEEL ASSY ............................................................51-7
REPLACMENT(FUEL FILTER ASSY) ........................ 12A-10, 12D-11 STEP BOARD..............................................................................88-17
REPLACMENT(FUEL LEVEL SENSOR ASSY) ......... 12A-11, 12D-12 STEP LAMPS ARE INOPERATIVE(LIGHT SYSTEM) ..............04-530
REPLAEMENT(FOG LAMP SWITCH) ........................................ 64-24 STEP LAMPS ARE INOPERATIVE(LIGHTING SYSTEM)........04-645
RETRACTOR ASSY...................................................................... 63-8 STOP LAMP IS INOPERATIVE (ONE SIDE)
REVERSE DATA DOES NOT DISPLAY OR DISPLAY (LIGHTING SYSTEM)...................................................04-512, 04-629
INCORRECTLY(COMINED DISPLAY) ..................................... 04-746 STOP LAMPS ARE INOPERATIVE
REVERSE RADAR SYSTEM .................................................... 04-748 (BOTH SIDES)(LIGHTING SYSTEM)...........................04-509, 04-626
REVERSE RADAR SYSTEM IS INOPERATIVE AT ALL STRUT ROD ................................................................................31-25
(REVERSE RADAR SYSTEM).................................................. 04-755 SUN VISOR ASSY.......................................................................88-14
REVERSE RADAR SYSTEM IS INOPERATIVE WITHIN SYMPTOM OF FAILURE
SPECIFIED DISTANCE(REVERSE RADAR SYSTEM) ........... 04-764 (DIESEL ENGINE CONTROL SYSTEM (BJ493ZQ)) ................04-144
REVERSE RADAR SYSTEM IS OPERATIVE BUT SYSTEM COMPONENTS DESCRIPTION
THERE IS NO OBSTACLE BEHIND VEHICLE (CNG ENGINE CONTROL SYSTEM) ...................................... 11D-17
(REVERSE RADAR SYSTEM).................................................. 04-767 SYSTEM COMPONENTS DESCRIPTION
REVERSE RADAR SYSTEM IS OPERATIVE WHEN THE (GASOLINE ENGINE CONTROL SYSTEM) ............................ 11A-14
SHIFT LEVER IS OUT OF REVERSE POSITION SYSTEM DESCRIPTION
(REVERSE RADAR SYSTEM).................................................. 04-762 (REAR WINDOW DEFROSTER SYSTEM)...............................04-834
ROAD TEST(FRONT SUSPENSION)........................................... 31-4 SYSTEM DESCRIPTION(REVERSE RADAR SYSTEM)..........04-750
ROCKER ARM/ROCKER SHAFT .............................................15A-37 SYSTEM DESCRIPTION(WIPER AND WASHER) ...................04-673
ROOF PANEL ............................................................................. 88-29 SYSTEM FUNCTION INTRODUCTION
(DIESEL ENGINE CONTROL SYSTEM).........................11B-8, 11C-5
S SYSTEM OVERVIEW(CNG ENGINE CONTROL SYSTEM) ..... 11D-2
SYSTEM OVERVIEW
S - SIDE OF CHASSIS HARNESS(CONNECTOR VIEWS) ..... 71-201 (DIESEL ENGINE CONTROL SYSTEM).........................11B-2, 11C-2
S - SIDE OF CHASSIS HARNESS SYSTEM OVERVIEW
(WIRE HARNESS & CONNECTOR LOCATION VIEWS)......... 71-215 (GASOLINE ENGINE CONTROL SYSTEM) .............................. 11A-2
SEAT .......................................................................02-32, 03-45, 84-1 SYSTEM WIRING DIAGRAM SECTION EXAMPLE
SEAT BELT ...................................................................... 02-28, 03-42 (HOW TO USE THIS MANUAL) ....................................................71-2
SEAT BELT SYSTEM ................................................................... 63-1
SEAT BELT WARNING SYSTEM ................................................. 63-2 T
SELF-CHECK FUNCTION IS INOPERATIVE
(REVERSE RADAR SYSTEM).................................................. 04-759 T - CHASSIS HARNESS(CONNECTOR VIEWS) .....................71-202
SERIAL NUMBER (SN)(IDENTIFICATION INFORMATION)........ 01-9 T - CHASSIS HARNESS
SERVICE DATA(AXLE AND PROPELLER SHAFT)................... 03-29 (WIRE HARNESS & CONNECTOR LOCATION VIEWS) .........71-215
SERVICE DATA(BRAKE)............................................................ 03-32 TAIL LAMPS ARE INOPERATIVE(LIGHT SYSTEM)................04-554
SERVICE DATA(CLUTCH) ......................................................... 03-37 TAIL LAMPS ARE INOPERATIVE(LIGHTING SYSTEM) .........04-663
SERVICE DATA(COOLING) ....................................................... 03-21 TERMINALS OF COMBINED DISPLAY
SERVICE DATA(DOOR) ............................................................. 03-46 (COMBINED DISPLAY) .............................................................04-736
TERMINALS OF INSTRUMENT CLUSTER W
(INSTRUMENT CLUSTER) ......................................... 04-847, 04-888
TERMINALS OF MAIN POWER WINDOW
U - FUEL TANK WIRE HARNESS(CONNECTOR VIEWS) ...... 71-203
LOCK/UNLOCK SWITCH(POWER WINDOWS) .......................04-777 U - FUEL TANK WIRE HARNESS
