Cool Bear Maintenance Manual

FOREWORD
Great Wall COOL BEAR is equipped with GW4G13 or GW4G15 gasoline engine which adapts the latest VVT tech-
nology and comes up to the Euro IV standard. The vehicle employs the MacPherson front suspension and the body is
made of extra-light structural steel. The high-strength front and rear bumpers and the energy-absorbing area ensure
the completeness and safety of the seat room. The manual is compiled to meet the needs of the after-sales service
technicians, with particular emphasis on the maintenance precaution, removal and installation of each system and
maintenance technology parameters, but it does not include all items about repair and service.
This manual is supplied by Great Wall Motor Company Limited, and is made for the use of persons who have spe-
cial techniques and certifications. If non-specialized or uncertified technicians perform repair or service and only use
this manual for reference or without proper equipment or tools, this may cause serious injury to you or other persons
nearby and also cause damage to your customer’s vehicle.
In order to prevent dangerous operation and damage to your customer’s vehicle, be sure to follow the instructions
shown below:
The contents must be read thoroughly. It is especially important to have a good understanding of all the contents writ-
ten in the PRECAUTION of “INTRODUCTION” section.
The service method written in this manual is very effective to perform repair and service. When performing the opera-
tions following the procedures in this manual, be sure to use tools specified and recommended. If using non-specified
tools other than recommended tools and service methods, be sure to confirm the safety of the technicians and that
there is no possibility of personal injury or vehicle damage before starting the operation.
If part replacement is necessary, the part must be replaced with the same part number or equivalent part. Do not re-
place it with an inferior quality part.
It is important to note that this manual contains various CAUTIONS and NOTICES that must be carefully observed
in order to reduce the risk of personal injury during service or repair, or reduce the possibility that improper service
or repair may damage the vehicle or render it unsafe. It is also important to understand that these CAUTIONS and
NOTICES are not exaggerations and bring about possible hazardous consequences that might result from failure to
follow these instructions.
Please read the PRECAUTION before working around airbag system components or circuits. If you do not follow the
PRECAUTION, it may lead to airbag deployment, causing serious accident. If airbag system and other system need
repairing to avoid the airbag deployment or injury to person, you had better repair the airbag system first, then other
systems.
All information in this manual is based on the latest product information at the time of publication. However, specifi-
cations and procedures are subject to change without notice.
We cannot guarantee that all the contents written in this manual are right, though we compile it as much as we can.
Users cannot claim for damages from the Great Wall Motor Company only according to the content of the manual, we
are not responsible for the loss caused by using the manual. Any criticism and comment are welcome as the ability of
compilers is limited.
Great Wall Motor Company Limited has the right to explain this manual.
Compiler
August, 2008
FOREWORD.indd 1 2008-10-21 9:48:07

FOREWORD.indd 2 2008-10-21 9:48:07
CHASSIS AND BODY
REPAIR MANUAL
GENERAL GL
MAINTENANCE AND CARE MA
ENGINE ACCESSORY SYSTEM EG

DRIVETRAIN DT
SUSPENSION SP
BRAKE BR
STEERING SR
AUDIO/VISUAL SYSTEM AV
AIR CONDITIONING SYSTEM AC
SAFETY SUPPLEMENTARY RESTRAINT SYSTEM RS
VEHICLE INTERIOR IR
VEHICLE EXTERIOR ET
BODY BO
ELECTRICAL WIRING DIAGRAM EWD
CONTENTS.indd 1 2008-10-7 8:14:33

CONTENTS.indd 2 2008-10-7 8:14:33
GL-
GENERAL
INTRODUCTION
How To Use This Manual.................................................. GL-3
Identification Information................................................... GL-6
Repair Instruction.............................................................. GL-7
How To Troubleshoot ECU Controlled Systems............... GL-22
Terms................................................................................ GL-33 GL
PREPARATION
Exhaust System................................................................ GL-34
Cooling System................................................................. GL-34
Drive Shaft/Axle................................................................ GL-35
Clutch................................................................................ GL-38
Front Suspension System................................................. GL-39
Rear Suspension System................................................. GL-40
Tire and Wheel.................................................................. GL-41
Brake System.................................................................... GL-42
Parking Brake System...................................................... GL-43
Steering System................................................................ GL-44
Power Steering System.................................................... GL-45
Audio & Visual System...................................................... GL-47
Air Conditioning System.................................................... GL-48
Supplemental Restraint System........................................ GL-51
Seat Belt........................................................................... GL-52
Lighting System................................................................ GL-53
Combination Meter............................................................ GL-54
Seat................................................................................... GL-55
Wiper and Washer System............................................... GL-55
Windshield/Window Glass/Mirror...................................... GL-56
Engine Hood/Door............................................................ GL-57
Exterior/Interior Trim......................................................... GL-58
SERVICE SPECIFICATIONS
Engine Mechanical............................................................ GL-59
Transmission/Transaxle.................................................... GL-61
Fuel................................................................................... GL-62
Ignition.............................................................................. GL-62
01-GENERAL.indd 1 2008-10-21 9:46:08

GL-
Start and Charge ............................................................. GL-62

Discharge Control............................................................. GL-63
Exhaust System................................................................ GL-63
Cooling System................................................................. GL-64
Drive Shaft/Axle................................................................ GL-65
Clutch................................................................................ GL-66
Front Suspension System................................................. GL-67
Rear Suspension System................................................. GL-69
Tire and Wheel.................................................................. GL-69
Brake System.................................................................... GL-70
Parking Brake System...................................................... GL-71
Steering System................................................................ GL-72
Power Steering System.................................................... GL-72
Air Conditioning System.................................................... GL-74
Supplemental Restraint System........................................ GL-75
Seat Belt........................................................................... GL-75
Combination Meter............................................................ GL-75
Seat................................................................................... GL-76
Wiper and Washer System............................................... GL-76
Windshield/Window Glass/Mirror...................................... GL-76
Electric Horn System........................................................ GL-77
Engine Hood/Door............................................................ GL-77
01-GENERAL.indd 2 2008-10-21 9:46:08

GENERAL GL-
INTRODUCTION
How To Use This Manual
General Information
1. General
(a) Repair operations can be separated into 3 main processes:
(1) Diagnosis
(2) Removing/installing, replacing, disassembling/reassembling, checking and adjusting
(3) Final inspection
(b) This manual explains the “Diagnosis” and “Removing and Installing, Replacing, Disassembling, Installing and
Checking, and Adjusting”. “Final Inspection” is omitted.
(c) The following essential operations are not written in this manual. However, these operations must be performed
in actual situations.
(1) Operations with a jack or lift
(2) Cleaning a removed part when necessary
(3) Visual check
2. Preparation
(a) Use of special service tools (SST) may be required, depending on the repair situation.
Be sure to use SST when they are required and follow the working procedure properly. A list of SST is in the
PREPARATION section of this manual.
3. Repair procedures
(a) Component drawing is placed under the title where necessary.
(b) Non-reusable parts, grease application areas, precoated parts and tightening torque are specified in the compo-
nent drawings.
01-GENERAL.indd 3 2008-10-21 9:46:08

GL- GREAT WALL COOL BEAR REPAIR MANUAL
Example:
Bleeder Screw
8.3 (85, 73 in.·lbf)
Bleeder Screw Cap
9.8 (100, 87 in.·lbf) Piston Spring
l Piston Dust Cover
Piston l Cup
l Piston Dust Cover
15 (155, 11)
Pin
Pin Plug Piston
Hole Plug Rear Brake Cylinder
l Cup Parking Brake Shoe Lever

Parking Brake Cable l C-washer
Pin Assembly LH
Brake Shoe
Parking Brake Shoe Hold-Down Brake Shoe
Push Rod Kit LH Spring Hold-down
Spring Cup
Backing Plate
Brake Leading
Rear Brake Shoe Assembly
Brake Shoe
Automatic Adjust
Return Spring
Lever
Rear Brake Automatic Tension Spring

Adjust Lever Tension
Spring
Brake Trailing
Shoe Assembly
Brake Shoe Hold-Down
Spring Brake Shoe Hold-down
Spring Cup
N·m (kgf·cm, ft·lbf) : Specified torque
Rear Brake Drum
l Non-reusable part
Grease
High temperature grease
ALA001G
01-GENERAL.indd 4 2008-10-21 9:46:09

GENERAL GL-
(c) Tightening torque, grease application areas, and non-reusable parts are described as important points in the pro-
cedures.
Caution:
There are cases where such information can only be explained by using an illustration. In these cas-
es, all the information such as torque, oil, etc. are described in the illustration.
(d) The installation procedures are the removal procedures in the reverse order. However, only installation proce-
dures requiring additional information are included.
(e) Only items with key points are described in the text. What to do and other details are placed in illustrations next
to the text. Both the text and illustrations are accompanied by standard values and notices.
(f) Illustrations of similar models are sometimes used. In those cases, specific details may be different from the ac-
tual vehicle.
(g) Procedures are presented in a step-by-step format:
(1) The illustration shows what to do and where to do it.
(2) The task heading tells what to do.
(3) The explanation text tells how to perform the task. It also tells information, such as specifications and
warnings.
Example:
Task heading: what you will be doing
Illustration
what to do and where
7. Inspect and adjust vacuum booster
push rod
(d) If the clearance is outside of the specified
range, fix the push rod by using SST and
SST
adjust the length of the protruding adjust-
ing bolt. Detailed text: how to perform task
SST 09737-00020
ALA002G
Set part No.
Hint:
This format provides an experienced technician with a FAST TRACK to the necessary information. The task
headings are easy to read and the text below the task heading provides detailed information. Important specifica-
tions and warnings always are written in bold type.
4. Service specifications
(a) SPECIFICATIONS are presented in bold-faced text throughout the text where needed. The specifications are
also found in the SERVICE SPECIFICATIONS section for quick reference.
5. Terms Definition
Caution Indicates the possibility of injury to you or other people.
Notice Indicates the possibility of damage to the components being repaired.
Hint Provides additional information to help you perform repairs.
6. SI UNIT
(a) The UNITS used in this manual comply with the SI UNIT (International System of Units) standard. For your
convenience, we also provide units from the metric system and the English system.
Example:
Torque: 30 N·m (310 kgf·cm, 22 ft·lbf)
01-GENERAL.indd 5 2008-10-21 9:46:09

Identification Information
Vehicle Identification and Serial Numbers
1. Vehicle identification number

(a) The vehicle identification number is stamped on the vehicle
identification number plate and certification label, as shown
A
in the illustration.
A: Vehicle Identification Number Plate
B: Certification Label
ALA003G
ALA004G
2. Engine model and transmission model

(a) The engine model is stamped on the cylinder block of the en-
gine and the transmission model is stamped on the housing,
A
as shown in the illustration.
B A: GW4G13/GW4G15
B: ZM007Q
ALA005G
01-GENERAL.indd 6 2008-10-21 9:46:10

GENERAL GL-
Repair Instruction
Precaution
1. Basic repair hint
(a) Hints on operations
6
4
ALA006G
• Always wear a clean uniform.

1 Attire
• Hat and safety shoes must be worn.
• Set a grill cover, fender cover, seat cover and floor mat before starting the
2 Vehicle protection
operation.
• In case of working with 2 or more persons, be sure to check safety in one an-
other.
• When working with the engine running, take care to the ventilation of the
workshop.
3 Safe operation • In case of operating on a high temperature parts, rotating, moving and vibrat-
ing parts, take care not to burn or injure yourself.
• When jacking up the vehicle, be sure to support the specified location with a
safety stand.
• When lifting up the vehicle, apply a safety equipment.
Preparation of tools and • Before starting operation, prepare a tool stand, SST, gauge, oil, shop rag and
4
measuring gauge parts for replacement.
01-GENERAL.indd 7 2008-10-21 9:46:11

• Diagnose with a thorough understanding of the trouble phenomenon and per-

form effective operation.
• Before removing the parts, check the assembly for general condition, defor-
Removal and installa-
mation and damage.
5 tion, disassembly and
• When a structure is complicated, take a note or put matchmakers to avoid
assembly operations
mistakes during reassembly.
• Clean and wash the removed parts if necessary, and assembly them after a
thorough check.
• Place the removed parts in the correct order to avoid mixing up or making
them dirty.
• As for non-reusable parts such as a gasket, an O-ring, and a self-lock nut,
6 Removed parts
change them with new ones following the instruction of this manual.
• Organize the replaced parts in a box and keep them for customer inspection,
if necessary.
(b) Jacking up and supporting vehicle

(1) Care must be taken when jacking up and supporting the
vehicle. Be sure to lift and support the vehicle at the
proper locations (See page GL-20).
(c) Precoated parts
(1) Precoated parts are bolts, nuts, etc. that are coated with
a seal lock adhesive at the factory.
(2) If a precoated part is retightened, loosened or moved in
any way, it must be recoated with the specified adhe-
sive.
Seal Lock Adhesive (3) When reusing precoated parts, clean off the old adhe-
sive and dry the part with compressed air. Then apply
ALA007G new seal lock adhesive appropriate to the bolt, nut, etc.
Notice:
Perform the torque with the lower limit value of the
torque tolerance.
(4) Depending on the seal lock adhesive to apply, there
may be a cases where it is necessary to leave it for a
specified time until it hardens.
(d) Gaskets
(1) When necessary, use a seal lock adhesive on gaskets to
prevent leakage.
(e) Bolts, nuts and screws
(1) Carefully observe all the specifications for tightening
torques. Always use a torque wrench.
01-GENERAL.indd 8 2008-10-21 9:46:11

GENERAL GL-
Medium Current Fuse and High Current Fuse

(f) Fuses
Equal Amperage Rating (1) When replacing fuses, be sure that a new fuse has the
30A 30A correct amperage rating. Do not exceed the rating or
use one with a lower rating.
ALA008G
Illustration Symbol Part name Abbreviation
Fuse FUSE
BE5594 IN0365
Medium Current Fuse M-FUSE

BE5595 IN0366
High Current Fuse H-FUSE

D27353 IN0367
ALA009G
01-GENERAL.indd 9 2008-10-21 9:46:12

GL-10 GREAT WALL COOL BEAR REPAIR MANUAL
(g) Clips
(1) The removal and installation methods of typical clips
used in vehicle body parts are shown in the table below.
Hint:
If the clip is damaged during the operation procedure,
always replace it with a new clip.
Shape (Example) Removal/Installation
Clip
Pliers
Clip Remover
Protective Tape
Screwdriver
Protective Tape
Scraper
ALA010G
01-GENERAL.indd 10 2008-10-21 9:46:12

GENERAL GL-11
Shape (Example) Removal/Installation
Removal Installation
ALA011G
01-GENERAL.indd 11 2008-10-21 9:46:12

(h) Removal and installation of vacuum hoses

(1) To disconnect vacuum hoses, pull off the end of the
hose, not the middle.
Wrong Correct
ALA012G
(2) When disconnecting vacuum hoses, use tags to identify

where they should be reconnected.
(3) After completing the job, double check that the vacuum
hoses are properly connected. The label under the en-
gine hood shows the proper connecting part.
(4) When using a vacuum gauge, never force the hose onto
a connector that is too large. Use a step-down adapter
for adjustment.
ALA013G Once the hose has been stretched, it may leak air.
(i) Torque when using torque wrench with extension tool

(1) When SST or extension tool is combined with the
L1 L2 torque wrench to extend its entire length, if you tighten
until the reading of the torque wrench reaches the speci-
fied torque value, the actual torque becomes excessive.
(2) In this manual, only the specified torque is described. In
case of using SST or extension tool, calculate the read-
ing of the torque wrench by the following formula.
ALA014G
(3) Formula T’ = T × L2/(L1 + L2)

T’ Reading of torque wrench {N·m (kgf·cm, ft·lbf)}
L1 L2 T Torque {N·m (kgf·cm, ft·lbf)}
L1 Length of SST or extension tool (cm)
L2 Length of torque wrench (cm)
2. For vehicles equipped with SRS airbag and seat belt

pretensioner
ALA015G
01-GENERAL.indd 12 2008-10-21 9:46:14

GENERAL GL-13
Hint:
The vehicle is equipped with a Supplemental Restraint Sys-
tem (SRS), and seat belt pretensioner.
Failure to carry out service operations in the correct sequence
could cause the SRS to unexpectedly deploy during servic-
ing, possibly leading to serious accident.
Furthermore, if a mistake is made when servicing the SRS, it
is possible that the SRS may fail to operate properly.
Before servicing (including removal or installation of parts,
inspection or replacement), be sure to read the following
items carefully. Then follow the correct procedures described
in this manual.
(a) General notes

(1) Malfunction symptoms of the SRS are difficult to confirm, so the diagnostic trouble codes (DTCs) become
the most important source of information when troubleshooting. When troubleshooting the SRS, always
inspect the DTCs before disconnecting the battery (See page RS-12).
(2) To avoid serious injury, servicing the SRS must be started 90 seconds after meeting the following condi-
tions:
• The ignition switch is tuned to the LOCK position.
• The negative (-) terminal cable is disconnected from the battery.
(The SRS is equipped with a back-up power source. So, if work is started within 90 seconds after discon-
necting the negative (-) terminal cable from the battery, the SRS may deploy). Disconnecting the negative (-)
terminal cable will erase clock memory and audio system presets.
Write down data as necessary before disconnecting the cable. To avoid erasing the memory settings, never
use a back-up power supply.
(3) In minor collisions where the SRS does not deploy, the driver airbag assembly, passenger airbag assembly
and seat belt pretensioner should be inspected before further use of the vehicle (See pages RS-12, RS-26).
(4) Never use the SRS parts from another vehicle. When replacing the parts, replace them with new ones.
(5) Before repairing, removing the airbag ECU assembly if impacts are likely to be applied to the assembly
during repairs.
(6) Never disassemble and repair the airbag ECU assembly, driver airbag assembly, passenger airbag assembly
or seat belt pretensioner.
(7) Replace the airbag ECU assembly, driver airbag assembly or passenger airbag assembly if: 1) damage has
occurred from being dropped; 2) if there are cracks, dents or other defects in the case, bracket or connector.
(8) Do not directly expose the airbag ECU assembly, driver airbag assembly, passenger airbag assembly or the
seat belt pretensioner to hot air or flames.
(9) Never use multimeter to measure driver airbag assembly and passenger airbag assembly, or the airbag will
deploy and injury may result.
(10) Information labels are attached to the SRS components. Follow the instructions on the notices.
(11) After work on the SRS is completed, check the SRS warning light.
01-GENERAL.indd 13 2008-10-21 9:46:14

Mark (b) Clock spring (in combination switch)

(1) The steering wheel must be fixed correctly to the steer-
ing column with the clock spring at the neutral position,
otherwise cable disconnection and other problems may
occur. Refer to page SR-10 concerning the correct in-
stallation of the steering wheel.
ALA016G
(c) Driver airbag assembly (w/airbag)

(1) When removing driver airbag assembly or handling a new electric horn button, it should be placed with the
pad top surface facing up. See illustration below.
Placing it with the pad surface facing downward may lead to a serious accident if the airbag accidentally
inflates. Also, do not place anything on top of electric horn buttons.
(2) Never measure the resistance of the airbag squib. Or it may cause the airbag to inflate, which could cause
serious injury.
(3) Grease or detergents of any kind should not be applied to the steering wheel pad.
(4) Store the driver airbag assembly where the ambient temperature remains below 93°C (200°F), has low hu-
midity and is away from electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors.
These connectors contain shorting springs. This feature reduces the possibility of the airbag or seat belt
pretensioner deploying due to currents entering the squib wiring.
(6) When disposing of the vehicle or driver airbag assembly, the airbag should be inflated by SST before dis-
posal (See page RS-30). Perform the operation in a safe place away from electrical noise.
01-GENERAL.indd 14 2008-10-21 9:46:14

GENERAL GL-15
Example:
Correct Wrong
ALA017G
Example:
ALA018G
(d) Passenger airbag assembly

(1) Always place a removed or new passenger airbag assembly with the airbag deployment direction facing
upward. Placing the airbag assembly with the airbag deployment direction facing downward could cause a
serious accident if the airbag inflates.
(2) Never measure the resistance of the airbag squib, or it may cause the airbag to inflate, which could cause
serious injury.
(3) Grease or detergents of any kinds should not be applied to passenger airbag assembly.
(4) Store airbag assembly where the ambient temperature remains below 93°C (200°F), has low humidity and
is away from electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors (4 yellow
pins).
(6) When disposing of a vehicle or the airbag assembly unit by itself, the airbag should be deployed by SST
before disposal (See page RS-30). Activate in a safe place away from electrical noise.
01-GENERAL.indd 15 2008-10-21 9:46:15

Example:
ALA019G
(e) Seat belt pretensioner

(1) Never measure the resistance of the seat belt pretensioner. This may activate the seat belt pretensioner,
which could cause serious injury.
(2) Never disassemble the seat belt pretensioner.
(3) Never install the seat belt pretensioner on another vehicle.
(4) Store the seat belt pretensioner where the ambient temperature remains below 80°C (176°F), has low hu-
midity and is away from electrical noise.
(5) When using electric welding anywhere on the vehicle, disconnect the airbag ECU connectors.
(6) As a safety measure, always activate the seat belt pretensioner before disposal (See page RS-55). Activate
in a safe place away from electrical noise. (The seat belt pretensioner becomes hot after activation. Allow it
to cool before disposing. Never use water to cool seat belt pretensioner)
(7) Oil or water should not be put on the front seat outer belt and the front seat outer belt should not be cleaned
with any type of detergent.
Example:
ALA020G
(f) Airbag ECU assembly

(1) Never reuse an airbag ECU assembly which has been involved in a collision where its SRS has deployed.
(2) The connectors to the airbag ECU assembly should be connected or disconnected with ECU mounted on
the floor. If the connectors are connected or disconnected while the airbag ECU assembly is not mounted
to the floor, it could cause accidental deployment of the SRS.
(3) To avoid serious injury, servicing the SRS must be started 90 seconds after meeting the following condi-
tions:
• The ignition switch is tuned to the LOCK position.
• The negative (-) terminal cable is disconnected from the battery.
(g) Wire harness and connector
(1) The SRS wire harness is integrated with the instrument panel wire harness assembly. All connectors in the
system are a standard yellow color. If the SRS wire harness becomes disconnected or the connector be-
comes broken, repair or replace it.
01-GENERAL.indd 16 2008-10-21 9:46:15

GENERAL GL-17
3. Electronic control
Negative (-) Terminal (a) Removal and installation of battery terminal
(1) Before performing electronic work, disconnect the bat-
tery negative (-) terminal cable before hand in order to
prevent it from shorting and burning out.
(2) When disconnecting and installing the terminal cable,
turn the ignition switch and lighting switch OFF and
loosen the terminal nut completely. Perform these op-
ALA021G erations without twisting or prying the terminal.
(3) When the battery terminal cable is removed, all the data
stored (Clock, CD player, DTCs, etc.) are erased. Be-
fore removing the cable, make a record of the settings
of each memory system.
(4) When the battery negative (-) terminal cable is discon-
nected, memories of various systems are erased. Refer
to the PRE-CHECK for each system to make sure
whether or not the system needs to be initialized after
the battery negative (-) terminal cable is disconnected.
If necessary, be sure to initialize the system.
(b) Handling of electronic parts
(1) Do not open the cover or case of the ECU unless abso-
lutely necessary.
(If the IC terminals are touched, the IC may be rendered
inoperative by static electricity).
(2) To disconnect electronic connectors, pull the connector
itself, not the wires.
(3) Be careful not to drop electronic components, such as
sensors or relays. If they are dropped on a hard floor,
Wrong
ALA022G they should be replaced and not be reused.
(4) When cleaning the engine with steam, protect the elec-
tronic components, air filter and emission-related com-
ponents from water.
(5) Never use an impact wrench to remove or install tem-
perature switches or temperature sensors.
(6) When checking the continuity at the wire connector, in-
sert the tester probe carefully to prevent terminals from
bending.
01-GENERAL.indd 17 2008-10-21 9:46:16

4. Removal and installation of fuel control parts

(a) Place for removing and installing of fuel system parts
(1) Work in a place with good air ventilation without any
ignition sources, such as a welder, grinder, drill, electric
motor or stove.
(2) Never work in a place such as a pit or near a pit because
vaporized fuel will collect in those places.
(b) Removal and installation of fuel system parts
(1) Prepare a fire extinguisher before starting operations.
(2) To prevent static electricity, install a ground cable on
the fuel changer, vehicle and fuel tank, and do not spray
the area with water. The work surface will become
slippery. Do not clean up spills with water as this will
spread the gasoline and create a fire hazard.
(3) Never use any electric equipment like an electric motor
or a working light, as they may create sparks or a high
temperature.
(4) Never use an iron hammer, as it may create sparks.
(5) Dispose of shop rags containing fuel deposits separately
by a fire-resistant container.
5. Removal and installation of engine intake parts
(a) Any metal particle enters the inlet pass may damage the en-
gine.
(b) When removing and installing the inlet system parts, cover
the openings of the removed parts and engine openings. Use
clean shop rags, gummed tape, or other suitable materials.
(c) When installing the inlet system parts, check that no metal
particles have entered the engine or the installed part.
ALA023G
01-GENERAL.indd 18 2008-10-21 9:46:16

GENERAL GL-19
6. Handling of hose clamps

Spring Type Clamp
(a) Before removing the hose, check the clamp position so you
can restore it in the same way.
(b) Replace a deformed or dented clamp with a new one.
(c) When reusing a hose, attach the clamp on the clamp track
portion of the hose.
(d) For a spring type clamp, you can adjust and secure it after in-
Clamp Track
stallation by slightly pushing spring plate in the direction of
ALA024G the arrow marks as shown in the illustration.
7. For vehicles equipped with mobile communication sys-

tems
(a) Install the antenna as far away from the ECU and sensors of
the vehicle electronic systems as possible.
(b) Install an antenna feeder at least 20 cm (7.87 in.) away from
the ECU and sensors of the vehicle electronic systems. For
details of the ECU and sensors locations, refer to the section
on applicable components.
ALA025G (c) Keep the antenna feeder separate from other wirings as much
as possible. This will prevent signals from the communica-
tion equipment from affecting vehicle equipment and vice
versa.
(d) Check that the antenna and feeder are correctly adjusted.
(e) Do not install any high-powered mobile communication sys-
tem.
8. For vehicles equipped with catalytic converter
Notice:
If a large amount of unburned gasoline or gasoline vapors flow into the converter, it may cause over-
heat and create a fire hazard. To prevent this, observe the following precautions.
(a) Use only unleaded gasoline.
(b) Avoid engine prolonged idling.
(c) Avoid a spark jump test.
(1) Perform a spark jump test only when absolutely necessary. Perform this test as rapidly as possible.
(2) While testing, never run the engine.
(d) Avoid a prolonged engine compression measurement.
Engine compression measurements must be performed as rapidly as possible.
01-GENERAL.indd 19 2008-10-21 9:46:17

Vehicle Lift and Support Locations

1. Notice about vehicle condition when jacking up the vehicle
(a) The vehicle must be unloaded before jacking up the vehicle. Never jack up/lift up a heavy-loaded vehicle.
(b) When removing heavy equipment such as the engine and transmission, the center of gravity of the vehicle may
shift. To stabilize the vehicle: place a balance weight in a location where it will not roll or shift; or use a trans-
mission jack to hold the jacking support.
2. Notice for using 4 post lift
(a) Follow the safety procedures outlined in its instruction manual.
(b) Use precautionary measures to prevent the free wheel beam from damaging tires or wheels.
(c) Using a wheel stopper, fix the vehicle.
3. Notice for using jack and safety stand
(a) Always use the wheel stopper when work in a flat place.
Rubber Attachment (b) Use a safety stand with a rubber attachment, as shown in the
illustration.
(c) Apply the jack and rigid rack to the specified location on the
vehicle.
(d) When jacking up the front wheels, release the parking brake
and place wheel stoppers only behind the rear wheels. When
jacking up the rear wheels, place wheel stoppers only in front
of the front wheels.
ALA026G (e) The jack should not be used without the rigid rack.
(f) When jacking up only the front wheels or only the rear wheels, place wheel stoppers on both sides of the wheels
touching the ground.
(g) When jacking down the vehicle with its front wheels jacked up, release the parking brake and place wheel stop-
pers only in front of the rear wheels. When jacking down a vehicle with its rear wheels jacked up, place wheel
stoppers only behind the front wheels.
: Jack Position
: Support Position, Pantograph Jack Position
: Center of Vehicle Gravity

(unloaded condition)
ALA027G
01-GENERAL.indd 20 2008-10-21 9:46:18

GENERAL GL-21
4. Notice for using swing arm type lift

(b) Use cradle with a rubber attachment, as shown in the illustration.
(c) When using the lift, its center should be as close to the vehicle’s center of gravity as possible.
(d) Set the vehicle on the cradle as level as possible. Then match the groove of the cradle to the rigid rack support
location. Do not raise the vehicle too high because the vehicle may become unstable.
(e) Be sure to lock the swing arm during the operation.
(f) Lift the vehicle up off the ground, and shake it to make sure that it is stable.
5. Notice for using plate type lift
(b) Use a plate lift attachments.
(c) Refer to the table below to determine how to properly set the vehicle.
Right and left set position • Place the vehicle over the center of the lift.
• Align the cushion gum ends of the plate with the attachment lower ends (A and C).
Front and rear set position
• Align the attachment upper end (B) with the rocker flange front side notch.
(d) Lift the vehicle up off the ground, and shake it to make sure that it is stable.
Center of Lift
Swing Arm Type Lift
: Center of Vehicle Gravity

(unloaded condition) Rubber
Attachment
Plate Type Lift
Attachment Dimensions
85 mm (3.35 in.)
B 70 mm
A C 100 mm (93.94 in.) (2.76 in.)
200 mm (7.87 in.)
Attachment
ALA028G
01-GENERAL.indd 21 2008-10-21 9:46:19

How To Troubleshoot ECU Controlled Systems

General Information
A large number of ECU controlled systems are used in the vehicle. ECU controlled systems are considered to be very
intricate, requiring a high level of technical knowledge to troubleshoot. However, most problem checking procedures
only involve inspecting the ECU controlled system’s circuits one by one.
An adequate understanding of the system and a basic knowledge of electricity is enough to perform effective trouble-
shooting, accurate diagnoses and necessary repairs. Detailed information and troubleshooting procedures on major
ECU controlled systems in this vehicle are outlined below:
System See page
1. ABS with EBD BR-34
2. Supplemental restraint system RS-1
3. Combination meter IR-21
4. Power door lock control system IR-52
5. Wireless door lock control system IR-57
For using tester

• Before using the diagnosis tool or tester, the diagnosis tool’s instruction book or tester’s operator manual should be
read thoroughly.
• If the diagnosis tool or tester cannot communicate with the ECU controlled systems, there is a problem on the ve-
hicle side or tester side.
(1) If the communication is normal when the tester is connected to another vehicle, inspect the diagnosis data
link line (Bus ⊕
line) or ECU power circuit of the vehicle.
(2) If communication is still impossible when the tester is connected to another vehicle, the problem is prob-
ably in the tester itself, so perform the self test procedures outlined in the Tester Operator’s Manual.
How To Proceed With Troubleshooting

Hint:
Carry out troubleshooting in accordance with the procedures below. Only a basic procedure is shown. Details in the
DIAGNOSTICS section show the most effective methods for each circuit. Confirm the troubleshooting procedures
for the relevant circuit before beginning troubleshooting.
1 Vehicle brought to workshop
2 Customer problem analysis
(a) Ask the customer about the conditions and environment when the problem occurred.
3 Symptom confirmation and DTC (and freeze frame data) check
(a) Check the battery positive voltage.

Voltage: 11 - 14 V (Engine stops)
(b) Visually check the wire harness, connectors and fuses for open and short, etc.
(c) Warm up the engine to the normal operating temperature.
(d) Confirm the problem symptoms and conditions, and check for DTCs according to the related chart.
OK Go to step 5
01-GENERAL.indd 22 2008-10-21 9:46:19

GENERAL GL-23
NG
4 DTC chart
(a) Check the results obtained in step 3, then confirm the inspection procedures for the system and part using the
DTC chart.
Go to step 6
5 Problem symptoms table
(a) Check the results obtained in step 3. Confirm the inspection procedures for the system and part using the prob-
lem symptoms table.
6 Circuit inspection or parts inspection
(a) Confirm the circuit in the system or the part that should be checked using the problem symptoms table or the re-
sults obtained in step 4.
7 Repair
(a) Repair the affected system or part according to the instructions in step 6.
8 Confirmation test
(a) After completing repairs, confirm that the problem has been solved. (If the problem does not reoccur, perform a
confirmation test under the same conditions and in the same environment as when it occurred for the first time)
End
01-GENERAL.indd 23 2008-10-21 9:46:19

Customer Problem Analysis

Hint:
In troubleshooting, the problem symptoms must be confirmed accurately. Preconceptions should be discarded in order
to give an accurate judgement. To ascertain what the problem symptoms are, it is extremely important to ask the cus-
tomer about the problem and the conditions at the time it occurred.
As much information as possible should be gathered for the reference, even the past problems that seem unrelated
may help in some cases. In the DIAGNOSTIC section, a customer problem analysis table is provided for each system.
The following 5 items are important points in the problem analysis:
Important points with customer problem analysis
• What ––––– Vehicle model, system name
• When ––––– Date, time, occurrence frequency
• Where ––––– Road conditions
• Under what conditions? ––––– Running conditions, driving conditions, weather conditions
• How did it happen? ––––– Problem symptoms
(Sample) supplemental restraint system check sheet
Customer problem analysis check

Supplemental restraint system check sheet Inspector’s name
VIN
Customer’s name Production date / /

Licence no.
km
Date vehicle brought in / / Odometer reading miles
Date problem first occurred
Weather ¨Fine ¨Cloudy ¨Rainy ¨Snowy Öther
Temperature Approx.
¨Starting Ïdling
Vehicle operation condition ¨Driving [ ¨Constant speed Äcceleration ¨Deceleration
Öther ]
01-GENERAL.indd 24 2008-10-21 9:46:19

GENERAL GL-25
Symptom Confirmation and Diagnostic Trouble Code

Hint:
The diagnostic system in the vehicle fulfills various functions.
The first function is the Diagnostic Trouble Code (DTC) Check. In a DTC Check, a previous malfunction’s DTC can
be checked by a technician during troubleshooting. (A DTC is a code stored in the ECU memory whenever a mal-
function in the signal circuits to the ECU occurs)
Another function is the Input Signal Check, which checks if the signals from various switches are sent to the ECU
correctly.
By using these check functions, the problem areas can be narrowed down and troubleshooting is more effective.
Diagnostic functions are incorporated in the following systems in the vehicle.
Input signal Diagnostic test
Diagnostic trou-
System check mode
ble code check
(sensor check) (active test)
ABS with EBD
Supplemental Restraint System
Combination meter
In the DTC Check, it is very important to determine whether the problem indicated by the DTC is: 1) still occurring;
2) occurred in the past but has returned to normal. In addition, the DTC should be compared to the problem symptom
to see if they are related. For this reason, DTCs should be checked before and after confirmation of symptoms (i.e.,
whether or not problem symptoms exist) to determine current conditions, as shown in the table below.
Never skip the DTC Check. Failure to check DTCs may, depending on the case, result in unnecessary troubleshooting
for systems operating normally or lead to repairs not pertinent to the problem. Follow the procedures listed above in
the correct order.
A flow chart showing how to proceed with troubleshooting using the DTC Check is shown below. Directions from the
flow chart will indicate how to proceed either to DTC troubleshooting or to the troubleshooting of the problem symp-
toms table.
01-GENERAL.indd 25 2008-10-21 9:46:19

1 DTC check
2 Make a note of DTCs displayed and then clear the memory
3 Symptom confirmation
Symptoms exist
No symptoms exist
A Go to step 5
4 Simulation test using the symptom simulation methods
5 DTC check
DTC displayed
No DTC displayed
If a DTC was displayed in the initial DTC check, it indicates that

the trouble may have occurred in a wire harness or connector in
that circuit in the past.
Therefore, check the wire harness and connectors (See page
GL-28).
A System normal
Troubleshooting of each problem symptom

The problem is still occurring in a place other than the diagnostic circuit (The DTC displayed first is either for a past
problem or a secondary problem).
01-GENERAL.indd 26 2008-10-21 9:46:20

GENERAL GL-27
Symptom Simulation
Hint:
The most difficult case in troubleshooting is that no problem symptoms occur. In such cases, a thorough customer
problem analysis must be carried out. A simulation of the same or similar conditions and environment in which the
problem occurred in the customer’s vehicle should be carried out. No matter how much skill or experience a techni-
cian has, troubleshooting without confirming the problem symptoms will lead to important repairs being overlooked
and lead to mistakes or delays.
Example:
With a problem that only occurs when the engine is cold or occurs as result of vibration caused by the road during
driving, the problem can never be determined as long as the symptom are being checked on a stationary vehicle or a
vehicle with a warmed-up engine. Vibration, heat or water penetration (moisture) is difficult to reproduce. The symp-
tom simulation tests below are effected substitutes for the conditions and can be applied on a stationary vehicle.
Important points in the symptom simulation test:
In the symptom simulation test, the problem symptoms as well as the problem area or parts must be confirmed. First,
narrow down the possible problem circuits according to the symptoms. Then, connect the tester and carry out the
symptom simulation test, judging whether the circuit being tested is defective or normal. Also, confirm the prob-
lem symptoms at the same time. Refer to the problem symptoms table for each system to narrow down the possible
causes.
Vibrate Slightly 1. Vibration method: When vibration seems to be the ma-
jor cause.
(a) Part and sensor
(1) Apply slight vibration with a finger to the part of the
sensor considered to be the cause of the problem and
check whether or not the malfunction occurs.
Shake Slightly
HINT:
Applying strong vibration to relays may result in open
Vibrate Slightly ALA029G relays.
(b) Connectors
(1) Slightly shake the connector vertically and horizontally.
(c) Wire harness
(1) Slightly shake the wire harness vertically and horizon-
tally.
The connector joint and fulcrum of the vibration are the
major areas that should be checked thoroughly.
2. Heat method: If the problem seems to occur when the
area in question is heated.
Malfunction
(a) Heat the component that is the possible cause of the malfunc-
tion with a hair dryer or similar device. Check whether or not
the malfunction occurs.
Notice:
• Do not heat to more than 60°C (140°F) (Exceeding
this temperature may damage components).
ALA030G • Do not apply heat directly to the parts in the ECU.
01-GENERAL.indd 27 2008-10-21 9:46:20

3. Water sprinkling method: When the malfunction seems

to occur on a rainy day or in a high-humidity.
(a) Sprinkle water onto the vehicle and check whether or not the
malfunction occurs.
Notice:
• Never sprinkle water directly into the engine com-
partment. Indirectly change the temperature and
humidity by applying water spray onto the front of
ALA031G the radiator.
• Never apply water directly onto the electronic com-
ponents.
Hint:
If the vehicle has or had a water leakage problem, the leak-
age may have damaged the ECU or connections. Look for
evidence of corrosion or shorts. Proceed with caution during
water tests.
4. Others: When a malfunction seems to occur when elec-
trical load is excessive.
(a) Turn on all the electrical loads including the heater blower,
ON
front combination light, rear window defogger, etc., and
check if the malfunction occurs.
OFF OFF
ALA032G
Electronic Circuit Inspection Procedure

1. Basic inspection
(a) Resistance measuring condition of electronic parts
(1) Unless stated, all resistance is measured at an ambient temperature of 20°C (68°F). Resistances measured
may be not as specified if measured at high temperatures, i.e. immediately after the vehicle has been run-
ning. Measurements should be made when the engine has cooled down.
(b) Handling of connector
(1) When disconnecting a connector, first squeeze the mat-
ing halves tightly together to release the lock, then press
the lock claw and separate the connector.
(2) When disconnecting a connector, do not pull on the har-
Wrong
nesses. Grasp the connector directly and separate it.
(3) Before connecting the connector, check that there are
no deformed, damaged, loose or missing terminals.
Correct
ALA033G (4) When connecting a connector, press firmly until you
hear the lock close with a “click” sound.
(5) If check the connector with an electrical tester, check it
from the backside (Harness side) of the connector using
a mini test lead.
01-GENERAL.indd 28 2008-10-21 9:46:23

GENERAL GL-29
Notice:
• As a waterproof connector cannot be checked
from the backside, check by connecting a sub
harness.
• Do not damage the terminals by moving the
inserted tester needle.
Looseness of Crimping (c) Connector checking points
(1) Checking when the connector is connected: Squeeze
the connector together to confirm that it is fully inserted
Core Wire and locked.
(2) Checking when the connector is disconnected: Check
Terminal
Deformation by pulling the wire harness lightly from the backside
of the connector. Look for unlatched terminals, missing
Pull Lightly terminals, loose crimps or broken conductor wires.
ALA034G Notice:
When testing a gold-plated female terminal, al-
ways use a gold-plated male terminal.
(3) Checking the contact pressure of the terminal: Prepare
a spare male terminal. Insert it into a female terminal,
and check for good tension when inserting and after full
engagement.
Same terminal as a
male terminal
ALA035G
(d) Repair method of connector terminal

(1) If there is any dirt on the terminal, clean the contact
point by an air gun or shop rag. Never polish the con-
tact point by a sandpaper as the paintings may come
off.
(2) If there is abnormal contact pressure, replace the female
terminal.
Correct Wrong If the male terminal is gold-plated (Gold color), use a
ALA036G gold-plated female terminal; if it is silver-plated (Silver
color), use a silver-plated female terminal.
(3) Damaged, deformed, or corroded terminals should be
replaced. If the terminal will not lock into the housing,
the housing may have to be replaced.
01-GENERAL.indd 29 2008-10-21 9:46:24

(e) Handling of wire harness

Wrong (1) If removing a wire harness, check the wiring and
clamping before proceeding so that it can be restored in
the same way.
(2) Never twist, pull or slacken the wire harness more than
necessary.
(3) Never make the wire harness come into contact with
a high temperature part, rotating, moving, vibrating or
ALA037G sharp-edged parts. Avoid panel edges, screw tips and
similar sharp items.
(4) When installing parts, never pinch the wire harness.
(5) Never cut or break the cover of the wire harness.
If it is cut or broken, replace it or securely repair it with
vinyl tape.
2. Check open circuit
Fig. 1 (a) For an open circuit in the wire harness in Fig. 1, perform a
ECU
C OPEN B A resistance check (Step b) or a voltage check (Step c).
Sensor
1 1 1 1
2 2 2 2
ALA038G
(b) Check the resistance.