TERMINALS OF OUTSIDE MIRROR DEFROST SWITCH
(OUTSIDE MIRROR) .................................................................04-820
VACUUM REGULATOR.................................................. 13B-6, 13C-5
TERMINALS OF POWER DOOR LOCK CONTROL UNIT VALVE / VALVE SPRING..........................................................15B-45
(POWER DOOR LOCKS) ..........................................................04-918
VALVE/VALVE SPRING.............................................. 15A-60, 15C-55
TERMINALS OF POWER WINDOW CONTROLLER
WASHER NOZZLE...................................................................... 65-17
(POWER WINDOWS) ................................................................04-779 WASHER PUMP IS INOPERATIVE - REAR WINDOW
TERMINALS OF POWER WINDOW SWITCH RH
(WIPER AND WASHER) ........................................................... 04-708
(POWER WINDOWS) ................................................................04-778
WASHER PUMP IS INOPERATIVE - WINDSHIELD
TERMINALS OF RADIO(AUDIO SYSTEM)...............................04-713 (WIPER AND WASHER) ........................................................... 04-694
TERMINALS OF REMOTE KEYLESS ENTRY RECEIVER
VE DISPENSING PUMP ASSY.................................................12B-17
(POWER DOOR LOCKS) ..........................................................04-919
VE PUMP BASIC STRUCTURE
TERMS.........................................................................................01-35 (DIESEL ENGINE CONTROL SYSTEM) ..................................11B-10
THE FIXED SPEED ADJUSTING SCREW
VEHICLE CONTROL SYSTEM........................................ 02-35, 03-48
(SAS) ADJUSTMENT(THROTTLE BODY)................. 11A-25, 11D-32
VEHICLE DOOR INNER GUARD BOARD ................................. 88-19
THE FUNCTION OF POWER DOOR LOCKS IS INOPERATIVE VEHICLE IDENTIFICATION NUMBER (VIN)
(USING THE KEY)(POWER DOOR LOCKS) ............................04-923
(IDENTIFICATION INFORMATION) ............................................. 01-7
THERMOSTAT ..............................................17A-20, 17B-20, 17C-21
VEHICLE LIFT AND SUPPORT LOCATIONS
THROTTLE BODY ...................................................... 11A-24, 11D-31 (REPAIR INSTRUCTION) ........................................................... 01-18
THROTTLE BODY ASSY ......................................................... 14A-17
VEHICLE SPEED
THROTTLE BODY CLEANING(THROTTLE BODY) .. 11A-24, 11D-31
SENSOR .............................. 11A-63, 11B-44, 11C-38, 11D-70, 35-50
THROTTLE POSITION SENSOR............................... 11B-48, 11C-17 VENT DUCT ................................................................................ 61-10
THROTTLE POSITION SENSOR (TPS) .................... 11A-35, 11D-42
WHEEL FENDER .......................................................................... 88-9
TIRE AND WHEEL........................................................... 02-15, 03-28
WHEN THE WIPER SWITCH IS OFF, THE WIPER
TIRE AND WHEEL SYSTEM.........................................................33-1 BLADE DOES NOT RETRACT(WIPER AND WASHER) ......... 04-697
WINDSHIELD ..................................................................... 02-30, 82-6
(AXLE AND PROPELLER SHAFT)..............................................03-30
U-JOINT ........................................................................................ 34-9
TORQUE SPECIFICATION(BRAKE)...........................................03-32
WIPER....................................................................................... 04-670
TORQUE SPECIFICATION(CLUTCH) ........................................03-37 WIPER AND WASHER .......................................02-29, 03-44, 04-670
TORQUE SPECIFICATION(COOLING) ......................................03-21
WIPER AND WASHER SYSTEM.................................................. 65-1
TORQUE SPECIFICATION(DOOR) ............................................03-46
WIPER AND WASHER(WIRING DIAGRAM)............................ 71-105
TORQUE SPECIFICATION(EMISSION CONTROL)......... 03-7, 03-15 WIPER ASSY ................................................................................ 65-5
TORQUE SPECIFICATION(ENGINE CONTROL SYSTEM).........03-3
WIPER BLADE WITH BRACKET ASSY ..................................... 65-16
TORQUE SPECIFICATION(EXHAUST)......................................03-20
WIPER IS INOPERATIVE - REAR WINDOW
(WIPER AND WASHER) ........................................................... 04-700
(EXTERIOR AND INTERIOR TRIM)............................................03-47
WIPER IS INOPERATIVE IN INTERMITTENT