Fig. 2
(1) Disconnect connectors A and C and measure the resis-
tance between them.
ECU Resistance: 1 Ω or less
Sensor Hint:
1 1 1
Measure the resistance while lightly shaking the wire
2 2 2
harness vertically and horizontally.
C B A
Fig. 2:
ALA039G Between terminal 1 of connector A and terminal 1 of
connector C → 10 kW or higher
Between terminal 2 of connector A and terminal 2 of
connector C → Below 1 W
In this case, an open circuit exists between terminal 1
of connector A and terminal 1 of connector C.
(2) Disconnect connector B and measure the resistance
Fig. 3
between the connectors.
ECU Fig. 3:
Sensor Between terminal 1 of connector B1 and terminal 1 of
connector A → Below 1 W
Between terminal 1 of connector B2 and terminal 1 of
1 1 1 1
connector C → 10 kW or higher
2 2 2 2
C B2 B1 A In this case, an open circuit exists between terminal 1
ALA040G of connector B2 and terminal 1 of connector C.
01-GENERAL.indd 30 2008-10-21 9:46:25

GENERAL GL-31
(c) Check the voltage.

Fig. 4
(1) In a circuit in which voltage is applied to the ECU con-
nector terminal, an open circuit can be checked by con-
5V ducting a voltage check.
Sensor 0V Fig. 4:
1 14 V 1 1 With each connector still connected, measure the volt-
2 2 2
age between the body ground and terminal 1 of connec-
C B A
tor A at the ECU 5 V output terminal, terminal 1 of con-
ALA041G nector B and terminal 1 of connector C, in that order.
(2) Example results:
5 V: Between terminal 1 of connector A and body
ground
5 V: Between terminal 1 of connector B and body
ground
0 V: Between terminal 1 of connector C and body
ground
If your results match the examples above, an open cir-
cuit exists in the wire harness between terminal 1 of B
and terminal 1 of C.
3. Check short circuit
(a) If the wire harness is ground shorted (Fig. 5), locate the sec-
Fig. 5
tion by conducting a resistance check with the body ground
Short (Below).
C B A
1 1 1
2 2 2
ALA042G
(b) Check the resistance with the body ground.

Fig. 6
(1) Disconnect connectors A and C and measure the resis-
tance between terminals 1 and 2 of connector A and the
ECU body ground.
Sensor Resistance: 10 Ω or higher
1 1 1 Hint:
2 2 2
C A Measure the resistance while lightly shaking the wire
B
harness vertically and horizontally.
ALA043G In the case of Fig. 6:
Between terminal 1 of connector A and body ground →
Below 1 W
Between terminal 2 of connector A and body ground →
10 kW or higher
In this case, a short circuit exists between terminal 1 of
connector A and terminal 1 of connector C.
01-GENERAL.indd 31 2008-10-21 9:46:26

Fig. 7 (2) Disconnect connector B and measure the resistance be-

tween terminal 1 of connector A and the body ground,
and terminal 1 of connector B2 and the body ground.
Fig. 7:
ECU
Sensor Between terminal 1 of connector A and body ground →
1 1 1 1 10 kW or higher
2 2 2 2
Between terminal 1 of connector B2 and body ground →
C B2 B1 A
Below 1 W
ALA044G In this case, a short circuit exists between terminal 1 of
connector B2 and terminal 1 of connector C.
4. Check and replace ECU
Notice:
• Start an inspection of the connector from the back-
side of the connector at the wire harness side with
the connector connected to the ECU.
• When no measuring condition is specified, perform
the inspection with the engine stopped and the igni-
tion switch ON.
• Check that the connectors are fully seated. Check
for loose, corroded or broken wires.
(a) First check the ECU ground circuit. If it is faulty, repair it.
If it is normal, the ECU could be faulty. Replace the ECU
with a normal functioning one and check if the symptoms oc-
cur.
(1) Measure the resistance between the ECU ground termi-
Example
nal and body ground.
Resistance: 1 Ω or less
Ground
ALA045G
ECU Side (2) Disconnect the ECU connector. Check the ground ter-
minals (On the ECU side and wire harness side) for evi-
dence of bending, corrosion or foreign material. Lastly
Ground check the contact pressure of the female terminals.
W/H Side
Ground
ALA046G
01-GENERAL.indd 32 2008-10-21 9:46:27

GENERAL GL-33
Terms
Abbreviations Used In This Manual
Abbreviations Meaning
ABS Anti-lock brake system
A/C Air conditioner
CD Compact disc
CPU Central processing unit
DTC Diagnostic trouble code
EBD Electronic brake force distribution
ECU Electronic control unit
GAS Gasoline
GND Ground
HI High
LH Left-hand
LO Low
MAX. Maximum value
MIN. Minimum value
N Neutral
RH Right-hand
SRS Supplemental restraint system
SSM Special service materials
SST Special service tools
T/M Transmission
VIN Vehicle identification number
VVT-i Variable valve timing-intelligent
W/H Wire harness
1st First
2nd Second
2WD Two wheel drive vehicle (4 × 2)
3rd Third
4th Fourth
5th Fifth
01-GENERAL.indd 33 2008-10-21 9:46:27

PREPARATION
Exhaust System
Equipment
Torque wrench
Vernier caliper
Wooden block
Cooling System
Recommended Tools
09082-00040 Electrical Tester Cooling Fan System
(09083-00150) Test Lead Set Cooling Fan System
Equipment
Heater
Radiator filler cap tester
Slide caliper
Thermometer
Torque wrench
Wooden block
Coolant
Item Capacity Classification
Engine coolant 5.5 liters (5.7 US qts, 4.9 lmp. qts) Ethylene-glycol antifreeze
01-GENERAL.indd 34 2008-10-21 9:46:28

GENERAL GL-35
Drive Shaft/Axle
SST
09520-00031 Rear Axle Shaft Puller Front Axle Hub Sub-
assembly LH
09520-01010 Drive Shaft Remover Attachment Front Drive Shaft
09520-24010 Differential Propeller Shaft Gear Front Drive Shaft

Shaft Puller
(09520-32040) Shock Absorber Set Front Drive Shaft
09521-24010 Rear Axle Shaft Puller Front Drive Shaft
09527-10011 Rear Axle Shaft Bearing Remover Front Drive Shaft
09527-17011 Rear Axle Shaft Bearing Remover Front Axle Hub Sub-
assembly LH
09608-16042 Front Hub Bearing Adjusting Tool Front Axle Hub Assembly
(09608-02021) Bolt & Nut Front Axle Hub Assembly
(09608-02041) Holder Front Axle Hub Assembly
09608-32010 Steering Knuckle Oil Seal Replace Front Axle Hub Sub-
assembly LH
09628-00011 Ball Joint Puller Lower Suspension Arm
01-GENERAL.indd 35 2008-10-21 9:46:31

09628-10011 Ball Joint Puller Front Axle Hub Bolt LH

Rear Axle Hub Bolt
09628-62011 Ball Joint Puller Tie Rod End Sub-assembly
09930-00010 Drive Shaft Nut Punch Front Drive Shaft

Front Axle Hub Sub-
assembly LH
09950-00020 Bearing Remover Front Drive Shaft
09950-40011 Puller B Set Front Axle Hub Sub-

assembly LH
(09951-04020) Hanger 200 Front Axle Hub Sub-

assembly LH
(09952-04010) Slide Arm Front Axle Hub Sub-

assembly LH
(09953-04020) Center Bolt 150 Front Axle Hub Sub-

assembly LH
(09954-04010) Arm 25 Front Axle Hub Sub-

assembly LH
(09955-04011) No.1 Claw Front Axle Hub Sub-

assembly LH
(09957-04010) Attachment Front Axle Hub Sub-

assembly LH
(09958-04011) Holder Front Axle Hub Sub-

assembly LH
09950-60010 Replacer Set Front Axle Hub Sub-

assembly LH
01-GENERAL.indd 36 2008-10-21 9:46:34

GENERAL GL-37
(09951-00370) Replacer 37 Front Axle Hub Sub-

assembly LH

assembly LH
09950-60020 Replacer Set No.2 Front Axle Hub Sub-

assembly LH

assembly LH
09950-70010 Handle Set Front Axle Hub Sub-

assembly LH
(09951-07100) Handle 100 Front Axle Hub Sub-

assembly LH
Recommended Tools
09011-12301 Socket Wrench 30 mm Front Drive Shaft
Front Axle Hub Sub-
assembly LH
09905-00012 No.1 Snap Ring Expander Front Drive Shaft
09905-00013 Snap Ring Pliers Front Axle Hub Sub-

assembly LH
(09904-00090) Claw Set Front Axle Hub Sub-

assembly LH
Equipment
Torque wrench
Dial indicator with magnetic base
Lubricant
Item Capacity
Front drive shaft Outboard joint 155 to 170 g (5.5 to 6.1 oz.)
grease:
Inboard joint grease: 125 to 135 g (4.5 to 4.8 oz.)
01-GENERAL.indd 37 2008-10-21 9:46:36

Clutch
SST
09023-00100 Union Nut Wrench 10 mm Clutch Master Cylinder
Assembly
10
Clutch Release Cylinder

Assembly
09301-00210 Clutch Guide Tool Clutch Assembly
09333-00013 Universal Joint Bearing Remover Clutch Assembly

& Replacer
Recommended Tools
09031-00030 Pin Punch Clutch Master Cylinder
Assembly
09040-00011 Hexagon Wrench Set Clutch Master Cylinder

Assembly
Clutch Pedal Sub-assem-
bly
09905-00013 Snap Ring Pliers Clutch Master Cylinder
Assembly
Equipment
Vernier caliper
Torque wrench
Lubricant
Brake fluid - SAE J1703 or FMVSS No.116 DOT 3
01-GENERAL.indd 38 2008-10-21 9:46:37

GENERAL GL-39
Front Suspension System

SST
09628-00011 Ball Joint Puller Front Suspension Lower
Control Arm LH
09670-00010 Front Crossmember Guide Tool Auxiliary Frame Sub-

assembly
09727-30021 Coil Spring Compressor Front Shock Absorber With

Coil Spring
(09727-00010) Bolt Set Front Shock Absorber With

Coil Spring
(09727-00021) Arm Set Front Shock Absorber With

Coil Spring
(09727-00031) Compressor Front Shock Absorber With

Coil Spring
Equipment
Torque wrench
Tire pressure gauge
Alignment tester
Toe-in gauge
Angle gauge
Camber-caster-kingpin gauge
Engine sling device
Drill
Chain block
01-GENERAL.indd 39 2008-10-21 9:46:39

Rear Suspension System

SST
09023-00100 Union Nut Wrench 10 mm Rear Break No.4 Pipe
Rear Break No.3 Pipe
10
09309-37010 Transmission Bearing Replacer Rear Twist Beam Assembly

09909-
09710-14013 Rear Suspension Bushing Tool Set Rear Twist Beam Assembly
(09710-00021) Pipe Rear Twist Beam Assembly
09950-40011 Puller B Set Rear Twist Beam Assembly
(09951-04010) Hanger 150 Rear Twist Beam Assembly
(09952-04010) Slide Arm Rear Twist Beam Assembly
(09953-04010) Center Bolt 100 Rear Twist Beam Assembly
(09953-04030) Center Bolt 200 Rear Twist Beam Assembly
(09954-04020) Arm 100 Rear Twist Beam Assembly
(09955-04031) No.3 Claw Rear Twist Beam Assembly
(09955-04051) No.5 Claw Rear Twist Beam Assembly
01-GENERAL.indd 40 2008-10-21 9:46:41

GENERAL GL-41
(09957-04010) Attachment Rear Twist Beam Assembly
(09958-04011) Holder Rear Twist Beam Assembly
09950-60010 Replacer Set Rear Twist Beam Assembly
(09951-00560) Replacer 56 Rear Twist Beam Assembly
Equipment
Torque wrench
Wheel balancer
Tire pressure gauge
Alignment tester
Toe-in gauge
Camber-caster-kingpin gauge
Drill (Safety equipment: protective goggles, etc.) Shock absorber disposal
Tire and Wheel

Equipment
Tire pressure gauge
Wheel balancer
01-GENERAL.indd 41 2008-10-21 9:46:42

Brake System
SST
09023-00100 Union Nut Wrench 10 mm Brake Master Cylinder
Sub-assembly
Vacuum Booster Assembly
10
Front Brake
Rear Brake
ABS Controller Assembly
09214-76011 Crankshaft Pulley Replacer Skid Control Sensor
09214-
09520-00031 Rear Axle Shaft Puller Skid Control Sensor
(09520-00040) Shock Absorber Skid Control Sensor
09521-00020 Drive Shaft Boot Clamping Tool Skid Control Sensor
09703-30010 Brake Shoe Return Spring Tool Rear Brake
09718-00010 Shoe Hold Down Spring Driver Rear Brake
09737-00020 Vacuum Booster Push Rod Wrench Brake Master Cylinder

Sub-assembly
09950-00020 Bearing Remover Propeller Oil Seal
01-GENERAL.indd 42 2008-10-21 9:46:43

GENERAL GL-43
Equipment
Micrometer
Brake drum gauge
Slide caliper
Torque wrench
Brake Fluid
Brake fluid - DOT4
Parking Brake System

SST
09718-00010 Shoe Hold Down Spring Driver Parking Brake Cable As-
sembly LH
Equipment
Torque wrench
01-GENERAL.indd 43 2008-10-21 9:46:43

Steering System
SST
09612-22011 Tilt Handle Bearing Replacer Steering Column
09950-50013 Puller C Set Steering Column
(09951-05010) Hanger 150 Steering Column
(09952-05010) Slide Arm Steering Column
(09953-05020) Center Bolt 150 Steering Column
(09954-05021) No.2 Claw Steering Column
Recommended Tools
09904-00010 Expander Set Steering Column
(09904-00020) No.1 Claw Steering Column
Equipment
Torque wrench
01-GENERAL.indd 44 2008-10-21 9:46:45

GENERAL GL-45
Power Steering System

SST
09023-12700 Union Nut Wrench 17 mm Power Steering System
09023-38200 Union Nut Wrench 12 mm Power Steering System
09240-00020 Wire Gauge Set Power Steering System
09612-00012 Rack & Pinion Steering Rack Power Steering System

Housing Stand
09612-24014 Steering Gear Housing Overhaul Power Steering System

Tool Set
(09613-22011) Steering Rack Shaft Bushing Puller Power Steering System
09616-00011 Steering Worm Bearing Adjusting Power Steering System

Socket
09628-00011 Ball Joint Puller Power Steering System
09628-62011 Ball Joint Puller Power Steering System
09630-00014 Power Steering Gear Housing Power Steering Oil Pump

Overhaul Tool Set
(09631-00132) Power Steering Oil Pump Cradle Power Steering Oil Pump
09631-10041 Steering Rack Cover D Power Steering System
01-GENERAL.indd 45 2008-10-21 9:46:48

09631-12071 Steering Rack Oil Seal Test Tool Power Steering System
(09633-00010) Packing Power Steering System
09670-00010 Front Crossmember Guide Tool Power Steering System
09922-10010 Variable Open Wrench Power Steering System
09950-60010 Replacer Set Power Steering Oil Pump

(09951-00200) Replacer 20 Power Steering System
(09951-00280) Replacer 28 Power Steering Oil Pump
(09952-06010) Adapter Power Steering System
09950-70010 Handle Set Power Steering Oil Pump

Power Steering Gear
01-GENERAL.indd 46 2008-10-21 9:46:50

GENERAL GL-47
(09951-07100) Handle 100 Power Steering Oil Pump

Power Steering Gear
(09951-07200) Handle 200 Power Steering System
(09951-07360) Handle 360 Power Steering System
Recommended Tools
09025-00010 Torque Wrench (30 kgf-cm) Power Steering Oil Pump
09040-00011 Hexagon Wrench Set Power Steering System
(09043-30190) Straight Hexagon Wrench 21 Power Steering System
09043-30190 Straight Hexagon Wrench 19 Power Steering System
09905-00012 No.1 Snap Ring Expander Power Steering Oil Pump
Equipment
Torque wrench
Feeler gauge
Micrometer
Vernier caliper
Lubricant
Power steering fluid (Total) 0.7 liters (0.7 US qts, 0.6 lmp.qts) ATF DEXRON®II or III
Audio & Visual System

Equipment
Ohmmeter
01-GENERAL.indd 47 2008-10-21 9:46:52

Air Conditioning System

SST
07110-58060 Air Conditioner Service Tool Set Refrigerant
A/C Assembly
Compressor Assembly
Super-cooling Type Con-
denser Assembly
(07117-58060) Refrigerant Drain Service Valve Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
(07117-58070) T-Joint Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
(07117-58080) Quick Disconnect Adapter Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
(07117-58090) Quick Disconnect Adapter Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
(07117-78050) Refrigerant Charging Gauge Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
(07117-88060) Refrigerant Charging Hose Refrigerant
A/C Assembly
Compressor Assembly
denser Assembly
A/C Assembly
Compressor Assembly
denser Assembly
01-GENERAL.indd 48 2008-10-21 9:46:54

GENERAL GL-49

A/C Assembly
Compressor Assembly
denser Assembly
09870-00015 A/C Quick Joint Puller No.1 A/C Assembly
09870-00025 A/C Quick Joint Puller No.2 A/C Assembly
09950-50013 Puller C Set A/C Assembly
(09951-05010) Hanger 150 A/C Assembly
(09952-05010) Slide Arm A/C Assembly
(09953-05020) Center Bolt 150 A/C Assembly
(09954-05021) No.2 Claw A/C Assembly
01-GENERAL.indd 49 2008-10-21 9:46:55

Recommended Tools
09040-00011 Hexagon Wrench Set A/C Assembly
denser Assembly
(09043-20050) Socket Hexagon Wrench 5 A/C Assembly
(09043-30140) Straight Hexagon Wrench 14 Super-cooling Type Con-

denser Assembly
09041-00030 Torx Driver T30 A/C Assembly
09042-00010 Torx Socket T30 A/C Assembly
09070-20010 Moulding Remover A/C Controller Assembly

A/C Assembly
09216-00021 Belt Tension Gauge Compressor Assembly
95416-00140 Gas Leak Detector Refrigerant

(Halogen Leak Detector) A/C Assembly
(DENSO Part No.) Compressor Assembly
Super-cooling Type
Condenser Assembly
Equipment
Voltmeter
Anmeter
Ohmmeter
Vinyl tape
Hexagon wrench 4 mm (0.15 in.)
Gas leak detector
Radiator filler cap tester
Torque wrench
Lubricant
Compressor oil - ND-OIL 8
01-GENERAL.indd 50 2008-10-21 9:46:57

GENERAL GL-51

SST
09082-00700 SRS Airbag Deployment Tool Passenger Airbag Assem-
bly
Driver Airbag Assembly
09082-00780 Airbag Deployment Wire Passenger Airbag Assem-

Sub-harness No.6 bly
09082-00802 Airbag Deployment Wire Driver Airbag Assembly

Sub-harness No.8
(09082-10801) Wire A Driver Airbag Assembly
(09082-30801) Wire C Driver Airbag Assembly
09950-50013 Puller C Set Clock Spring Sub-assem-

bly
(09951-05010) Hanger 150 Clock Spring Sub-assem-

bly
(09952-05010) Slide Arm Clock Spring Sub-assem-

bly
(09953-05020) Center Bolt 150 Clock Spring Sub-assem-

bly
(09954-05021) No.2 Claw Clock Spring Sub-assem-

bly
01-GENERAL.indd 51 2008-10-21 9:46:58

Equipment
Torque wrench
Bolt length: 35.0 mm (1.378 in.)
Pitch: 1.0 mm (0.039 in.) Airbag disposal
Diam.: 6.0 mm (0.236 in.)
Tire width: 185 mm (7.28 in.)
Airbag disposal
Inner diameter: 360 mm (14.17 in.)
Tire with disc wheel width: 185 mm (7.28 in.)
Airbag disposal
Plastic bag Airbag disposal
Seat Belt
SST
09082-00700 SRS Airbag Deployment Tool Front Seat Belt
09082-00770 Airbag Deployment Wire Front Seat Belt

Sub-harness No.5
Recommended Tools
09082-00040 Electrical Tester Seat Belt Warning System
Equipment
Torque wrench
01-GENERAL.indd 52 2008-10-21 9:46:58

GENERAL GL-53
Lighting System
Recommended Tools
09082-00040 Electrical Tester Lighting System
(09083-00150) Test Lead Set Lighting System
Equipment
Voltmeter
Anmeter
Ohmmeter
Vinyl tape
Torque wrench
01-GENERAL.indd 53 2008-10-21 9:46:59

Combination Meter
SST
09950-50013 Puller C Set Lower Instrument Panel
(09951-05010) Hanger 150 Lower Instrument Panel
(09952-05010) Slide Arm Lower Instrument Panel
(09953-05020) Center Bolt 150 Lower Instrument Panel
(09954-05021) No.2 Claw Lower Instrument Panel
Recommended Tools
09082-00040 Electrical Tester Combination Meter
(09083-00150) Test Lead Set Combination Meter
09042-00010 Torx Socket T30 Lower Instrument Panel
09070-20010 Moulding Remover Upper Instrument Panel

Body
Lower Instrument Panel
Equipment
Torque wrench
Adhesive tape To avoid surface damage
01-GENERAL.indd 54 2008-10-21 9:46:59

GENERAL GL-55
Seat
Equipment
Hog ring pliers
Hog ring
Torque wrench
Wiper and Washer System

SST
09843-18040 Diagnosis Check Wire No.2 Wiper and Washer System
Recommended Tools
09082-00040 Electrical Tester Wiper and Washer System
(09083-00150) Test Lead Set Wiper and Washer System
(09083-00150) Test Lead Set Wiper and Washer System
Equipment
Voltmeter
Anmeter
Ohmmeter
Vinyl tape
Wire brush
Torque wrench
01-GENERAL.indd 55 2008-10-21 9:46:59

Windshield/Window Glass/Mirror
Recommended Tools
09082-00040 Electrical Tester Power Window Control
System
Window Defogger Sys-
tem
Power Mirror Control
System
(09083-00150) Test Lead Set Power Window Control
System
Equipment
Knife
Piano wire Windshield
Plastic sheet To avoid surface damage
Sealer gun
Torque wrench
Wooden block or similar object For tying both piano wire ends
01-GENERAL.indd 56 2008-10-21 9:46:59

GENERAL GL-57
Engine Hood/Door
SST
09812-00010 Door Hinge Set Bolt Wrench Front Door
09812-00020 Door Hinge Set Bolt Wrench Front Door
Recommended Tools
09041-00020 Torx Driver T25 Front Door
Rear Door
09042-00010 Torx Socket T30 Front Door

Rear Door
09042-00020 Torx Socket T40 Back Door
Equipment
Brass bar
Clip remover
Hammer
Plastic-faced hammer
Torque wrench
01-GENERAL.indd 57 2008-10-21 9:47:00

Exterior/Interior Trim
Recommended Tools
09070-20010 Moulding Remover Roof Heading
Front Door Glass Weath-
erstrip Assembly Outer
LH
Rear Door Outer Weath-
erstrip LH
Equipment
Washer
Clip remover
Heat light Moulding
Piano wire Moulding
Torque wrench
Wooden block or similar object For tying both piano wire ends
01-GENERAL.indd 58 2008-10-21 9:47:01

GENERAL GL-59
SERVICE SPECIFICATIONS
Engine Mechanical
Repair Data
New drive belt deflection Fan and generator 7.0 to 8.5 mm (0.28 to 0.33 in.)
Pressure: 98 N (10 kgf, 22 lbf) Power steering oil pump 8.0 to 10.0 mm (0.31 to 0.39 in.)
Old drive belt deflection Fan and generator 11.0 to 13.0 mm (0.43 to 0.51 in.)
Pressure: 98 N (10 kgf, 22 lbf) Power steering oil pump 11.0 to 13.0 mm (0.43 to 0.51 in.)
New driving belt tension Fan and generator 490 to 690 N (50 to 70 kgf, 110 to 155 lb)
Power steering oil pump 445 to 667 N (45 to 68 kgf, 100 to 150 lb)
Old driving belt tension Fan and generator 340 to 440 N (35 to 45 kgf, 76 to 100 lb)
Power steering oil pump 267 to 445 N (27 to 45 kgf, 60 to 100 lb)
Ignition timing 8 to 12 BTDC
Idling speed M/T 650 ± 50 r/min
Piston diameter 74.945 to 74.955 mm (2.9506 to 2.9510 in.)
Piston pin temperature at 20°C (68°F) 18.013 to 18.016 mm (0.7092 to 0.7093 in.)
Piston pin aperture 18.001 to 18.004 mm (0.7087 to 0.7088 in.)
Oil clearance Standard value 0.009 to 0.015 mm (0.0004 to 0.0006 in.)
Maximum value 0.050 mm (0.0020 in.)
Standard value 0.045 to 0.068 mm (0.0018 to 0.0027 in.)
Piston clearance
Connecting bar linearity Maximum value 0.05 mm (0.0020 in.)/100 mm (3.94 in.)
Connecting bar camber Maximum value 0.05 mm (0.0020 in.)/100 mm (3.94 in.)
Piston ring groove clearance No.1 0.03 to 0.07 mm (0.0012 to 0.0028 in.)
No.2 0.02 to 0.06 mm (0.0008 to 0.0024 in.)
Piston ring end clearance Standard value No.1 0.25 to 0.35 mm (0.0098 to 0.0138 in.)
No.2 0.35 to 0.50 mm (0.0138 to 0.0197 in.)
Oil (Side rail) 0.10 to 0.35 mm (0.0039 to 0.0138 in.)
Maximum No.1 0.91 mm (0.0358 in.)
No.2 1.06 mm (0.0417 in.)
Oil (Side rail) 0.82 mm (0.0323 in.)
Connecting rod bolt diameter Standard value 6.6 to 6.7 mm (0.260 to 0.264 in.)
Crankshaft circle runout Maximum value 0.03 mm (0.0012 in.)
Main journal diameter 45.988 to 46.000 mm (1.8106 to 1.8110 in.)
Main journal taper and out-of-round Maximum value 0.02 mm (0.0008 in.)
Crank pin diameter 39.992 to 40,000 mm (1.5745 to 1.5748 in.)
Crank pin taper and out-of-round Minimum value 0.02 mm (0.0008 in.)
Crank timing sprocket diameter Standard value 51.72 mm (2.0362 in.)
(With chain) Minimum value 50.5 mm (1.988 in.)
Crankshaft bearing cap set bolt diameter Standard value 7.3 to 7.5 mm (0.287 to 0.295 in.)
Minimum value 7.2 mm (0.283 in.)
Crankshaft oil clearance Standard value 0.01 to 0.023 mm (0.0004 to 0.0009 in.)
01-GENERAL.indd 59 2008-10-21 9:47:01

Tight plug depth 0.2 to 1.2 mm (0.008 to 0.047 in.)

Cylinder head setting straight pin protrusion part 8.5 to 9.5 mm (0.335 to 0.374 in.)
Straight pin protrusion part Pin A 3.5 to 4.5 mm (0.138 to 0.177 in.)
Pin B 18.5 to 19.5 mm (0.728 to 0.768 in.)
Pin C 8.5 to 9.5 mm (0.335 to 0.347 in.)
Pin D 11.5 to 12.5 mm (0.453 to 0.492 in.)
Torque Specification
Part tightened N·m kgf·cm ft·lbf
Generator × Engine Bolt A 19 189 14
Bolt B 54 550 40
Power steering oil pump × Engine 35 357 26
Engine under cover LH × Body 5.0 51 44 in.·lbf
Engine under cover RH × Body 5.0 51 44 in.·lbf
Exhaust manifold front heat insulator × Exhaust mani-
8.0 82 71 in.·lbf
fold
Manifold bracket × Cylinder block sub-assembly 37 377 27
Engine mounting insulator LH × Engine mounting
78 796 59
bracket LH
Engine rear mounting insulator × Engine rear mounting
78 796 59
bracket
Engine mounting insulator RH × Body Bolt 78 796 59
Nut 78 796 59
Auxiliary frame sub-assembly × Body Bolt A 120 1,224 90
Bolt B 145 1,480 109
Front suspension lower control arm LH × Steering
98 999 72
knuckle
Front axle hub nut × Front drive shaft 225 2,295 162
Tie rod end assembly LH × Steering knuckle 50 510 38
Front speed sensor LH × Steering knuckle 8.0 82 71 in.·lbf
Oil pan drain plug × No.2 oil pan 38 382 28
Front exhaust pipe assembly × Exhaust manifold 60 612 45
Spark plug × Cylinder head 18 184 13
Auxiliary frame strut rod × Body 46 470 34
Water filler × Radiator 7.5 76 66 in.·lbf
01-GENERAL.indd 60 2008-10-21 9:47:01

GENERAL GL-61
Transmission/Transaxle
Transmission control cable assembly × Body 5.0 51 44 in.·lbf
Floor shift lever assembly × Floor 12 122 9
Wire harness clamp × Transaxle 5.0 51 44 in.·lbf
Ground wire × Engine mounting bracket LH 26 260 19
Air filter bracket × Transaxle 19 195 14
Clutch release cylinder × Brake hose 16 163 12
No.1 engine hanger × Engine 40 408 29
Auxiliary frame strut rod set bolt 46 469 35
Auxiliary frame sub-assembly × Body Bolt A 120 1,224 90
Bolt B 145 1,480 109
Engine mounting bracket LH × Transaxle 78 796 58
Engine Rear Mounting Bracket × Transaxle Bolt A 68 694 51
Bolt B 68 694 51
Engine mounting insulator LH × Engine mounting
78 796 58
bracket LH
Engine rear mounting insulator × Engine rear mounting
78 796 58
bracket
Starter assembly × Transaxle 37 380 27
Starter assembly × Starter wire harness 9.8 100 87 in.·lbf
Transaxle × Engine 33 340 24
Filler plug × Transaxle 33 337 25
Drain plug × Transaxle 39 400 29
Clutch release cylinder assembly × Transaxle 12 120 9
Filler plug × Transaxle 39 400 29
01-GENERAL.indd 61 2008-10-21 9:47:01

Fuel
Repair Data
Fuel pump
When 20°C (68°F) 0.2 to 3.0 Ω
Resistance
Rear row seat cushion bracket sub-assembly RH ×
5.0 51 44 in.·lbf
Floor
Fuel tank assembly × Body 26 264 19
Parking brake cable assembly LH × Body 5.4 55 48 in.·lbf
Parking brake cable assembly RH × Body 5.4 55 48 in.·lbf
Exhaust manifold × Exhaust pipe assembly front 60 612 45
Exhaust pipe assembly × Exhaust pipe assembly tail 60 612 45
Ignition
Repair Data
Spark plug Made by DENSO K16R-U
Recommended spark plug Made by NGK BKR5EYA
Electrode gap K16R-U, BKR5EYA 0.7 to 0.8 mm (0.028 to 0.031 in.)
Spark plug × Cylinder head 18 184 13
Ignition coil (With igniter) × Cylinder head cover 9.0 92 80 in.·lbf
Start and Charge

Repair Data
Starter assembly
Specified current 90 A or lower when voltage is 11.5 V
Battery
Except maintenance-free
battery Standard specific gravity When 20°C (68°F) 1.27 to 1.29
Voltage When 20°C (68°F) 12.5 to 12.9 V
Engine under cover LH × Body 5.0 51 44 in.·lbf
01-GENERAL.indd 62 2008-10-21 9:47:02

GENERAL GL-63
Discharge Control
Repair Data
Heated oxygen sensor HT (1) - +B (2) Continuity
Resistance HT (1) - E2 (4) No continuity
Rear heated oxygen sensor HT (1) - +B (2) Continuity
Resistance HT (1) - E2 (4) No continuity
Exhaust System
Repair Data
Compression spring
Minimum length 40.5 mm (1.594 in.)
Heated oxygen sensor × Rear catalytic converter 60 612 45
Sub muffler assembly × Rear catalytic converter 60 612 45
Main muffler assembly × Sub muffler assembly 60 612 45
Exhaust pipe rear shield bracket × Body 20 199 40
01-GENERAL.indd 63 2008-10-21 9:47:02

Cooling System
Repair Data
Thermostat
Valve opening temperature 80 to 84°C (176 to 183°F)
Valve lift When 95°C (205°F) 8.5 mm (0.335 in.) or more
Radiator filler cap sub-assembly
Standard opening pressure 93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi)
Minimum opening pressure 78 kPa (0.8 kgf/cm2, 11.3 psi)
Cooling fan
Standard amperage 11.7 to 14.7 A
Continuity
Cooling fan relay Between terminal No continuity
1 and 2
Specified condition Between terminal Continuity (When battery voltage is applied to terminals 1
3 and 5 and 2)
No.2 cooling fan relay Between terminal Continuity
1 and 2
Specified condition Between terminal Continuity
3 and 4
Between terminal No continuity
3 and 5 Continuity (When battery voltage is applied to terminals 1
and 2)
Cooling fan resistor
Resistance When 20°C (68°F) 1.17 to 1.43 W
Water pump × Oil pump assembly 11 112 8.1
Water pump pulley × Water pump 15 153 11
Water inlet × Cylinder body sub-assembly 9.0 92 80 in.·lbf
Radiator assembly × Fan shroud 7.5 76 66 in.·lbf
Radiator upper cross beam × Body 5.0 51 44 in.·lbf
Radiator upper cross beam × Reservoir condenser 9.8 100 7.2
Engine hood lock support × Body 5.0 51 44 in.·lbf
Engine hood lock assembly × Engine hood lock support 8.0 82 71 in.·lbf
Water filler × Radiator 7.5 76 66 in.·lbf
01-GENERAL.indd 64 2008-10-21 9:47:02

GENERAL GL-65
Drive Shaft/Axle
Repair Data
Front axle hub bearing: bearing play Maximum: 0.05 mm (0.0020 in.)
Front axle hub sub-assembly: deviation Maximum: 0.07 mm (0.0028 in.)
Rear axle hub & bearing assembly: bearing play Maximum: 0.05 mm (0.0020 in.)
Rear axle hub & bearing assembly: deviation Maximum: 0.07 mm (0.0028 in.)
Front wheel set nut 110 1,122 83
Rear wheel set nut 110 1,122 83
Transaxle drain plug 39 398 29
Tie rod end assembly × Steering knuckle 50 510 38
Suspension lower control arm × Steering Knuckle 98 1,000 72
Front stabilizer bar × Suspension lower control arm 37 377 28
Brake hose and front speed sensor × Front shock ab-
29 300 22
sorber assembly
Front speed sensor × Steering Knuckle 8.0 82 71 in.·lbf
Front axle hub nut 225 2,295 162
Front brake disc housing × Steering knuckle 8.3 85 73 in.·lbf
Front axle assembly × Front shock absorber assembly 132 1,350 97
Front brake caliper assembly × Steering knuckle 88 900 65
Rear axle hub & bearing assembly × Rear twist beam 50 510 38
01-GENERAL.indd 65 2008-10-21 9:47:02

Clutch
Repair Data
Pedal height to the dash panel 134.3-144.3 mm (5.287-5.681 in.)
Clutch pedal free play 4-11 mm (0.157-0.433 in.)
Clutch pedal push rod play on the top end of the
1.0-5.0 mm (0.039-0.197 in.)
pedal
Slotted spring pin protrusion part 1.5-3.5 mm (0.059-0.138 in.)
Distance between clutch release point and the full
25 mm (0.98 in.) or more
stroke end position
Clutch disc rivet head depth Maximum 0.3 mm (0.012 in.)
Clutch disc assembly runout Minimum 0.8 mm (0.031 in.)
Diaphragm spring finger Maximum depth: 0.5 mm (0.020 in.)
wear Maximum width: 6.0 mm (0.236 in.)
Flywheel sub-assembly
runout
Diaphrag m s p r i n g t i p
Maximum depth: 0.5 mm (0.020 in.)
alignment
Clutch pedal sub-assembly × Clutch pedal bracket 37 375 27
Clutch pedal stopper bolt × Clutch pedal bracket 18 186 13
Clutch pedal bracket × Body 12 120 9
Clutch master cylinder push rod clevis lock nut 12 120 9
Clutch master cylinder × Clutch hose 15 155 11
Clutch master cylinder × Body 12 120 9
Clutch release cylinder bleeder screw 8.4 86 74 in.·lbf
Clutch release cylinder × Transaxle housing 12 120 9
Clutch release cylinder × Clutch hose 15 155 11
Clutch release cylinder × Clutch release end 25 250 18
Clutch cover assembly × Flywheel sub-assembly 19 195 14
Release fork support × Transaxle assembly 37 375 27
01-GENERAL.indd 66 2008-10-21 9:47:02

GENERAL GL-67
Front Suspension System

Repair Data
Vehicle height A-B: 82 mm (3.22 in.)
D-C: 12 mm (0.47 in.)
Front wheel toe-in -0°04’ ± 15’
(Total) Rack end length 1.5 mm (0.059 in.) or less
difference
Front Wheel turning angle Inner turning angle 32° ~ 34°
wheel Outer turning angle 28° ~ 30°
alignment Front wheel camber -0°29’ ± 15’
RH-LH error 30’ (0.5°) or less
Front wheel king pin 2°08’ ± 15’
caster RH-LH error 30’ (0.5°) or less
Kingpin inclination 9°49’ ± 15’
RH-LH error 30’ (0.5°) or less
Lower control arm
Front sus-
ball pin turning 5.0 N·m (51 kgf·cm, 44 in.·lbf) or less
pension
torque
A: Ground clearance of front wheel center

B: Ground clearance of front suspension lower control arm front bolt center
C: Ground clearance of rear twist beam set bolt center
D: Ground clearance of rear wheel center
01-GENERAL.indd 67 2008-10-21 9:47:03

Tie rod end lock nut 37 377 28
Steering knuckle × Shock absorber 132 1,350 97
Front wheel hub nut 110 1,122 83
Front shock absorber pillar upper mounting seat ×
33 340 25
Piston rod
Front shock absorber pillar upper mounting pressure
40 408 30
plate × Body
Speed sensor wire bracket set bolt 29 300 22
Cowl top outer panel × Body 5.0 51 44 in.·lbf
Auxiliary frame sub-assembly × Body Bolt A: 120 1,224 90
Bolt B: 145 1,480 109
Auxiliary frame sub-assembly × Transverse engine
78 796 58
mounting insulator
Auxiliary frame sub-assembly × Steering combination
7.8 80 69 in.·lbf
tube
Power steering gear × Auxiliary frame sub-assembly 107 1,091 80
Stabilizer bar bolt set nut 37 377 28
Steering Knuckle × Lower control arm ball pin 98 1,000 72
Suspension lower control arm × Bolt A: 170 1,734 128
Auxiliary frame sub-assembly Bolt B: 107 1,091 80
Stabilizer bar mounting bracket × Auxiliary frame sub-
37 375 27
assembly
01-GENERAL.indd 68 2008-10-21 9:47:03

GENERAL GL-69
Rear Suspension System

Repair Data
Rear Toe-in (total) -0°13’ ± 15’

wheel Camber -0°43’ ± 15’
alignment RH-LH error 30’ (0.75°) or less
Piston rod set nut 25 255 18
Shock absorber × Rear twist beam 120 1,224 90
Rear axle hub rear set nut 50 510 38
Parking brake cable bracket set bolt 5.4 55 48 in.·lbf
Speed sensor wire bracket set bolt 8.0 82 71 in.·lbf
Rear twist beam × Body 80 816 60
Hub nut 110 1,122 83
Tire and Wheel

Repair Data
Front: 200 kPa (2.0 kgf/cm2, 29 psi)
Cold tire infla- 185/65/R 15 84T
Rear: 200 kPa (2.0 kgf/cm2, 29 psi)
tion pressure
Spare tire: 420 kPa (4.2 kgf/cm2, 60.9 psi)
Tire runout 1.4 mm (0.055 in.) or less
Imbalance after adjustment 5.0 g (0.011 lb) or less
01-GENERAL.indd 69 2008-10-21 9:47:03

Brake System
Repair Data
Brake pedal height (To the cushion) 124.5-134.5 mm (4.902-5.293 in.)
Brake pedal free play 6-9 mm (0.24-0.36 in.)
Brake lamp switch clearance 0.5-2.4 mm (0.020-0.094 in.)
Pedal reverse distance from the dash panel at 490 N (50 kgf, 110 lbf) Longer than 55 mm (2.17 in.)
The gap between vacuum booster rod and piston (with SST) 0 mm (0 in.)
Front wheel brake pad thickness Standard value 11.0 mm (0.433 in.)
Front wheel brake disc thickness Standard value 22.0 mm (0.866 in.)
Front wheel brake disc runout Maximum value 0.05 mm (0.0020 in.)
Rear brake drum inside diameter Standard value 200.0 mm (7.874 in.)
Rear wheel brake drum brake shoe Standard value 4.0 mm (0.157 in.)
lining thickness Minimum value 1.0 mm (0.039 in.)
Rear wheel brake pad thickness Standard value 10.0 mm (0.394 in.)
Bleeder screw 8.3 85 73 in.·lbf
Vacuum booster clevis lock nut 26 265 19
Brake pedal bracket sub-assembly × Brake pedal sub-
37 375 27
assembly
Vacuum booster × Body 13 130 9
Brake pedal bracket sub-assembly × Body 21 214 15
Brake master cylinder × Piston stopper bolt 10 102 7
Brake master cylinder × Vacuum booster 13 127 9
Brake line union nut 16 163 12
Wheel nuts 103 1,050 76
Front brake cylinder set bracket × Steering knuckle 88 900 65
Front brake cylinder × Front brake cylinder set bracket 34 347 25
Front brake caliper × Brake hose 29 296 21
Rear drum brake wheel cylinder × Deck board 9.8 100 87 in.·lbf
ABS controller assembly × ABS controller bracket 5.4 55 48 in.·lbf
01-GENERAL.indd 70 2008-10-21 9:47:03