TORQUE SPECIFICATION(FRONT SUSPENSION)..................03-26
MODE - REAR WINDOW(WIPER AND WASHER) .................. 04-704
TORQUE SPECIFICATION(FUEL)................................................03-6
WIPER MOTOR ASSY.................................................................. 65-9
WIPERS ARE INOPERATIVE - WINDSHIELD
(HEATER AND AIR CONDITIONING) .........................................03-41
(WIPER AND WASHER) ........................................................... 04-677
TORQUE SPECIFICATION(IGNITION).......................................03-23
WIPERS ARE INOPERATIVE AT HIGH SPEED - WINDSHIELD
TORQUE SPECIFICATION(INTAKE AIR)...................................03-18
(WIPER AND WASHER) ........................................................... 04-686
TORQUE SPECIFICATION(LIGHTING)......................................03-43
WIPERS ARE INOPERATIVE AT LOW SPEED - WINDSHIELD
TORQUE SPECIFICATION(LUBRICATION)...............................03-22
(WIPER AND WASHER) ........................................................... 04-682
TORQUE SPECIFICATION(PARKING BRAKE) .........................03-33
WIPERS ARE INOPERATIVE IN INTERMITTENT
TORQUE SPECIFICATION(POWER STEERING)......................03-40
MODE - WINDSHIELD(WIPER AND WASHER) ...................... 04-690
TORQUE SPECIFICATION(REAR SUSPENSION) ....................03-27
WIRE HARNESS & CONNECTOR LOCATION VIEWS ........... 71-204
TORQUE SPECIFICATION(SEAT BELT) ...................................03-42
WIRING DIAGRAM ..................................................................... 71-13
TORQUE SPECIFICATION(SEAT) .............................................03-45
UPPER CONTROL ARM............................................................. 31-15
TORQUE SPECIFICATION(STARTING AND CHARGING)........03-25
UPSTREAM OXYGEN SENSOR ................................ 11A-48, 11D-55
TORQUE SPECIFICATION(STEERING COLUMN)....................03-38
USAGE METHOD
TORQUE SPECIFICATION(TIRE AND WHEEL) ........................03-28
TORQUE SPECIFICATION(TRANSMISSION) ...........................03-35
USE AND MAINTENANCE(BATTERY) ........ 20A-23, 20B-24, 20C-24
TORQUE SPECIFICATION(VEHICLE CONTROL SYSTEM) .....03-48
TORQUE SPECIFICATION(WIPER AND WASHER)..................03-44
TORSION BAR SPRING..............................................................31-13
Z
TRANSMISSION.............................................................. 02-21, 03-34
1 - EGR VALVE LIFT SENSOR OR CIRCUIT FAULT
TRANSMISSION OPERATION MECHANISM ASSY ....................41-1
TURBOCHARGER ASSY ........................................... 14B-14, 14C-17
TURN SIGNAL LAMPS ARE INOPERATIVE 15 - GLOW PLUG RELAY ADHESION
(HAZARD WARNING LAMPS ARE NORMAL)
16 - GLOW PLUG RELAY NO POWER
(LIGHTING SYSTEM) .................................................. 04-492, 04-609
TURN SIGNAL LAMPS ARE INOPERATIVE (DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-206
2 - EGR VALVE IS STUCK AND DOES NOT CLOSE
(ONE SIDE)(LIGHTING SYSTEM) .............................. 04-503, 04-620
2 - SPEED SENSOR MEASURING CIRCUIT OPEN
(ANTI-LOCK BRAKE SYSTEM) ................................................ 04-376
3 - EGR VALVE SEAT CARBON AND CLOSE LAX 4 - STOP VALVE DRIVER CIRCUIT OPEN
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-189 (ANTI-LOCK BRAKE SYSTEM) ................................................04-380
3 - SPEED SENSOR MEASURING CIRCUIT SHORT 4 - THROTTLE POSITION SENSOR OR CIRCUIT FAULT
(ANTI-LOCK BRAKE SYSTEM) ................................................ 04-376 (DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-193
31 - TIMING SOLENOID VALVE OR CIRCUIT FAULT 5 - SPEED SENSOR OR CIRCUIT FAULT
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-210 (DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-206
32 - TIMING STROKE SENSOR OR CIRCUIT FAULT 5 - STOP VALVE DRIVER CIRCUIT SHORT
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-214 (ANTI-LOCK BRAKE SYSTEM) ................................................04-380
34 - RETURN FUEL SOLENOID VALVE OPEN OR CIRCUIT 6 - ENGINE COOLANT TEMPERATURE
FAULT(DIESEL ENGINE CONTROL SYSTEM (4D20) )......... 04-219 SENSOR OR CIRCUITFAULT
35 - RETURN FUEL SOLENOID VALVE ADHESION (DIESEL ENGINE CONTROL SYSTEM (4D20) )......................04-197
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-219 6 - PRESSURE RELIEF VALVE DRIVER CIRCUIT OPEN
36 - RETURN FUEL SOLENOID VALVE NO POWER (ANTI-LOCK BRAKE SYSTEM) ................................................04-384
(DIESEL ENGINE CONTROL SYSTEM (4D20) ) ..................... 04-219 7 - PRESSURE RELIEF VALVE DRIVER CIRCUIT SHORT
(ANTI-LOCK BRAKE SYSTEM) ................................................04-384