GENERAL GL-71

ABS controller bracket × Body 19 194 14
Front speed sensor × Steering knuckle 8.0 82 71 in.·lbf
Front speed sensor wire harness clamp × Shock absorber 29 296 21
Front speed sensor wire harness clamp × Body 8.0 82 71 in.·lbf
Yaw rate sensor × Body 14 143 10
Parking Brake System

Repair Data
When parking brake lever travel is at 196 N (20 kgf, 44.1 lbf): Click sound for 6-7 times.
Wheel nuts 103 1,050 76
Parking brake set nut 5.4 55 48 in.·lbf
Parking brake handle × Body 13 127 9
Front middle heat insulator × Body 5.5 55 48 in.·lbf
Parking brake cable assembly LH × Body 5.4 55 48 in.·lbf
Parking Brake Cable Assembly LH × Deck board 7.8 80 69 in.·lbf
01-GENERAL.indd 71 2008-10-21 9:47:03

Steering System
Repair Data
Steering wheel free play Maximum value 30 mm (1.18 in.)
Cross rod × Rack end 74 755 55
Steering propeller shaft joint × Steering connecting
28 286 21
shaft
Steering column set bolt 21 210 15
Propeller shaft × Main shaft 28 286 21
Steering wheel lock nut 50 510 37
Steering wheel pad set bolt 8.8 90 78 in.·lbf

Repair Data
Power steering system
Fluid level rise Maximum value 5 mm (5.08 mm.)
Fluid pressure when idle and valve
5,900 kPa (60 kgf/cm2, 852 psi)
close
Steering effort when idling (Reference value) 6 N·m (60 kgf·cm, 53 in.·lbf)
Power steering gear
Tie rod end assembly torque 0.8-3.4 N·m (8.2-34.7 kgf·cm, 7.1-30.1 in.·lbf)
01-GENERAL.indd 72 2008-10-21 9:47:04

GENERAL GL-73
Power steering oil pump
Power steering oil Pressure sensor 21 214 15
Pressure feed tube × Power steering oil pump 30 306 23
Power steering gear
Tie rod end assembly lock nut 37 377 28
Power steering gear set bolt 107 1,091 80
Steering connecting shaft set bolt 28 290 21
Steering gear shield set bolt (a): 18 178 13 in.·lbf
(b): 35 360 26 in.·lbf
Auxiliary frame sub-assembly set bolt A: 120 1,224 90
B: 145 1,480 109
Engine rear mounting × Auxiliary frame sub-assembly 78 796 59
Auxiliary frame strut rod set bolt RH, LH 46 469 35
Pressure feed tube × Power steering gear 27 (25) 273 (255) 20 (18)
Steering combination tube clamp set bolt 7.8 80 69 in.·lbf
Steering propeller shaft joint × Steering connecting shaft 28 290 21
01-GENERAL.indd 73 2008-10-21 9:47:04

Air Conditioning System

Repair Data
Refrigerant charge amount Standard value 500 ± 20 g
A/C blower assembly
Evaporator expansion valve × Evaporator sub-assembly 10 102 90 in.·lbf
A/C pipe assembly × Evaporator expansion valve 10 102 90 in.·lbf
Suction hose sub-assembly × Body 9.8 100 87 in.·lbf
Compressor assembly
Compressor assembly × Engine 64 653 48
Suction hose sub-assembly × Compressor assembly 10 102 90 in.·lbf
Compressor discharge pipe assembly × Compressor as-
10 102 90 in.·lbf
sembly
Condenser with reservoir assembly
Cover × Condenser with reservoir assembly 2.9 29 25 in.·lbf
Condenser upper mount assembly × Condenser with
3.9 40 35 in.·lbf
reservoir assembly
Condenser with reservoir assembly × Body 9.8 100 87 in.·lbf
Condenser outlet pipe × Condenser with reservoir as-
10 102 90 in.·lbf
sembly
Compressor discharge pipe assembly × Condenser with
10 102 90 in.·lbf
reservoir assembly
Engine hood lock support sub-assembly × Body 5.0 51 44 in.·lbf
01-GENERAL.indd 74 2008-10-21 9:47:04

GENERAL GL-75

Driver airbag assembly × Steering wheel assembly 8.8 90 78 in.·lbf
Steering wheel assembly × Steering column assembly 50 510 37
Passenger airbag assembly × Instrument panel rein-
20 200 14
forcement member
Passenger airbag assembly × Upper instrument panel 5 50 43 in.·lbf
Seat Belt
Front seat belt
Passenger seat outer belt assembly (Upper bolt) × Body 5.0 51 44 in.·lbf
Passenger seat outer belt assembly (Lower bolt) × Body 38 388 29
Passenger seat buckle assembly × Front seat 38 388 29
Seat belt adjuster × Body 38 388 29
Front outer seat belt (End plate) × Body 38 388 29
Front outer seat belt (Guide ring) × Body 38 388 29
Rear seat belt
Rear seat 3 point type outer belt assembly × Body 38 388 29
Rear seat 3 point type outer belt assembly (End plate) ×
38 388 29
Body
Rear seat 3 point type outer belt assembly (Guide ring) ×
38 388 29
Body
Rear seat buckle w/center belt assembly RH × Body 38 388 29
Rear seat buckle w/center belt assembly LH × Body 38 388 29
Rear seat setting cross member assembly × Body 23 235 17
Seatback hinge × Body 42 430 31
Combination Meter
Instrument panel reinforcement member × Passenger
20 204 14
airbag
01-GENERAL.indd 75 2008-10-21 9:47:04

Seat
Front seat assembly
Front seat × Body 64 653 48
Front seat buckle assembly × Front seat adjuster 41 418 30
Front seatback assembly × Front seat adjuster 43 440 32
Rear seat assembly
Rear seatback assembly × Rear seatback hinge 37 377 27
Rear seat setting cross member assembly × Body 23 235 17
Rear seatback hinge × Body 42 428 31
Rear seatback knuckle × Body 21 214 15
Rear seat belt assembly × Rear seatback frame 42 428 31
Wiper and Washer System

Windshield wiper link assembly × Windshield wiper
5.4 55 47 in.·lbf
motor assembly
Windshield wiper motor & link assembly × Body 5.4 55 47 in.·lbf
Front wiper arm and blade assembly LH × Windshield
20 205 15
wiper link assembly
Front wiper arm and blade assembly RH × Windshield
20 205 15
wiper link assembly
Rear wiper motor assembly × Body 5.4 55 47 in.·lbf
Rear wiper arm and blade × Rear wiper motor assembly 5.4 55 47 in.·lbf
Windshield/Window Glass/Mirror
Outside rear view mirror assembly LH
Door outside rear view mirror assembly × Front door 8.0 82 71 in.·lbf
01-GENERAL.indd 76 2008-10-21 9:47:04

GENERAL GL-77
Electric Horn System

Low tone electric horn assembly
Low tone electric horn assembly × Body 19.5 199 14
High tone electric horn assembly
High tone electric horn assembly × Body 19.5 199 14
Engine Hood/Door
Engine hood
Engine hood × Engine hinge 23 235 17
Engine hood × Engine hood lock 7.0 71 62 in.·lbf
Front door
Door check × Body 30 306 22
Door check × Door panel 5.5 56 49 in.·lbf
Rear lower frame sub-assembly × Door panel 6.2 63 55 in.·lbf
Door glass × Front door regulator sub-assembly 8.0 82 72 in.·lbf
Door hinge × Body 23 235 17
Door hinge × Door panel 23 235 17
Door lock × Door panel 5.0 51 44 in.·lbf
Door lock striker × Body 23 235 17
Door outside handle × Door panel 5.5 56 49 in.·lbf
Door outside rear view mirror × Door panel 8.0 82 71 in.·lbf
Power glass regulator motor × Glass regulator 5.4 55 48 in.·lbf
Glass regulator × Door panel 8.0 82 71 in.·lbf
Rear door
Door check × Body 30 306 22
Door check × Door panel 5.5 56 49 in.·lbf
Door window division bar sub-assembly × Door panel 5.0 51 44 in.·lbf
01-GENERAL.indd 77 2008-10-21 9:47:05

MEMO
01-GENERAL.indd 78 2008-10-21 9:47:05

MA-
MAINTENANCE AND CARE
MAINTENANCE, CARE AND CHECK

Outside Vehicle General Maintenance.............................. MA-2
Inside Vehicle General Maintenance................................ MA-2
General Maintenance Under Engine Hood ...................... MA-4
Engine On-vehicle Inspection........................................... MA-5
Brake On-vehicle Inspection............................................. MA-5 MA
Chassis On-vehicle Inspection.......................................... MA-6
Body On-vehicle Inspection.............................................. MA-7
Power Source System Inspection..................................... MA-7
02-MAINTENANCE AND CARE.indd 1 2008-10-20 16:56:35

MA- GREAT WALL COOL BEAR REPAIR MANUAL
MAINTENANCE, CARE AND CHECK

Outside Vehicle General Maintenance
Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform the main-
tenance himself or take the vehicle to a service center.
Check the parts of the vehicle described below on a daily basis. In most cases, special tool are not required.
The procedures for general maintenance are as follows.
1. General notes
• Maintenance requirements vary depending on the country.
• Check the maintenance schedule in the owner’s manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed,
whichever reaches the specification first.
• Maintain similar intervals between periodic maintenance unless noted.
• Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions.
2. Tire
(a) Check the tire pressure with a gauge. Make adjustments if necessary.
(b) Check the surfaces of tires for cuts, damage or excessive wear.
3. Wheel nuts
(a) Check for nuts that are loose or missing. Tighten them if necessary.
4. Tire rotation
(a) Check the maintenance schedule in the owner’s manual supplement.
5. Windshield wiper blades
(a) Check the blades for wear or cracks when they are unable to wipe the windshield clean. Replace them if neces-
sary.
6. Fluid leaks
(a) Check under the vehicle for leaking fuel, oil, water and other fluids.
(b) If you smell gasoline fumes or notice any leaks, find out the causes and correct them.
7. Doors and engine hood
(a) All of the doors and back door operate smoothly, and that all the latches lock securely.
(b) When the primary latch is released, check if the engine hood secondary latch prevents the engine hood from
opening.
Inside Vehicle General Maintenance

Performing these maintenance checks on the vehicle is the owner’s responsibility. The owner may perform the main-
tenance himself or take the vehicle to a service center.
Check the parts of the vehicle described below on a daily basis. In most cases, special tool are not required.
The procedures for general maintenance are as follows.
1. General notes
• Maintenance requirements vary depending on the country.
• Check the maintenance schedule in the owner’s manual supplement.
• Following the maintenance schedule is mandatory.
• Determine the appropriate time to service the vehicle using either miles driven or time (month) elapsed,
whichever reaches the specification first.
• Maintain similar intervals between periodic maintenance unless noted.
• Failing to check each vehicle part could lead to poor engine performance and increase exhaust emissions.

MAINTENANCE AND CARE MA-
2. Lights
(a) Check that if the front combination Lamp, stop lights, the rear combination Lamp, turn signal lamps, and other
lamps illuminate or blink. Also, check if they have enough brightness.
(b) Check if the headlights are aimed properly.
3. Warning lights and buzzers
(a) Check that all the warning lights and buzzers can work.
4. Electric horn
(a) Check that the electric horn can work.
5. Windshield
(a) Check for scratches, pits or abrasions.
6. Windshield wiper and washer
(a) Check if the wind washers are aimed properly. Also, check if the washer fluid hits the center of the operating
rage of each wiper on the windshield.
(b) Check if there is any streak left after the wiper working.
7. Windshield defroster
(a) When the heater or air conditioner is on the defroster setting, check if air comes out of the defroster outlet.
8. Rear view mirror
(a) Check that the rear view mirror is securely mounted.
9. Sun visor
(a) Check that the sun visors move freely and are securely mounted.
10. Steering wheel
(a) Check that the steering wheel has the proper free play. Also check for steering difficulty, and unusual noises.
11. Seat
(a) Check if the seat adjusters, seatback recliner and other front seat controls operate smoothly.
(b) Check that the locks hold securely in all latched positions.
(c) Check that the headrest moves up and down smoothly and that the locks hold securely in all latched positions.
(d) When the rear seatbacks are folded down, check if the latches lock securely.
12. Seat belt
(a) Check that the seat belt system such as the buckles, retractors and anchors operate properly and smoothly.
(b) Check that the belt webbing is not cut, frayed, worn or damaged.
13. Accelerator pedal
(a) Check the pedal for smooth operation, uneven pedal effort and catching.
14. Clutch pedal (See page DT-27)
(a) Check the pedal for smooth operation.
(b) Check that the steering wheel has the proper free play.
15. Break pedal (See page BR-10)
(a) Check the pedal for smooth operation.
(b) Check that the pedal has the proper reserve distance and free play.
(c) Start the engine and check the vacuum booster function.
16. Brakes
(a) In a safe place, check that the vehicle remains straight when applying the brakes.
17. Parking brake (See page BR-45)
(a) Check that the lever has the proper range of motion.
(b) On a slight slope, check if the parking brake can stabilize the vehicle alone.

General Maintenance Under Engine Hood

1. General notes
• Maintenance items vary depending on the country. Check the maintenance schedule as shown in the owner’s
manual supplement.
• Every service item in the periodic maintenance schedule must be performed.
• Periodic maintenance service must be performed according to whichever interval in the periodic mainte-
nance schedule occurs first, the odometer reading (miles) or the time interval (months).
• Maintenance service after the last period should be performed at the same interval as before unless noted.
• Failure to do even one of the items could lead to poor engine performance and increase exhaust emissions.
2. Windshield washer fluid
(a) Check that there is sufficient fluid in the tank.
3. Engine coolant level
(a) Check that the coolant level is between the “F” and “L” lines on the see-through reservoir.
4. Radiator and hoses
(a) Check that the front part of the radiator is clean and not blocked by leaves, dirt or bugs.
(b) Check the hoses for cracks, twist, rot or loose connections.
5. Brake fluid level
(a) Check that the brake fluid level is near the upper level line on the see-through reservoirs.
Hint:
The brake fluid and the clutch fluid are from one reservoir.
6. Engine drive belt
(a) Check the drive belt for fraying, cracks, wear or oiliness.
7. Engine oil level
(a) Check the level on the dipstick when the engine stops.
8. Power steering fluid level
(a) Check the level on the dipstick.
(b) The level should be in the “HOT” or “COLD” range depending on the fluid temperature.
9. Manual transmission fluid level
(a) Park the vehicle on a level surface.
(b) With the engine idling, shift the lever in N position and pull tightly the parking break lever.
(c) Release the transmission refill plug, with wrench.
(d) Check that the lever is beneath the filler 10 - 15mm. If the level is lower, refill transmission fluid. If not, dis-
charge the fluid.
10. Exhaust system
(a) If any change in the sound of the exhaust or the smell of the exhaust fumes is noticed, determine and correct the
causes.

Engine On-vehicle Inspection

Hint:
Inspect these items on a cooled down engine.
1. Inspect drive belt (See page MA-5)
2. Replace spark plugs
3. Inspect air filter
(a) Remove the air filter.
(b) Visually check that the air filter is not excessively damaged,
Outside
dirty or oily. Replace the air filter if necessary.
(c) Clean the filter with compressed air.
First blow from the inside of the filter thoroughly then blow
from the outside.
Inside
(d) Reinstall the air filter.
ALB001G 4. Replace air filter core
(a) Replace the air filter core with a new one.
5. Replace engine oil and oil filter
6. Replace engine coolant (See page EG-9)
7. Inspect gasket in fuel tank cap
8. Inspect fuel lines and connections, fuel tank vapor vent
system hoses and fuel tank
(a) Visually check the fuel lines for cracks, leakage, loose con-
nections, deformation and tank bolt looseness.
9. Inspect exhaust pipes and mountings
(a) Visually check the pipes, hangers and connections for severe
corrosion, leaks and damage.
Brake On-vehicle Inspection

1. Inspect air filter
Hint:
Operate in a well-lighted area. Turn the front wheels fully to
the right or left before beginning.
(a) Check all the brake lines and hoses for:
• Damage
• Wear
• Deformation
ALB002G • Crack
• Corrosion
• Leak
• Bend
• Twist

(b) Check all the clamps for tightness and the connections for
leakage.
(c) Check that the hoses and lines are not near sharp edges, mov-
ing parts or the exhaust system.
(d) Check that the lines are installed from the center of the grom-
mets.
2. Inspect front brake pads and discs
3. Inspect rear brake linings and drums
4. Inspect or change brake fluid (See page BR-5)
Brake Fluid: DOT4 synthetic brake fluid
Chassis On-vehicle Inspection

1. Inspect steering linkage
(a) Check the steering wheel free play (See page SR-4).
(b) Check the steering linkage for looseness or damage.
(1) Check that the tie rod ends do not have excessive play.
(2) Check that the dust seals and boots are not damaged.
(3) Check that the boot clamps are not loose.
2. Inspect steering gear housing oil
(a) Check the steering gear housing for oil leakage.
If oil is leaking, find the cause and repair it.
3. Inspect ball joints and dust covers
(a) Inspect the ball joints for excessive looseness.
(1) Jack up the front of the vehicle and place wooden blocks with a height of 180 to 200 mm (7. 09 to 7. 87 in. )
under the front tires.
(2) Lower the vehicle until the front coil spring reaches about half its ordinary load. Place stands under the ve-
hicle for safety.
(3) Check that the front wheels are pointing straight ahead. Use chocks.
(4) Using a lever, pry up the end of the lower arm. Check the amount of play.
Maximum ball joint vertical play: 0 mm (0 in.)
If there is any play, replace the ball joint.
(b) Check the dust cover for damage.
4. Inspect drive shaft boots
(a) Check the drive shaft boots for loose clamps, grease leakage, twist or damage.
5. Check transaxle oil (fluid)
(a) Visually check the transaxle for oil (fluid) leakage.
If oil is leaking, find the cause and repair it.
6. Tire rotation (See page SP-41)

Body On-vehicle Inspection

1. Tighten bolts and nuts on chassis and body
(a) Tighten the bolts and nuts on the chassis parts listed below, if necessary.
• Front axle and suspension
• Drive train
• Rear axle and suspension
• Brake system
• Engine mounting
• Other chassis parts
(b) Tighten the bolts and nuts on the body parts listed below, if necessary.
• Seat belt system
• Seat
• Doors and engine hood
• Body mountings
• Fuel tank
• Exhaust pipe system
• Other body parts
2. Replace air conditioning filter
(a) Remove the small glove box.
(b) Remove the filter case from the filter outlet.
(c) Remove the filter from the filter case.
(d) Replace the filter with a new one.
(e) The installation procedures are the removal procedures in the reverse order.
Power Source System Inspection

1. Generator
(a) Inspect the generator for radiation.
(b) Inspect the generator belt tension and pulley installation.
(c) Inspect the brush pressure and the segment surface.
(d) Inspect the connection of the battery line.
(e) Inspect that if the connector is damaged.
(f) Inspect that if the rectifier is dirty.
(g) Inspect the wear of bearing.
2. Battery
(a) Inspect the battery housing for crack, fracture or damage.
(b) Inspect the battery ground wire.
(c) Inspect the battery according to the working condition of headlamp.
3. Charge indicator
(a) Inspect the wire line of charge indicator.
(b) Inspect that if the filament is blown.
(c) Inspect that if generator generates electricity.

MEMO

EG-
ENGINE ACCESSORY SYSTEM
EXHAUST SYSTEM
Exhaust Pipe Assembly.................................................... EG-2
COOLING SYSTEM
On-vehicle Inspection....................................................... EG-6
Cooling Fan System.......................................................... EG-8
Engine Coolant................................................................. EG-9
Radiator Assembly............................................................ EG-11
MOUNTING SYSTEM EG
Engine Mount.................................................................... EG-14
03-ENGINE ACCESSORY SYSTEM.indd 1 2008-10-21 8:25:42

EG- GREAT WALL COOL BEAR REPAIR MANUAL
EXHAUST SYSTEM
Exhaust Pipe Assembly
Components
Front Heat Insulator
Exhaust Manifold
Compression 60 (612, 45)
Spring
Bolt Oxygen
Sensor
Gasket No.2
Spherical Rear Catalytic Converter
Gasket 60 (612, 45) Assembly
Spherical Gasket
Middle Heat
Insulator
Bolt
60 (612, 45)
Compression
Spring
Exhaust Pipe Rear Shield Bracket

Front Exhaust
Hanging Sub Muffler
Rear Heat Insulator
Rear Exhaust
Main Muffler Hanging

ALC001G

ENGINE ACCESSORY SYSTEM EG-
Replacement
Hint:
The installation procedures are the removal procedures in the re-
verse order. However, only installation procedures requiring addi-
tion information are included.
Caution:
The removal of all components in the exhaust system should
be carried out after 30 minutes when the engine stops, so as
to avoid causing harm due to high temperature components.
1. Remove main muffler
(a) Using torx wrench, remove the 2 bolts and 2 compression
springs in the connection between the main muffler front
flange and the sub muffler rear flange.
(b) Remove the 3 rear exhaust hangings, main muffler and
spherical gasket.
Caution:
Hold the exhaust pipes assembly when performing this
ALC002G operation to prevent them from falling, and causing the
injury to the operator.
2. Remove sub muffler
(a) Using torx wrench, remove the 2 bolts in the connection
between the sub muffler front flange and rear catalytic con-
verter assembly rear flange.
(b) Remove the 2 bolts and the exhaust pipe rear shield support.
(c) Remove the 2 front exhaust hangings from the sub muffler
assembly, and remove the sub muffler assembly.
Caution:
ALC003G Hold the front exhaust pipes assembly when performing
this operation to prevent them from falling, and causing
the injury to the operator.
3. Remove rear catalytic converter assembly
(a) Disconnect the oxygen sensor connector.
(b) Remove the 2 bolts, 2 compression springs in the connection
between the exhaust manifold rear flange surface and rear
catalytic converter assembly front flange, and remove the
spherical gasket.
(c) Remove the rear catalytic converter assembly.
Caution:
ALC004G Hold the front exhaust pipes assembly when performing
this operation to prevent them from falling, and causing
the injury to the operator.

4. Install rear catalytic converter assembly

(a) Using vernier calipers, measure the free length of the com-
pression spring.
Minimum length: 40.5 mm (1.594 in.)
If the minimum length is not as specified, replace the com-
pression spring.
ALC005G
(b) Using a plastic hammer and a wooden block, tap in a new

spherical gasket until its surface is flush with the exhaust
manifold.
Hint:
The main role of spherical gasket is sealing, the great defor-
mation may occur after the first installation, which influ-
ences the sealing effect, it is suggested that do not reuse it, if
necessary, reuse it once.
ALC006G
(c) Connect the oxygen sensor connector.

(d) Install the 2 bolts and 2 compression springs in the connec-
tion between the exhaust manifold rear flange surface and
rear catalytic converter assembly front flange.
(e) Install the rear catalytic converter assembly.
Hint:
ALC004G The distance between the exhaust pipe assembly and parts on
the both sides is not less than 15 mm.

5. Install sub muffler

(a) Using torx wrench, install the 2 bolts in the connection be-
tween the sub muffler front flange and rear catalytic convert-
er assembly rear flange.
(b) Install the exhaust pipe rear shield bracket with the 2 bolts.
(c) Install the 2 front exhaust hangings to the sub muffler assem-
ALC003G bly, and install the sub muffler assembly.
Hint:
To help the installation, apply appropriate silicon oil to the
installation hole of rubber hangings before installation, the
rubber hangings should receive strength evenly after installa-
tion.
6. Install main muffler
(a) Using vernier calipers, measure the free length of the com-
pression spring.
If the minimum length is not as specified, replace the com-
pression spring.
(b) Using torx wrench, install the 2 bolts and 2 compression
springs in the connection between the main muffler front
ALC002G flange and sub muffler rear flange.
(c) Install the 3 rear exhaust hangings, main muffler and spheri-
cal gasket.
Hint:
To help the installation, apply a small amount of silicon oil
to the installation hole of rubber hangings before installation,
the rubber hangings should receive force evenly after instal-
lation.
7. Check for exhaust gas leakage

COOLING SYSTEM
On-vehicle Inspection
1. Check cooling system for leakage
Caution:
To avoid being burned, do not remove the radiator filler
cap while the engine and radiator are still hot. Thermal
expansion will cause hot engine coolant and steam to
spill from the radiator.
(a) Fill the radiator with coolant and attach the radiator filler cap
tester.
ALC007G (b) Warm up the engine.
(c) Pump it to 137 kPa (1.4 kgf/cm2, 19.9 psi), and check that the
pressure does not drop.
If the pressure drops, check the hoses, radiator and water
pump for leakage. If there are no signs or traces of external
coolant leakage, check the heater core, cylinder block and
head.
2. Check engine coolant level in the reservoir
(a) The engine coolant should be between the “L” and “F” lines
when the engine is cold.
If low, check for leakage and add ethylene glycol coolant
(-35°C) up to the “F” line.
3. Check engine coolant quality
(a) Remove the radiator filler cap.
Caution:
(b) Check the radiator filler cap and radiator filler for rust and
dirt. The coolant should be free from oil.
If excessively dirty, replace the coolant.
(c) Reinstall the radiator filler cap.
4. Check fins blockage
(a) If fins are clogged, wash them with water or a steam cleaner
and dry them with compressed air.
Notice:
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.
ALC008G

Injection pressure Injection distance

kPa (kgf/cm2, psi) mm (in.)
2,942 to 4,903
300 (11.811)
(30 to 50, 427 to 711)
4,903 to 7,845
500 (19.685)
(50 to 80, 711 to 1,138)
• If the fins are bent, straighten them with a screw-
driver or plier.
• Do not expose electronic component to water.
Inspection
1. Inspect radiator filler cap sub-assembly
Notice:
• If the radiator filler cap is contaminated, clean it with
water.
• Before using a radiator filler cap tester, wet the
pressure relief valve and vacuum valve with engine
coolant or water.
• When performing following steps (a) to (b), keep the
tester at an angle of over 30° above horizontal.
(a) Using a radiator filler cap tester, slowly pump the tester and
Radiator Filler Cap Tester check that air is coming from the vacuum valve.
Pump speed: 1 push/3 seconds or more
Notice:
30° or above
Push the pump at a constant speed.
If air is not coming from the vacuum valve, replace the radia-
tor filler cap.
Radiator Filler
Cap Tester (b) Pump the tester and measure the pressure relief valve open-
ALC009G ing pressure.
Pump speed: 1 push within 1 second
Notice:
The above pump speed is for the first pump only (in or-
der to close the vacuum valve). After the first pump, the
pump speed can be reduced.
Standard opening pressure:
93 to 123 kPa (0.95 to 1.25 kgf/cm2, 13.5 to 17.8 psi)
Minimum opening pressure:
78 kPa (0.8 kgf/cm2, 11.3 psi)
If the opening pressure is less than minimum, replace the ra-
diator filler cap.
Hint:
Use the tester’s maximum reading as the opening pressure.

Cooling Fan System

1. Check cooling fan operation at a low temperature (Below 83°C (181°F))
(a) Turn the ignition switch to the ON position.
(b) Check that the cooling fan stops.
If not, check the cooling fan relay and engine coolant temperature sensor. Check for disconnection or circuit
open between them.
(c) Disconnect the engine coolant temperature sensor connector.
(d) Check that the cooling fan rotates.
If not, check the fuses, cooling fan relay, ECM and cooling fan. Check for short in a circuit between the cooling
fan relay and engine coolant temperature sensor.
(e) Reconnect the engine coolant temperature sensor connector.
2. Check cooling fan operation at a high temperature (Below 93°C (199°F))
(a) Start the engine, and raise coolant temperature to above 93°C (199°F).
Hint:
Coolant temperature is detected by the engine coolant temperature sensor on the water outlet.
(b) Check that the cooling fan rotates.
If not, replace the engine coolant temperature sensor.
Note: Cooling fan operation
Direction of rotation Low speed High speed
(View from the radiator) (r/min) (r/min)
Counterclockwise 1850 ± 150 2500 ± 150
3. Inspect cooling fan
(a) Disconnect the cooling fan connector.
(b) Connect a battery and ammeter to the cooling fan.
(c) Check that the cooling fan rotates smoothly. Also, check the reading on the ammeter.
Standard amperage: 11.7 to 14.7 A
(d) Reconnect the cooling fan connector.
Inspection
1. Inspect cooling fan relay
3
(a) Continuity Check
(1) Using an ohmmeter, check for continuity between each
5 3 5 terminal.
Specified condition:
1 2
Terminal No. Specified condition
1-2 Continuity
2 1 No continuity
ALC010G 3-5 Continuity
(Apply battery voltage to terminals 1 and 2)

2. Inspect cooling fan relay NO.2

(a) Continuity Check
3 (1) Using an ohmmeter, check for continuity between each
3 5 5 terminal.
2 1 Specified condition:
1 2 Terminal No. Specified condition
1-2 Continuity
No continuity
ALC011G 3-5 Continuity
(Apply battery voltage to terminals 1 and 2)
3. Inspect cooling fan resistor
(a) Using an ohmmeter, measure the resistance between the ter-
minals.
Resistance: 1.17 to 1.43 W at 20°C (68°F)
Engine Coolant
Replacement
1. Drain engine coolant
Caution:
(a) Remove the radiator filler cap.
(b) Loosen the radiator drain cock and drain engine coolant.
Water Drain Cock Sub-assembly
Radiator Filler Cap

Sub-assembly
Radiator Drain Cock Sub-assembly

ALC012G

EG-10 GREAT WALL COOL BEAR REPAIR MANUAL
2. Add engine coolant

(a) Tighten the radiator drain cock, and fill coolant into the ra-
diator until it overflows.
Capacity: 5.5 L (5.7 US qts, 4.9 lmp. qts)
Hint:
• Press the radiator inlet and outlet hoses several times by
hand.
• If the coolant level gets lower, add coolant.
(b) Tighten the radiator filler cap.
(c) Fill engine coolant into the reservoir until it reaches the full
level line.
(d) Warm up the engine until the thermostat valve begins to
open.
Hint:
Press the radiator inlet and outlet hoses several times by hand
during warming up.
(e) Stop the engine and wait until the coolant temperature gets
cold.
(f) Then remove the radiator filler cap and check the coolant
level.
(g) If the level gets lower, perform the procedures from (a) to (f)
again.
(h) If the level does not get lower, add engine coolant to adjust
the reservoir coolant level.
3. Check for engine coolant leakage
(a) Fill the radiator with engine coolant and attach a radiator
filler cap tester.
(b) Pump it to 137 kPa (1.4 kgf/cm2, 1.99 psi) and check for
leakage.

ENGINE ACCESSORY SYSTEM EG-11
Radiator Assembly
Components
Radiator Filler Set Bracket Radiator Filler Assembly

Radiator Upper Mounting
Radiator Inlet
Pipe
Radiator
Assembly
B Type Worm Drive

Hose Hoop
Radiator Outlet Pipe

Radiator
Lower
Mounting
Overflow Tube
Power Fan With Steel Type Elastic Hoop

Expansion Tank Assembly
ALC013G
Replacement
1. Disconnect battery negative terminal
2. Drain engine coolant (See page EG-9)
3. Disconnect radiator inlet pipe
4. Disconnect radiator outlet pipe
5. Remove front bumper upper grille body (See page
BO-38)
6. Remove front bumper body (See page BO-38)
7. Remove engine hood lock assembly
(a) Remove the 3 bolts, clip and engine hood lock.
ALC014G

8. Remove engine hood lock support

(a) Remove the 5 bolts and the engine hood lock support.
ALC015G
9. Remove radiator upper member

(a) Remove the 2 bolts and disconnect the condenser from radia-
tor upper member.
(b) Remove the 4 bolts and radiator upper member.
ALC016G
10. Remove radiator assembly

(a) Disconnect the connector from the cooling fan motor, and
then remove the radiator assembly from the engine compart-
ment.
(b) Remove the 2 radiator upper mountings and the 2 radiator
lower mountings.
ALC017G
(c) Remove the 4 bolts and detach the power fan with expansion
tank assembly.
(d) Remove the 2 bolts and water filler.
ALC018G
11. Install radiator assembly

(a) Install the water filler with 2 bolts.
(b) Install the power fan with expansion tank assembly with 4
bolts.
Torque: 7.5 N·m (76 kgf·cm, 66 in.·lbf)
ALC018G

(c) Install the 2 radiator upper mountings and radiator lower

mountings to the radiator.
(d) Install the radiator assembly and connect the connector to the
cooling fan motor.
ALC017G
12. Install radiator upper member

(a) Install the radiator upper member with 4 bolts.
(b) Install the condenser to the radiator upper member with 2
bolts.
Torque: 9.8 N·m (100 kgf·cm, 7.2 ft·lbf)
ALC016G
13. Install engine hood lock support

(a) Install the engine hood lock support with 5 bolts.
ALC015G
14. Install engine hood lock assembly

(a) Temporarily install the engine hood lock assembly with the 3
bolts.
15. Adjust engine hood (See page BO-2)
16. Install front bumper body
17. Install front bumper upper grille body
18. Add engine coolant (See page EG-10)
ALC014G 19. Check for engine coolant leakage (See page EG-10)
20. Connect battery negative terminal

MOUNTING SYSTEM
Engine Mount
Components
78 (795, 58) 78 (795, 58)
41 (418, 31)
112 (1142, 84)
Engine Mount LH
Engine Mount RH
Engine Mounting Bracket LH

78 (795, 58) Engine Rear Mounting Bracket
Engine Rear Mounting
78 (795, 58) 78 (795, 58)

68 (694, 51)
78 (795, 58)

ALC019G
Removal
Hint:
verse order.
1. Separate engine
(a) Hang the engine with a crane.
(b) Using a socket wrench, remove the 2 bolts and 1 nut from the
engine mount RH.
ALC020G

(c) Using a socket wrench, remove the 1 bolt from the rear en-
gine mount.
ALC021G
(d) Using a socket wrench, remove the 1 bolt from the engine
mount LH.
ALC022G
2. Remove engine mount RH

(a) Using a socket wrench, remove the 3 bolts and the engine
mount RH from the body.
ALC023G
3. Remove rear engine mount

(a) Using a socket wrench, remove the 2 nuts, 1 bolt and the rear
engine mount from the auxiliary frame.
ALC024G
4. Remove engine mount LH

mount LH from the engine mount support LH.
ALC025G

5. Remove engine mounting bracket LH

mounting bracket LH from the transmission.
ALC026G
6. Remove rear engine mounting bracket

(a) Using a socket wrench, remove the 3 bolts and the rear en-
gine mounting bracket from the transmission.
ALC027G

DT-
DRIVETRAIN
DRIVE SHAFT/AXLE
Problem Symptoms Table................................................. DT-2
On-vehicle Inspection....................................................... DT-2
Front Axle Drive Shaft....................................................... DT-4
Front Axle Hub Sub-assembly LH..................................... DT-17
Front Axle Hub Bolt LH..................................................... DT-21
Rear Axle Hub & Bearing Assembly LH............................ DT-22
Rear Axle Hub Bolt LH...................................................... DT-23
CLUTCH
Problem Symptoms Table................................................. DT-25
Clutch Pedal Sub-assembly.............................................. DT-26 DT
Clutch Master Cylinder Assembly..................................... DT-32
Clutch Release Cylinder Assembly................................... DT-36
Clutch Assembly............................................................... DT-39
Clutch Start Switch Assembly........................................... DT-43
Clutch Hydraulic Pressure System Bleeding.................... DT-44
04-DRIVETRAIN.indd 1 2008-10-21 10:54:13

DT- GREAT WALL COOL BEAR REPAIR MANUAL
DRIVE SHAFT/AXLE
Problem Symptoms Table
Use the table below, with suspected areas listed in numerical order, to determine the cause of the problem. Inspect and
repair or replace parts as necessary according to the steps on the following pages.
Symptom Suspected area See page
1. Wheel SP-37
2. Front wheel alignment SP-7
3. Rear wheel alignment SP-26
4. Front wheel hub bearing (Worn) DT-2
Wandering while driving 5. Rear wheel hub bearing (Worn) DT-3
6. Front shock absorber with coil spring SP-10
assembly
7. Steering linkage (Loosen or worn) -
8. Stabilizer bar SP-22
1. Wheel balance SP-43
2. Hub bearing (Worn) DT-2
Front wheel shimmy
3. Front shock absorber with coil spring SP-10
assembly
1. Outboard joint (Worn) DT-10
Noise (Drive shaft)
2. Inboard joint (Worn) DT-8
1. Inspect front axle deviation and play
(a) Remove the front wheel.
(b) Remove the front brake caliper assembly
(See page DT-18).
(c) Remove the front brake disc.
(d) Inspect the bearing play.
(1) Using a dial indicator, check for play near the center of
ALD001G
the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If play exceeds the maximum, replace the front axle
hub bearing.
(e) Inspect the axle hub deviation.
(1) Using a dial indicator, check for deviation in the surface
of the axle hub outside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If deviation exceeds the maximum, replace the front
axle hub sub-assembly.
(f) Install the front brake disc
(g) Install the front brake caliper
ALD002G (See page DT-20).
(h) Install the front wheel.
Torque: 110 N·m (1,122 kgf·cm, 83 ft·lbf)
04-DRIVETRAIN.indd 2 2008-10-21 10:54:14

DRIVETRAIN DT-
2. Inspect rear axle deviation and play

(a) Remove the rear wheel.
(b) Remove the rear brake drum.
(c) Inspect the bearing play.
(1) Using a dial indicator, check for play near the center of
the axle hub.
Maximum: 0.05 mm (0.0020 in.)
If play exceeds the maximum, replace the rear axle hub
ALD003G & bearing assembly.
(d) Inspect the axle hub deviation.