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Edition: January 2011 VOLUME 1

Printing: February 2011 INTRODUCTION 01

HOW TO USE THIS MANUAL

WARNING Indicates the possibility of injury to you or other persons.

CAUTION Indicates the possibility of damage to the components being

7. INTERNATIONAL SYSTEM OF UNITS.

LHD/RHD Series Engine Transmission Models

BJ491EQ3-30 TC5RYA4 6536B1DWA-00ZA03 6536B1DWA-00ZA04

LHD/RHD Series Engine Transmission Models

LHD BJ493ZQ-13ke 5RYL 5026A12DA-00ZA01 5026EC2DA-00ZA01

BJ5026 5026EC5WA-03ZA04 5026EC5WA-03ZA08

BJ491EQ1-40 TC5RYA4 6536B1DWA-0RZA06 6536B1DWA-0RZA07

SERIAL NUMBER (SN)

• Be sure to wear a clean uniform.

• Perform safty inspection each other, when 2 or more persons servic-

• Diagnose problems with a thorough understanding of the trouble

Illustration Symbol Part Name

Shape (Example) Removal / Installation 01

Shape (Example) Removal / Installation

(h) Removal and installation of vacuum hoses.

• When disconnecting vacuum hoses, use tags to identify

(i) Torque when using a torque wrench with extension tool.

L1 Length of SST or extension tool (mm) 01

• Do not drop electronic components, such as sensors or

• When cleaning the engine with steam, protect the

3. REMOVAL AND INSTALLATION OF FUEL CONTROL PARTS.

(a) When removing and installing the inlet system parts,

5. HANDLING OF HOSE CLAMPS.

VEHICLE LIFT AND SUPPORT LOCATIONS

Audio System Chapter 04 diagnostics - audio system

Combined Display Chapter 04 diagnostics - combined display

Chapter 04 diagnostics - engine control system-BJ491EQ

Horn System Chapter 04 diagnostics - horn system

Instrument Cluster Chapter 04 diagnostics - instrument cluster

Lighting System Chapter 04 diagnostics - light system

Outside Mirror Chapter 04 diagnostics - outside mirrors

Power Door Locks Chapter 04 diagnostics - power door locks

Power Windows Chapter 04 diagnostics - power windows

Reverse Radar System Chapter 04 diagnostics - reverse radar system

Wiper And Washer Chapter 04 diagnostics - wiper and washer

FOR USING HAND-HELD TESTER

HOW TO PROCEED WITH TROUBLESHOOTING

2. CUSTOMER PROBLEM ANALYSIS

(a) Check the battery positive voltage.

CUSTOMER PROBLEM ANALYSIS

Under what conditions? Running conditions, driving conditions, weather conditions 01

SYMPTOM CONFIRMATION AND DTC (INCLUDING DATA STREAM) CHECK

System System Description DTC Signal Check Data Stream Symptom

Does DTC display? 01

Does any symptom exist? 01

7. PROCEED WITH PROBLEM SYMPTOMS TABLE 01

2. VIBRATION METHOD: When vibration seems to be

3. HEAT METHOD: If the problem seems to occur when

PROBLEM SYMPTOMS TABLE

ELECTRONIC CIRCUIT INSPECTION PROCEDURE

(b) Handling of connectors. 01

Check the contact pressure of the terminal:

(d) Repair method of connector terminal.

(e) Handling of wire harness.

2. CHECK OPEN CIRCUIT.

(b) Check the resistance.

3. CHECK SHORT CIRCUIT.

(b) Check the resistance.