(1) Using a dial indicator, check for deviation in the surface
of the axle hub inside the hub bolt.
Maximum: 0.07 mm (0.0028 in.)
If deviation exceeds the maximum, replace the rear axle
hub & bearing assembly.
(e) Install the rear brake drum.
(f) Install the rear wheel.
ALD004G Torque: 110 N·m (1,122 kgf·cm, 83 ft·lbf)
04-DRIVETRAIN.indd 3 2008-10-21 10:54:14

Front Axle Drive Shaft

Components
Front Axle Drive Shaft Assembly RH
l Front Axle Drive Shaft Hole RH

Snap Ring
l Front Axle Drive Shaft Hole
LH Snap Ring
Front Speed Sensor LH

Front Drive Shaft Assembly LH
8.0 (82, 71 in.lbf)
Brake Hose
29 (300, 22)
l Cotter Pin
50 (510, 38)
37 (377, 28)
Washer
Bush
Front Stabilizer Bar

Tie Rod End Assembly LH
l 225 (2,295, 162)

Bush
98 (1,000, 72) Front Axle Hub Nut LH
Washer
l Lock Pin
Front Suspension Lower Control Arm LH

l Non-reusable part
ALD005G
04-DRIVETRAIN.indd 4 2008-10-21 10:54:15

DRIVETRAIN DT-
Front Axle Drive Shaft LH Outboard

Joint Shaft Assembly l Front Axle Drive Shaft LH
Outboard Joint Boot No.2 Clamp
Supply
Parts:
l Front Axle Drive Shaft
l Outboard Joint LH Outboard Joint Boot
Dust Cover Clamp
Supply
Parts:
RH: l Drive Shaft Damper

Setting Clamp
One Touch
Clamp Type
Claw Engagement
Type
Or
Claw Engagement
Type
Front Axle Drive
Shaft Damper RH One Touch Clamp Type
l Front Axle Drive Shaft LH

One Touch Inboard Joint Boot No.2 Clamp
Clamp Type
Or Claw Engagement Type
l Front Axle Drive Shaft

LH Inner Shaft Snap
Or Ring
l Inboard Joint Boot
l Front Axle Drive
Shaft LH Inboard l Front Axle Drive Shaft
Joint Boot Clamp LH Oil Seal
Tripod Joint Assembly
One Touch Clamp Type
Front Axle Drive Shaft LH

l Non-reusable part Inboard Joint Assembly
ALD006G
04-DRIVETRAIN.indd 5 2008-10-21 10:54:15

Overhaul
Hint:
Overhaul the right side following the same procedures as for the
left side.
1. Drain transaxle oil
2. Remove front wheel
3. Remove engine under cover LH
4. Remove front axle hub nut LH
(a) Using SST and a hammer, pry up the areas protruding of the
front axle hub nut LH.
SST 09930-00010
Notice:
Loosen the staked part of the nut completely, otherwise
the screw of the drive shaft may be damaged.
SST (b) While applying the brakes, remove the front axle hub nut
ALD007G
LH.
5. Separate front speed sensor LH

LH: (a) Remove the bolt and the clip, and separate the front speed
sensor LH and the brake hose from the front shock absorber
assembly LH.
Hint:
The positions of the bolt and clip on the right side differ from
RH:
those on the left side.
ALD008G
(b) Remove the bolt, and separate the front speed sensor LH
from the steering knuckle.
Notice:
• Be careful not to damage the speed sensor.
• Prevent foreign matter from adhering to the speed
sensor.
ALD009G
04-DRIVETRAIN.indd 6 2008-10-21 10:54:16

DRIVETRAIN DT-
6. Remove front stabilizer bar

(a) Hold the bolts with the spanner (10 mm), and remove the
nut.
(b) Remove 2 washers and 2 bushes and separate the front stabi-
lizer bar.
ALD010G
7. Remove front suspension lower control arm LH

(a) Remove the lock pin and the nut.
(b) Using SST, separate the front suspension lower control arm
LH from the steering knuckle.
SST 09628-00011
SST
ALD011G
8. Remove tie rod end assembly LH

SST (a) Remove the cotter pin and the nut.
(b) Using SST, separate the tie rod end assembly LH from the
steering knuckle.
SST 09628-62011
9. Separate front axle hub assembly LH
(a) Using a plastic hammer, separate the front axle drive shaft
assembly LH from the front axle hub assembly LH.
ALD012G Notice:
• Be careful not to damage the boot.
• Be careful not to damage the speed sensor rotor.
10. Remove front axle drive shaft assembly LH
(a) Using SST, remove the front axle drive shaft assembly LH.
SST SST 09520-01010, 09520-24010 (09520-32040)
Notice:
• Be careful not to damage the oil seal and the boot.
• Be careful not to drop the drive shaft assembly.
SST
ALD013G
04-DRIVETRAIN.indd 7 2008-10-21 10:54:16

11. Remove front axle drive shaft assembly RH (drive shaft

RH)
(a) Using a brass bar and a hammer, remove the front axle drive
shaft assembly RH.
Notice:
• Be careful not to damage the oil seal and the boot.
• Be careful not to drop the drive shaft assembly.
ALD014G
12. Fix front axle hub assembly LH

Notice:
• The hub bearing could be damaged if it is subjected
to the vehicle’s weight, such as when moving the
SST vehicle with the drive shaft removed.
• Therefore, if it is necessary to place the vehicle’s
weight on the hub bearing, first support it with SST.
SST 09608-16042 (09608-02021, 09608-02041)
ALD015G
13. Inspect front axle drive shaft assembly LH

Notice:
Keep the drive shaft assembly level during inspection.
(a) Check that there is no remarkable clearance in the radial di-
rection of the outboard joint.
(b) Check that the inboard joint slides smoothly in the axial di-
rection.
(c) Check that there is no remarkable clearance in the radial di-
ALD016G rection of the inboard joint.
(d) Check the boots for damage.
One Touch Clamp 14. Remove front axle inboard joint boot LH No.2 clamp
Type: (a) One touch clamp type:
Using a screwdriver, unclamp the front axle inboard joint
boot LH No.2 clamp as shown in the illustration.
(b) Claw engagement type:
Using needle nose pliers, remove the front axle inboard joint
ALD017G
04-DRIVETRAIN.indd 8 2008-10-21 10:54:17

DRIVETRAIN DT-
One Touch Clamp 15. Remove front axle inboard joint boot LH clamp
Type: (a) One touch clamp type:
Using a screwdriver, unclamp the front axle inboard joint
boot LH clamp as shown in the illustration.
Claw Engagement
Type: Using needle nose pliers, remove the front axle inboard joint
boot LH clamp as shown in the illustration.
16. Separate front axle inboard joint boot
ALD018G (a) Separate the inboard joint boot from the front axle inboard
joint assembly LH.
17. Remove front axle inboard joint assembly LH
Matchmarks (a) Remove the grease from the front axle inboard joint assem-
bly LH.
(b) Put matchmarks on the front axle inboard joint assembly LH
and outboard joint shaft assembly.
Notice:
Do not use a punch for marking.
(c) Remove the front axle inboard joint assembly LH from the
ALD019G outboard joint shaft assembly.
(d) Using a snap ring expander, remove the drive shaft LH inner
shaft snap ring.
ALD020G
Brass Bar (e) Put matchmarks on the outboard joint shaft assembly and the
Matchmarks tripod joint assembly.
Notice:
Do not use a punch for marking.
(f) Using a brass bar and a hammer, remove the tripod joint as-
sembly from the outboard joint shaft assembly.
Notice:
Do not tap the roller.
ALD021G (g) Separate the front axle inboard joint boot LH No.2 clamp,
inboard joint boot, and the front axle inboard joint boot LH
clamp.
04-DRIVETRAIN.indd 9 2008-10-21 10:54:18

DT-10 GREAT WALL COOL BEAR REPAIR MANUAL
One Touch Clamp 18. Remove drive shaft damper setting clamp (drive shaft
Type RH)
Hint:
The following procedure is only for right side disassembly.
(a) One touch clamp type:
Claw Engagement
Type: Using a screwdriver, unclamp the damper setting clamp as
shown in the illustration.
ALD022G Using needle nose pliers, remove the damper setting clamp
19. Remove drive shaft damper (drive shaft RH)
Hint:
The following procedure is only for right side disassembly.
(a) Remove drive shaft damper RH
20. Remove front axle outboard joint boot LH No.2 clamp
(a) Using a screwdriver, unclamp the outboard joint boot LH
No.2 clamp.
ALD023G
21. Remove front axle inboard joint boot LH clamp

(a) Using a screwdriver, unclamp the front axle inboard joint
boot LH clamp.
22. Remove front axle outboard joint boot
(a) Remove the outboard joint boot from the outboard joint shaft
assembly.
(b) Remove the grease from the outboard joint.
ALD024G
23. Remove front axle drive shaft hole LH snap ring

(a) Using a screwdriver, remove the drive shaft hole LH snap
ring.
ALD025G
04-DRIVETRAIN.indd 10 2008-10-21 10:54:18

DRIVETRAIN DT-11
24. Remove front axle drive shaft LH oil seal

(a) Using SST and a press, remove the drive shaft LH oil seal.
SST
SST 09950-00020
Notice:
Be careful not to drop the inboard joint assembly.
ALD026G
SST 25. Install front axle drive shaft LH oil seal

(a) Using SST and a press, install the drive shaft LH oil seal.
SST 09527-10011
Notice:
• Be careful not to damage the oil seal.
• Oil seal should be installed completely.
26. Install front axle drive shaft hole LH snap ring
(a) Install a new drive shaft hole LH snap ring.
ALD027G 27. Install front axle outboard joint boot
(a) Wrap the spline of the outboard joint shaft with vinyl tape to
prevent the boot from being damaged.
(b) Install the new parts on the inboard joint shaft assembly in
the following order.
(1) Front axle outboard joint boot LH No.2 clamp
(2) Outboard joint boot
(3) Front axle outboard joint boot LH clamp
(c) Pack the front axle outboard joint assembly LH with grease.
Grease capacity: 155 to 170 g (5.5 to 6.1 oz.)
(d) Install the outboard joint boot to the outboard joint shaft as-
sembly.
28. Install front axle outboard joint boot LH No.2 clamp
Hold
(a) Install the front axle outboard joint boot LH No.2 clamp on
Turn the outboard joint boot.
SST
(b) Place SST onto the front axle outboard joint boot LH No.2
clamp.
SST 09521-24010
(c) Tighten the SST so that the front axle outboard joint boot LH
No.2 clamp is pinched.
ALD028G
Notice:
Do not overtighten the SST.
04-DRIVETRAIN.indd 11 2008-10-21 10:54:19

(d) Using SST measure the clearance of the front axle outboard
SST
joint boot LH No.2 clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.031 in.) or less
Notice:
When the measured value exceeds the specified value,
retighten the clamp.
ALD029G
29. Install front axle outboard joint boot LH clamp

Hold
(a) Mount drive shaft in a vise.
SST (b) Install the front axle outboard joint boot LH on the outboard
joint boot.
(c) Place SST onto the front axle outboard joint boot LH clamp.
SST 09521-24010
(d) Tighten the SST so that the front axle outboard joint boot LH
clamp is pinched.
ALD030G Notice:
Do not overtighten the SST.
(e) Using SST measure the clearance of the front axle outboard
joint boot LH clamp.
SST 09240-00020 (09242-00080)
Clearance: 0.8 mm (0.031 in.) or less
Notice:
SST When the measured value exceeds the specified value,
retighten the clamp.
ALD031G
30. Install drive shaft damper (drive shaft RH)

Hint:
The following procedure is only for RH installation.
(a) Install the drive shaft damper RH on the outboard joint shaft
assembly.
31. Install drive shaft damper setting clamp (drive shaft RH)
Hint:
The following procedure is only for RH installation.
(a) Install the damper setting clamp to the shaft.
Notice:
Be sure to install the clamp in the correct position.
04-DRIVETRAIN.indd 12 2008-10-21 10:54:19

DRIVETRAIN DT-13
One Touch Clamp (b) One touch clamp type:

Type: Using a screwdriver, install the damper setting clamp as
(c) Claw engagement type:
Claw Engagement
Using needle nose pliers, install the damper setting clamp as
Type: shown in the illustration.
ALD032G
32. Install front axle drive shaft LH inboard joint assembly

Hint:
Before installing the boot, please wrap the spline of the drive
shaft with vinyl tape to prevent the boot from being dam-
aged.
(a) Install the new parts on the outboard joint shaft assembly in
the following order.
(1) Front axle inboard joint LH clamp
(2) Inboard Joint Boot
(3) Front axle inboard joint LH No.2 clamp
(b) Align the matchmarks, install the tripod joint assembly to the
outboard joint assembly.
(c) Using a brass bar and a hammer, install the tripod joint as-
sembly.
Notice:
• Do not tap the roller.
• Be sure to install the tripod joint in the correct direc-
Matchmarks tion.
ALD033G
(d) Using a snap ring expander, install a new drive shaft LH in-
ner shaft snap ring.
(e) Apply grease to the front axle inboard joint assembly LH.
Grease capacity: 125 to 135 g (4.5 to 4.8 oz.)
ALD020G
04-DRIVETRAIN.indd 13 2008-10-21 10:54:20

(f) Align the matchmarks, install the front axle inboard joint as-
Matchmarks sembly LH to the outboard joint shaft assembly.
ALD019G
33. Install front axle inboard joint boot

(a) Install the inboard joint boot to the inboard joint assembly
and the outboard joint shaft assembly.
One Touch 34. Install front axle inboard joint boot LH No.2 clamp
Clamp Type (a) One touch clamp type:
Using a screwdriver, install the front axle inboard joint boot
LH No.2 clamp as shown in the illustration.
Claw Engagement Using needle nose pliers, install the front axle inboard joint
Type:
ALD034G
One Touch
35. Install front axle inboard joint boot LH clamp
Clamp Type (a) One touch clamp type:
Using a screwdriver, install the front axle inboard joint boot
LH clamp as shown in the illustration.
Claw Engagement Using needle nose pliers, install the front axle inboard joint
Type: boot LH clamp as shown in the illustration.
ALD035G
36. Inspect front axle drive shaft

Notice:
Keep the drive shaft assembly level during inspection.
(a) Check that there is no remarkable clearance in the outboard
joint.
(b) Check that the inboard joint slides smoothly in the axial di-
rection.
(c) Check that there is no remarkable clearance in the radial di-
ALD016G rection of the inboard joint.
(d) Check the boots for damage.
04-DRIVETRAIN.indd 14 2008-10-21 10:54:20

DRIVETRAIN DT-15
37. Install front axle drive shaft assembly LH

(a) Apply the gear oil to the spline of the inboard joint shaft as-
sembly.
(b) Align the shaft splines, install the front axle drive shaft as-
sembly LH with a brass bar and a hammer.
Notice:
• Install the snap ring with the opening side facing
down.
ALD036G • Be careful not to damage the boot and the oil seal.
Hint:
Whether the inboard joint shaft is in contact with the pinion
shaft or not can be known from the sound or feeling when
driving it in.
38. Install front axle drive shaft assembly RH (drive shaft
RH)
Hint:
Apply the same procedure to the right side.
Notice:
• Install the snap ring with the opening side facing
down.
• Be careful not to damage the boot and the oil seal.
39. Install front axle hub assembly LH
(a) Install the drive shaft assembly LH to the front axle hub as-
sembly LH.
Notice:
• Be careful not to damage the outboard joint boot.
• Be careful not to damage the speed sensor rotor.
• Do not excessively push the front axle assembly
LH.
40. Install tie rod end assembly LH
(a) Install the tie rod end assembly LH to the steering knuckle
with the nut.
(b) Install a new cotter pin.
Notice:
If the holes for the cotter pin are not aligned, tighten the
nut up to 60° again.
41. Install front suspension lower control arm LH
(a) Install the front suspension lower control arm LH to the
steering knuckle with the nut.
(b) Install a new lock pin.
Notice:
If the holes for the lock pin are not aligned, tighten the
nut up to 60°.
04-DRIVETRAIN.indd 15 2008-10-21 10:54:20

42. Install front stabilizer bar

(a) Install the front stabilizer bar with 2 washers, 2 bushes and
the nut, as shown in the illustration.
Notice:
Be sure to install the bush and washer in the correct di-
rection.
(b) Turn the nut with a wrench (10 mm).
ALD037G
LH: 43. Install front speed sensor LH

(a) Install the front speed sensor LH and the brake hose on the
front shock absorber assembly LH with the bolt and clip.
Hint:
RH:
The positions of the bolt and clip on the right side differ from
those of the left side.
ALD008G
(b) Install the front speed sensor LH on the steering knuckle

with the bolt.
Notice:
• Do not damage the speed sensor.
• Keep the speed sensor clean.
• Do not twist the sensor wire harness when installing
the sensor.
ALD009G
44. Install front axle hub nut LH

(a) Install a new hub nut LH.
(b) Using a chisel and a hammer, stake the hub nut LH.
45. Install engine under cover LH
46. Install front wheel
47. Add transaxle oil
ALD038G 48. Check and adjust transaxle oil
49. Inspect and adjust front wheel alignment (See page
SP-7)
50. Check for ABS speed sensor signal
04-DRIVETRAIN.indd 16 2008-10-21 10:54:21

DRIVETRAIN DT-17
Front Axle Hub Sub-assembly LH

Components
Brake Hose
132 (1,350, 97)

8.0 (82, 71 in.lbf)
l Cotter Pin
Front Drive Shaft

Assembly LH
Front Axle Hub Assembly LH 50 (510, 38)
29 (300, 22)
Washer 37 (277, 28)
Tie Rod End Assembly LH
88 (900, 65) Front Brake

Front Brake Caliper Disc
Assembly LH
Front Stabilizer
Bar
Bush
l Clip
Washer
98 (1,000, 72)
225 (2,295, 162)
l Front Axle Hub Nut LH
l Front Axle
Hub Hole
LH Snap
Ring l Front Axle Hub
Hole LH Snap
Ring 8.3 (85, 73 in.·lbf)
Front Axle Hub Bolt LH
Steering
Knuckle LH Front Axle Hub Sub-
×4 assembly LH
Front Brake Disc Housing LH

l Non-reusable part
ALD039G
04-DRIVETRAIN.indd 17 2008-10-21 10:54:21

Replacement
1. Remove front wheel LH (See page DT-44)
2. Remove front axle hub nut LH (See page DT-6)
SST 09930-00010
3. Separate front speed sensor LH (See page DT-6)
4. Remove front brake caliper assembly LH
(a) Remove the 2 bolts, remove the front brake caliper assembly
Notice:
Use a string or other device to keep the brake caliper
from hanging down.
5. Remove front brake disc
6. Separate front stabilizer bar (See page DT-7)
ALD040G 7. Separate front suspension lower control arm LH (See
page DT-7)
SST 09628-00011
8. Separate tie rod end assembly LH (See page DT-7)
SST 09628-62011
9. Remove front axle hub assembly LH (See page DT-7)
10. Separate front shock absorber assembly LH
(a) Remove 2 bolts, 2 nuts and separate front shock absorber as-
sembly LH from steering knuckle assembly LH.
ALD041G
11. Remove front axle hub hole LH snap ring

(a) Using snap ring pliers, remove the front axle hub hole LH
snap ring.
ALD042G
12. Remove front axle hub sub-assembly LH

(a) Using SST, remove the front axle hub sub-assembly LH.
SST 09520-00031
SST
ALD043G
04-DRIVETRAIN.indd 18 2008-10-21 10:54:22

DRIVETRAIN DT-19
(b) Using SST, remove the inner race of the hub bearing LH
SST from the front axle hub sub-assembly LH.
SST 09950-60010 (09951-00370), 09950-40011
(09951-04020, 09952-04010, 09953-04020,
09954-04010, 09955-04011, 09957-04010,
09958-04011)
13. Remove front brake disc bearing LH
(a) Remove the 3 bolts and the front dust cover LH.
ALD044G
14. Remove front axle hub LH bearing

(a) Place the inner race of the hub bearing LH on the outer race
SST of the hub bearing LH.
(b) Using SST and a press, remove the outer race of the hub
bearing LH from the steering knuckle.
SST 09527-17011, 09950-60010 (09951-00600),
09950-70010 (09951-07100)
SST
Notice:
ALD045G Be sure to position the steering knuckle horizontally.
15. Install front axle hub bearing LH

SST (a) Using SST and a press, install a new front axle hub bearing
LH on the steering knuckle.
SST 09950-60020 (09951-00680), 09950-70010
(09951-07100)
16. Install front brake disc housing LH
(a) Install the front brake disc housing LH with the 3 bolts.
ALD046G
17. Install front axle hub sub-assembly LH

(a) Using SST and a press, install the front axle hub sub-assem-
SST
bly LH.
SST 09950-60020 (09951-00680), 09950-70010
(09951-07100), 09608-32010
SST
ALD047G
18. Install front axle hub hole LH snap ring

(a) Using snap ring pliers, install a new front axle hub hole LH
snap ring.
ALD042G
04-DRIVETRAIN.indd 19 2008-10-21 10:54:23

19. Install front shock absorber assembly LH

(a) Install the 2 bolts, the nuts and the front shock absorber as-
sembly LH to the steering knuckle LH.
Notice:
When reusing the bolts and nuts, apply the small
amount of engine oil to the screw part of the nuts.
20. Install front axle hub LH (See page DT-15)
ALD041G 21. Install tie rod end assembly LH (See page DT-15)
22. Install front suspension lower control arm LH (See page
DT-15)
23. Install front stabilizer bar (See page DT-16)
24. Install front brake disc
25. Install front brake caliper assembly LH
(a) Install the brake caliper assembly with the 2 bolts to the
steering knuckle.
26. Install front axle hub nut LH
(a) Install a new hub nut LH.
ALD040G Notice:
Use a string or other device to keep the brake caliper
from hanging down.
29. Inspect front axle deviation and play (See page DT-2)
31. Install front brake caliper assembly LH
32. Install front speed sensor LH (See page DT-16)
33. Tighten front axle hub nut LH
(a) Using a chisel and a hammer, stake the hub nut LH.
SP-7)
ALD038G
04-DRIVETRAIN.indd 20 2008-10-21 10:54:23

DRIVETRAIN DT-21
Front Axle Hub Bolt LH

Replacement
Hint:
Components: See page DT-17
2. Remove front brake caliper assembly LH (See page
DT-18)
4. Remove front axle hub bolt LH
(a) Using SST and a screwdriver or an equivalent, remove the
front axle hub bolt LH.
SST 09628-10011
SST
ALD048G
5. Install front axle hub bolt LH

(a) Install the washer and the nut to a new hub bolt LH as shown
Washer in the illustration.
Nut (b) Using a screwdriver or an equivalent to hold the front axle
hub sub-assembly LH, install the hub bolt LH by tightening
the nut.
7. Install front brake caliper assembly LH (See page
ALD049G DT-20)
04-DRIVETRAIN.indd 21 2008-10-21 10:54:23

Rear Axle Hub & Bearing Assembly LH

Components
Rear Speed Sensor Wire Harness LH
50 (510, 38)
l Rear Axle Hub Bolt LH
50 (510, 38)
Rear Brake Drum

l Non-reusable part
ALD050G
04-DRIVETRAIN.indd 22 2008-10-21 10:54:23

DRIVETRAIN DT-23
Replacement
1. Remove rear wheel
2. Remove rear brake drum
3. Separate speed sensor wire harness
(a) Separate the speed sensor connector.
4. Remove rear axle hub & bearing assembly LH
(a) Remove the 4 bolts and the rear axle hub & bearing assembly
LH.
ALD051G
5. Install rear axle hub & bearing assembly LH

(a) Install the rear axle hub & bearing assembly LH with the 4
bolts.
6. Connect speed sensor wire harness
(a) Connect the speed sensor connector.
Notice:
Do not twist the sensor wire harness when connecting
ALD051G it.
7. Inspect rear axle deviation and play (See page DT-3)
8. Install rear brake drum sub-assembly
9. Install rear wheel
Rear Axle Hub Bolt LH

Replacement
Hint:
Components: See page DT-22
3. Remove rear axle hub bolt LH
(a) Using SST and a screwdriver or an equivalent to remove the
hub bolt LH.
SST 09628-10011
SST
ALD052G
04-DRIVETRAIN.indd 23 2008-10-21 10:54:24

4. Install rear axle hub bolt LH

(a) Install the washer and the nut to a new rear hub bolt LH as
Washer shown in the illustration.
Nut (b) Using a screwdriver or an equivalent to hold the hub & bear-
ing assembly, install the rear hub bolt LH by tightening the
nut.
5. Install rear brake drum
ALD053G Torque: 110 N·m (1,120 kgf·cm, 83 ft·lbf)
04-DRIVETRAIN.indd 24 2008-10-21 10:54:24

DRIVETRAIN DT-25
CLUTCH
Precautions for clutch system installing:
1. Apply grease to the contact surface of the clutch pedal and clutch master cylinder push rod clevis.
2. Tighten only as specified torque for tube connection.
(a) Tube and master cylinder: M10 16 ± 2 N·m
(b) Clutch tube and hose: M10 16 ± 2 N·m
3. Be sure to bleed out air bubble completely when bleeding the clutch system. At this time, check that
the brake fluid level in the reservoir should be between MIN and MAX.
1. Engine mounting (Loosen) -
2. Clutch disc assembly (Excessive runout) DT-40
3. Clutch disc assembly (Oily) -
Clutch grabs/chatters 4. Clutch disc assembly (Worn out) DT-40
5. Clutch disc torsion damper (Damaged) -
6. Clutch disc assembly (Glazed) DT-40
7. Diaphragm spring (Out of tip alignment) DT-42
1. Clutch line (Air in line) DT-44
Clutch pedal is spongy 2. Clutch cylinder cup (Damaged) -
3. Clutch release cylinder cup (Damaged) -
1. Clutch release bearing assembly (Worn, -
Clutch is noisy dirty, or damaged)
2. Clutch disc torsion damper (Damaged) -
1. Clutch pedal (Free play is out of adjust- DT-27
ment)
Clutch slips 3. Clutch disc assembly (Worn out) DT-40
4. Diaphragm spring (Damaged) DT-42
5. Pressure plate (Distortion) -
6. Flywheel sub-assembly (Distortion) DT-41
1. Clutch pedal (Free play is out of adjust- DT-27
ment)
2. Clutch line (Air in line) DT-44
3. Clutch cylinder cup (Damaged) -
4. Clutch release cylinder cup (Damaged) -
Clutch does not disengage 5. Clutch disc assembly (Out of true) DT-41
6. Clutch disc assembly (Excessive runout) DT-40
7. Clutch disc assembly (Broken) -
8. Clutch disc assembly (Dirty or burned) -
10. Clutch disc assembly (Lack of spline grease) -
04-DRIVETRAIN.indd 25 2008-10-21 10:54:24

Clutch Pedal Sub-assembly

Components
12 (120, 9)
Clutch Master Cylinder Push
Rod Clevis Hole Pin
Lock Pin Clutch Pedal Support Sub-assembly
Clutch Pedal Shaft 37 (375, 27)
l Clutch Pedal Bush
12 (120, 9)
Clutch Pedal Stopper Bolt
Clutch Pedal Spring 12 (120, 9)

l Clutch Pedal Bush
l Clutch Master Cylinder Push
Rod Clevis Bush
Clutch Pedal Sub-assembly
: Specified torque
N·m (kgf·cm, ft·lbf) ：规定扭矩 Clutch Pedal Pad
●Non-reusable
l 不可重复使用零件 part
MP Grease
ALD054G
04-DRIVETRAIN.indd 26 2008-10-21 10:54:24

DRIVETRAIN DT-27
Clutch Pedal Adjustment

Height Adjust
Point 1. Inspect and adjust clutch pedal sub-assembly
(a) Turn over the floor carpet.
Push Rod Play (b) Check that the pedal height is correct.
Pedal height from dash panel:
134.3 to 144.3 mm (5.287 to 5.681 in.)
Push Rod Play (c) Adjust the pedal height.
and Free Play Clutch Pedal
Adjust Point (1) Loosen the lock nut and turn the stopper bolt until the
Height ALD055G
height becomes correct. Tighten the lock nut.
(d) Check that the clutch pedal free play and the push rod play
are correct.
(1) Depress the pedal until clutch resistance begins to be
felt.
Clutch pedal free play:
4 to 11 mm (0.157 to 0.433 in.)
(2) Gently depress the pedal until the resistance begins to
increase a little.
Push rod play at pedal top:
1.0 to 5.0 mm (0.039 to 5.004 mm.)
(e) Adjust the clutch pedal free play and the push rod play.
(1) Loosen the lock nut and turn the push rod until the free
play and the push rod play become correct.
(2) Tighten the lock nut.
(3) After adjusting the clutch pedal free play, check the
clutch pedal height.
Clutch Pedal Free Play
ALD056G
04-DRIVETRAIN.indd 27 2008-10-21 10:54:25

(f) Check the clutch release point.

(1) Pull the parking brake lever and install the wheel
stopper.
25 mm (0.98 in.) or more
(2) Start the engine and run at idle.
Release Point
(3) Without depressing the clutch pedal, slowly adjust
the shift lever into the reverse position until the gears
contact.
Full Stroke (4) Gradually depress the clutch pedal and measure the
End Position ALD057G stroke distance from the point that the gear noise stops
(release point) up to the full stroke end position.
Standard distance: 25 mm (0.984 in.) or more
(From pedal stroke end position to release point)
If the distance is not as specified, perform the following
operations:
• Check the clutch pedal height.
• Check the push rod play and the clutch pedal free
play.
• Bleed the clutch line.
• Check the clutch cover assembly and the disc
assembly.
• Check the pedal stroke.
Pedal stroke:
120 to 130 mm (4.724 to 5.118 in.)
04-DRIVETRAIN.indd 28 2008-10-21 10:54:25

DRIVETRAIN DT-29
Replacement
1. Remove clutch pedal spring
2. Remove clutch master cylinder push rod clevis hole pin
(a) Remove the lock pin and the hole pin.
ALD058G
3. Remove clutch pedal support sub-assembly

(a) Remove the 2 nuts, the bolt and the clutch pedal support sub-
assembly.
ALD059G
4. Remove clutch pedal sub-assembly

(a) Remove the clutch pedal shaft and the nut.
(b) Remove the clutch spring.
(c) Remove the clutch pedal from the clutch pedal support.
ALD060G
5. Remove clutch pedal stopper bolt

(a) Loosen the lock nut and remove the clutch pedal stopper
bolt.
(b) Remove the lock nut from the clutch pedal stopper bolt.
6. Remove clutch pedal pad
ALD061G
04-DRIVETRAIN.indd 29 2008-10-21 10:54:26

7. Remove clutch pedal bush

(a) Remove the 2 bushes from the clutch pedal.
ALD062G
8. Remove clutch master cylinder push rod clevis bush

(a) Using a 8 mm hexagon wrench and a hammer, remove the
clevis bush from the clutch pedal.
ALD063G
9. Install clutch master cylinder push rod clevis bush

(a) Apply MP grease to the inside of a new clevis bush.
(b) Install the clevis bush on the clutch pedal.
Hint:
Install the clevis bush from the left side of the vehicle.
MP Grease ALD064G
10. Install clutch pedal bush

(a) Apply MP grease to both sides of 2 new bushes.
(b) Install the 2 bushes to the clutch pedal.
11. Install clutch pedal pad
MP Grease
ALD062G
12. Install clutch pedal sub-assembly

(a) Install clutch pedal spring.
(b) Install the clutch pedal on the clutch pedal support with the
clutch pedal shaft and the nut.
Hint:
Install the clutch pedal shaft from the left side of the vehicle.
ALD060G
04-DRIVETRAIN.indd 30 2008-10-21 10:54:26

DRIVETRAIN DT-31
13. Install clutch pedal stopper bolt

(a) Install the lock nut on the clutch pedal stopper bolt but do not
tighten.
(b) Install the clutch pedal stopper bolt such that its end touches
the clutch pedal bush.
Hint:
Temporarily tighten the lock nut.
ALD061G
14. Install clutch pedal support sub-assembly

(a) Install the clutch pedal support on the vehicle with the 2 nuts
and the bolt.
ALD059G
15. Install clutch master cylinder push rod clevis hole pin
(a) Apply MP grease to the contact surface of the hole pin and
the clevis bush.
(b) Connect the clevis to the clutch pedal with the hole pin.
Hint:
Install the hole pin from the left side of the vehicle.
16. Inspect and adjust clutch pedal sub-assembly (See
page DT-27)
MP Grease
ALD065G 17. Connect battery negative cable
04-DRIVETRAIN.indd 31 2008-10-21 10:54:26

Clutch Master Cylinder Assembly

Components
Clutch Reservoir Tube

Clutch Pedal Spring
Clutch Master Cylinder Inlet Union
Lock Pin
l Clutch Reservoir Grommet
Clutch Master Cylinder Boot
12 (120, 9) Thrust Plate
Slotted Spring Pin
12 (120, 9)
Snap Ring
Push Rod
Spring Piston
Clutch Master Cylinder Push
12 (120, 9) Rod Clevis Hole Pin
Master Cylinder Body
15 (155, 11)
N·m (kgf·cm, ft·lbf) ：规定扭矩

: Specified torque
l●Non-reusable
不可重复使用零件 part
Grease
MP Grease ALD066G
04-DRIVETRAIN.indd 32 2008-10-21 10:54:27

DRIVETRAIN DT-33
Overhaul
1. Remove brake master cylinder sub-assembly (See
page BR-13)
2. Remove ABS controller assembly (See page BR-40)
3. Remove vacuum booster assembly (See page BR-18)
4. Remove clutch pedal spring
5. Remove clutch master cylinder push rod clevis hole pin
(a) Remove the lock pin and the hole pin.
6. Drain brake fluid
ALD058G
7. Remove clutch reservoir tube

(a) Loosen the clamp and remove the clutch reservoir tube from
the clutch master cylinder assembly.
ALD067G
8. Disconnect clutch hose of clutch master cylinder

(a) Using SST, disconnect the clutch hose.
SST 09023-00100
Hint:
Use a container to catch the fluid.
9. Remove clutch master cylinder assembly
(a) Remove the 2 nuts and clutch master cylinder assembly.
ALD068G
10. Remove clutch master cylinder kit

(a) Using a pin punch and a hammer, drive out the slotted spring
pin.
(b) Remove the inlet union and the grommet.
(c) Loosen the lock nut, and remove the push rod clevis.
(d) Remove the lock nut from the push rod.
(e) Remove the boot from the cylinder body.
ALD069G
04-DRIVETRAIN.indd 33 2008-10-21 10:54:27

(f) While pushing the push rod, remove the snap ring with snap
ring pliers.
(g) Remove the push rod from the cylinder body.
Notice:
The piston may pop out of the cylinder body. Therefore,
slowly remove the push rod from the cylinder body.
(h) Remove the thrust plate from the push rod.
(i) Remove the piston with spring from the cylinder.
ALD070G Notice:
Be careful not to damage the inside of the cylinder
body.
11. Install clutch master cylinder kit
(a) Coat the parts with grease, as shown in the illustration.
(b) Install the piston with spring into the master cylinder.
Notice:
body.
(c) Install the thrust plate to the push rod.
(d) Install the push rod to the cylinder body.
ALD071G
(e) While pushing the push rod, install the snap ring with snap
ring pliers.
(f) Install the boot on the cylinder body.
(g) Install the lock nut on the push rod.
(h) Temporarily install the push rod clevis with the lock nut on
the push rod.
(i) Install the inlet union and a new grommet.
ALD070G
(j) Using a pin punch and a hammer, drive in the slotted spring
Protrusion Part
1.5 to 3.5 mm pin.
(0.059 to 0.138 in.) 12. Install clutch master cylinder assembly
(a) Install the clutch master cylinder assembly with the 2 nuts.
ALD072G
04-DRIVETRAIN.indd 34 2008-10-21 10:54:28

DRIVETRAIN DT-35
13. Connect clutch hose to clutch master cylinder

(a) Using SST, connect the clutch hose.
SST 09023-00100
ALD068G
14. Install clutch reservoir tube

White Mark (a) Connect the clutch reservoir tube with the clamp to the clutch
master cylinder assembly.
Notice:
• Connect the clutch reservoir tube, taking care not to
twist it.
• Face the white mark upward.
ALD073G
15. Install clutch master cylinder push rod clevis hole pin
(a) Apply MP grease to the contact surface of the hole pin and
the clevis bush.
(b) Connect the clevis to the clutch pedal assembly with the hole
pin.
Hint:
Install the hole pin from the right side of the vehicle.
(c) Install the lock pin to the hole pin.
MP Grease
ALD065G 16. Install clutch pedal spring
17. Install vacuum booster assembly (See page BR-19)
18. Install ABS controller assembly (See page BR-38)
19. Install brake master cylinder sub-assembly (See page
BR-14)
20. Bleed clutch line
(a) Fill the brake reservoir with brake fluid and bleed clutch sys-
tem.
21. Check for clutch fluid leakage
22. Check fluid level in reservoir
23. Inspect and adjust clutch pedal sub-assembly (See
page DT-27)
04-DRIVETRAIN.indd 35 2008-10-21 10:54:28

Clutch Release Cylinder Assembly

Components
Union Bolt
25 (250, 18)
Clutch Release Union

l Gasket
l Gasket
Bleeder Screw Cap 15 (155, 11)
Release Cylinder Bleeder Screw

(87 kgf·cm, 74 in.·lbf)
12 (120, 9) l Spring Piston

Push Rod
Release Cylinder Body
N·m (kgf·cm, ft·lbf) : Specified torque Boot

l Non-reusable part
Grease
ALD074G
04-DRIVETRAIN.indd 36 2008-10-21 10:54:28

DRIVETRAIN DT-37
Overhaul
1. Disconnect clutch hose from clutch release cylinder
(a) Using SST, disconnect the clutch hose.
SST 09023-00100
Hint:
Use a container to catch the fluid.
SST ALD075G
2. Remove clutch release cylinder assembly

(a) Remove the 2 bolts and the clutch release cylinder assembly.
3. Remove clutch release union
(a) Remove the union bolt.
(b) Remove the clutch release union and the 2 gaskets.
4. Remove clutch release cylinder kit
(a) Remove the boot from the cylinder body.
(b) Remove the push rod from the cylinder body.
ALD076G (c) Remove the piston from the cylinder body.
Notice:
body.
(d) Remove the spring from the cylinder body.
(e) Remove the bleeder screw cap from the bleeder screw.
5. Remove release cylinder bleeder screw
6. Install release cylinder bleeder screw
7. Install clutch release cylinder kit
(a) Install the bleeder screw cap on the bleeder plug.
(b) Install a new spring on the cylinder body.
(c) Coat a new piston with grease, as shown in the illustration.
(d) Install the piston on the cylinder body.
Notice:
body.
(e) Install the push rod to the cylinder body.
(f) Install the boot on the cylinder body.
ALD077G
8. Install clutch release union

(a) Install the clutch release union with the union bolt and 2 new
gaskets, as shown in the illustration.
0o ± 3o Notice:
Installation angle of the clutch release union should be
0° ± 3° against the body.
ALD078G
04-DRIVETRAIN.indd 37 2008-10-21 10:54:29

9. Install clutch release cylinder assembly

(a) Install the clutch release cylinder assembly with the 2 bolts.
ALD076G
10. Connect clutch hose to clutch release cylinder

(a) Using SST, connect the clutch hose.
SST 09023-00100
11. Bleed clutch line
(a) Fill the brake reservoir with brake fluid and bleed the clutch
system.
SST ALD075G 12. Check for clutch fluid leakage
04-DRIVETRAIN.indd 38 2008-10-21 10:54:29

DRIVETRAIN DT-39
Clutch Assembly
Components
Flywheel Sub-assembly
Clutch Disc Assembly

Clutch Cover Assembly
19 (195, 14)
Clutch Release
Bearing Assembly
×6
Release Bearing Hub Clip
Clutch Release Fork Sub-assembly
37 (375, 27)
Release Fork Support
N·m (kgf·cm, ft·lbf) :：规定扭矩

Specified torque
Clutch Spline Grease
Clutch Release Fork Boot
Release Hub Grease
ALD079G
04-DRIVETRAIN.indd 39 2008-10-21 10:54:29

Overhaul
1. Remove transaxle assembly
2. Remove clutch release fork sub-assembly
(a) Remove the clutch release fork from the transaxle assembly.
3. Remove clutch release fork boot
4. Remove clutch release bearing assembly
(a) Remove the clutch release bearing assembly from the clutch
release fork.
5. Remove release bearing hub clip
6. Remove release fork support
ALD080G (a) Remove the support and release fork from the transaxle.
7. Remove clutch cover assembly

(a) Align the matchmark on the clutch cover assembly with the
one on the flywheel sub-assembly.
(b) Loosen each set bolt one turn at a time until spring tension is
released.
(c) Remove the set bolts and pull off the clutch cover assembly.
Notice:
Do not drop the clutch disc assembly.
Matchmarks ALD081G 8. Remove clutch disc assembly
9. Inspect clutch disc assembly

(a) Using vernier calipers, measure the rivet head depth.
Maximum rivet depth: 0.3 mm (0.012 in.)
Replace the clutch disc assembly as necessary.
(b) Install the clutch disc assembly on the transaxle assembly.
Notice:
Take care not to insert the clutch disc assembly in the
wrong direction.
ALD082G
(c) Using a dial gauge, check the clutch disc assembly runout.
Minimum runout: 0.8 mm (0.031 in.)
Replace the clutch disc assembly as necessary.
Transaxle
Side
ALD083G
04-DRIVETRAIN.indd 40 2008-10-21 10:54:30

DRIVETRAIN DT-41
10. Inspect clutch cover assembly

B (a) Using vernier calipers, inspect the diaphragm spring for
A depth and width of wear.
Maximum:
A (Depth): 0.5 mm (0.020 in.)
B (Width): 6.0 mm (0.236 in.)
Replace the clutch cover assembly as necessary.
ALD084G
11. Inspect flywheel sub-assembly

(a) Using a dial gauge, inspect the flywheel sub-assembly for
runout.
Maximum runout: 0.1 mm (0.004 in.)
Replace the flywheel sub-assembly as necessary.
ALD085G
12. Inspect clutch release bearing assembly

(a) Turn the release bearing by hand while applying force in the
axial direction.
Hint:
• The bearing is permanently lubricated and requires no
cleaning or lubrication.
• Replace the release bearing assembly as necessary.
ALD086G
13. Install clutch disc assembly

(a) Insert SST in the clutch disc assembly, then insert them in
SST the flywheel sub-assembly.
SST 09301-00210
Flywheel Notice:
Side Take care not to insert the clutch disc assembly in the
wrong direction.
ALD087G
04-DRIVETRAIN.indd 41 2008-10-21 10:54:31

14. Install clutch cover assembly

7
SST 1 (Temporarily) (a) Align the matchmark on the clutch cover assembly with that
on the flywheel sub-assembly.
3
(b) Tighten the 6 bolts in order, starting from the bolt located
near the pin on the top as shown in the illustration.
6
4
Hint:
• Following the order in the illustration, tighten the bolts
2 Matchmarks little by little each time.
ALD088G
• Move SST up and down, right and left lightly after

checking that the disc is in the center to tighten the bolts.
SST 09301-00210
15. Inspect and adjust clutch cover assembly
(a) Using a dial gauge with the roller instrument, check the dia-
phragm spring tip non-alignment.
Maximum non-alignment: 0.5 mm (0.020 in.)
ALD089G
(b) If non-alignment is not as specified, adjust it by using SST.

SST 09333-00013
16. Install release fork support
(a) Install the release fork support on the transaxle assembly.
17. Install clutch release fork boot
18. Install release bearing hub clip
SST
ALD090G
19. Install clutch release fork sub-assembly

(a) Apply release hub grease to the release fork and release bear-
ing assembly contact, the release fork and push rod contact
and the release fork pivot points.
(b) Install the release fork on the release bearing assembly.
20. Install clutch release bearing assembly
(a) Apply the clutch spline grease to the input shaft spline.
(b) Install the bearing on the release fork first and then install
Release Hub Grease
ALD091G them on the transaxle assembly.
Notice:
After installation, move the fork forward and backward
to check that the release bearing slides smoothly.
21. Install transaxle assembly
04-DRIVETRAIN.indd 42 2008-10-21 10:54:32

DRIVETRAIN DT-43
Clutch Start Switch Assembly

1. Check clutch start system
(a) Check that the engine does not start when the clutch pedal is
released.
(b) Check that the engine starts when the clutch pedal is fully
depressed.
If necessary, replace the clutch start switch assembly.
Inspection
1. Inspect clutch start switch assembly
(a) Check the continuity between the terminals when the switch
is ON and OFF.
Switch position Condition
ON (Pressed) Continuity
OFF (Free) No continuity
8.0 ± 0.5 mm
(0.315 ± 0.020 in.)
ALD092G
Replacement
1. Remove clutch start switch assembly
(a) Disconnect the clutch start switch assembly connector.
(b) Remove the 2 nuts and the clutch start switch assembly from
the bracket.
(c) Remove the nut and clutch start switch assembly from the
bracket.
2. Install clutch start switch assembly
ALD093G (a) Install the clutch start switch assembly with the nut.
(b) Install the clutch start switch with the 2 nuts.
(c) Connect the clutch start switch assembly connector.
3. Inspect clutch start switch assembly (See page DT-43)
04-DRIVETRAIN.indd 43 2008-10-21 10:54:32

Clutch Hydraulic Pressure System Bleeding

Hint:
After repairing for clutch hydraulic pressure operation system, the
air may enters into the lines; also the hydraulic pressure system
while adding brake fluid. After entering, because of shortening
master cylinder push rod stroke, that is pedal operation stroke,
then make the clutch do not disengage.
1. Fill reservoir with brake fluid
Brake fluid: DOT4 synthetic brake fluid
Hint:
The level of brake fluid in the reservoir should be between
the MIN and MAX lines.
ALD094G
2. Lift up the vehicle

(a) Lift the vehicle up to appropriate level with lift.
ALD095G
3. Bleed clutch hydraulic pressure system

(a) Connect plastic tube to the bleeder screw.
(b) Depress the clutch pedal several times, then loosen the bleed-
er screw with the pedal depressed.
(c) When fluid stops coming out, tighten the bleeder screw, then
release the pedal.
(d) Repeat (b) and (c) until all the air in the brake fluid is com-
C
pletely bled out.
ALD096G Hint:
Air bleeding needs two persons to operate in combination
with each other.
4. After bleeding the air completely, it needs to check and
adjust pedal free play again and add brake fluid
04-DRIVETRAIN.indd 44 2008-10-21 10:54:34

SP-
SUSPENSION
FRONT SUSPENSION SYSTEM

Problem Symptoms Table................................................. SP-2
Components...................................................................... SP-3
Front Wheel Alignment...................................................... SP-7
Front Shock Absorber with Coil Spring Assembly............. SP-10
Steering Knuckle............................................................... SP-15
Front Suspension Lower Control Arm LH......................... SP-18
Front Stabilizer Bar........................................................... SP-22
REAR SUSPENSION SYSTEM

Problem Symptoms Table................................................. SP-26
Rear Wheel Alignment...................................................... SP-26
Components...................................................................... SP-27
Rear Shock Absorber Assembly LH.................................. SP-28 SP
Rear Coil Spring LH.......................................................... SP-30
Rear Twist Beam Assembly.............................................. SP-33
TIRE AND WHEEL

Tire.................................................................................... SP-37
Wheel................................................................................ SP-43
05-SUSPENSION.indd 1 2008-10-21 8:19:25

SP- GREAT WALL COOL BEAR REPAIR MANUAL
FRONT SUSPENSION SYSTEM

1. Tire (Worn or improperly inflated) SP-37
2. Wheel alignment (Incorrect) SP-7
Wander/pulls 4. Hub bearing (Worn) DT-2
5. Steering gear (Out of adjustment or bro- SR-12
ken)
6. Suspension parts (Worn) -
1. Vehicle (Overloaded) -
Bottoming 2. Spring (Weak) SP-10
3. Shock absorber (Worn) SP-10
2. Stabilizer bar (Bent or broken) SP-22
Sways/pitches
3. Spring (Weak) SP-10
2. Wheel (Out of balance) SP-43
Front wheel shimmy 5. Ball joint (Worn) SP-18
8. Steering gear (Out of adjustment or bro- SR-12
ken)
Abnormal tire wear
05-SUSPENSION.indd 2 2008-10-21 8:19:25

SUSPENSION SP-
Components
20 (205, 15)
Front Wiper Arm Bolt Cover
Front Wiper Arm

Assembly RH Clip 20 (205, 15)
Front Wiper Arm Assembly LH

Clip
Ventilation Cover
Plate Body RH
Ventilation Cover
Plate Body LH
5.5 (56, 49 in·lbf)
Ventilation Cover Plate
Sealing Strip
5.0 (51, 44 in·lbf) Front Wiper Linkage & Motor Assembly

Hose
Cowl Top Outer Panel
Wire Harness
(Wiper)

ALE001G
05-SUSPENSION.indd 3 2008-10-21 8:19:26

40 (408, 30)
Front Shock Absorber
Upper Dust Cover
l 33 (340, 25)
Front Shock Absorber Pillar

Upper Mounting Pressure Front Shock Absorber
Plate Pillar Upper Mounting
Seat
Seal Washer
Front Coil Spring Upper

Mounting Seat
Dust Cover
Front
Front Shock Absorber Bumper
With Coil Spring Assembly
Front Coil Spring LH
132 (1,350, 97)
29 (300, 22)
Wheel Speed Sensor Brake Hose

Wiring Harness Front Shock Absorber
Assembly LH

l Non-reusable part ALE002G
05-SUSPENSION.indd 4 2008-10-21 8:19:26

SUSPENSION SP-
LH: Front Stabilizer Bar
Washer
Bushing
Washer Front Suspension Lower Control Arm LH

Bushing
Washer Washer
Bushing
107 (1,088, 79)

l 37 (377, 28)
l Lock Pin
98 (1,000, 72)
Washer
170 (1,734, 128)
Bushing
Washer
l 37 (377, 28)

05-SUSPENSION.indd 5 2008-10-21 8:19:27

Engine Hood
37 (377, 28)
l 37 (377, 28)
Washer
7.8 (80, 69 in·lbf) Bushing
Front Stabilizer Mounting Bracket RH
37 (377, 28)
Front Stabilizer
Bar Bush
Front Stabilizer Mounting Bracket LH
Front Front Stabilizer Bar Bush
Stabilizer
Steering Combination Tube Bar
l 37 (377, 28)
107 (1,092, 80)
Washer
Bushing
Bushing
Washer
107 (1,092, 80)
Front Stabilizer
Bar Link Power Bushing
Washer Washer
Steering Gear
Bushing
Front Stabilizer Bar Link

145 (1,480, 110) Washer
Bushing
120 (1,224, 90)
Lock Pin l
145 (1,480, 110)
98 (1,000, 72)
l Lock Pin
Auxiliary Frame Strut Rod RH
Washer
Bushing 98 (1,000, 72)
l 37 (377, 28)
78 (796, 59)
Washer
46 (470, 34) 120 (1,224, 90) Bushing
Washer
Auxiliary Frame
Strut Rod LH l 37 (377, 28)
46 (470, 34)
05-SUSPENSION.indd 6 2008-10-21 8:19:27

SUSPENSION SP-
Front Wheel Alignment

Adjustment
1. Inspect tire (See page SP-37)
2. Measure vehicle height
Vehicle height
B A A - B mm (in.) D - C mm (in.)
82 (3.22) 12 (0.47)
Measuring points:
A: Ground clearance of front wheel center
B: Ground clearance of front suspension lower control arm
front bolt center
C D
ALE005G
C: Ground clearance of rear twist beam set bolt center
D: Ground clearance of rear wheel center
Notice:
Before inspecting the wheel alignment, adjust the ve-
hicle height to the specified value.
Hint:
Bounce the vehicle at the corners up and down to stabilize
the suspension and inspect the vehicle height.
3. Inspect toe-in
A D B Toe-in:
Front A + B: -0°04’ ± 15’
Toe-in (total)
C - D: 0 ± 2 mm (0 ± 0.08 in.)
If the toe-in is not within the specified value, adjust it at the
rack ends.
C 4. Adjust toe-in
Notice:
ALE006G
Before inspecting toe-in, adjust camber correctly first.
(a) Remove the rack boot set clamps.
(b) Loosen the tie rod end lock nuts.
(c) Turn the right and left rack ends by an equal amount to adjust
the toe-in.
Hint:
Adjust the toe-in to the center of the specified value.
ALE007G
05-SUSPENSION.indd 7 2008-10-21 8:19:28

(d) Make sure that the lengths of the right and left rack ends are
the same.
Rack end length difference: 1.5 mm (0.059 in.) or less
(e) Tighten the tie rod end lock nuts.
(f) Place the boots on the seats and install the clamps.
Hint:
Make sure that the boots are not twisted.
ALE008G
A-B A B
5. Inspect wheel turning angle
(a) Turn the steering wheel fully and measure the turning angle.
Wheel turning angle
Front
Inside wheel Outside wheel
32° - 34° 28° - 30°
If the right and left inside wheel turning angles differ from
A: Inside
B: Outside the specified value, check the right and left rack end lengths.
ALE009G
6. Inspect front wheel camber, kingpin caster and kingpin

inclination
Gauge Front wheel camber, kingpin caster and kingpin inclina-
tion:
Alignment Front wheel -0°29’ ± 15’
Tester camber Right-left error 30’ (0.5°) or less
Kingpin caster 2°08’ ± 15’
Right-left error 30’ (0.5°) or less
ALE010G Kingpin 9°49’ ± 15’
inclination Right-left error 30’ (0.5°) or less
If the front wheel kingpin caster and kingpin inclination are
not within the specified values, after the camber has been
correctly adjusted, recheck the suspension parts for any dam-
age and/or worn-out parts.
7. Adjust camber
(a) Remove the front wheel.
(b) Remove the 2 nuts on the lower side of the shock absorber.
(c) Clean the installation surface of the shock absorber and the
steering knuckle.
ALE011G
05-SUSPENSION.indd 8 2008-10-21 8:19:28

SUSPENSION SP-
(d) Temporarily install the 2 nuts.

(e) Adjust the camber by pushing or pulling the lower side of the
shock absorber in the direction which the camber adjustment
(-) (+) 1
is required.
2
(f) Tighten the nuts.
(g) Install the front wheel.
: Use adjusting bolt
ALE012G (h) Inspect the camber.
Hint:
• Adjust the camber to the center of the specified value.
• Adjusting value for the set bolts is 6’ to 30’ (0.1° to 0.5°).
If the camber is not within the specified value, using the
following table, estimate how much additional camber
adjustment will be required, and select the camber ad-
justing bolt.
Notice:
Tighten the adjusting bolt with a washer and a new nut.
Bolt Set bolt Adjusting bolt
90105-14140 90105-14146 90105-14147
1 Dot 2 Dots
11 11 11
ALE013G ALE014G ALE015G
Adjusting
value 1 2 1 2 1 2
15’ ● ●
30’ ● ●
45’ ● ●
1°00’ ● ●
(i) Perform the steps mentioned above again. In step (b), replace
1 or 2 selected bolts.
Hint:
When replacing 2 bolts, replace 1 bolt at a time.
05-SUSPENSION.indd 9 2008-10-21 8:19:29

SP-10 GREAT WALL COOL BEAR REPAIR MANUAL
Front Shock Absorber with Coil Spring As-

sembly
Overhaul
Hint:
Components: See page SP-3 and SP-4
1. Remove front wiper arm bolt cover
2. Remove front wiper arm assembly LH
3. Remove front wiper arm assembly RH
4. Remove ventilation cover plate sealing strip (See page
ET-6)
5. Remove ventilation cover plate body LH (See page
ET-6)
6. Remove ventilation cover plate body RH (See page
ET-6)
7. Remove front wiper linkage & motor assembly (See
page ET-6)
8. Remove cowl top outer panel
(a) Disconnect the hose and the wire harness (wiper).
(b) Remove the cowl top outer panel with the 8 bolts.
10. Disconnect brake hose
(a) Remove the bolt and disconnect the brake hose and the speed
sensor wire harness clamp from the shock absorber bracket.
ALE016G
11. Remove front shock absorber with coil spring assembly

(a) Remove the 2 nuts and the bolts, and disconnect the shock
absorber from the steering knuckle.
ALE011G
05-SUSPENSION.indd 10 2008-10-21 8:19:30

SUSPENSION SP-11
(b) Remove the shock absorber with coil spring with the 3 nuts.
(c) Remove front shock absorber pillar upper mounting pressure
plate.
ALE017G
12. Fix front shock absorber with coil spring assembly

(a) Install the 2 nuts and bolt on the bracket at the lower side of
the shock absorber and secure it in a vise.
(b) Using SST, compress the coil spring.
SST　09727-30021 (09727-00010, 09727-00021,
09727-00031)
Notice:
SST
Do not use an impact wrench. It will damage the SST.
ALE018G 13. Remove front shock absorber upper dust cover
(a) Remove the dust cover from the front shock absorber pillar
upper mounting seat.
14. Remove center nut
(a) Using the 2 nuts and a screwdriver or an equivalent to secure
the front shock absorber , remove the center nut.
Notice:
Be careful not to damage the front shock absorber pillar
upper mounting seat stud bolts.
15. Remove front shock absorber pillar upper mounting
seat
ALE019G 16. Remove seal washer
17. Remove front coil spring upper mounting seat
18. Remove dust cover
19. Remove front coil spring LH
20. Remove front bumper
21. Remove front shock absorber assembly LH
22. Inspect front shock absorber assembly LH
(a) Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual sound during op-
eration.
If there is any abnormality, replace the shock absorber with a
new one.
ALE020G Notice:
When disposing of the shock absorber, see DISPOSAL
on page SP-13.
23. Install front shock absorber assembly LH
24. Install front bumper
05-SUSPENSION.indd 11 2008-10-21 8:19:30

25. Install front coil spring LH

(a) Using SST, compress the coil spring.
SST
SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
Notice:
Do not use an impact wrench. It will damage the SST.
ALE021G
(b) Install the coil spring on the shock absorber.

Hint:
Fit the lower end of the coil spring into the gap of the spring
lower seat.
Outside
ALE022G
26. Install dust cover

(a) Install the dust cover with the “△” mark facing the outside
of the vehicle.
27. Install front coil spring upper mounting seat
(a) Install the spring upper mounting seat with the “OUT” mark
facing the outside of the vehicle.
28. Install seal washer
29. Install front shock absorber pillar upper mounting seat
30. Install center nut
(a) Using the 2 nuts and a screwdriver or an equivalent to secure
the front shock absorber, install a new center nut.
Notice:
Be careful not to damage the front shock absorber pillar
upper mounting seat stud bolts.
(b) Remove the SST.
ALE023G SST 09727-30021 (09727-00010, 09727-00021,
09727-00031)
05-SUSPENSION.indd 12 2008-10-21 8:19:31

SUSPENSION SP-13
(c) Apply MP grease to front shock absorber pillar upper mount-

MP Grease
ing seat.
ALE024G
31. Install front shock absorber upper dust cover

32. Install front shock absorber with coil spring assembly
(a) Install front shock absorber pillar upper mounting pressure
plate.
(b) Install the shock absorber with coil spring with the 3 nuts.
(c) Connect the shock absorber to the steering knuckle.
(d) Install the 2 bolts and the nuts.
Notice:
When installing the bolt keep it from rotating and tight-
en the nut.
33. Install brake hose
(a) Fix the brake hose and the speed sensor wire harness clamp
on the shock absorber bracket with the bolt.
35. Install cowl top outer panel
(a) Install the cowl top outer panel with the 8 bolts.
(b) Connect the hose and the wire harness (Wiper).
36. Install front wiper linkage & motor assembly (See page
ET-7)
37. Install ventilation cover plate body RH
38. Install ventilation cover plate body LH
39. Install ventilation cover plate sealing strip
40. Install front wiper arm and blade assembly LH
41. Install front wiper arm and blade assembly RH
42. Install windshield wiper arm bolt cap
SP-7)
05-SUSPENSION.indd 13 2008-10-21 8:19:31

Disposal
Hint:
Disposal of the RH is the same as that of the LH.
1. Dispose of front shock absorber assembly LH
(a) Fully extend the shock absorber rod.
A B
(b) Using a drill, make a hole in the cylinder somewhere be-
tween A and B as shown in the illustration to discharge the
gas inside.
Caution:
• Be careful when drilling because shards of metal
may fly about, so always use the proper safety
ALE025G equipment.
• The gas is colorless, odorless and non-poisonous.
05-SUSPENSION.indd 14 2008-10-21 8:19:32

SUSPENSION SP-15
Steering Knuckle
Removal
Hint:
Removal of the RH is the same as that of the LH.
1. Remove front wheel LH (See page SP-45)
2. Remove front axle hub nut LH
(a) Using SST and a hammer, pry up the areas protruding of the
front axle hub nut LH.
SST 09930-00010
Notice:
Loosen the staked part of the nut completely, otherwise
the screw of the drive shaft may be damaged.
SST
(b) While applying the brakes, remove the front axle hub nut
ALE026G LH.
3. Separate front wheel speed sensor LH and brake hose

(a) Remove the bolt, and separate the front speed sensor LH
Notice:
• Be careful not to damage the speed sensor.
• Prevent foreign matter from adhering to the speed
sensor.
ALE027G
(b) Remove the brake hose.

Notice:
When removing the brake hose, the brake liquid will
outflow, which needs to be stored in a container. Be
aware of personal protection, because the brake liquid
is corrosive.
Brake Hose
Speed Sensor
ALE028G

(a) Remove the 2 bolts, separate the front brake caliper assembly
ALE029G
05-SUSPENSION.indd 15 2008-10-21 8:19:32

5. Separate front stabilizer bar

(a) Using a wrench (10 mm) to secure the bolt, and remove the
nut.
(b) Remove 2 washers, 2 bushes and separate the front stabilizer
bar.
ALE030G
6. Separate front suspension lower control arm LH

(a) Remove the lock pin and the nut.
(b) Using SST, separate the front suspension lower control arm
SST
ALE031G
7. Separate tie rod end assembly LH

SST (a) Remove the lock pin and the nut.
(b) Using SST, separate the tie rod end assembly LH from the
steering knuckle.
ALE032G
8. Separate front shock absorber assembly LH

(a) Remove 2 bolts, 2 nuts and separate front shock absorber as-
sembly LH from steering knuckle assembly LH.
9. Remove front axle drive shaft assembly LH
(a) Using a plastic hammer, separate the front axle drive shaft
assembly LH from the front axle hub assembly LH.
Notice:
• Be careful not to damage the boot.
ALE033G • Be careful not to damage the speed sensor rotor.
10. Remove front axle hub LH hole snap ring (See page
DT-18)
(a) Using snap ring pliers, remove the front axle hub LH hole
snap ring.
11. Remove front axle hub sub-assembly LH (See page
DT-18)
05-SUSPENSION.indd 16 2008-10-21 8:19:33

SUSPENSION SP-17
12. Remove steering knuckle LH

(a) Remove 3 bolts and the steering knuckle LH.
Steering Knuckle LH
ALE034G
Installation
Hint:
verse order.
05-SUSPENSION.indd 17 2008-10-21 8:19:33


Replacement
Hint:
• Components: See page SP-5
• The removal of front suspension lower control arm RH is the
same as that of the LH.
1. Remove front wheel (See page SP-45)
2. Separate front suspension lower control arm LH (See
page SP-16)
SST 09628-00011
3. Separate front stabilizer bar (See page SP-16)
4. Remove front suspension lower control arm LH
(a) Remove the 2 bolts, nut and the front suspension lower con-
trol arm LH.
Notice:
Do not turn the nut.
ALE035G
5. Inspect front suspension lower control arm LH

(a) As shown in the illustration, flip the ball joint stud back and
forth 5 times before installing the nut.
(b) Using a torque wrench, turn the nut continuously at a rate of
2 to 4 seconds per turn and take the torque reading on the 5th
turn.
Turning torque:
5.0 N·m (51 kgf·cm, 44 in.·lbf) or less
ALE036G (c) Check the ball joint stud for any damage.
(d) Check the ball joint stud dust cover for any damage. Replace
it if necessary.
Caution:
Do not remove the ball joint stud from the lower control
arm weldment assembly. Replace the whole lower con-
trol arm with ball joint stud assembly if the ball joint stud
is damaged or cannot be turned agilely.
6. Replace ball joint stud dust cover
(a) Using SST, turn and remove the ball joint stud dust cover
clip ring.
SST (b) Replace the ball joint stud dust cover. Install the clip ring
with the same SST.
ALE037G
05-SUSPENSION.indd 18 2008-10-21 8:19:34

SUSPENSION SP-19
7. Inspect lower control arm big bush and small bush

(a) Clean surfaces of the lower control arm big bush and small
bush with water. Check for any damage, wear or crack, re-
place it if necessary.
ALE038G
8. Replace lower control arm big bush

(a) Before removing, put two marks on the lower control arm
according to position of the bush for locating reference when
installing.
ALE039G
(b) Using SST, push the lower control arm big bush out on a
SST
press, replace it with a new one.
(c) Measure the installation hole of lower control arm big bush
-0.2
f55-0.3. Replace the lower control arm weldment assembly if
the measured value is not as specified.
SST ALE040G
(d) Align the marks before installing

Put two marks on the new lower control arm big bush at the
same location to align with those on the lower control arm
when installing, which keeps the relative angle unchanged.
ALE041G
(e) Using SST, install a new lower control arm big bush on the
press.
SST
SST
ALE042G
05-SUSPENSION.indd 19 2008-10-21 8:19:35

9. Replace lower control arm small bush

Part to be (a) Using a sander, cut away the rubber flange of the lower con-
planished
trol arm small bush and planish it.
Caution:
Be careful not to damage the lower control arm when
Part to be
planished using the sander.
ALE043G
(b) Using SST, push the lower control arm small bush out on a
SST
press, replace it with a new one.
(c) Measure the installation hole of lower control arm small bush
+0.05
f310 . Replace the lower control arm weldment assembly if
the measured value is not as specified.
SST
ALE044G
(d) Using SST, install a new lower control arm small bush on the
SST press.
SST
ALE045G
10. Temporarily tighten front suspension lower control arm

LH
(a) Temporarily tighten the front suspension lower control arm
LH with the 2 bolts and the nuts.
11. Connect front suspension lower control arm LH (See
page DT-15)
12. Connect front stabilizer bar (See page SP-25)
ALE035G Torque: 110 N·m (1,122 kgf·cm, 83 ft·lbf)
05-SUSPENSION.indd 20 2008-10-21 8:19:35

SUSPENSION SP-21
14. Fully tighten front suspension lower control arm LH

(a) Install the lower suspension arm with the 2 bolts.
A
Torque:
Bolt A: 170 N·m (1,734 kgf·cm, 128 ft·lbf)
Bolt B: 107 N·m (1,091 kgf·cm, 80 ft·lbf)
Notice:
B 15. Inspect and adjust front wheel alignment (See page
ALE046G SP-7)
05-SUSPENSION.indd 21 2008-10-21 8:19:36

Front Stabilizer Bar

Replacement
Hint:
Components: See page SP-6
2. Remove engine hood
3. Suspend engine assembly (See page EG-14)
page SP-16)
SST 09628-00011
5. Separate front suspension lower control arm RH
SST 09628-00011
Hint:
Separation of the RH is the same as that of the LH.
6. Separate front stabilizer bar
(a) While holding the front stabilizer link with the spanner, re-
move the nut.
(b) Remove the 2 washers and bushes, and then remove the front
stabilizer link.
(c) Perform the procedure above on the other side.
ALE047G
7. Separate power steering gear

(a) Remove the 4 bolts and the 4 nuts, and separate the power
steering gear.
Hint:
Suspend the power steering gear.
ALE048G
8. Separate steering combination tube

(a) Remove the bolt and separate the steering combination tube.
9. Remove auxiliary frame strut rod LH
(a) Remove the 2 bolts and the auxiliary frame strut rod LH.
10. Remove auxiliary frame strut rod RH
(a) Remove the 2 bolts and the auxiliary frame strut rod RH.
ALE049G
05-SUSPENSION.indd 22 2008-10-21 8:19:36

SUSPENSION SP-23
11. Separate auxiliary frame sub-assembly

(a) Remove the bolt and the 2 nuts.
P ALE050G
(b) Support the auxiliary frame sub-assembly with the jack.

(c) Remove the 4 bolts and separate the auxiliary frame sub-
assembly.
ALE051G
12. Remove front stabilizer bar

(a) Remove the 4 bolts, 2 bushings and front stabilizer mounting
bracket LH and RH.
(b) Remove the front stabilizer bar.
ALE052G
13. Install front stabilizer bar

(a) Install the stabilizer bar, the 2 bushings, and the mounting
brackets with the 4 bolts.
Notice:
Install the bushings with the slit facing the rear side of
Paint Line the vehicle.
Hint:
ALE053G Install the bushings on the outside of each paint line.
05-SUSPENSION.indd 23 2008-10-21 8:19:37

14. Connect auxiliary frame sub-assembly

(a) Align the holes of the auxiliary frame and body.
(b) Perform the procedure above on the other side.
ALE054G
(c) Install the auxiliary frame sub-assembly with the 4 bolts.

Torque:
A Bolt B: 145 N·m (1,480 kgf·cm, 109 ft·lbf)
A
B
B ALE055G
(d) Install the bolt and the 2 nuts.

P ALE050G
15. Install auxiliary frame strut rod LH

(a) Install the auxiliary frame strut rod LH with the 2 bolts.
16. Install auxiliary frame strut rod RH
(a) Install the auxiliary frame strut rod RH with the 2 bolts.
17. Connect steering combination tube
(a) Connect the steering combination tube with the bolt.
ALE049G
05-SUSPENSION.indd 24 2008-10-21 8:19:37

SUSPENSION SP-25
18. Connect power steering gear

(a) Install the power steering gear with the 4 bolts and the 4 nuts.
Notice:
ALE048G
19. Connect front stabilizer bar

(a) Install the 2 washers and bushings.
(b) While holding the front stabilizer link with the spanner, in-
stall the nut.
Hint:
Support the lower control arm with the jack.
(c) Perform the procedure above on the other side.
ALE047G 20. Connect front suspension lower control arm LH (See
page DT-15)
21. Connect front suspension lower control arm RH
Hint:
Connection of the RH is the same as that of the LH.
23. Install engine hood
24. Inspect engine hood (See page BO-2)
25. Adjust engine hood (See page BO-2)
SP-7)
05-SUSPENSION.indd 25 2008-10-21 8:19:37

REAR SUSPENSION SYSTEM

Wander/pulls
1. Vehicle (Overloaded) -
Bottoming 2. Spring (Weak) SP-30
Sways/pitches
2. Wheel (Out of balance) SP-43
Rear wheel shimmy
Abnormal tire wear
Rear Wheel Alignment

Inspection
1. Inspect tire (See page SP-37)
2. Measure vehicle height (See page SP-7)
Notice:
Before inspecting the wheel alignment, adjust the ve-
hicle height to the specified value.
3. Inspect rear wheel toe-in
A D B Toe-in:
Front A + B: +0°13’ ± 15’
Toe-in (total)
C - D: 3.2 ± 3.0 mm (0.13 ± 0.12 in.)
If the toe-in is not within the specified value, inspect and re-
place the suspension parts as necessary.
C
ALE006G
05-SUSPENSION.indd 26 2008-10-21 8:19:38

SUSPENSION SP-27
4. Inspect camber
(a) Install the camber-caster-kingpin gauge or position the ve-
hicle on the wheel alignment tester.
(b) Inspect the camber.
Camber:
Camber -0°43’ ± 15’
Right-left error 30’ or less
If the measured value is not within the specified value, in-
spect the suspension parts for damage and/or wear. Replace
them as necessary because the camber is not adjustable.
Components
Washer 25 (255, 18)

Rear Shock Absorber Upper Mounting Bush No.1
Rear Shock Absorber Upper Mounting Bush No.2
Rear Coil Spring Upper Insulator
Bush Bracket
Rear Shock Ab- Rear Bumper

Coil Spring Rear RH
sorber Assembly
Rear Shock
RH Rear Coil Spring Upper
Absorber
Dust Cover Insulator
Rear Coil Spring Lower Insulator
Rear Shock
Rear Brake Drum Sub-assembly Absorber Rear Coil Spring LH
Assembly LH
Brake Rear Coil Spring Lower
16 (163, 12) Hose Insulator
l Clip
Rear Axle Hub & Bearing

Assembly RH ×4 50 (510, 38) Brake Hose
Washer
120 (1,223, 89) 50 (510, 38)
Rear Break
l (87 kgf·cm, 48 in.·lbf)
Assembly
×4
Rear Axle Bracket
Bush RH l 80 (816, 60) Washer
Rear Brake Drum
Rear Axle Bracket Bush LH Sub-assembly
Rear Twist Beam
Wheel Speed Sensor Wiring Harness

l Clip
(87 kgf·cm, 71 in.·lbf)

(87 kgf·cm, 48 in.·lbf) 16 (163, 12)

05-SUSPENSION.indd 27 2008-10-21 8:19:38

Rear Shock Absorber Assembly LH

Replacement
Hint:
1. Remove rear absorber cap
3. Remove rear shock absorber assembly LH
(a) Support rear twist beam with a jack.
ALE057G
(b) While holding the piston rod, remove the 2 nuts.

(c) Remove the washer and the rear shock absorber upper
mounting bush No.1 and No.2.
ALE058G
(d) Remove the nut, the washer and the rear shock absorber as-
sembly LH.
(e) Remove the rear bumper and the rear shock absorber dust
cover.
ALE059G
4. Inspect rear shock absorber assembly LH

(a) Compress and extend the shock absorber rod and check that
there is no abnormal resistance or unusual sound during op-
eration.
If there is any abnormality, replace the shock absorber with a
new one.
Caution:
When disposing of the shock absorber, see Disposal on
ALE060G page SP-27.
05-SUSPENSION.indd 28 2008-10-21 8:19:39

SUSPENSION SP-29
5. Install rear shock absorber assembly LH

(a) Install the rear bumper and the rear shock absorber dust cov-
er.
(b) Install the shock absorber, the rear shock absorber upper
mounting bush No.1 and No.2 and the washer on the body.
(c) While holding the piston rod, install the lower nut so that the
piston rod protrudes 15 to 18 mm (0.591 to 0.709 in.) from
the lower nut.
(d) Install the upper nut and tighten it against the lower one.
ALE061G
(e) While lifting the rear twist beam with the jack, install the
shock absorber on the rear twist beam with the washer and
the nut.
ALE059G

7. Inspect rear wheel alignment (See page SP-26)
Disposal
1. Dispose of rear shock absorber assembly LH
(a) Fully extend the shock absorber rod.
40 mm (1.6 in.) 70 mm (2.8 in.)
(b) Using a drill, make a hole in the cylinder as shown in the il-
lustration to discharge the gas inside of it.
Caution:
• Be careful when drilling because shards of metal
may fly about, so always use the proper safety
equipment.
ALE062G • The gas is colorless, odorless and non-poisonous.
05-SUSPENSION.indd 29 2008-10-21 8:19:39

Rear Coil Spring LH

Replacement
Hint:
2. Separate wheel speed sensor wiring harness
(a) Disconnect the wheel speed sensor connector.
(b) Remove the bolt and separate the wheel speed sensor wiring
harness from the rear twist beam.
Hint:
Separation of the RH is the same as that of the LH.
ALE063G
3. Separate rear brake tube No.4

(a) Using SST, separate the rear brake tube No.4.
SST SST 09023-00100
(b) Remove the clip.
Notice:
The clip should not be reused.
SST 09023-00100
ALE064G Hint:
Disconnection of the rear brake tube No.3 is the same as that
of the rear brake tube No.4.
5. Separate parking brake cable assembly LH
(a) Remove the nut and disconnect the parking brake cable as-
sembly LH from the rear twist beam.
6. Separate parking brake cable assembly RH
Hint:
Separation of the parking brake cable assembly RH is the
same as that of the parking brake cable assembly LH.
ALE065G
7. Loosen rear twist beam assembly

(a) Loosen the 2 bolts.
ALE066G
05-SUSPENSION.indd 30 2008-10-21 8:19:40

SUSPENSION SP-31
8. Separate rear shock absorber assembly LH

(a) Support the right and left sides of the rear twist beam with
jack.
(b) Remove the nut and the washer, and separate the rear shock
absorber assembly LH.
9. Separate rear shock absorber assembly RH
Hint:
ALE059G 10. Remove rear coil spring LH
(a) Remove the coil spring LH, the upper insulator and the lower
insulator by slowly lowering the jack.
11. Install rear coil spring LH
(a) Install the rear coil spring upper insulator so that its gap fits
to the end of the rear coil spring LH.
ALE067G
(b) Install the rear coil spring lower insulator and the rear coil
spring LH to the rear twist beam.
Notice:
Be sure to install the coil spring so that the paint mark
comes to under the vehicle.
Paint Mark
ALE068G
12. Temporarily tighten rear shock absorber assembly LH

(a) While lifting the jack, install the rear shock absorber assem-
bly LH to the rear twist beam.
(b) Temporarily tighten the nut and the washer.
13. Temporarily tighten rear shock absorber assembly RH
Hint:
ALE059G
05-SUSPENSION.indd 31 2008-10-21 8:19:40

14. Connect parking brake cable assembly LH

(a) Install the parking brake cable assembly LH with the nut.
15. Connect parking brake cable assembly RH
Hint:
ALE065G
16. Connect rear brake tube No.4

(a) Using SST, connect the brake line to the brake hose.
SST SST 09023-00100
(b) Install the clip.
SST 09023-00100
Hint:
ALE064G Connection of the rear brake tube No.3 is the same as that of
the rear brake tube No.4.
18. Connect wheel speed sensor wiring harness
(a) Install the wheel speed sensor wiring harness with the bolt.
(b) Connect the wheel speed sensor wiring harness.
Hint:
ALE063G
19. Fully tighten rear twist beam assembly

(a) Stabilize the shock absorber assembly.
If the bolt cannot be tightened at this position, support the
rear twist beam with the jack and load the rear compartment
with a mass of approximately 90 kg (198 lb.).
Length of shock absorber: 250 mm (9.8 in.)
(b) Fully tighten the bolt.
ALE069G 20. Fully tighten rear shock absorber assembly LH
(a) Fully tighten the nut.
21. Fully tighten rear shock absorber assembly RH
Hint:
Installation of the RH is the same as that of the LH.
22. Bleed brake line (See page BR-5)
25. Check ABS speed sensor signal
05-SUSPENSION.indd 32 2008-10-21 8:19:41

SUSPENSION SP-33
Rear Twist Beam Assembly

Replacement
Hint:
2. Separate wheel speed sensor wiring harness (See
page SP-30)
3. Separate rear brake tube No.4 (See page SP-30)
SST 09023-00100
SST 09023-00100
Hint:
Disconnection of the rear brake tube No.3 is the same as that
of the rear brake tube No.4.
5. Separate parking brake cable assembly LH (See page
SP-30)
6. Separate parking brake cable assembly RH
Hint:
7. Remove rear brake drum sub-assembly
8. Remove rear axle hub & bearing assembly LH
(a) Remove the nut and separate the parking brake cable assem-
bly LH from the rear twist beam.
ALE065G
(b) Remove the 4 bolts and the rear axle hub & bearing assembly
LH.
(c) Separate the rear brake assembly from the rear twist beam.
ALE070G
9. Remove rear axle hub & bearing assembly RH

Hint:
10. Loosen rear twist beam assembly
11. Separate rear shock absorber assembly LH (See page
SP-31)
05-SUSPENSION.indd 33 2008-10-21 8:19:41

12. Separate rear shock absorber assembly RH

Hint:
13. Remove rear coil spring LH (See page SP-31)
14. Remove rear coil spring RH
Hint:
15. Remove rear twist beam assembly
(b) Remove the 2 bolts and the rear twist beam.
ALE066G
16. Remove rear axle bracket bushing LH

(a) Using a chisel and a hammer, bend the 2 portions of the
bushing rib.
Hint:
Bend the bushing rib until the claw of SST can be hung.
(b) Using SST, remove the bushing from the rear twist beam.
SST
Bend Portions
SST 09309-37010, 09950-40011 (09951-04010,
09952-04010, 09953-04010, 09954-04020,
ALE071G 09955-04051, 09957-04010, 09958-04011)
Notice:
If the rear twist beam has been scratched, apply the
paint.
17. Remove rear axle bracket bushing RH
SST 09309-37010, 09950-40011 (09951-04010,
09952-04010, 09953-04010, 09954-04020,
09955-04051, 09957-04010, 09958-04011)
Hint:
18. Install rear axle bracket bushing LH
Front (a) Position the rear axle bracket bushing LH with the rear twist
beam as shown in the illustration.
7.2° ± 3°
ALE072G
05-SUSPENSION.indd 34 2008-10-21 8:19:41

SUSPENSION SP-35
(b) Using SST, install the bushing on the rear twist beam.
Rubber SST 09710-14013 (09710-00021), 09950-40011
SST Portions (09951-04010, 09952-04010, 09953-04030,
09954-04020, 09955-04031, 09957-04010,
09958-04011), 09950-60010 (09951-00560)
Notice:
• Hang the claw of SST to the bushing deeply and
SST firmly.
ALE073G • Do not scratch the rubber portion of the bushing.
• Do not deform the bushing rib.
19. Install rear axle bracket bush RH
SST 09710-14013 (09710-00021), 09950-40011
(09951-04010, 09952-04010, 09953-04030,
09954-04020, 09955-04031, 09957-04010,
09958-04011), 09950-60010 (09951-00560)
Hint:
20. Temporarily tighten rear twist beam assembly
(b) Install the rear twist beam, and temporarily tighten the 2
bolts.
21. Install rear coil spring LH (See page SP-31)
22. Install rear coil spring RH
Hint:
ALE066G 23. Temporarily tighten rear shock absorber assembly LH
24. Temporarily tighten rear shock absorber assembly RH
Hint:
25. Install rear axle hub & bearing assembly LH
(a) Install the rear brake assembly and the rear axle hub & bear-
ing assembly LH with the 4 bolts.
26. Install rear axle hub & bearing assembly RH
Hint:
27. Install rear brake drum sub-assembly
ALE070G 28. Adjust rear drum brake shoe clearance (See page
BR-33)
29. Connect parking brake cable assembly LH (See page
BR-50)
30. Connect parking brake cable assembly RH
Hint:
31. Connect rear brake tube No.4 (See page SP-32)
SST 09023-00100
05-SUSPENSION.indd 35 2008-10-21 8:19:42


SST 09023-00100
Hint:
Connection of the rear brake tube No.3 is the same as that of
the rear brake tube No.4.
33. Connect wheel speed sensor wiring harness (See page
SP-32)
34. Fully tighten rear twist beam assembly
35. Fully tighten rear shock absorber assembly LH (See
page SP-32)
36. Fully tighten rear shock absorber assembly RH
Hint:
Tightening of the RH is the same as that of the LH.
05-SUSPENSION.indd 36 2008-10-21 8:19:42

SUSPENSION SP-37
TIRE AND WHEEL

Tire
Instruction
This model uses tubeless tire. It is the best designed state when the inflation pressure reaches the recommended value,
and the tire’s load reaches the full load state. Proper tire pressure and proper driving habits affects the longevity of the
tire greatly. This not only realizes the ride comfort, stability and maneuverability of the vehicle, but also reduces tread
wear, extends the tire life and avoids damaging the tire. Overload, overspeed and unnecessary emergency braking can
all speed up the tire wear.
The pressure is too high, and the The tire pressure is normal The tire pressure is too low, and the
tread center worn tire shoulder worn
ALE074G
The measurement of the tire pressure should be done in normal temperature. The tire pressure will rise due to heat
produced by movement while driving, and will return to normal after it cools, so do not bleed the tire when the pres-
sure is high. Even the tire is used in normal condition, the pressure also naturally decreases slowly. So the pressure
should be checked periodically (once a month is suitable). The spare tire should be available at any time. The recom-
mended inflation pressure of this model is the result of careful calculations. The tire pressure should be checked in
cold tire status. And adjust the pressure to specified value. Checking the tire pressure at least once a month or every
time before long-distance travel is recommended, including spare tire.
Tire inflation
Due to the heat produced by movement, the size of new tire may
increase in early using time, thus make the relative pressure de-
crease. So the tire has to be inflated after it is used for 24 hours or
tracks 2000 ~ 3000 km.
(a) Check whether the tire inflation pressure is normal.
Cold tire inflation pressure:
Front, rear
Tire size
KPa (kgf/cm2, psi)
185/65R15 88H 220 (2.2, 32)
(b) Check the runout of the tire by a dial indicator.
The runout of the tire: 1.4 mm (0.055 in.) or less
ALE075G
05-SUSPENSION.indd 37 2008-10-21 8:19:42

Tire inflation precautions:

1. Be careful when inflating. Observe the barometer until it
reaches the specified value, so as to avoid tire blow-out due
to over-inflation.
2. After the vehicle stops, inflate the tire when it has cooled
down. For the temperature of the tire rises while the vehicle
is traveling, which affects the pressure.
3. Check the valve and the valve core. If the valve core does not
fit the valve well, with the phenomenon of bulge and hollow
or other objection exit, it is inconvenient to measure the pres-
sure and inflate the tire.
4. Take care to inflate cleanly. The inflated air should not con-
tain water and oil, so as not to make the rubber seal deterio-
rate and damage.
5. The air should not be bled after the specified pressure is ex-
ceeded too much. and it should not be over-inflated due to
staying out for a long time. Exceeding the specified value too
much will make the cords over-extending, which causes its
strength reduce, and affects the longevity of the tire.
6. Wipe the dust on the valve and do not loose the valve core
before inflation. Apply suds to the valve after inflation, and
check for leakage (Air bubbles will be produced if there has
leakage.), and match all the valve caps and install them tight-
ly to avoid the dust entering inside the valve.
7. The barometer both in-vehicle or used in tire repair shop
should be calibrated periodically to ensure the checking is
exact.
Malfunction that the tire pressure could cause:

Higher than recommended Lower than recommended The same axle has
pressure pressure different pressures
Possible 1. Bumpily driving 1. The tire makes noise when 1. Braking unbalanced;
malfunction 2. Tire scratched or tire turning; 2. Turning is ahead;
body broken 2. Could not turning nimbly 3. Operation fails;
3. Tire center tread broken 3. The edge of the tread wear 4. Deflection when accel-
fast. faster and not uniformly; erating.
4. The tire rim is scratched or
broken;
5. The tire cords is broken;
6. The tire temperature is
high;
7. Operation fails;
05-SUSPENSION.indd 38 2008-10-21 8:19:42

SUSPENSION SP-39
Tire and wheel (steel) assembly instructions

Align the radiation shape hard component of the tire (high point)
with the minimum radius of the wheel (low point) when assem-
bling the tire and wheel. The “high point” of the tire is marked
with the paint point on external side of the tire at the beginning.
This paint point will be washed off. The “low point” of the tire
is marked with the paint point on wheel flange at the beginning.
A line should be marked on the tire and wheel to ensure that the
tire and wheel are assembled on the same place before removal,
if the paint point cannot be found on the tire. Whenever to install
the tire, it needs redo the dynamic balance of the tire and wheel to
ensure the driving stability. For assembling of common tire, pay
attention to the following points:
1. Pay attention that the specification of the tire and the rim are
matched. And there should be no distortion, rust, crack and
breach, etc., otherwise it may cause damage to the tire.
2. It should be kept clean when installing the rim to the tire. It
may cause the tire heating partially if hard objects such as
sand, scrap iron, etc. entered the tire.
3. Do not assemble tire with different specification and pattern
on the same vehicle, otherwise it may cause unevenly worn.
4. Pay attention to protect the valve when removing the tire,
and make sure the valve core is well and clean.
5. Eliminate the stones, hard objects or other sharp objects to
avoid damage to the tire.
6. The cracking and cut on tire tread, tire shoulder and tire side
should be renewed and repaired. If the damage parts cannot
be repaired in time, it will result in severe damage to the tire.
It will affect the ride comfort, maneuverability, calibration of
odometer, ground clearance of the vehicle, and clearance of
tire or snow tire chains to body and chassis, if use tires with
other size or type. A set of new tire installed to the same axle
is recommended. If only one tire is needed to be replaced, it
should match a tire that is closed to the original one to make
the braking and traction balanced.
Caution:
Do not use tires of different structures at same time,
such as the radial tire and the bias tire, etc., except in
an emergency. If different kinds of tires are used to-
gether, the vehicle maneuverability and stability will be
severely affected and may cause the vehicle to be out
of control.
05-SUSPENSION.indd 39 2008-10-21 8:19:42

A Tire abnormal wear

There are a lot of reasons that cause this phenomena, that is the
abnormal wear of the tire, including abnormity wear and fast wear,
such as abnormal tire pressure, lacking periodic tire rotation, pool
B driving habit and abnormal front wheel alignment, etc.
Please replace the tire when the phenomenon listed
below occur:
1. When the wear is different between front and rear tire.
ALE076G
2. When uneven wear exists on any of the tread.
3. When the wear is different between left and right front tire.
4. When the wear is different between left and right rear tire.
5. When the tire tread is abnormally worn and the tire to ground
point is flattened.
Check the front wheel alignment when the phenom-
enon below occur:
1. When the wear is different between left and right front tire.
2. When uneven wear exists on any of the tire tread.
3. When the vein strips or vein blocks on the single surface of
front wheel is severe wear.
A: Hard turning, shortage of pressure or lack of periodic tire ro-
tation.
B: Front wheel alignment is abnormal, or the structure of the
tire or wheel is not unified.
Wear mark
Some wear marks are evenly distributed in the grooves of the tire
veins (as shown in the left illustration A). These marks show that
the tire must be replaced. The usage limitation of the tire means
A that the remaining depth of the vein reaches 1.6 mm (That is flush
with the main vein groove). Replace the tire before it happens for
your safety. Stop using when the cord layer is revealed by severe
wear, or the depth of the damage reaches the cord layer or metal
ALE077G strip layer.
Radial tire swing

The swing means the front or back of the vehicle or the front and
back of the vehicle oscillate to both sides at the same time. The
reason of the tire swing is that the tire bead is not straight. The
most obvious case may occurs when the vehicle is driven at a
speed of (8 ~ 48) km/h. The malfunction tire can be found by road
test of the vehicle. If the malfunction exists in the back side, the
back of the vehicle will swing left and right (Or it can be called
ALE078G “swing”). The driver will feel that someone is pushing the vehicle
in one side at the time. The swing will be more obvious, if the
malfunction is in the front side.
05-SUSPENSION.indd 40 2008-10-21 8:19:43

SUSPENSION SP-41
Vehicle road test

1. Driving the vehicle, and find out whether the swing happens
in the front wheel or the back wheel. Then replace the normal
wheel (That has been verified in other vehicle with the same
model) in the place where the swing happened.
2. Replace the rear wheel if cannot distinguish which wheel
swings. Continue road testing, and re-install the original
wheels if the condition improved obviously, replacing one
each time, until the wheel which causes swing is found.
3. Replace four normal tires, if there is no obvious improve-
ment. Then check one by one using the method described
above.
Front
Tire rotation
Rotate the tire periodically as specified to ensure even wear. The
rotation principle as shown in the left illustration. Radial tire
should be rotated periodically, and inflated as specified.
Caution:
The shoulder of the radial tire, especially the front tires, usu-
ally worn faster due to the structure reason. Tire rotation
is done once when driving (8000 ~ 12000) km, which can
ALE079G make the life of the tires increased by 20%. It makes the pe-
riodic tire rotation much necessary.
Adjust the tire pressure to the

specified value
Take road test in a straight level road

back and forth
Exchange the front tires, then take the

road test described above.
Swing to the Has been corrected, if it is valid, replace Swing to

same direction the tire another direction
Install the tire to its original

Replace a “well performed
place and detect the front
tire” in the front part
wheel rotation
Has not been corrected, re-

Has been corrected, place a “well performed tire”
replace the tire in another side of front part
Has not been corrected,

Has been corrected,
indicating that the “well
replace the tire
performed tire” is not good
ALE080G
05-SUSPENSION.indd 41 2008-10-21 8:19:43

Reasons for drift

• Incorrect tire and front wheel alignment.
• Uneven brake force.
• Tire structure problems.
Tire manufacturing methods will also cause the vehicle drift.
For example, the collocation of wire ties inside the tire. The
wire ties, which is on the center line of the drift tire in radial tire,
generates lateral force, while the tire rolling straightly. If the tire
diameter at one side is more than that at the other side, the tire
will drift one side. Thus generates lateral force (That is taper ef-
fect force) will also cause vehicle drift. If the front wheel is
aligned, the above procedure is also suit for tire drift judg-
ment. The tires of rear wheel will not cause drift.
Tire installation and removal
• Use a tire changer to install or remove tires. Follow the instruc-
tions of the machine instruction manual when operating the
machine. Do not replace the tires with the manual tools or crow
(for tire removal and installation), thus will damage the tire
edge or wheel rim.
• The grease, old rubber and light rust on the edge base of rim
bead must be cleaned with wire brush or thick wire cotton. The
edge part must be thoroughly lubricated first with specified tire
lubricant before installing or removing the tire.
• After installation, inflate to the specified pressure and check if
the bead is placed fully.
Caution:
Do not over-inflate the tire. When the bead expansion ex-
ceeds the safety limits of the rim, the bead may crack, and
lead to a serious injury. Do not exceed the specified pres-
sure when inflating. If the specified pressure cannot make
the bead fixed properly, bleed air, then lubricate and
inflate again.
How to use spare tire

• The standard inflation pressure of the tire is 420 kPa.
• The measurement of the spare tire should be done in normal
temperature.
• After inflate the spare tire, check for air leaks with soapy water
and tighten valve core cap.
• The spare tire should be available at any moment, and check
the tire pressure at least once a month.
ALE081G • The usage limit is that the remaining depth of the vein reaches
1.6 mm, stop using it when the cord layer is revealed by severe
wear, or the depth of the damage reaches the cord layer or met-
al strip layer.
05-SUSPENSION.indd 42 2008-10-21 8:19:46

SUSPENSION SP-43
Caution:
• The setting location of wear indication is shown by “△” on
the edge of the spare tire (as shown in the illustration).
• The highest speed of the spare tire is 80 km/h, and the
longest distance for one driving is 200 km.
• Each vehicle can only use one spare tire.
• Spare tire is only for temporary use, please have the main
tires repaired or replaced in professional repair shop.
ALE082G
Wheel
General balance procedures
Clean the dirt, etc. that existed in the inner side of the rim.
Caution:
The small stones in the tread must be removed to avoid
flying off when balance rotating, doing this can gain good
balance. The damage condition of the tire must be checked
carefully, then do the balance work according to the sugges-
tion of the balance device manufacturer.
Off-the-car balance
Most of the off-the-car-balancers are more accurate than the on-
the-car-rotating-balancers. It is easy to use and dynamic (two
sides) balance can be performed. Although they do not correct
the imbalance of the brake drum or brake disc as the on-the-car-
balancers, they can overcome this deficiency by its accuracy.
On-the-car balance
On-the-car-balance is different according to the equipment and
tool manufacturer. So, always follow the instructions of each man-
ufacturer when performing the balance work.
Caution:
The vehicle speed should be controlled in 55 km/h, which
displays on speedometer. This limit is necessary, for speed-
ometer only displays half of the real wheel speed, when
one driving wheel skids and the other holds still. Be careful
when the wheel skids, because the skid wheel may reach a
extremely high speed. Thus may cause the tire peeled off or
the differential damaged, and lead to a serious injury or seri-
ous vehicle damage.
05-SUSPENSION.indd 43 2008-10-21 8:19:46

Dynamic balance and static balance

[A] [B] 2 There are two types of the wheel balance: dynamic and static bal-
ance. Diagram 1 is static balance, and diagram 2 is dynamic bal-
ance. Static balance is that all the weight distribution surrounding
the wheels are equal. If the wheel is static imbalance, it may lead
to up and down runout, which is called jump vibration. This case
3
will result in uneven wear of the tire at last, Take diagram 1 for
1
Diagram 1 example.
ALE083G
1. Wheel runout point [A]: Without wheel weight
2. With wheel weight [B]: With wheel weight
3. Axes center
Dynamic balance is that all the weight distribution on the two
[C] [D] 2 sides of the wheel center are equal, so that the assembly will not
produce a tendency from center side to another side while the tires
spinning. If the wheels are imbalanced in dynamic, it will lead to
swing vibration, Take diagram 2 for example.
1. Wheel swing vibration point [A]: Without wheel weight
2. Wheel weight location [B]: With wheel weight
3
1 3. Axes center
Diagram 2
ALE084G
Ways to detect the wheel dynamic balance are as

follows:
1. Clean the wheels that will be detected, get rid of the dirt,
sand stones, and remove the used weight.
2. Inflate the wheels to specified value.
3. Install the wheel to the balancer, and tighten it up.
4. Turn the power switch on, and check if the indication device
indicates right.
ALE085G
5. Key in the rim diameter, width, and measure the distance
from the rim edge to the box and key in the value.
6. Set down the protector, press the start key and begin to mea-
sure.
7. Read out the mass and location of inner and outer wheel dy-
namic imbalance from the indication device when the wheel
stops rotating automatically.
8. Turn the wheel with your hand slowly, and stop turning the
wheel when the dynamic balancer indication device sends a
signal.
9. Place the dynamic imbalance mass, which is displayed on
dynamic balancer, on the right top of the rim edge, according
to the inner and outer location, and fix it securely.
10. Restart the dynamic balancer, and perform the dynamic bal-
ance test until the dynamic imbalance mass is less than 5 g
(The machine displays it is qualified).
05-SUSPENSION.indd 44 2008-10-21 8:19:47

SUSPENSION SP-45
11. Remove the wheel, and turn the power switch off, then the
test is finished. The operation is different when using the
dynamic balancer of different sizes and brands, so read the
instruction manual carefully before using.
Wheel repair
To repair the wheel with welding, heating or hammering is not
allowed. All the wheels damaged must be replaced. It must be
replaced when the wheel has the following troubles: distortion,
hollow, bigger lateral or radial runout, gas leakage from the joint,
bolt hole is elongated, nut with cap cannot be locked tightly, or
heavy rust. When the wheel has excessive runout, it will generate
bad vibration. The new wheel should be the same as the original
wheel in load capacity, diameter, rim depth, setover and installa-
tion structure. If the size and type of the wheel is not suitable, it
will affect the longevity of the wheels and bearing, effect of brak-
ing and cooling, calibration of speed/odometer, ground clearance
of wheels and clearance of tires with body, chassis, etc.
Wheel removal (steel wheel)

1. Remove the wheel house and loosen the nut, one or two turns
is suitable.
2. Lift up the vehicle.
3. Screw off the nut, and remove the wheel.
Nut tighten torque: (110 ± 10) N·m
Caution:
Never loose the tightened wheel by heating, or the lon-
ALE086G gevity of the wheel may be shortened by heating and
the hub bearing may be damaged.
Wheel installation (steel wheel)

B A The installation is in the reverse order, and performing according
to the following requirements:
The wheel nut must be tightened to the specified torque in order
to avoid distortion of the wheel or brake disc. Align the hole of
the wheel cover with the inflating valve when installing the wheel
C D cover. Tighten order: A-C-B-D
Caution:
ALE087G Wipe the corrosion layer on the wheel’s installation surface
and brake drum or brake disc surface with a wire brush
before installing the wheel. So that there is well contact
between the metals on the installation surface when install-
ing the wheel, or the wheel nuts may loose, and cause the
wheel break off while driving.
05-SUSPENSION.indd 45 2008-10-21 8:19:47

MEMO
05-SUSPENSION.indd 46 2008-10-21 8:19:47

BR-
BRAKE
BRAKE SYSTEM
Parts Location................................................................... BR-2
Precaution......................................................................... BR-3
Problem Symptoms Table................................................. BR-3
Brake Fluid........................................................................ BR-5
Brake Pedal Sub-assembly............................................... BR-9
Brake Master Cylinder Sub-assembly............................... BR-13
Vacuum Booster Assembly............................................... BR-16
Front Brake ...................................................................... BR-21
Rear Brake........................................................................ BR-27
ABS Brake System........................................................... BR-34
ABS Controller Assembly.................................................. BR-38
Front Speed Sensor LH.................................................... BR-41
Rear Speed Sensor LH..................................................... BR-42
PARKING BRAKE SYSTEM BR

Parts Location................................................................... BR-44
Problem Symptoms Table................................................. BR-44
Adjustment........................................................................ BR-45
Parking Brake Handle....................................................... BR-46
Parking Brake Cable Assembly LH................................... BR-48
06-BRAKE.indd 1 2008-10-21 8:17:59

BR- GREAT WALL COOL BEAR REPAIR MANUAL
BRAKE SYSTEM
Parts Location
Front Brake Assembly LH Front Brake Assembly RH
Front Speed Sensor Front Speed Sensor Assembly RH

Assembly LH
Brake Pedal Sub-assembly
Brake Line Assembly
Parking Brake Handle
Parking Brake Cable

Assembly RH
Parking Brake Cable Assembly LH
Rear Speed Sensor

Rear Speed Sensor Assembly RH
Assembly LH
Rear Brake Assembly RH

Rear Brake Rear Brake Assembly LH
Drum
ALF001G
06-BRAKE.indd 2 2008-10-21 8:17:59

BRAKE BR-
Precaution
• Care must be taken to replace each part properly as it could affect the performance of the brake system and result
in a driving hazard. Replace the ones with parts having the same part numbers or equivalent.
• It is very important to keep the parts and the working area clean when repairing the brake system.
• If the vehicle is equipped with a mobile communication system, refer to the precaution in the INTRODUCTION
section.

Hint:
Refer to the table below to help find the cause of the problem. The numbers indicate the priority of the possible cause
of problem. Check each part in the order. If necessary, replace these parts.
1. Fluid leaks in brake system -
2. Air in brake system BR-5
3. Piston seal (Worn or damaged) BR-23
4. Fluid lacks severely in brake reservoir -
Low pedal position or spongy pedal
5. Brake shoe clearance (Out of adjustment) BR-33
6. Brake master cylinder (Faulty) BR-13
7. Booster push rod (Out of adjustment) BR-14
8. Brake pedal free play (Maximal) BR-10
1. Brake pedal free play (Minimal) BR-10
2. Parking brake lever travel BR-45
(Out of adjustment)
3. Parking brake cable (Sticking) -
4. Brake shoe clearance (Out of adjustment) BR-33
5. Brake pad (Cracked or distorted) -
6. Brake shoes (Cracked or distorted) -
Brake drag
7. Disc brake piston (Stuck) BR-23
8. Rear wheel brake cylinder piston (Stuck) BR-30
9. Brake drum (Out-of-round) -
10. Tension or return spring (Damaged) BR-29
12. Vacuum leaks in booster system -
13. Brake master cylinder (Faulty) BR-13
1. Disc brake piston (Stuck) BR-23
2. Rear wheel brake cylinder piston (Stuck) -
3. Brake pad (Oily) -
4. Brake shoes (Oily) -
Brake pull
5. Front wheel alignment (Out of alignment) SP-7
6. Brake disk (Scored) -
7. Brake drum (Scored) -
06-BRAKE.indd 3 2008-10-21 8:17:59

1. Fluid leaks in brake system -

2. Air in brake system BR-5
3. Brake pad (Worn) -
4. Brake shoes (Worn) -
Brake inefficiency 6. Brake shoe clearance (Out of adjustment) BR-33
7. Brake pad (Oily) -
8. Brake pad (Glazed) -
11. Vacuum leaks in booster system -
2. Mounting bolt (Loose) -
4. Brake pad snap spring plate (Loose) BR-22
5. Brake guide pin (Worn) -
Brake noise 6. Brake pad (Dirt) -
7. Brake pad (Glazed) -
8. Brake guide pin, return spring or tension BR-32
spring (Damage)
9. Anti-squeal shim (Damage) BR-26
10. Brake shoe hold-down spring (Damage) BR-29
06-BRAKE.indd 4 2008-10-21 8:17:59

BRAKE BR-
Brake Fluid
Bleeding
Hint:
If any work is performed in the brake system or if air in the brake
lines is suspected, bleed the air out of the brake system.
Notice:
Wash the brake fluid off immediately if it adheres to any
painted surfaces.
1. Fill reservoir with brake fluid

Brake fluid: DOT4 synthetic brake fluid
Hint:
The level of brake fluid in the reservoir should be between
the MIN and MAX lines.
ALF002G
2. Bleed master cylinder

Hint:
If the master cylinder has been disassembled or if the reser-
voir becomes empty, bleed the air out of the master cylinder.
Two people are needed to work when bleeding master cylin-
der.
(a) Disconnect the brake lines from the master cylinder.
SST 09023-00100
ALF003G (b) Slowly depress and hold the brake pedal.
(c) Plug up the outer holes with your fingers, and release the
brake pedal.
(d) Repeat (b) and (c) 3 or 4 times.
(e) Connect the brake lines to the master cylinder.
SST 09023-00100
ALF004G
3. Bleed brake line

(a) Connect plastic tube to the bleeder screw.
(b) Depress the brake pedal several times, then loosen the bleed-
er screw with the pedal depressed.
(c) When brake fluid stops coming out, tighten the bleeder
screw, then release the brake pedal.
(d) Repeat (b) and (c) until all the air in the brake fluid is com-
ALF005G pletely bled out.
06-BRAKE.indd 5 2008-10-21 8:18:00

(e) Repeat the above procedures to bleed the air out of the brake
line for each wheel.
4. Bleed ABS controller
Notice:
After performing the usual air bleeding in the brake sys-
tem, if the height or feel of the brake pedal cannot be
obtained, bleed ABS controller assembly with the hand-
held tester by following the procedures below.
(a) Depress the brake pedal more than 20 times with the engine
off.
(b) Connect the hand-held tester to the DLC3, then turn the igni-
tion switch on.
Notice:
Do not start the engine.
Hand-held Tester (c) Select AIR BLEEDING on the hand-held tester.
Hint:
Please refer to the Hand-held Tester Operator’s Manual for
further details.
(d) Bleed the air out of the brake line with “Step1: Increase” on
the hand-held tester display.
Notice:
• Bleed out the air by following the steps displayed
DLC3
ALF006G on the hand-held tester.
• Never empty the brake fluid in the master cylinder
reservoir.
(1) Connect plastic tube to the bleeder screw.
(2) Depress the brake pedal several times, then loosen the
bleeder screw with the brake pedal depressed.
(3) When brake fluid stops coming out, tighten the bleeder
(4) Repeat (2) and (3) until all the air in the brake fluid is
completely bled out.
(5) Repeat the above procedures to bleed the air out of the
ALF005G brake line for each wheel.
(e) Bleed the air out of the suction line with “Step 2: Inhalation”
on the hand-held tester display.
Notice:
on the hand-held tester.
reservoir.
(1) Connect the plastic tube to either one of the bleeder
screws at the right front wheel or the right rear wheel
and loosen the bleeder screw.
(2) Operate the ABS controller assembly by using the
hand-held tester to bleed the air.
06-BRAKE.indd 6 2008-10-21 8:18:00

BRAKE BR-
Notice:
• The operation stops automatically in 4
seconds.
• At this time, be sure to release the brake
pedal.
(3) Check that the operation stops by using the screen of
the hand-held tester.
(5) For the rest of the wheels, bleed the air in the same way
as stated in the above procedures.
(f) Bleed the air out of the pressure reduction line with “Step 3:
Decrease” on the hand-held tester display.
Notice:
reservoir.
screws.
(2) Loosen the bleeder screw
(3) Operate the ABS controller assembly by using hand-
held tester, completely depress the brake pedal and keep
depressing it.
Notice:
• The operation stops automatically in 4 sec-
onds. When performing this procedure con-
tinuously, an interval of at least 20 seconds is
required.
• When the operation is completed, the brake
pedal slightly goes down, this is a normal phe-
nomenon when the solenoid valve opens.
• During this procedure, the pedal seems heavy,
but completely depress it so that the brake
fluid comes out from the bleeder screw.
• Be sure to keep depressing the brake pedal.
Never depress and release the pedal repeat-
edly.
(4) Tighten the bleeder screw, then release the brake pedal.
(6) Repeat the above procedures to bleed the air out of the
brake line for each wheel.
(g) Bleed the air out of the brake line again with “Step 4: In-
crease” on the hand-held tester display.
06-BRAKE.indd 7 2008-10-21 8:18:00

Notice:
reservoir.
screws.
(2) Depress the brake pedal several times, then loosen the
bleeder screw of one of the above wheels with the pedal
depressed.
(3) When brake fluid stops coming out, tighten the bleeder
ALF005G (5) Repeat the above procedures to bleed the air out of the
brake line for each wheel.
5. Check fluid level in reservoir
(a) Check the fluid level and add brake fluid, if necessary.
Brake Fluid: DOT4 synthetic brake fluid
ALF002G
06-BRAKE.indd 8 2008-10-21 8:18:01

BRAKE BR-

Components
21 (214, 15)
Brake Lamp Switch Assembly

23 (235, 17)
Brake Pedal Bracket Sub-assembly
Brake Lamp Switch
Lock Nut
26 (265, 19)
Brake Pedal
Return Spring
23 (235, 17) 23 (235, 17)
l
l Brake Pedal Bush
Brake Pedal
Shaft
Pin Clevis
Brake Lamp
Switch Pad
37 (375, 27)
Lock Pin
Brake Pedal Pad
Non-reusable part
Grease
ALF007G
06-BRAKE.indd 9 2008-10-21 8:18:01

BR-10 GREAT WALL COOL BEAR REPAIR MANUAL
Adjustment
Brake Lamp Switch Assembly 1. Check and adjust brake pedal height
(a) Check brake pedal height.
Pedal height from dash panel:
120 to 130 mm (4.800 to 5.200 in.)
(b) Adjust brake pedal height.
Push (1) Remove the instrument panel lower shield.
Rod
(2) Disconnect the connector from the brake lamp switch
assembly.
Pedal Height
ALF008G (3) Loosen the brake lamp switch lock nut, and remove the
brake lamp switch assembly.
(4) Loosen the brake master cylinder push rod clevis lock
nut.
(5) Adjust the pedal height by turning the pedal push rod.
(6) Tighten the push rod lock nut.
(7) Install brake lamp switch assembly.
(8) Connect the connector to the brake lamp switch assem-
bly.
(9) Push the brake pedal in 6 to 9 mm (0.24 to 0.36 in.),
and turn the brake lamp switch assembly to lock the nut
in the position where the brake lamp goes off.
(10) After the installation, push the brake pedal in 6 to 9 mm
(0.24 to 0.36 in.), and check that the brake lamp comes
on.
2. Check 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.
(b) Depress the brake pedal until the resistance begins to be felt,
and then measure the distance as shown in the illustration.
Pedal free play: 6 to 9 mm (0.24 to 0.36 in.)
If the clearance is not as specified, check the brake lamp
Pedal Free Play switch clearance.
ALF009G If the clearance is OK, then troubleshoot the brake system.
brake lamp switch clearance:
0.5 to 2.4 mm (0.020 to 0.094 in.)
3. Check pedal reserve distance
(a) Release parking brake handle.
With the engine running, depress the pedal and measure the
pedal reserve distance as shown in the illustration.
Pedal reserve distance from dash panel at 490 N (50 kgf, 110
lbf): More than 55 mm (2.17 in.)
If the reserve distance is not as specified, troubleshoot the
Pedal Reserve brake system.
Distance ALF010G
06-BRAKE.indd 10 2008-10-21 8:18:01

BRAKE BR-11
Replacement
2. Remove instrument panel body (See page IR-31)
3. Separate master cylinder push rod clevis
(a) Disconnect the brake lamp switch connector.
(b) Remove the brake pedal return spring.
Brake Pedal
Return Spring (c) Remove the lock pin and the pin clevis and separate the
master cylinder push rod clevis from the brake pedal sub-
assembly.
Lock Pin
Pin Clevis
ALF011G
4. Remove brake pedal bracket assembly

Brake Pedal Bracket
(a) Remove the bolt from the brake pedal bracket assembly.
Instrument Panel
Reinforcement
Member
ALF012G
(b) Remove the 4 nuts and the brake pedal bracket assembly.
5. Remove brake pedal sub-assembly
(a) Remove the brake pedal shaft and the nut from the brake
pedal bracket sub-assembly.
(b) Remove the brake pedal sub-assembly and the 2 bushes.
6. Remove brake lamp switch assembly
(a) Loosen the brake lamp switch lock nut.
(b) Remove the brake lamp switch assembly from the brake
ALF013G pedal bracket sub-assembly.
7. Brake pedal pad
(a) Remove the brake pedal pad from the brake pedal bracket
sub-assembly.
8. Install brake pedal pad
(a) Install the brake pedal pad to the brake pedal bracket sub-
assembly.
9. Install brake lamp switch assembly
(a) Install brake lamp switch assembly with the nut.
06-BRAKE.indd 11 2008-10-21 8:18:02

10. Install brake pedal sub-assembly

(a) Apply grease to the ends and sides of 2 new brake pedal
bushes.
(b) Install the brake pedal sub-assembly and the 2 brake pedal
bushes on the brake pedal bracket with the brake pedal shaft
and the nut.
Grease ALF014G
11. Install brake pedal bracket assembly

(a) Install the brake pedal bracket assembly with the 4 nuts.
ALF013G
(b) Install the bolt on the brake pedal bracket assembly.

Brake Pedal Bracket
Instrument Panel
Reinforcement
Member
ALF012G
12. Connect master cylinder push rod clevis

(a) Apply grease to the pin clevis.
(b) Install the pin clevis and the lock pin.
Brake Pedal
Return Spring Notice:
The direction for the lock pin installation is as shown in
the illustration.
(c) Install the brake pedal return spring.
Lock Pin (d) Connect the brake lamp switch connector to the brake lamp
Pin Clevis
ALF011G switch assembly.
13. Install instrument panel body
14. Check and adjust brake pedal height (See page BR-10)
15. Check pedal free play (See page BR-10)
16. Check pedal reserve distance (See page BR-10)
17. Inspect SRS warning light (W/SRS airbag)
06-BRAKE.indd 12 2008-10-21 8:18:02

BRAKE BR-13
Brake Master Cylinder Sub-assembly

Replacement
Hint:
Components: See page BR-16
Notice:
painted surfaces.
2. Remove air filter cap sub-assembly
3. Disconnect clutch reservoir tube
(a) Slide the clamp and disconnect the clutch reservoir tube.
4. Remove brake master cylinder
(a) Disconnect the level warning light switch connector.
(b) Using SST, disconnect the 2 brake lines from the brake mas-
ter cylinder.
SST 09023-00100
ALF015G
(c) Remove the 2 nuts, and pull out the brake master cylinder.
ALF016G
5. Remove brake master less reservoir cylinder sub-as-

sembly
(a) Pull out the brake reservoir pin clevis.
ALF017G
06-BRAKE.indd 13 2008-10-21 8:18:03

(b) Remove the brake reservoir and 2 grommets.

Cap
(c) Remove the cap from the brake reservoir.
Brake Reservoir
Grommet
ALF018G
6. Install brake master less reservoir cylinder sub-assembly

Grommet (a) Apply grease to the 2 grommets and install them onto the
brake master less reservoir cylinder.
(b) Install the cap to the brake reservoir.
Brake Master Cylinder

Rectangle Grommet
Grease ALF019G
(c) Install the brake reservoir assembly with the brake reservoir
pin clevis.
Notice:
Install the pin clevis securely to the groove of the reser-
voir and master cylinder.
7. Inspect and adjust vacuum booster push rod
Notice:
Make an adjustment with the vacuum booster assembly
ALF020G having no vacuum. (Depress the brake pedal several
times with the engine stopped)
Hint:
Adjustment of the vacuum booster push rod is performed
when the brake master cylinder sub-assembly is replaced
with a new one. The adjustment is not necessary when the
brake master cylinder sub-assembly is reinstalled and the
vacuum booster assembly is replaced with a new one.
(a) Apply the chalk to the tip of an accessory tool.
Hint:
The accessory tool is enclosed with the new brake master
cylinder sub-assembly.
06-BRAKE.indd 14 2008-10-21 8:18:03

BRAKE BR-15
Accessory Tool (b) Place the accessory tool in the vacuum booster assembly.
(c) Measure the clearance between the vacuum booster push rod
and the accessory tool.
Clearance: 0 mm (0 in.)
Hint:
Adjust the clearance in the following cases:
• If there is a clearance between the accessory tool and the
shell of the vacuum booster (floating accessory tool), and
ALF021G the clearance is too small.
• If the chalk does not stick on the tip of the vacuum
booster push rod, and the clearance is too large.
(d) If the clearance is outside of the specified range, fix the push
rod by using SST and adjust the length of the protruding ad-
justing bolt.
SST 09737-00020
SST
Hint:
When adjusting the push rod, depress the brake pedal suffi-
ciently so that the push rod sticks out.
ALF022G
8. Install brake master cylinder

(a) Install the brake master cylinder to the booster with the 2
nuts.
ALF016G
(b) Using SST, connect the 2 brake lines to the brake master cyl-
inder.
SST 09023-00100
(c) Connect the level warning light switch connector.
9. Connect clutch reservoir tube
(a) Slide the clamp and connect the clutch reservoir tube.
10. Install air filter cap sub-assembly
ALF015G 11. Fill reservoir with brake fluid (See page BR-5)
12. Bleed master cylinder (See page BR-5)
13. Bleed clutch line (See page DT-44)
14. Check fluid level in reservoir (See page BR-8)
15. Check for brake fluid leakage
06-BRAKE.indd 15 2008-10-21 8:18:03


Components
Battery Hook
Air Filter Assembly
Battery Plate
Battery
Plate
Bracket
Cap
Battery Assembly
Vacuum Check Valve Assembly

Battery Carrier
Brake Reservoir
Adjusting Fork
Brake Master Cylinder
ABS Mounting
Bracket Assembly Connector
ALF023G
06-BRAKE.indd 16 2008-10-21 8:18:04

BRAKE BR-17
Good No Good 1. Inspect vacuum booster

(a) Airtightness check.
(1) Start the engine and stop it after 1 or 2 minutes. Depress
the brake pedal several times slowly.
Hint:
If the pedal goes down farthest at the 1st time, but grad-
3rd
2nd ually rises at the 2nd or 3rd time, the booster is airtight.
1st
(2) Depress the brake pedal while the engine is running,
ALF024G and stop the engine with the pedal depressed.
Hint:
If there is no change in the pedal reserve distance after
depressing and holding the pedal for 30 seconds, the
booster is airtight.
(b) Operating check.
AC
C ON
AC
C ON (1) Depress the brake pedal several times with the ignition
L O CK
START
L O CK
switch OFF and check that there is no change in the

START
pedal reserve distance.

(2) Depress the brake pedal and start the engine.
Hint:
If the pedal goes down slightly, the operation is normal.
2. Inspect vacuum check valve
ALF025G (a) Inspect the vacuum check valve.
(1) Slide the clamp and disconnect the vacuum hose.
(2) Remove the vacuum check valve.
(3) Check that there is ventilation from the booster to the
Ventilation No Ventilation
engine, and no ventilation from the engine to the booster.
(4) If any fault is found, replace the vacuum check valve.
ALF026G
06-BRAKE.indd 17 2008-10-21 8:18:04

Replacement
Notice:
painted surfaces.
2. Remove air filter sub-assembly
3. Disconnect clutch reservoir tube
(a) Slide the clamp and disconnect the clutch reservoir tube.
4. Remove brake master cylinder (See page BR-13)
SST 09023-00100
5. Remove battery
6. Remove ABS controller with bracket (See page BR-40)
Vacuum 7. Remove vacuum booster assembly
Hose Clamp (a) Slide the clamp and disconnect the vacuum hose from the
vacuum booster assembly.
Vacuum
Booster
ALF027G
(b) Remove the brake pedal return spring, lock pin and pin clevis.
Push Rod Clevis (c) Loosen the push rod clevis lock nut.
Lock Nut
Brake Pedal
Return Spring
Lock Pin Pin Clevis

ALF028G
(d) Remove the 4 nuts and the push rod clevis.

(e) Pull out the vacuum booster assembly and the gasket.
ALF013G
06-BRAKE.indd 18 2008-10-21 8:18:05

BRAKE BR-19
8. Install vacuum booster assembly

(a) Install the vacuum booster assembly and a new gasket.
(b) Install the vacuum booster assembly with the 4 nuts and the
push rod clevis.
ALF013G
(c) Apply grease to the pin clevis.

(d) Install the lock pin and the pin clevis.
Notice:
Brake Pedal
Return Spring The direction for the lock pin installation is as shown in
Front the illustration.
(e) Install the brake pedal return spring.
Lock Pin
Pin Clevis
Grease ALF029G
Vacuum (f) Connect the vacuum hose to the vacuum booster assembly
Hose Clamp and slide the clamp.
9. Inspect and adjust vacuum booster push rod
Vacuum Notice:
Booster Make an adjustment with the vacuum booster assembly
having no vacuum. (Depress the brake pedal several
times with the engine stopped)
Hint:
ALF027G Adjustment of the vacuum booster push rod is performed
when the brake master cylinder sub-assembly is replaced
with a new one. The adjustment is not necessary when the
brake master cylinder sub-assembly is reinstalled and the
vacuum booster assembly is replaced with a new one.
(a) Apply the chalk to the tip of an accessory tool.
Hint:
The accessory tool is enclosed with the new brake master
cylinder sub-assembly.
Accessory Tool (b) Place the accessory tool in the vacuum booster assembly.
(c) Measure the clearance between the vacuum booster push rod
and the accessory tool.
Clearance: 0 mm (0 in.)
Hint:
Adjust the clearance in the following cases:
• If there is a clearance between the accessory tool and the
shell of the vacuum booster (floating accessory tool), and
ALF021G the clearance is too small.
• If the chalk does not stick on the tip of the vacuum
booster push rod, and the clearance is too large.
06-BRAKE.indd 19 2008-10-21 8:18:05

(d) If the clearance is outside of the specified range, fix the push
rod by using SST and adjust the length of the protruding ad-
justing bolt.
SST 09737-00020
SST
Hint:
When adjusting the push rod, depress the brake pedal suffi-
ciently so that the push rod sticks out.
10. Install ABS controller with bracket (See page BR-40)
ALF022G 11. Install brake master cylinder (See page BR-15)
SST 09023-00100
12. Connect clutch reservoir tube
(a) Slide the clamp and connect the clutch reservoir tube.
13. Install air filter sub-assembly
14. Install battery
15. Fill reservoir with brake fluid (See page BR-5)
18. Bleed clutch line (See page DT-44)
19. Check and adjust brake pedal height (See page BR-10)
20. Check brake pedal free play (See page BR-10)
21. Check brake pedal reserve distance (See page BR-10)
24. Check ABS controller with hand-held tester
06-BRAKE.indd 20 2008-10-21 8:18:05

BRAKE BR-21
Front Brake
Components
Front Disc Brake

Guide Pin
l Guide Pin Dust Cover

Front Disc Brake
88 (900, 65) Cylinder Set Bracket LH
l Guide Pin Dust Cover No.2 Anti-squeal

Shim Brake Pad
88 (900, 65)
No.1 Anti-squeal Shim
No.2 Anti-squeal
Front Disc Brake Shim
Brake Hose
Guide Pin
Front Disc Brake
Bleeder Screw
Union Bolt
8.3 (85, 73 in.·lbf) No.1 Anti-squeal Shim
30 (310, 22)
34 (347, 25)
Front Disc Brake
Cylinder Sub-assembly LH
l Piston Seal
l Copper Gasket
l Piston Dust Cover
Brake Pad Snap Spring Plate
Bleeder Screw Cap
34 (347, 25)
N·m (kgf·cm, ft·lbf) : Specified torque l Set Ring

Non-reusable part
Front Disc Brake Piston
Grease
Disc brake grease
ALF030G
06-BRAKE.indd 21 2008-10-21 8:18:05

Overhaul
Hint:
Overhaul the RH by using the same procedures as those for the
LH.
Notice:
painted surfaces.
3. Remove front disc brake cylinder sub-assembly
(a) Remove the union bolt and the copper gasket from the front
disc brake cylinder sub-assembly, then disconnect the brake
hose.
ALF031G
(b) Hold the front disc brake guide pin, and remove the 2 bolts.
4. Remove front brake pad kit (Pad only)
(a) Remove the brake pad with the anti squeal shims.
5. Remove front anti squeal shim kit
(a) Remove the No.1 anti squeal shim and the No.2 anti squeal
shim from the each pad.
6. Remove front brake pad snap spring plate
(a) Remove the 2 front brake pad snap spring plates from the
ALF032G front disc brake cylinder set bracket.
Front Disc Brake Guide Pin 7. Remove front disc brake guide pin
(a) Remove the 2 front disc brake guide pin from the front disc
brake cylinder set bracket.
ALF033G
8. Remove guide pin dust cover

Front Disc Brake Cylinder Set Bracket (a) Remove the 2 guide pin dust covers from the front disc brake
cylinder set bracket.
Guide Pin Dust Cover

ALF034G
06-BRAKE.indd 22 2008-10-21 8:18:06

BRAKE BR-23
9. Remove front disc brake cylinder set bracket

(a) Remove the 2 bolts and the front disc brake cylinder set
bracket.
ALF035G
10. Remove piston dust cover

(a) Using a screwdriver, remove the set ring and the piston dust
cover.
ALF036G
11. Remove front disc brake piston

(a) Place a shop rug between the front disc brake piston and the
front disc brake cylinder.
(b) Use compressed air to remove the front disc brake piston
from the front disc brake cylinder sub-assembly.
Caution:
Do not place your fingers in front of the piston when us-
Shop Rug ing compressed air.
ALF037G Notice:
Be careful not to spatter the brake fluid.
12. Remove piston seal
(a) Using a screwdriver, remove the piston seal from the front
disc brake cylinder.
Notice:
Do not damage the inner cylinder and cylinder groove.
13. Remove front disc brake bleeder screw
(a) Remove the bleeder screw cap and the front disc brake bleed-
er screw from the front disc brake cylinder sub-assembly.
ALF038G 14. Inspect brake cylinder and piston
(a) Check the cylinder bore and the front disc brake piston for
rust or scoring.
06-BRAKE.indd 23 2008-10-21 8:18:06

15. Inspect pad lining thickness

(a) Using a ruler, measure the pad lining thickness.
Standard thickness: 11.0 mm (0.433 in.)
Minimum thickness: 8.5 mm (0.039 in.)
16. Inspect front brake pad snap spring plate
(a) Inspect the 2 front brake pad snap spring plates. Make sure
that they have sufficient rebound, no deformation, cracks or
wear, and have had all rust, dirt and foreign matters cleaned
ALF039G off.
17. Inspect disc thickness

(a) Using a micrometer, measure the disc thickness.
ALF040G

Matchmarks
(a) Place matchmarks on the brake disc and the axle hub.
(b) Remove the brake disc.
(a) Aligning the matchmarks, install the front brake disc.
Hint:
When replacing the brake disc with a new one, select the
installation position where the front brake disc has the mini-
ALF041G mum axial runout.
20. Inspect brake disc axial runout

(a) Temporarily fasten the brake disc with the hub nuts.
(b) Using a dial gauge, measure the disc axial runout at 10 mm
(0.39 in.) away from the outer edge of the brake disc.
Maximum disc axial runout: 0.11 mm (0.0020 in.)
(c) If the disc axial runout is maximum value or greater, check
the bearing play in the axial direction and the axle hub run-
ALF042G out.
If the bearing play and the axle hub runout are not abnormal,
adjust the disc axial runout or grind it on a brake lathe.
21. Temporarily tighten front disc brake bleeder screw
(a) Temporarily install the front disc brake bleeder screw to the
front disc brake cylinder.
(b) Install the bleeder screw cap to the bleeder screw.
22. Install piston seal
(a) Apply grease to a new piston seal.
(b) Install the piston seal to the front disc brake cylinder.
06-BRAKE.indd 24 2008-10-21 8:18:07

BRAKE BR-25
23. Install front disc brake piston

Piston Dust Cover (a) Apply grease to the front disc brake piston and a new piston
dust cover.
(b) Install the piston dust cover to the front disc brake piston.
(c) Install the piston to the front disc brake cylinder.
Notice:
Piston Do not install the piston to the disc brake cylinder forc-
ibly.
Grease
ALF043G
24. Install piston dust cover

Piston Dust Cover Front Disc (a) Install a new piston dust cover to the front disc brake cylin-
Brake Piston
der sub-assembly.
Notice:
Install the dust cover securely to the grooves of the cyl-
inder and piston.
Set Ring (b) Using a screwdriver, install the set ring.
Notice:
ALF044G Do not damage the piston dust cover.
25. Install front disc brake cylinder set bracket

(a) Install the front disc brake cylinder set bracket with the 2
bolts.
ALF035G
26. Install guide pin dust cover

Front Disc Brake Cylinder Set Bracket (a) Apply grease to the sealing surface of 2 new dust boots.
(b) Install the 2 guide pin dust covers to the front disc brake cyl-
inder set bracket.
Guide Pin Dust Cover

Grease
ALF045G
Front Disc Brake Guide Pin 27. Install front disc brake cylinder guide pin
(a) Apply grease to the sliding part and the sealing surface of the
2 front disc brake cylinder guide pins.
(b) Install the 2 front disc brake guide pins to the front disc brake
cylinder set bracket.
28. Install front brake pad snap spring plate
(a) Install the 2 front brake pad snap spring plates to the front
Grease disc brake cylinder set bracket.
ALF046G
06-BRAKE.indd 25 2008-10-21 8:18:08

29. Install front anti squeal shim kit

No.1 Anti-squeal
(a) Apply disc brake grease to both sides of each No.1 and No.2
Shim
anti squeal shim.
(b) Install the anti squeal shims to each pad.
30. Install front brake pad kit (Pad only)
If necessary, replace the anti squeal shim kit when replacing
the brake pad.
No.2 Anti-squeal Shim
(a) Install the brake pad kit to the front disc brake cylinder set
Disc Brake Grease
ALF047G bracket.
Notice:
There should be no oil or grease adhering to the friction
surfaces of the pads and the brake disc.
31. Install front disc brake cylinder sub-assembly
(a) Install the front disc brake cylinder sub-assembly with the 2
bolts.
ALF048G
(b) Install a new copper gasket and the brake hose with the union
bolt.
Hint:
Install the brake hose lock securely to the lock hole of the
disc brake cylinder sub-assembly.
ALF031G SST 09023-00100
06-BRAKE.indd 26 2008-10-21 8:18:08

BRAKE BR-27
Rear Brake
Components
Bleeder Screw
8.3 (85, 73 in.·lbf) Bleeder Screw Cap
9.8 (100, 87 in.·lbf) Piston Spring

l Piston Dust Cover
Piston l Cup
l Piston Dust Cover
15 (155, 11)
Pin
Pin Plug Piston
Hole Plug Rear Brake Cylinder
l Cup Parking Brake Shoe Lever

Parking Brake Cable l C-washer
Pin Assembly LH
Brake Shoe
Parking Brake Shoe
Hold-down Brake Shoe
Push Rod Kit LH Hold-down
Spring
Spring Cup
Backing Plate
Brake Leading
Rear Brake Automatic Brake Shoe Shoe Assembly
Adjust Lever Return Spring
Tension Spring
Rear Brake Automatic
Adjust Lever Tension
Spring
Brake Trailing Shoe Assembly
Brake Shoe Hold-

Down Spring Brake Shoe Hold-down Spring Cup

Rear Brake Drum
l Non-reusable part
Grease
High temperature grease
ALF049G
06-BRAKE.indd 27 2008-10-21 8:18:08

Overhaul
Hint:
Overhaul the RH by using the same procedures as those for the
LH.
1. Inspect rear drum brake shoe lining thickness
(a) Remove the hole plug, and check the brake shoe lining thick-
ness through the hole.
If the thickness is less than the minimum, replace the brake
shoes.
ALF050G Notice:
painted surfaces.
(a) Release the parking brake handle, and remove the brake
Rear Brake Automatic
Adjust Lever drum.
Hint:
If the brake drum cannot be removed easily, perform the fol-
lowing procedures.
Contract (b) Remove the hole plug and insert a screwdriver into the hole
on the backing plate, and hold the rear brake automatic adjust
ALF051G lever away from the adjuster.
(c) Using another screwdriver, adjust the brake shoe adjuster by
turning the adjusting wheel.
5. Inspect brake drum inside diameter
(a) Using a brake drum gauge or an equivalent, measure the in-
side diameter of the drum.
Standard inside diameter: 200.0 mm (7.874 in.)
Maximum inside diameter: 201.0 mm (7.913 in.)
ALF052G
SST 6. Separate parking brake shoe push rod kit LH

(a) Using SST, disconnect the brake shoe return spring from the
brake trailing shoe assembly and the brake leading shoe as-
sembly.
SST 09703-30010
Notice:
Be careful not to damage the wheel cylinder dust cover.
ALF053G
06-BRAKE.indd 28 2008-10-21 8:18:09

BRAKE BR-29
7. Remove brake trailing shoe assembly

(a) Using SST, remove the brake shoe hold-down spring cup, the
brake shoe hold-down spring and the pin.
SST 09718-00010
(b) Remove the brake trailing shoe assembly and tension spring.
8. Remove parking brake shoe push rod kit LH
SST
(a) Remove the parking brake shoe push rod kit LH from the
brake leading shoe assembly.
ALF054G
9. Remove rear brake automatic adjust lever LH

(a) Remove the rear brake automatic adjust lever tension spring
and the rear brake automatic adjust lever.
ALF055G
10. Remove brake leading shoe assembly

(a) Using SST, remove the brake shoe hold-down spring cup, the
SST brake shoe hold-down spring and the pin.
SST 09718-00010
ALF056G
(b) Using needle-nose pliers, disconnect the parking brake cable

LH from the parking brake shoe lever.
ALF057G
11. Remove rear brake parking brake shoe lever sub-as-

sembly
(a) Using a screwdriver, remove the C-washer and the parking
C-washer brake shoe lever.
ALF058G
06-BRAKE.indd 29 2008-10-21 8:18:10

12. Inspect rear drum brake shoe lining thickness

(a) Using a ruler, measure the thickness of the brake shoe lining.
If the lining thickness is equal to the minimum thickness
or less, or there is severe or uneven wear, replace the brake
shoe.
ALF059G
13. Inspect brake drum and rear drum brake shoe lining for
proper contact
(a) Apply chalk to the inside surface of the brake drum, then
grind the brake drum on the brake shoe lining to fit.
If the contact between the brake drum and the brake shoe
lining is improper, repair it by using a brake shoe grinder or
replace the brake shoe assembly.
ALF060G
14. Remove rear wheel brake cylinder assembly

(a) Using SST, disconnect the brake line.
SST 09023-00100
Hint:
Use a container to catch the brake fluid.
(b) Remove the bolt and the rear wheel brake cylinder assembly.
15. Remove rear wheel cylinder cup kit
(a) Remove the 2 piston dust covers from the rear wheel brake
ALF061G cylinder.
(b) Remove the 2 pistons and the piston spring.
(c) Remove the 2 cups from each piston.
16. Inspect brake wheel cylinder
(a) Check the cylinder bore and the piston for rust or scoring.
17. Remove rear drum brake bleeder screw
(a) Remove the rear drum brake bleeder screw from the rear
wheel cylinder assembly.
18. Install rear wheel cylinder cup kit
(a) Apply grease to the 2 cups and the 2 pistons.
(b) Install the cups to each piston.
(c) Install the piston spring and the 2 pistons to the rear wheel
brake cylinder.
(d) Install the 2 new piston dust covers to the rear wheel brake
cylinder.
19. Temporarily tighten rear drum brake bleeder screw
Grease (a) Install the rear drum brake bleeder screw to the rear wheel
ALF062G cylinder assembly.
06-BRAKE.indd 30 2008-10-21 8:18:11

BRAKE BR-31
20. Install rear wheel brake cylinder assembly

(a) Install the rear wheel brake cylinder assembly with the bolt.
(b) Using SST, connect the brake line.
SST 09023-00100
ALF061G
21. Apply high temperature grease

(a) Apply high temperature grease to the brake shoe attached
surface of the backing plate.
High Temperature Grease

ALF063G
22. Install rear brake parking brake shoe lever sub-assembly

(a) Using needle-nose pliers, install a new C-washer and the
parking brake lever.
ALF064G
23. Install brake leading shoe assembly

(a) Using needle-nose pliers, connect the parking brake cable
LH to the parking brake shoe lever.
ALF057G
(b) Using SST, install the brake leading shoe assembly, the brake
guide pin, the brake shoe hold down spring and the brake
SST shoe hold down spring cup.
SST 09718-00010
ALF056G
06-BRAKE.indd 31 2008-10-21 8:18:11

24. Install rear brake automatic adjust lever LH

(a) Install the rear brake automatic adjust lever LH and the rear
brake automatic adjust lever tension spring to the brake trail-
ing shoe assembly.
ALF055G
25. Install parking brake shoe push rod kit LH

(a) Apply high temperature grease to the adjusting bolt and as-
semble.
(b) Install the brake shoe return spring to the push rod kit.
High Temperature Grease

ALF065G
(c) Install the parking brake shoe push rod kit LH as shown in
the illustration.
Backing Plate
Parking Brake Shoe Push

Rod Kit
ALF066G
26. Install brake trailing shoe assembly

(a) Connect the tension spring to the brake trailing shoe assem-
bly and brake leading shoe assembly.
(b) Using SST, install the brake trailing shoe assembly, the brake
guide pin, the brake shoe hold down spring and the brake
shoe hold down spring cup.
SST
SST 09718-00010
ALF054G
(c) Using needle-nose pliers, connect the tension spring to the

brake trailing shoe assembly and brake leading shoe assem-
bly.
ALF067G
06-BRAKE.indd 32 2008-10-21 8:18:12

BRAKE BR-33
SST 27. Connect parking brake shoe push rod kit LH

(a) Using SST, connect the brake shoe return spring to the brake
trailing shoe assembly and brake leading shoe assembly.
SST 09703-30010
Notice:
Be careful not to damage the wheel cylinder dust cover.
28. Check rear drum brake installation
(a) Check that each part is installed properly.
ALF068G
LH: RH:
Front Front
ALF069G
(b) Measure the brake drum inside diameter and the diameter of
the brake shoes.
The difference between the diameters is the correct brake
shoe clearance.
Brake shoe clearance: 0.25 mm (0.024 in.)
Notice:
There should be no oil or grease adhering to the friction
surfaces of the brake shoe lining and the brake drum.
ALF070G 29. Install rear brake drum
30. Adjust rear drum brake shoe clearance

Rear Brake Automatic (a) Temporarily install the 2 hub nuts.
Adjust Lever (b) Remove the hole plug, and turn the adjuster to expand the
brake shoe until the drum locks.
(c) Rotate the adjuster by 8 notches.
(d) Install the hole plug.
Expand 31. Fill reservoir with brake fluid (See page BR-5)
ALF071G SST 09023-00100
06-BRAKE.indd 33 2008-10-21 8:18:12


37. Check parking brake lever travel (See page BR-45)
38. Adjust parking brake lever travel (See page BR-45)
ABS Brake System

1. ABS brake system description (With EBD)
ABS brake system detects wheel speed by speed sensor, and sends the treated speed signal to ECU which con-
trols solenoid operation based on the speed signal and the pressure of brake cylinder to avoid wheel lock.
Electronic brake force distribution (EBD), when ABS does not work during braking, adjusts rear wheel brake
pressure by parts of ABS to balance the brake pressure of front and rear wheels, which reaches optimum effi-
ciency of braking.
2. System diagram
ABS Control Unit (ECU)
Vacuum Booster and Brake

Master Cylinder
Wheel Speed Work Order

Signal
Speed Sensor
Hydraulic Pressure
Regulator
Rear Brake Cylinder
ALF072G
06-BRAKE.indd 34 2008-10-21 8:18:13

BRAKE BR-35
3. Precaution
(a) In order to judge whether the fault is in the brake system or in ABS system, sometimes, the ABS system needs
to quit working, namely, disconnect the connector of ABS ECU or fuse, at this time, the ABS and EBD do not
work, emergency braking should be avoided as much as possible as it is easy to drift and sideslip on the muddy,
icy and snowy roads.
(b) There is a low fault rate in the ABS system, when a fault occurs in the brake system (Warning light does not il-
luminate), the fault in the brake system should be solved first and then the fault in the ABS system.
(c) The time that ABS begins to work on the rainy or sandstone road is longer than that on the good road, as the
unstable attachment coefficient on those roads makes the measurement and calculation of the sliding ratio differ-
ent, so the driver should be reminded of taking great care to drive on those roads described above.
(d) ABS ECU precautions:
(1) ABS ECU is extremely easy to be damaged when being collided or knocked, therefore, the ECU should be
paid attention not to be collided or knocked.
(2) The ECU is also easy to be damaged when being placed under the high-temperature environment. There-
fore, the ECU should be removed from the vehicle which is to be painted.
(3) Do not remove the electric elements and the wire harness plug in the system with the power switch ON, so
as not to damage the ECU. Ignition switch should be turned OFF if removing is required. The connector
should also be disconnected from the ECU when the elements or circuit in the system are welded.
(4) The ECU should not be smeared with oil, especially for the terminal of the ECU; otherwise the terminal of
the ECU will have a poor contact.
4. Common faults and trouble shooting
(a) ABS hydraulic pressure regulator makes a loud noise when braking
(1) The motor in the hydraulic pressure regulator is ceaselessly turning when ABS is operating, at this time,
the resilience on the brake pedal can be felt by the driver, the resilience varies according to the different
vehicle speed and road conditions.
(2) The noise from where the motor operates can also be heard when performing the motion test. The noise
from where the motor operates can be heard occasionally without braking when the vehicle is driving, the
reason of which is that ABS is detecting the element, but not a fault.
(3) The motion test can be performed if the noise from ABS hydraulic pressure regulator is abnormal, which is
compared with the normal vehicle to determine whether the noise from ABS hydraulic pressure regulator is
normal or not.
(b) Inlet and outlet solenoid valve malfunction
Each time the ignition switch on, ABS control unit will perform self-test automatically, if inlet or outlet solenoid
valve are found to be short or open, ABS control unit will record this fault, turn malfunction indicator on and
quit operating. If the corresponding DTC is read by tester, and the fault in the solenoid valve is determined by
the motion test, replace the hydraulic pressure regulator assembly directly.
X431 data flow: inlet or outlet solenoid valve will change operating conditions quickly when ABS is operating.
EVFL - front inlet valve LH close/open
AVFL - front outlet valve LH close/open
EVFR - front inlet valve RH close/open
AVFR - front outlet valve RH close/open
EVRR - rear inlet valve LH close/open
AVRR - rear outlet valve LH close/open
EVRR - rear inlet valve RH close/open
AVRR - rear outlet valve RH close/open
06-BRAKE.indd 35 2008-10-21 8:18:13

(c) Inlet and outlet solenoid valve malfunction

Detect the voltage between the sensor signal wire and the ground wire by using oscilloscope when starting the
engine.
Output signal when the wheel is still:
Or
V V
0 0
t t
ALF073G
Output signal when turning the wheel: the signal form is the rectangular wave signal with the voltage of 0.44 V
and 1.26 V, the duty ratio: 50:50.
0
t
ALF074G
X431 tester has the function to display the data flow in the form of waveform. As for intermittent faults, such
as wheel speed signal error (wheel speed sensor fault) that happens only when driving at a high speed or wheel
speed signal error that happens occasionally when driving, etc, and the wheel speed sensor can be determined
whether there is a fault or not by continuously observing its waveform. Keep the vehicle driving on a level road
in a straight line, at this time, the waveform of the 4 speed sensors is quite close, the signal wave of the 2 front
wheels or the 2 rear wheels can be compared at the same time.
Mechanical reason: the deformation of signal gear ring, the looseness of hub bearing and the dirty surface of
sensor, etc, might lead to the interruption or deviation of the wheel speed signal. Example of malfunction:
06-BRAKE.indd 36 2008-10-21 8:18:13

BRAKE BR-37
V (km/h)
60
30
Signal Interruption
t
ALF075G
As shown in the illustrations above, ABS control unit will record the sensor fault and turn on malfunction indi-
cator as soon as the intermittent fault of speed sensor is detected.
(d) Speed sensor rate malfunction
If ECU measured that the difference between one of speed sensors and the others is too big, the possible reason
may be that the clearance of gear ring speed sensor is out of tolerance or the speed sensor signal is interfered.
The sensor which signal is deviated should be firstly determined, then troubleshooting is performed according to
the DTC list.
06-BRAKE.indd 37 2008-10-21 8:18:13

ABS DTC list:

Trouble code Fault description
C0035 front speed sensor LH circuit fault, speed rate fault
C0040 front speed sensor RH circuit fault, speed rate fault
C0045 rear speed sensor LH circuit fault, speed rate fault
C0050 rear speed sensor RH circuit fault, speed rate fault
C0060 front ABS outlet solenoid valve LH malfunction
C0065 front ABS inlet solenoid valve LH malfunction
C0070 front ABS outlet solenoid valve RH malfunction
C0075 front ABS inlet solenoid valve RH malfunction
C0080 rear ABS outlet solenoid valve LH malfunction
C0085 rear ABS inlet solenoid valve LH malfunction
C0090 rear ABS outlet solenoid valve RH malfunction
C0095 rear ABS inlet solenoid valve RH malfunction
pump motor circuit malfunction, pump motor operation
C0110
error
C0121 solenoid relay circuit malfunction
C0161 brake switch circuit malfunction
speed sensor frequency error, speed sensor signal mal-
C0245
function
C0287 acceleration sensor malfunction
C0550 ECU malfunction
C0800 voltage malfunction, voltage is too low or high
short between positive pole and warning light, short be-
C0232
tween ground and warning light

Hand-held Tester 1. Connect hand-held tester:
(a) Connect the hand-held tester to the DLC3.
(b) Start the engine and run at idle.
(c) Select the ACTIVE TEST mode on the hand-held tester.
Hint:
Please refer to the Hand-held Tester Operator’s Manual for
further details.
2. Inspect actuator motor operation
DLC3
ALF006G (a) With the motor relay on, check the actuator motor operating
sound.
(b) Turn the motor relay off.
3. Inspect right front wheel operation
(a) Depress the brake pedal and hold it for approximately 15
seconds. Check that the brake pedal cannot be depressed.
(b) With the motor relay on, check that the pedal vibrates.
Notice:
Do not keep the motor relay on for more than 5 sec-
onds. When operating it continuously, set an interval of
more than 20 seconds.
06-BRAKE.indd 38 2008-10-21 8:18:14

BRAKE BR-39
(c) Turn the motor relay off and release the brake pedal.
Notice:
Be sure to follow the procedures below when turning on
a solenoid valve.
(d) With the brake pedal depressed, perform the following op-
erations.
(e) Turn the EVFR and AVFR solenoid valve on simultaneously,
and check that the pedal cannot be depressed.
Notice:
Do not keep the solenoid valves turned on for more
than 5 seconds. When operating it continuously, set an
interval of more than 20 seconds.
(f) Turn the EVFR and AVFR solenoid valves off simultane-
ously, and check that the pedal cannot be depressed.
(g) With the motor relay on, check that the pedal returns.
Notice:
Do not keep the motor relay on for more than 5 sec-
onds. When operating it continuously, set an interval of
more than 20 seconds.
(h) Turn the motor relay off and release the brake pedal.
4. Inspect other wheels operation
(a) Using the same procedures, check the solenoid valves of the
other wheels.
Notice:
Do not depress the brake pedal under the condition
that the reduction solenoid valve alone is turned on.
Hint:
• Left front wheel: EVFL, AVFL
• Right rear wheel: EVRR, AVRR
• Left rear wheel: EVRR, AVRR
06-BRAKE.indd 39 2008-10-21 8:18:14

Replacement
Notice:
painted surfaces.
2. Remove battery
3. Remove ABS controller with bracket
(a) Release the latch of the connector of ABS controller to dis-
ABS Controller connect the connector.
Assembly (b) Using SST, disconnect the 6 brake tubes from ABS control-
Insulator ler.
SST 09023-00100
ABS Mounting (c) Attach tags or make a memo to identify the place to recon-
Bracket Assembly
nect.
ALF076G
(d) Remove the 3 bolts and ABS controller with bracket.

4. Remove ABS controller assembly
ABS Controller (a) Remove the nut, 2 bolts and ABS controller assembly from
Assembly the ABS controller bracket.
Insulator 5. Install ABS controller assembly
ABS Mounting (a) Install ABS controller with the 2 nuts to ABS controller
Bracket Assem- bracket.
bly
ALF077G
6. Install ABS controller with bracket

(a) Install ABS controller with bracket with the 3 bolts.
ABS Controller Torque: 19 N·m (194 kgf·cm, 14 ft·lbf)
Assembly (b) Using SST, connect the 6 brake tubes to the correct positions
Insulator of ABS controller, according to the tags or making a memo.
ABS Mounting SST 09023-00100
Bracket Assem-
bly
(c) Connect connector of ABS controller.
ALF077G 7. Install battery
SST 09023-00100
13. Check ABS controller with hand-held tester
06-BRAKE.indd 40 2008-10-21 8:18:14

BRAKE BR-41

Replacement
Hint:
Replace the RH by using the same procedures as those for the LH.
2. Remove battery
3. Remove front speed sensor LH
(a) Disconnect the speed sensor connector.
ALF078G
(b) Remove the 2 clamp bolts holding the speed sensor wire har-
ness from the body and the shock absorber.
(c) Disconnect the resin clip and the speed sensor wire harness
from the shock absorber.
ALF079G
(d) Remove the bolt and the front speed sensor LH.
Notice:
Prevent foreign matter from attaching to the sensor tip.
ALF080G
4. Install front speed sensor LH

(a) Install the front speed sensor LH with the bolt.
Notice:
ALF080G
06-BRAKE.indd 41 2008-10-21 8:18:14

(b) Install the speed sensor wire harness with the 2 bolts on the
body and the shock absorber.
A
Torque:
Bolt A: 8.0 N·m (82 kgf·cm, 71 in.·lbf)
Bolt B: 29 N·m (300 kgf·cm, 22 ft·lbf)
Notice:
Do not twist the sensor wire harness when installing the
B
sensor.
ALF081G (c) Connect the resin clip and the speed sensor wire harness to
the shock absorber.
(d) Connect the speed sensor connector.
6. Install battery
ALF078G
Rear Speed Sensor LH

Replacement
Hint:
Replace the RH by using the same procedures as those for the LH.
1. Turn ignition switch to OFF position
2. Remove left rear wheel
3. Disconnect the rear wheel speed sensor connector LH.
(a) Disconnect the speed sensor connector.
(b) Remove the rubber bush of rear wheel speed sensor LH with
bracket assembly.
ALF082G
4. Remove rear speed sensor set bracket LH

(a) Remove the No.1 set bracket.
(b) Remove the No.2 set bracket.
ALF083G
06-BRAKE.indd 42 2008-10-21 8:18:15

BRAKE BR-43
5. Remove rear speed sensor assembly LH

(a) Remove the set clip of rear speed sensor LH.
(b) Remove rear speed sensor assembly LH.
Notice:
ALF084G
6. Install rear speed sensor LH

(a) Install the rear speed sensor LH with the bolt.
Notice:
ALF084G
7. Install rear speed sensor set bracket LH

(a) Install the No.1 set bracket.
(b) Install the No.2 set bracket.
ALF083G
8. Connect rear speed sensor connector LH

(a) Install the rubber bush of rear speed sensor LH with bracket
assembly.
(b) Connect the speed sensor connector.
9. Install left rear wheel
ALF082G
06-BRAKE.indd 43 2008-10-21 8:18:15

PARKING BRAKE SYSTEM

Parts Location
Parking Brake Cable Assembly RH
B
A
C D
B
ALF085G

1. Parking brake lever travel (Out of adjust- BR-45
ment)
2. Parking brake cable (Sticking) BR-48
3. Parking brake shoe clearance (Out of ad- BR-33
justment)
Parking brake drag 4. Parking brake shoe lining (Cracked or dis- BR-28
torted)
5. Tension or return spring (Damaged) BR-28
6. Parking brake drum (Worn or out of round) BR-28
7. The contact area between parking brake -
shoe lining and brake drum is too small.
06-BRAKE.indd 44 2008-10-21 8:18:16

BRAKE BR-45
Adjustment
2. Adjust rear drum brake shoe clearance (See page
BR-33)
4. Check parking brake lever travel
(a) Pull the parking brake handle all the way up, and count the
number of clicks.
Parking brake lever travel: 6 to 7 clicks at 196 N (20 kgf,
44.1 lbf)
5. Adjust parking brake lever travel
(a) Remove the parking brake handle cover plate.
(b) Remove the floor console mat.
(c) Remove the floor console assembly.
(d) Turn No.1 adjusting nut until the lever travel becomes cor-
rect.
(e) Tighten the lock nut.
No.1 Adjusting Nut Torque: 5.4 N·m (55 kgf·cm, 48 in.·lbf)
ALF086G
06-BRAKE.indd 45 2008-10-21 8:18:16


Components
Front Ash Tray Assembly

Cover Plate Floor Console Mat
Screw
Clip
Floor Console Assembly
13 (127, 9)
Parking Brake Switch Assembly
Parking Brake
Handle No.2 Adjusting Nut
13 (127, 9)
5.4 (55, 48 in.·lbf)
No.1 Adjusting Nut

Parking Brake Equalizer
Parking Brake Pull Rod

ALF087G
06-BRAKE.indd 46 2008-10-21 8:18:16

BRAKE BR-47
Replacement
1. Remove shift lever knob sub-assembly
2. Remove parking brake handle cover plate
3. Remove floor console mat
4. Remove floor console assembly
(a) Remove the screw.
(b) Using a clip remover, disengage the 2 clips, and remove the
floor console assembly.
5. Remove No.1 adjusting nut
(a) Remove the lock nut and No.1 adjusting nut.
Clip
ALF088G
6. Remove parking brake handle

(a) Disconnect the parking brake switch connector.
(b) Remove the 2 bolts and the parking brake handle.
7. Remove parking brake switch assembly
(a) Remove the screw and the parking brake switch.
8. Install parking brake switch assembly
(a) Install the parking brake switch with the screw.
9. Install parking brake handle
ALF089G (a) Connect the parking brake pull rod to the handle, and install
the lock nut and No.1 adjusting nut.
(b) Install the parking brake handle with the 2 bolts.
(c) Connect the parking brake switch connector.
06-BRAKE.indd 47 2008-10-21 8:18:16


Components
Parking Brake Equalizer
5.4 (55, 48 in.·lbf)
5.4 (55, 48 in.·lbf)

5.4 (55, 48 in.·lbf)
7.8 (80, 69 in.·lbf)
Grease
ALF090G
Replacement
Hint:
For removal and installation of parking brake cable assembly RH,
follow the same procedures as for the LH.
2. Remove parking brake handle cover plate
3. Remove floor console mat
4. Remove floor console assembly (See page BR-47)
5. Remove No.1 Adjusting nut
(a) Remove the No.1 adjusting nut.
6. Remove exhaust pipe rear protective support
(a) Remove the 2 bolts and the exhaust pipe rear shield support.
7. Remove sub muffler (See page EG-3)
8. Remove front floor middle heat insulator
(a) Remove the 3 bolts and the front floor middle heat insulator.
9. Separate parking brake cable assembly LH
(a) Remove the 4 bolts and disconnect the parking brake cable
LH from the body.
(b) Disconnect the parking brake cable assembly LH from the
parking brake equalizer, and remove the parking brake cable
LH.
ALF091G 10. Remove rear wheel
11. Remove rear brake drum (See page BR-28)
06-BRAKE.indd 48 2008-10-21 8:18:17

BRAKE BR-49
12. Remove brake trailing shoe assembly (See page

BR-29)
SST 09718-00010
13. Remove rear brake automatic adjust lever LH (See
page BR-29)
SST 09718-00010
14. Remove brake leading shoe assembly (See page
BR-29)
SST 09718-00010
15. Remove parking brake cable assembly LH
(a) Remove the bolt, and disconnect the parking brake cable as-
sembly LH from the backing plate.
16. Install parking brake cable assembly LH
(a) Connect the parking brake cable assembly LH to the parking
brake equalizer.
(b) Install the parking brake cable assembly LH with the 4 bolts.
ALF092G
ALF093G
06-BRAKE.indd 49 2008-10-21 8:18:17

17. Connect parking brake cable assembly LH

(a) Install the parking brake cable assembly LH with the bolt to
the backing plate.
18. Apply high temperature grease (See page BR-31)
19. Install brake leading shoe assembly (See page BR-31)
SST 09718-00010
20. Install brake leading shoe assembly return spring
ALF092G
21. Install rear brake automatic adjust lever LH (See page
BR-32)
SST 09718-00010
22. Install brake trailing shoe assembly (See page BR-32)
SST 09718-00010
23. Check rear drum brake installation (See page BR-33)
24. Install rear brake drum
25. Adjust rear drum brake shoe clearance (See page
BR-33)
27. Temporarily tighten No.1 adjusting nut
28. Install front floor middle heat insulator
(a) Install the front floor middle heat insulator with the 3 bolts.
ALF091G 29. Install sub muffler (See page EG-5)
30. Install exhaust pipe rear protective support
(a) Install the exhaust pipe rear protective support with the 2
bolts.
33. Check for exhaust gas leakage
06-BRAKE.indd 50 2008-10-21 8:18:17

SR-
STEERING
STEERING SYSTEM
Precaution......................................................................... SR-2
Problem Symptoms Table................................................. SR-2
On-vehicle Inspection....................................................... SR-4
Repair............................................................................... SR-4
Steering Column Assembly............................................... SR-6
Overhaul........................................................................... SR-7
POWER STEERING SYSTEM

Precaution......................................................................... SR-12
Problem Symptoms Table................................................. SR-12
On-vehicle Inspection....................................................... SR-13
Power Steering Oil Pump.................................................. SR-16
Power Steering Gear........................................................ SR-18
SR
07-STEERING.indd 1 2008-10-20 17:04:24

SR- GREAT WALL COOL BEAR REPAIR MANUAL
STEERING SYSTEM
Precaution
1. Handling precautions on steering system
(a) Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering sys-
tem and result in a driving hazard.
2. Handling precautions on SRS airbag system
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passen-
ger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing, possibly leading to serious accident. Before servicing (including removal or installation
of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint sys-
tem (See page RS-2).

Symptom Possible cause Troubleshooting
1. The clearance of the steering gear, 1. The clearance is adjusted by profes-
rack is excessive. sional. If it cannot be adjusted, replace
the steering gear.
2. The steering link inner/outer ball 2. Replace the ball joint stud as necessary
joint stud is worn. after check and confirming.
3. Steering joint is worn. 3. Replace the lower steering column.
Steering wheel 4. The connection of the steering shaft 4. Tighten the service bolt to specified
free play is excessive/ and the steering gear is loose. torque.
Abnormal noise 5. The connection of the steering wheel 5. Tighten the steering wheel lock nut;
and the steering column is loose. if the spline is worn, replace the
steering wheel or steering column.
6. The steering gear mounting bolt is 6. Tighten the steering gear mounting bolt.
loose.
7. Drive shaft slide spline is worn and 7. Replace the lower steering column.
loose.
07-STEERING.indd 2 2008-10-20 17:04:24

STEERING SR-

1. Tire pressure is insufficient. 1. Inflate the tire to specified air pressure.
2. Front wheel alignment is not correct. 2. Check and adjust the front wheel
alignment.
3. Clearance of the steering gear adjusting 3. Replace the steering or adjust the gear
block is small. adjusting block clearance by professional.
4. Steering column joint spider bearing 4. Replace the lower steering column.
is damaged.
5. Steering link ball joint stud is lack of 5. Replace the steering tie rod end.
oil or damaged.
6. Front shock absorber upper seat bearing 6. Replace the front shock absorber upper
is worn. seat connecting kit (refer to Front
Suspension repair part).
7. Lower control arm ball joint is damaged. 7. Replace the lower control arm (refer
to front suspension repair part).
Hard steering
8. Steering oil pump is damaged, resulting 8. Replace the power steering oil pump.
in the lack of output flow and input
pressure.
9. Power steering oil pump belt slips. 9. Adjust the belt tension.
10. The fluid of power steering gear 10. Replace the power steering gear.
leaks severely.
11. Power steering fluid contains bubbles. 11. Turn the steering wheel repeatedly in
There is abnormal noise. original place, bleeding out bubbles.
After leaving it untouched for 1
hours, fill the power steering fluid of
specified type.
12. Power steering fluid is insufficient. 12. Fill the power steering fluid of
specified type until the fluid goes up
to the specified line in the reservoir.
07-STEERING.indd 3 2008-10-20 17:04:24


1. Tire pressure is insufficient. 1. Inflate the tire to specified air pressure.
2. The poor wheel dynamic balance caused 2. Correct the wheel dynamic balancing.
by factors such as the wheel balance
weight dropped.
3. The lower control arm bush rubber is 3. Replace the lower control arm.
deteriorated. The difference between
the LH and RH rigidity is large.
4. The lubrication of front shock absorber 4. Charge grease as specified.
upper seat bearing, lower control arm
ball joint is insufficient.
Poor return/Stability is
5. Four wheel alignment parameters are 5. Measure and adjust the four wheel
poor when driving straight
not correct. alignment parameters.
6. The condition of steering gear rack 6. Replace the steering gear.
engaging is bad. The counter resistance
increases.
7. The steering column bearing and joint 7. Replace the steering column assembly.
spider bearing are damaged.
8. The oil volume of power steering oil 8. Replace the power steering oil pump.
pump is insufficient.
9. The performance of the steering gear 9. Replace the power steering gear.
inner control valve decreases.
Maximum
Free Play 1. Check steering wheel free play
(a) Stop the vehicle and face the tires straight ahead.
(b) Move the steering wheel gently clockwise by your hand
until the resistance increase, and check the steering wheel
free play.
30 mm (1.18 in.) Maximum free play: 30 mm (1.18 In.)
ALG001G
Steering Wheel Repair

Masking Tape 1. Steering off center repair procedure
(a) Inspect steering wheel off center.
Combination
Switch (1) Apply masking tape to the top center of the steering
Upper Cover wheel and combination switch upper cover.
(2) Drive the vehicle in a straight line for 100 meters at a
constant speed of 35 mph (56 km/h), and hold the steer-
ing wheel to maintain the course.
ALG002G
07-STEERING.indd 4 2008-10-20 17:04:24

STEERING SR-
(3) Draw a line on the masking tape as shown in the illus-

Combination Switch
Upper Cover tration.
Marked Line
Steering Wheel
Masking Tape
ALG003G
(4) Turn the steering wheel to the straight position.

Combination Switch
Upper Cover Hint:
Marked Line Refer to the upper surface of the steering wheel, steer-
Steering Wheel ing spoke and SRS airbag line for the straight position.
(5) Draw a new line on the masking tape on the steering
wheel as shown in the illustration.
(6) Measure the distance between the 2 lines on the mask-
ing tape on the steering wheel.
ALG004G (7) Convert the measured distance to the steering angle.
Measured distance 1 mm (0.04 in.) = Steering angle ap-
proximately 1°.
Hint:
Make a note of the steering angle.
(b) Adjust the steering angle.
(c) Perform the following procedure with left and right sides.
Tie Rod Rack End (1) Mark on the tie rod and rack end where it can easily be
seen.
(2) Using a paper gage, measure the distance between the
tie rod end and the rack end threads.
Marked Line
ALG005G
(3) Remove the RH and LH boot clamps from the rack

boots.
(4) Loosen the RH and LH lock nuts.
(5) Turn the RH and LH rack end by the same amount (but
in different directions) according to the steering angle.
Turn 360° of rack end (1.5 mm (0.059 in.) horizontal
movement) - 12° of steering angle.
(6) Tighten the RH and LH lock nuts.
ALG006G Torque: 37 N·m (377 kgf·cm, 28 ft·lbf)
Notice:
Make sure that the difference in length between
the RH and LH tie rod ends and rack end threads
are within 1.5 mm (0.059 in.).
(7) Install the RH and LH boot clamps.
07-STEERING.indd 5 2008-10-20 17:04:25

Steering Column Assembly

Components
Combination Switch Upper Cover Driver Airbag
Steering Wheel
Bolt
50 (510, 37)
8.8 (90, 78 in.·lbf)
8.8 (90, 78 in.·lbf)

Bolt
Combination Switch
Clock Spring Assembly
Assembly RH
Combination Switch
Lower Cover
Combination Switch
Assembly LH
Steering Column
25 (255, 19)
25 (255, 19)
28 (286, 21)
Steering Shaft
28 (286, 21)
Steering Column Dust Cover

ALG007G
07-STEERING.indd 6 2008-10-20 17:04:25

STEERING SR-
Overhaul
1. Precaution (See page RS-2).
2. Disconnect battery negative terminal (See page RS-2)
3. Place front wheels facing straight ahead
4. Remove driver airbag (See page RS-29)
(a) Remove the 2 bolts and driver airbag.
Bolt ALG008G
Lock Nut 5. Remove Steering Wheel

(a) Using socket wrench M18, turn the steering wheel lock nut
counterclockwise and remove it.
(b) Hold the steering wheel and shake it towards all directions
for several times and then pull out it.
ALG009G
Combination Switch Upper Cover 6. Remove combination switch cover

(a) Remove the 3 screws.
(b) Remove the combination switch upper cover.
(c) Remove the combination switch lower cover.
7. Remove clock spring sub-assembly (See page RS-37)
Combination
Switch Lower
Cover
ALG010G
8. Remove combination switch RH and LH and ignition

switch
(a) Disconnect the wire harness from the combination switch
Combination Combination and ignition switch.
Switch RH Switch LH
(b) Remove the combination switch LH.
Combination (c) Remove the combination switch RH.
Switch
ALG011G
07-STEERING.indd 7 2008-10-20 17:04:26

(d) Remove the ignition switch.
ALG012G
9. Separate steering column and steering shaft

(a) Put matchmarks on the steering shaft and steering column.
(b) Using socket wrench M13, remove the bolt, then separate the
steering shaft.
Bolt
ALG013G
Bolt (d=22) 10. Remove steering column

(a) Using socket wrench M13, remove the 3 bolts connecting to
the instrument panel reinforcement member.
(b) Pull out the steering column along the upper tip axis line of
the column.
Bolt
ALG014G
11. Remove steering column dust cover

(a) Turn the plastic clip counterclockwise by hand.
(b) Remove the steering column dust cover from the steering
shaft.
Clip
ALG015G
12. Spearate steering shaft and steering connecting shaft

(a) Put matchmarks on the steering shaft and steering connecting
shaft.
Bolt (b) Using M13 socket wrench, remove the bolt which connects
the steering shaft and steering connecting shaft.
(c) Remove the steering shaft.
ALG016G
07-STEERING.indd 8 2008-10-20 17:04:27

STEERING SR-
13. Remove steering connecting shaft

(a) Remove the steering connecting shaft protector assembly.
Connecting Shaft
Protector Assembly (b) Using M13 socket wrench, remove the bolt.
(c) Remove the steering connecting shaft.
Bolt
ALG017G
14. Install steering connecting shaft

(a) Connect the steering connecting shaft.
Connecting Shaft (b) Install the bolt.
Protector Assembly (c) Install the steering connecting shaft protector assembly.
Bolt
ALG017G
15. Connect steering shaft and steering connecting shaft

(a) Install the steering shaft.
(b) Connect the steering shaft to the steering connecting shaft.
Bolt
ALG016G
16. Install steering column dust cover

(a) Install the steering column dust cover to the steering shaft.
(b) Turn the plastic clip clockwise by hand.
Clip
ALG015G
Bolt (d=22) 17. Install steering column

(a) Insert the steering column assembly along the upper tip axis
line of the column.
(b) Install the 3 bolts connecting to the instrument panel rein-
forcement member.
Bolt
ALG014G
07-STEERING.indd 9 2008-10-20 17:04:28

SR-10 GREAT WALL COOL BEAR REPAIR MANUAL
18. Connect steering column and steering shaft

(a) Connect the steering shaft to the steering column.
Bolt
ALG013G
19. Install combination switch RH and LH and ignition

switch
(a) Install the ignition switch.
ALG012G
(b) Install the combination switch RH.

(c) Install the combination switch LH.
(d) Connect the wire harness to the combination switch and
Combination Combination ignition switch.
Switch RH Switch LH
20. Install clock spring sub-assembly (See page RS-38)
Combination
Switch
ALG011G
Combination Switch Upper Cover 21. Install combination switch cover

(a) Install the combination switch lower cover.
(b) Install the combination switch upper cover.
(c) Install the 3 screws.
Combination
Switch Lower
Cover
ALG010G
Lock Nut 22. Install steering wheel

(a) Insert the steering wheel downward.
(b) Using M18 socket wrench, turn the steering wheel lock nut
clockwise to install it.
ALG009G
07-STEERING.indd 10 2008-10-20 17:04:28

STEERING SR-11
23. Install driver airbag

(a) Install the 2 bolts and driver airbag.
24. Connect battery negative terminal
Bolt ALG008G
07-STEERING.indd 11 2008-10-20 17:04:28

POWER STEERING SYSTEM

Precaution
1. Handling precautions on steering system
(a) Care must be taken when replacing parts. Incorrect replacement may affect the performance of the steering sys-
tem and result in a driving hazard.
2. Handling precautions on SRS airbag system
(a) The vehicle is equipped with SRS (Supplemental Restraint System) such as the driver airbag and front passen-
ger airbag. Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly
deploy during servicing, possibly leading to serious accident. Before servicing (including removal or installation
of parts, inspection or replacement), be sure to read the precautionary notice for the supplemental restraint sys-
tem (See page RS-2).
Hint:
1. Tires (Improperly inflated) SP-37
2. Power steering fluid level (Low) SR-13
3. Front wheel alignment (Incorrect) SP-7
4. Steering system joints (Worn) -
Hard steering 5. Suspension lower rocker arm ball joint SP-18
(Worn)
6. Steering column (Binding) -
7. Power steering oil pump SR-16
8. Power steering gear SR-18
1. Tires (Improperly inflated) SP-37
2. Front wheel alignment (Incorrect) SP-7
3. Steering column (Binding) -
Poor return 4. Power steering gear SR-18
6. Suspension lower rocker arm ball joint SP-18
(Worn)
2. Suspension lower rocker arm ball joint SP-18
(Worn)
3. Steering connecting shaft sub-assembly -
Excessive free play
(Worn)
4. Steering shaft joints (Worn) -
5. Front wheel bearing (Worn) DT-2
1. Power steering fluid level (Low) SR-13
Abnormal noise
3. Power steering oil pump SR-16
07-STEERING.indd 12 2008-10-20 17:04:28

STEERING SR-13
1. Check steering oil pump belt
(a) Visually check the belt for excessive wear, frayed cords, etc.
If any defect is found, replace the steering oil pump belt.
Hint:
Cracks on the rib side of a belt are considered acceptable.
Replace the belt if there are any missing ribs.
ALG018G
2. Bleed power steering system

(a) Check the fluid level.
(b) Jack up the front of the vehicle and support it with stands.
(c) Turn the steering wheel.
(1) With the engine stopped, turn the wheel slowly from
lock to lock several times.
(d) Lower the vehicle.
(e) Start the engine.
(1) Idle the engine for a few minutes.
(f) Turn the steering wheel.
(1) With the engine idling, turn the wheel to the left or right
full lock position and keep it there for 2 to 3 seconds,
then turn the wheel to the opposite full lock position
and keep it there for 2 to 3 seconds.
(2) Repeat (1) several times.
(g) Stop the engine.
(h) Check for foaming or emulsification.
OK NG If the system has to be bled twice because of foaming or
emulsification, be sure to check whether the fluid leaks or not
in the system.
(i) Check the fluid level.
ALG019G
3. Check fluid level

(a) Keep the vehicle level.
(b) With the engine stopped, check the fluid level in the oil res-
ervoir.
MAX If necessary, add fluid.
MIN
Fluid: ATF DEXRON III
Hint:
Check that the fluid level is between the marks MAX and
ALG020G MIN.
(c) Start the engine and run at idle.
(d) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 80°C (176°F)
07-STEERING.indd 13 2008-10-20 17:04:30

(e) Check for foaming or emulsification.

OK NG If foaming or emulsification is identified, bleed the power
steering system.
ALG019G
(f) With the engine idling, measure the fluid level in the oil res-
5 mm (0.20 in.) or less ervoir.
(g) Stop the engine.
(h) Wait a few minutes and measure the fluid level in the oil res-
ervoir again.
Maximum fluid level rise: 5 mm (0.20 in.)
If a problem is found, bleed the power steering system.
(i) Check the fluid level.
Engine Idling Engine Stopped
ALG021G 4. Check steering fluid pressure
(a) Disconnect the pressure feed tube from the power steering
oil pump (See page SR-16).
(b) Connect SST as shown in the following illustration.
SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
Notice:
Check that the valve of the SST is in the open position.
(c) Bleed the power steering system.
(d) Start the engine and run at idle.
(e) Turn the steering wheel from lock to lock several times to
raise fluid temperature.
Fluid temperature: 75°C to 80°C (167 to 176°F )
07-STEERING.indd 14 2008-10-20 17:04:30

STEERING SR-15
Attachment Pressure Feed Tube SST
Power Steering Oil Pump
In Out
Attachment
ALG022G
(f) With the engine idling, close the valve of the SST and ob-
Steering serve the reading on the SST.
Oil
Reservoir
Minimum fluid pressure:
Power 5,900 kPa (60 kgf/cm2, 852 psi)
Steering Closed Notice:
Gear • Do not keep the valve closed for more than 10 sec-
Power
Steering
onds.
Oil Pump • Do not let the fluid temperature become too high.
SST ALG023G
(g) With the engine idling, open the valve fully.

Steering (h) Measure the fluid pressure at engine speeds of 1,000 rpm and
Oil
Reservoir 3,000 rpm.
Power Fluid pressure difference:
Steering
Open 490 kPa (5 kgf/cm2, 71 psi) or less
Gear
Notice:
Power
Do not turn the steering wheel.
Steering
Oil Pump
SST ALG024G
07-STEERING.indd 15 2008-10-20 17:04:31

(i) With the engine idling and the valve fully opened, turn the
Steering steering wheel to the full lock position.
Oil Minimum fluid pressure:
Reservoir
Full Lock Position 5,900 kPa (60 kgf/cm2, 852 psi)
Power
Steering Open
Notice:
Gear • Do not maintain the lock position for more than 10
Power
seconds.
Steering
Oil Pump • Do not let the fluid temperature become too high.
SST
ALG025G
(j) Disconnect SST.

SST 09640-10010 (09641-01010, 09641-01030,
09641-01060)
(k) Connect the pressure feed tube to power steering oil pump
(See page SR-17).
(l) Bleed the power steering system.
5. Check steering effort
(a) Center the steering wheel assembly.
(b) Remove driver airbag (See page RS-29).
(c) Start the engine and run at idle.
(d) Measure the steering effort in both directions.
Steering effort (Reference):
6 N·m (60 kgf·cm, 53 in.·lbf) or less
Hint:
ALG026G Take the tire type, the pressure and the contact surface into
consideration before making a diagnosis.
(e) Tighten the steering wheel assembly set nut.
(f) Install driver airbag (See page RS-29).
Power Steering Oil Pump

Replacement
1. Remove steering oil reservoir cover
2. Drain power steering fluid
(a) Disconnect the inlet hose of power steering oil pump and
store power steering fluid in a container.
3. Remove front wheel RH
4. Remove engine under cover RH
5. Separate pressure feed tube from oil pressure sensor
(a) Using SST, disconnect the pressure feed tube from the power
steering oil pump.
SST 09023-12700
SST (b) Disconnect the oil pressure sensor connector.
ALG027G
07-STEERING.indd 16 2008-10-20 17:04:31

STEERING SR-17
6. Remove power steering oil pump

A (a) Remove bolt A and power steering oil pump belt.
(b) Remove bolt B and power steering oil pump.
B
ALG028G
7. Install power steering oil pump

A (a) Install power steering oil pump to the bracket with bolt B.
(b) Install the oil pump belt, and install power steering oil pump
to the adjusting bracket with bolt A.
B
ALG028G
8. Connect pressure feed tube and oil pressure sensor

SST
(a) Using SST, connect pressure feed tube.
SST 09023-12700
Hint:
• Use a torque wrench with a fulcrum length of 345 mm
Fulcrum (13.58 in.).
Length
• This torque value is effective when SST is parallel to a
ALG029G torque wrench.
(b) Connect the oil pressure sensor connector.
9. Connect fuel inlet house to power steering oil pump
10. Adjust power steering oil pump belt
11. Inspect power steering oil pump belt deviation and ten-
sion (Reference)
12. Add power steering fluid (See page SR-13)
13. Bleed power steering system (See page SR-13)
14. Check for fluid leakage
15. Install engine under cover RH
16. Install front wheel RH
17. Check fluid level in reservoir (See page SR-13)
18. Install steering oil reservoir cover
07-STEERING.indd 17 2008-10-20 17:04:32

Power Steering Gear

Components
Steering Connecting
Steering Combination Tube Shaft Protector
25 (255, 18) Assembly
7.8 (80, 69 in.·lbf) *27 (273, 20)
18 (178, 13)
Steering Gear Shield
l Cotter Pin
50 (510, 38) Steering
28 (290, 21) Connecting Shaft
21 (216, 16)
107 (1,091, 80)
107 (1,091, 80)
Steering Gear Mounting Bracket
Auxiliary Frame Strut Rod RH

107 (1,091, 80)
50 (510, 38)
Steering Gear Mounting Bush
46 (470, 35) Power Steering Gear
Engine Rear Mounting
145 (1,480, 109)

l Lock Pin
Auxiliary Frame Sub-assembly

Auxiliary Frame
Strut Rod LH
98 (1,000, 72)
46 (470, 35)
145 (1,480, 109)

l Lock Pin
120 (1,224, 90) 78 (796, 59)
98 (1,000, 72)
120 (1,224, 90)

l Non-reusable part
ALG030G
07-STEERING.indd 18 2008-10-20 17:04:32

STEERING SR-19
Replacement
2. Remove steering column dust cover (See page SR-8)
3. Separate steering shaft joint
(a) Fix the steering wheel with the seat belt in order to prevent
rotation.
Hint:
This operation is also useful to prevent damaging the clock
spring.
ALG031G
(b) Put matchmarks on steering shaft joint and steering connect-

ing shaft.
(c) Loosen the bolt, then separate steering shaft joint from steer-
ing connecting shaft.
Matchmarks
ALG032G
4. Separate steering connecting shaft protector assembly

B A (a) Separate the clip A and the connecting shaft protector assem-
bly.
Notice:
Be careful not to damage clip B.
ALG033G
5. Open engine hood

6. Drain power steering fluid
8. Separate tie rod end assembly LH (See page SP-16)
SST 09628-62011
9. Separate tie rod end assembly RH
SST 09628-62011
Hint:
Perform the same procedure on the other side.
10. Remove engine under cover LH
11. Remove engine under cover RH
07-STEERING.indd 19 2008-10-20 17:04:33

12. Separate steering combination tube

Clamp Return Hose (a) Remove the clamp and disconnect the return hose.
(b) Using SST, disconnect the pressure feed tube.
SST 09023-12700
SST
Pressure
Feed Tube
ALG034G
(c) Remove the bolt and separate the pipe clamp.
ALG035G

page SP-16)
SST 09628-00011
14. Separate front suspension lower control arm RH
SST 09628-00011
Hint:
No.1 Engine Hanger 15. Suspend engine assembly
(a) Install 2 No.1 engine hangers with the bolts in the correct di-
rection.
Parts No.:
No.1 Engine Hanger: 12281-21010
Bolt: 91642-81025
(b) Attach the engine chain hoist to the engine hangers.
ALG036G Caution:
Do not hang the engine by hooking the chain to any
other parts.
16. Remove auxiliary frame sub-assembly
(a) Remove the 4 bolts and 2 strut rods.
ALG037G
07-STEERING.indd 20 2008-10-20 17:04:33

STEERING SR-21
(b) Remove the bolt and the 2 nuts, and separate the engine rear
mounting.
(c) Using a jack, support the auxiliary frame sub-assembly.
ALG038G
(d) Remove the 4 bolts and the auxiliary frame sub-assembly.
ALG039G
17. Remove steering gear shield

(a) Remove the 2 bolts and the shield.
18. Remove steering connecting shaft protector assembly
19. Remove steering connecting shaft
Matchmarks (a) Put matchmarks on power steering gear and the connecting
shaft.
(b) Remove the bolt and the connecting shaft.
ALG040G
20. Remove power steering gear

Matchmarks (a) Put matchmarks on power steering gear and mounting bracket.
Front
ALG041G
07-STEERING.indd 21 2008-10-20 17:04:34

(b) Remove the 4 bolts, the nuts, the mounting bracket, the bush
and power steering gear.
Notice:
• Hold the nut to turn the bolt as the nut has its own
stopper.
• Do not turn the nut.
ALG042G
21. Fix power steering gear

SST (a) Using SST, hold the power steering gear.
SST 09612-00012
Hint:
Wrap the SST with vinyl tape before use.
ALG043G
22. Remove tie rod end assembly LH

(a) Put matchmarks on the tie rod end assembly LH and the rack
end sub-assembly.
(b) Loosen the lock nut and remove the tie rod end assembly LH
and the lock nut.
Matchmarks
ALG044G
23. Remove tie rod end assembly RH

Hint:
24. Inspect tie rod end assembly LH
(a) Secure the tie rod end assembly LH in a vise.
(b) Install the nut to the ball joint.
(c) Flip the ball joint back and forth 5 times.
(d) Use a torx wrench to turn the nut continuously at a rate of
2 to 4 seconds per turn, and read the torque value at the 5th
turn.
Torque:
ALG045G 0.8 to 3.4 N·m (8.2 to 34.7 kgf·cm, 7.1 to 30.1 in.·lbf)
25. Remove tie rod end assembly RH
Hint:
07-STEERING.indd 22 2008-10-20 17:04:35

STEERING SR-23
26. Install tie rod end assembly LH

(a) Install the lock nut and tie rod end assembly LH to rack end
sub-assembly until the matchmarks are aligned.
Hint:
After adjusting toe-in, tighten the lock nut (See page SP-7).
Matchmarks
ALG044G
27. Install tie rod end assembly RH

Hint:
28. Install power steering gear
Matchmarks (a) Install the mounting bushing to the power steering gear.
(b) Align the matchmarks and install the mounting bracket to the
power steering gear.
Notice:
Install the bracket with the inscribed mark facing to the
front of the vehicle.
Front
ALG041G
(c) Install the power steering gear with the 4 bolts and the nuts.
Notice:
• Hold the nut to tighten the bolt as the nut has its
own stopper.
• Do not turn the nut.
ALG042G
29. Install steering connecting shaft

Matchmarks (a) Align the matchmarks on power steering gear and the con-
necting shaft.
(b) Install the bolt.
ALG040G
07-STEERING.indd 23 2008-10-20 17:04:35

30. Install steering connecting shaft protector assembly

31. Install steering gear shield
B
A (a) Install the shield with the bolt A as shown in the illustration.
(b) Install the bolt B to the shield.
ALG046G
32. Install auxiliary frame sub-assembly

(a) Using a jack, support the auxiliary frame sub-assembly.
(b) Align the holes of the auxiliary frame and body.
Hint:
ALG047G
(c) Install the auxiliary frame sub-assembly with the 4 bolts.

B B Torque:
Bolt B: 120 N·m (1,224 kgf·cm, 90 ft·lbf)
A A
ALG048G
(d) Connect the engine rear mounting with the bolt and the 2
nuts.
ALG038G
07-STEERING.indd 24 2008-10-20 17:04:36

STEERING SR-25
(e) Install the 2 strut rods with the 4 bolts.

ALG037G
33. Install front suspension lower control arm LH (See page

DT-15)
34. Install front suspension lower control arm RH
Hint:
35. Connect steering combination tube
(a) Using SST, connect pressure feed tube.
SST 09023-12700
Hint:
Use a torque wrench with a fulcrum length of 345 mm (13.58
SST Fulcrum Length in.).
This torque value is effective when SST is parallel to a
ALG049G torque wrench.
(b) Connect the return hose with the clamp.

(c) Install the pipe clamp to auxiliary frame sub-assembly with
the bolts.
ALG035G
36. Install tie rod end assembly LH (See page SR-23)

37. Install tie rod end assembly RH
Hint:
07-STEERING.indd 25 2008-10-20 17:04:36

39. Install steering shaft joint

(a) Align the matchmarks on steering shaft joint and steering
connecting shaft.
(b) Tighten the bolt.
Matchmarks
ALG032G

41. Install steering connecting shaft protector assembly
42. Add power steering fluid
43. Bleed power steering system (See page SR-13)
44. Check fluid level in reservoir (See page SR-13)
45. Check for fluid leakage
SP-7)
47. Install engine under cover LH
48. Install engine under cover RH
07-STEERING.indd 26 2008-10-20 17:04:36

AV-
AUDIO/VISUAL SYSTEM
AUDIO & VISUAL SYSTEM

Parts Location................................................................... AV-2
Problem Symptoms Table................................................. AV-3
Inspection.......................................................................... AV-4
CD Player Assembly......................................................... AV-4
Front Door Speaker Assembly LH.................................... AV-5
Front Tweeter Assembly LH.............................................. AV-6
D Pillar Mid-Low Tone Speaker Assembly LH................... AV-6
Antenna Wire Harness Assembly..................................... AV-7
Cigarette Lighter Assembly............................................... AV-8
Window Glass (Antenna Wire).......................................... AV-9
Power Socket.................................................................... AV-10
AV
08-AUDIO VISUAL SYSTEM.indd 1 2008-10-20 17:00:39

AV- GREAT WALL COOL BEAR REPAIR MANUAL
AUDIO & VISUAL SYSTEM

Parts Location
CD Player Bracket LH CD Player

CD Player Assembly
Bracket RH
A/C Control Knob
Glove Box Body

Center Console
Panel Body
Backup Power Socket
Cigarette Lighter
Assembly Small Glove
Box Body
Cigarette Lighter Socket Assembly
Cigarette Lighter Light Ring Assembly Cigarette Lighter Plug Assembly
ALH001G

AUDIO/VISUAL SYSTEM AV-
A Pillar Tweeter Assembly LH D Pillar Tweeter Assembly LH
Front Tweeter Assembly LH

W/Holder Antenna Assembly
Front Door Speaker

Assembly LH
Rear Door Woofer

Assembly LH D Pillar Mid-Low Tone
Speaker Assembly LH
Note:
Speakers RH are not showed.
ALH002G

Hint:
The causes of the problem and suspected areas of other speakers are the same as the following table.
No sound can be heard only from the front 1. Front door speaker assembly LH BO-10
door speaker LH. 2. Wire harness -
No sound can be heard only from the front 1. Front tweeter assembly LH AV-6
tweeter LH. 2. Wire harness -
1. D pillar mid-low tone speaker assembly AV-4
No sound can be heard only from the D pillar
LH
mid-low tone speaker LH.
2. Wire harness -

Inspection
Hint:
The inspection method of other speakers is the same as the front
door speaker LH or the D pillar mid-low tone speaker LH.
1. Front door speaker assembly LH
1 2
(a) Inspect front door speaker assembly LH continuity.
(1) Check that there is continuity between terminals.
Standard:
ALH003G
Tester connection Condition Specification
1-2 Always 4W
2. D pillar mid-low tone speaker assembly LH

(a) Inspect D pillar mid-low tone speaker assembly LH continu-
ity.
(1) Check that there is continuity between terminals.
Standard:
Tester connection Condition Specification
2
1-2 Always 6W
1
ALH004G
CD Player Assembly
Replacement
Hint:
Location: See page AV-2
2. Remove center console panel body (See page IR-30)
3. Remove CD player w/bracket assembly
(a) Remove the 4 bolts.
(b) Disconnect the connectors.
(c) Remove the CD player w/bracket assembly.
ALH005G
4. Remove CD player bracket RH

(a) Remove the 4 screws and the CD player bracket RH.
ALH006G

5. Remove CD player bracket LH

(a) Remove the 4 screws and the CD player bracket LH.
6. Replace CD player assembly
7. Install CD player assembly in the reverse order
ALH007G
Front Door Speaker Assembly LH

Replacement
Hint:
The replacement of front door speaker LH is the same as front
door speaker RH.
1. Remove front door triangular trim ��
LH��
(See page BO-8)
2. Remove front window main switch assembly LH (See
page BO-9)
3. Remove front door trim panel LH (See page BO-9)
4. Remove front door speaker assembly LH
(a) Remove the 3 screws and the 3 plastic clips.
(b) Remove the speaker.
(c) Disconnect the speaker connector.
ALH008G
5. Install front door speaker assembly LH

(a) Connect the speaker connector.
(b) Install the speaker.
(c) Install the 3 screws and the 3 plastic clips.
ALH008G

Front Tweeter Assembly LH

Replacement
Hint:
• The replacement of front tweeter assembly LH is the same as
front tweeter assembly RH.
• Location: See page AV-3
1. Remove instrument panel speaker shield LH
2. Remove front tweeter assembly LH
(a) Remove the 2 screws and the front tweeter assembly LH.
3. Replace front tweeter assembly LH
4. Install front tweeter assembly LH
(a) Connect the connector.
(b) Install the front tweeter assembly LH with the 2 screws.
Hint:
ALH009G
The installation procedures are the removal procedures in the
reverse order.
D Pillar Mid-Low Tone Speaker Assembly LH

Replacement
Hint:
• The removal procedure of D pillar mid-low tone speaker RH is
the same as D pillar mid-low tone speaker LH.
1. Remove rear rocker trim LH (See page IR-63)
2. Remove rear door sealing strip LH (See page BO-25)
3. Remove back door sealing strip
4. Remove spare-tire cover assembly
5. Remove rear seat belt assembly
6. Remove back door rocker shield (See page IR-64)
7. Remove C pillar lower trim panel assembly (See page
IR-64)
8. Remove D pillar mid-low tone speaker assembly LH
(a) Remove the 3 screws and the D pillar mid-low tone speaker
assembly LH.
9. Install D pillar mid-low tone speaker assembly LH
(a) Connect the connectors.
(b) Install the 3 screws and the D pillar mid-low tone speaker as-
sembly LH.
ALH010G
Hint:
reverse order.

Antenna Wire Harness Assembly

Replacement
Hint:
1. Remove roof headlining assembly (See page IR-66)
2. Remove instrument panel body (See page IR-29)
3. Remove w/holder antenna wire harness assembly
(a) Disconnect the connectors.
(b) Remove the 11 clamps and the bolts.
(c) Remove the w/holder antenna wire harness assembly.
: Clips
ALH011G
4. Install roof headlining assembly

Cigarette Lighter Assembly

Replacement
Hint:
3. Remove small glove box body (See page IR-35)
4. Remove cigarette lighter cover
(a) Disengage the 2 claws and remove the cigarette lighter cover.
: Claw ALH012G
5. Remove cigarette lighter assembly

(a) Remove the cigarette lighter plug assembly.
(b) Disengage the claw between the cigarette lighter socket as-
sembly and the cigarette lighter light ring assembly, turn the
cigarette lighter socket assembly in the direction as shown in
the illustration, and pull it out.
ALH013G
(c) Align the cigarette lighter socket assembly with the notch on
the cigarette lighter light ring assembly, and remove the ciga-
rette lighter assembly.
ALH014G
6. Install cigarette lighter assembly

(a) Align the cigarette lighter socket assembly with the notch on
the cigarette lighter light ring assembly, and push the ciga-
rette lighter assembly as hard as possible.
(b) Install the cigarette lighter plug assembly.

Window Glass (Antenna Wire)

Repair
1. Inspect window glass (Antenna wire)
Notice:
When cleaning the glass, use a soft, dry cloth, and wipe
Tester Probe
the glass in the direction of the wire. Be careful not to
Wire
damage the wire. Do not use detergents or glass clean-
Tin Foil ers with abrasive compound. When measuring voltage,
wind a piece of tin foil around the top of the negative
probe and press the tin foil against the wire with your
ALH015G finger, as shown in the illustration.
(a) Inspect the continuity, at the center of each antenna wire, as

ALH016G
2. Repair window glass (Antenna wire)

Repair Point
(a) Clean the broken wire tips with grease, wax and silicone re-
mover.
(b) Place masking tape along both sides of the wire to be re-
paired.
Masking (c) Thoroughly mix the repair agent.
Tape Broken Wire
ALH017G
(d) Using a fine tip brush, apply a small amount repair agent to
Fine Tip Brush the wire.
(e) After a few minutes, remove the masking tape.
(f) Do not repair the antenna wire for at least 24 hours.
Repair Point
Glass
ALH018G

AV-10 GREAT WALL COOL BEAR REPAIR MANUAL
Power Socket
Replacement
Hint:
• The procedures listed below are for the LHD.
3. Remove small glove box body (See page IR-35)
4. Remove power socket assembly
(a) Turn the power socket to disengage the notch.
ALH019G
(b) Partially pull out the power socket and turn it, until the pro-
trusion is aligned with the groove of the cover. Then remove
the power socket.
ALH020G
5. Remove power socket cover

(a) Disengage the 2 claws and remove the cover.
ALH021G

AUDIO/VISUAL SYSTEM AV-11
Installation
Hint:
The procedures listed below are for the LHD.
1. Install power socket cover
(a) Engage the 2 claws to install the power socket cover.
ALH021G
2. Install power socket assembly

(a) Align the back protrusion of the power socket with the
groove of the cover. Then push the power socket into the
cover.
3. Install small glove box body
4. Install center console panel body
ALH022G

MEMO

AC-
AIR CONDITIONING SYSTEM

Precaution......................................................................... 2
Problem Symptoms Table................................................. 3
On-vehicle Inspection....................................................... 4
Regular Inspection............................................................ 7
Refrigerant ....................................................................... 9
Refrigerant Line................................................................ 18
A/C Controller Assembly No.1.......................................... 19
A/C Controller Assembly No.2.......................................... 22
A/C Assembly.................................................................... 24
Compressor Assembly...................................................... 30
Super-cooling Type Condenser Assembly ....................... 31
AC
09-AIR CONDITIONING SYSTEM.indd 1 2008-10-21 10:55:04

AC- GREAT WALL COOL BEAR REPAIR MANUAL

Precaution
1. Do not handle refrigerant in an enclosed area or near
an open flame
2. Always wear eye protection
ALI001G
3. Be careful not to get liquid refrigerant in your eyes or on

your skin
(a) If liquid refrigerant gets in your eyes or on your skin, wash
the area with lots of cool water.
Caution:
Do not rub your eyes or skin.
(b) Apply clean petroleum jelly to the skin.
(c) Go immediately to a physician or hospital for professional
ALI002G treatment.
4. Never heat container or expose it to a naked flame
5. Be careful not to drop container or apply physical
shocks to it
6. Do not operate compressor without enough refrigerant
Wrong Correct
in refrigerant system
If there is not enough refrigerant in the refrigerant system, oil
LO HI LO HI
lubrication will be insufficient and compressor burnout may
occur. To avoid this, appropriate care should be taken.
7. Do not open high pressure manifold valve while com-
pressor is operating
If the high pressure valve opens, refrigerant flows in the re-
ALI003G verse direction and could cause the charging cylinder to rup-
ture, so open and close the low pressure valve only.
8. Be careful not to overcharge system with refrigerant
If refrigerant is overcharged, it causes problems such as in-
sufficient cooling, poor fuel economy, engine overheating,
etc.

AIR CONDITIONING SYSTEM AC-


1. HEATER fuse -
Whole functions of the A/C system do not 2. Instrument fuse -
operate. 3. A/C controller assembly No.2 AC-8
4. Wire harness or connector -
1. HEATER fuse -
2. Instrument fuse -
3. Blower speed regulating resistor AC-9
No blower operation or cannot work well 4. Blower relay AC-9
5. Blower assembly AC-9
6. A/C controller assembly No.2 AC-8
1. Blower assembly AC-9
2. Blower speed regulating resistor AC-9
Insufficient air out
1. Volume of refrigerant AC-9
2. Drive belt tension -
3. Refrigerant pressure AC-10
4. Compressor assembly AC-6
Temperature control: No cool air comes out
5. Pressure switch AC-6
6. Condenser fan -
1. Engine coolant volume EG-6
Temperature control: No warm air comes out
3. A/C assembly AC-24
Temperature control: Output air is warmer or
cooler than the set temperature or response is
2. Temperature damper cable -
slow.
Temperature control: No temperature control
2. Temperature damper cable -
1. A/C control knob assembly -
No air inlet control
No air outlet control
2. Position damper cable -
1. A/C switch AC-8
Engine idle up does not occur, or is continu- 2. Compressor assembly AC-6
ous 3. A/C controller assembly No.1 AC-19

1. A/C function inspection
(a) Install high pressure gauge.
(b) Set the vehicle to the conditions below [*1].
Item Condition
Vehicle Stop the vehicle in shade
Door Fully open
A/C switch On
Engine speed 2,000 rpm
Air inlet mode selector damper position Outer circle
Air outlet damper position Face
Set temperature MAX Cool
Blower speed HI
A/C inlet temperature *2 25 to 30°C
Condenser pressure (high pressure side gauge) *3 1.5 MPa (15.5 kgf/cm2)
HINT:
• *2 Since the correct judgment can be done only when the inlet air temperature stays between 25°C and 35°C,
postpone the test if the temperature is lower than 25°C.
• *3 When the condenser pressure (high pressure side gauge) is higher than 1.5 MPa (15.5 kgf/cm2), water the
condenser to decrease pressure. When the condenser pressure is too low, cover the front side of the condens-
er to increase pressure.
(c) Place a dry and wet bulb thermometer at the air inlet and insert the bulb of a dry bulb thermometer at the center
of the air outlet.
(d) Operate the air conditioner by following [*1] and stabilize the air outlet temperature (approx. 5 to 6 minutes).
(e) Measure the wet bulb temperature at the air inlet and the dry bulb temperature at the air outlet.
(f) Using the hygrometric chart below, determine the relative humidity value, based on the measured values of the
wet and dry bulb thermometers in the inlet.
30
Relative Humidity
0%
10
25
90
80
70
60
20
Wet Bulb Temperature 50
40
15
30
Relative Humidity
10 20
0
10
90
5 80
70
60 10
0 50
40
30
20
10
-5 -4 -3 -2 -1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 1819 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40
Dry Bulb Temperature (°C)
ALI004G

Example (1) For example, when the dry bulb temperature is 25°C,
Wet Bulb and the wet bulb temperature is 19.5°C, the relative hu-
Temperature 20
60
midity value is 60%, which is shown in the hygrometric
15 chart as the point where the 2 dotted lines intersect.
22 23 24 25 26 27
Dry Bulb Temperature (°C) ALI005G
(g) Using the standard performance chart below, find the point where the difference between the temperatures mea-
sured in the inlet and outlet, and the relative humidity intersect.
Standard:
The intersecting point is within the diagonal range shown in the chart.
26
24
22
20
Inlet and Outlet

18
Temperature Difference
(°C)
16
14
12
10
8
30 40 50 60 70
Relative Humidity %
ALI006G
Inlet and Outlet (1) For example, when the difference between temperatures
Temperature Difference Intersection
measured in the inlet and outlet is 17°C, and the relative
(°C) 22
20 humidity is 60%, the intersecting point is within the di-
18 agonal range. Therefore this air conditioner is normal.
16
14
12
10
50 60 70
Relative Humidity % ALI007G

1 2. Inspect pressure switch

(a) Magnetic clutch control:
2 3 Inspect pressure switch operation.
(1) Set the manifold gauge.
Low Pressure Side 4 High Pressure Side (2) Connect the two leads from the ohmmeter to terminal 4
and terminal 1.
(3) Check continuity between the terminals when refriger-
196 kPa 3,140 kPa
(2.0 kgf/cm2 28 psi) (32.0 kgf/cm2 455 psi) ant pressure is changed, as shown in the illustration.
OFF (No continuity) OFF (No continuity)ALI008G If operation is not as specified, replace the condenser
outlet tube (See page AC-18).
1 (b) Cooling fan control:
Inspect pressure switch operation.
2 3 (1) Connect the two leads from the ohmmeter to terminal 2
and terminal 3.
4 (2) Check continuity between the terminals when refriger-
1,770 kPa
OFF (18 kgf/cm2, 257 psi) ant pressure is changed, as shown in the illustration.
(No continuity) ON If operation is not as specified, replace the condenser
(Continuity) outlet tube (See page AC-18).
1,370 kPa
(14 kgf/cm2, 199 psi) ALI009G
3. Inspect compressor assembly

(a) Check the operation.
(1) Start the engine.
(2) Inspect compressor pulley.
Standard:
The compressor can connect and disconnect nor-
mally.
8103200-S16 8103100-S16
Two models of compressor

are equal optional products. ALI010G

(b) Inspect compressor assembly

(1) Disconnect the connector.
(2) Measure the resistance according to the value(s) in the
table below.
Standard:
Tester connection Specified condition
Terminal - Compressor case 4.5 ± 0.5 W
Hint:
When the refrigerant amount of A/C cycle cannot be
checked by the condition of the sight glass, connect the
pressure gauge to check if the system pressure is normal
or not while the compressor working. Jump connection
with the compressor relay or pressure switch can check
if there is cool air coming out from the A/C air outlet.
Regular Inspection
1. Evaporator thermistor
1 (a) Check the continuity of the evaporator thermistor.
2 (1) Measure the resistance between terminal 1 and terminal
2 while the evaporator thermistor is at different tem-
perature, as shown in the table.
ALI011G
Standard:
Temperature (°C) Lower limit value (kW) Standard value (kW) Upper limit value (kW)
-20 13.555 14.270 14.985
-15 10.275 10.817 11.359
-10 7.808 8.220 8.632
-5 6.004 6.321 6.638
0 4.609 4.852 5.095
2 4.227 4.377 4.527
2.5 4.170 4.270 4.370
3 4.080 4.163 4.246
4.3 3.850 3.910 3.970
5 3.686 3.786 3.886
10 2.925 2.985 3.045
15 2.200 2.341 2.482
20 1.823 1.869 1.906
25 1.470 1.500 1.530
30 1.180 1.204 1.228
35 0.9625 0.9821 1.0017
40 0.784 0.800 0.816
45 0.6449 0.6587 0.6713
50 0.5332 0.5441 0.555
55 0.4451 0.4542 0.4633
60 0.3701 0.3777 0.3853
65 0.3124 0.3188 0.3252
70 0.2638 0.2692 0.2746

Temperature (°C) Lower limit value (kW) Standard value (kW) Upper limit value (kW)
75 0.2241 0.2287 0.2333
80 0.1907 0.1946 0.1985
If resistance value is not as specified, replace the evaporator
thermistor.
2. A/C controller assembly No.2
5 (a) Check the continuity of the blower switch.
23 4
6 9 10
LO M1
table below.
OFF M2
Specified
H1 Condition/circuit Tester connection
condition
FF
OFF 4 - 5 - 6 - 9 - 10 10 kW or higher
O
LO 4-5 Below 1 W
ALI012G LO - M1 4-5-9 Below 1 W
M1 4-5-9 Below 1 W
M1 - M2 4 - 5 - 9 - 10 Below 1 W
M2 4 - 5 - 10 Below 1 W
M2 - HI 4 - 5 - 10 - 6 Below 1 W
HI 4-5-6 Below 1 W
If the value is not as specified, replace A/C controller
assembly No.2.
(b) Check operation of the light.
Connect positive (+) lead from the battery to terminal 2, neg-
ative (-) lead to terminal 5, then check that lamp illuminates.
If any of the lamp does not illuminate, replace A/C controller
assembly No.2.
(c) Check the continuity of A/C switch.
A/C
Measure the resistance according to the value(s) in the table
below.
Standard:
Specified
PASSENGER Switch operation Tester connection
condition
ON f - d and c Below 1 W
OFF f - d and c 10 kW or higher
f c d
ALI013G If the continuity is not as specified, replace A/C switch.
(d) Check operation of the indicator.
(1) Connect positive (+) lead from battery to terminal f,
negative (-) lead to terminal d.
(2) Press A/C switch and check that indicator goes on.
If the operation is not as specified, replace A/C switch.

3. Blower speed regulating resistor

(a) Check the continuity of the blower speed regulating resistor.
table below.
2 1 Standard:
4 3 1-2 1.09 ± 10% W
1-3 0.39 ± 10% W
ALI014G 1-4 1.27 ± 10% W
If value is not as specified, replace the blower speed
regulating resistor.
1 4. Blower assembly
2
(a) Check blower assembly
(1) Connect positive (+) lead from the battery to terminal 2,
negative (-) lead to terminal 1, then check that the mo-
tor works smoothly.
If the operation is not as specified, replace the blower
motor.
ALI015G
5. Blower relay
(a) Check the continuity of the relay.
30 87 85 table below.
30 87 Standard:
86 85 86
Specified
Condition Tester connection
condition
Constant 87 - 30 10 kW or higher
ALI016G Apply B+ between
87 - 30 Below 1 W
terminal 85 and 86
If the value is not as specified, replace relay.
Sight Glass
Refrigerant
H
1. Inspect refrigerant volume

(a) Check the sight glass on the condenser outlet pipe.
Test condition:
• Engine is running at 1,500 rpm.
• Blower speed control switch is at “HI”.
• A/C switch is ON.
ALI017G
• Temperature adjusting knob is in the “MAX COOL” po-
sition.
• Doors are fully open.

AC-10 GREAT WALL COOL BEAR REPAIR MANUAL
Item Symptom Refrigerant Corrective action

1. Check for gas leakage and repair if
necessary
1 Bubbles exist Insufficient*
2. Add refrigerant until bubbles disap-
pear
Empty, insufficient
2 No bubbles exist Refer to 3 and 4
or excessive
1. Check for gas leakage with gas leak

No temperature difference between Empty or nearly detector and repair if necessary
3
compressor inlet and outlet empty 2. Add refrigerant until bubbles disap-
pear
Considerable temperature difference

4 Proper or excessive Refer to 5 and 6
between compressor inlet and outlet
1. Recycle the refrigerant

Immediately after air conditioning is
5 Excessive 2. Evaporate air and supply a proper
turned off, refrigerant clears
amount of new refrigerant
Immediately after air conditioning
6 is turned off, refrigerant foams and Proper -
then becomes clear.
*: Bubbles in the sight glass with the vehicle interior temperature above normal temperature can be considered nor-
mal if cooling is sufficient.
2. Inspect refrigerant pressure with manifold gauge set

(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 condition:
• Temperature at the air inlet with the switch set at RE-
CIRC is 30 to 35°C (86 to 95°F).
• Engine is running at 1,500 rpm.
• Blower speed control switch is at “HI”.
• Temperature adjusting knob is in the “COOL” position.
• A/C switch is ON.
• Doors are fully open.

AIR CONDITIONING SYSTEM AC-11
04
(1) Normally functioning refrigeration system.
15 2
Gauge reading:
03 05
4 15 20
3 5
1
02 06
6 10 25
Low pressure side:

2 25
7
1
01 07 5 30
{cmHg kgf/cm2} 05 {cmHg kgf/cm2}
0.15 to 0.25 MPa (1.5 to 2.5 kgf/cm2)

0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
High pressure side:

MPa MPa
1.37 to 1.57 MPa (14 to 16 kgf/cm2)

R134a
ALI018G
(2) Moisture present in refrigeration system.
Condition: Periodically cools and then fails to cool
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
8 3
0
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 -01 35
MPa MPa
ALI019G
Symptom Probable cause Diagnosis Corrective action

• Drier is overly satu-
Moisture in refrigerant 1. Replace drier
rated
system will freeze at the 2. Remove moisture in
During operation, pres- • Moisture in refrigerant
expansion valve orifice, cycle by repeatedly
sure on low pressure side system will freeze at
causing the refrigeration evacuating air
cycles between normal the expansion valve
cycle to temporarily stop. 3. Charge appropriate
and vacuum orifice, causing the
However, when melted, volume of new refrig-
refrigeration cycle to
normal state is restored. erant
stop

(3) Insufficient cooling.
Condition: Cooling system does not function effectively.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01 35
MPa MPa
ALI020G

1. Check for gas leakage
and repair if necessary
• Pressure is low on
2. Charge appropriate vol-
both low and high
ume of new refrigerant
pressure sides
3. If indicated pressure
• Bubbles can be seen Gas leakage from refrig- • Insufficient cooling
value is close to 0,
through sight glass eration system • Leakage of refrigerant
when connected to
continually
gauge, create vacuum
• Cooling performance
after inspecting and
insufficient*
repairing the location
of leakage.

(4) Poor circulation of refrigerant.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALI021G

• Pressure is low on
both low and high
Refrigerant flow is
pressure sides
obstructed by dirt in the Reservoir is obstructed Replace reservoir
• Frost exists on pipe
reservoir
from condenser to
refrigeration unit

(5) Refrigerant does not circulate.
Condition: Cooling system does not function effectively. (Sometimes it may function)
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALI021G

1. Check the expansion
• Vacuum is indicated valve
on low pressure side • Refrigerant flow is 2. Remove all dirt by
and very low pressure obstructed by moisture blowing air into expan-
is indicated on high or dirt in refrigeration sion valve
Refrigerant does not cir-
pressure side system 3. Replace condenser
culate
• Frost or condensation • Refrigerant flow is 4. Evaporate air and sup-
is seen on piping on disrupted by gas leak- ply a proper amount of
both sides of reservoir/ ing internally through new refrigerant
dryer or expansion the expansion valve 5. For internal gas leak
valve at expansion valve, re-
place expansion valve

(6) Refrigerant is overcharged or cooling effectiveness of condenser is insufficient.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 35
-76 -76
085 0
-01 15 -01
35
MPa MPa
ALI022G

• Excessive refrigerant 1. Clean condenser
• Pressure is high on • Unable to develop in cycle → excessive 2. When cooling fan mo-
both low and high sufficient performance refrigerant was re- tor is operating, check
pressure sides due to excessive use charged cooling fan
• No air bubbles are of refrigeration system • Condenser cooling ef- 3. If 1 and 2 normal,
seen through sight • Cooling effectiveness fectiveness is insuffi- check the amount of
glass even when en- of condenser is insuf- cient → condenser fins refrigerant and supply
gine speed lowers ficient are clogged at cooling appropriate volume of
fan refrigerant
(7) Air present in cooling system.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
-01 15
085 0
-01
35
Note: These gauge indica-
MPa MPa tions occur when the refrig-
eration system is operating
and the refrigerant is charged
without vacuum purging.
ALI023G

• Pressure is high on
both low and high 1. Check compressor oil
pressure sides • Air present in refrig- to see if it is dirty or
• The low pressure pip- Air in system eration system insufficient
ing is too hot to touch • Insufficient purging 2. Vacuum and supply
• Bubbles can be seen new refrigerant
through sight glass

(8) Expansion valve malfunction.
Condition: Insufficient cooling.
04 15 2
03 05
4 15 20
3 5
1
02 06
2 6 10 25
25
7
1
01 07 5 30
0 8 3
-50 8.5 0
0 08 -76 35
-76
085 0
-01 15 -01
35
MPa MPa
ALI023G

both low and high • Excessive refrigerant
pressure sides Trouble in expansion in low pressure piping
Check expansion valve
• Frost or large amount valve • Expansion valve opened
of dew on piping on too wide
low pressure side
(9) Defective compression compressor.
Condition: Insufficient cooling.
04 15 2
03 05
4 15 20
3 5
1
02 06
6 10 25
2 25
7
1 5
01 07 30
0 8 3
-50 8.5 0
0 08
-76 -76 35
085 0
-01 15 - 01 35
MPa MPa
ALI024G

• Compressor failure
both low and high
Internal leak in compres- • Leakage from dam- Repair or replace
pressure sides
sor aged valve or broken compressor
• Pressure is too low on
sliding parts
high pressure side

Gauge readings (Reference)
Pressure on Low Pressure Side

MPa (kgf/cm2)
0.5 (5.0)
Blower HI Zone
0.4 (4.0)
1.06 (10.9)
0.3 (3.0) 0.27 (2.85)
1.2 (12.3)
0.22 (2.25)
0.2 (2.0) 0.2 (2.1) Blower LO Zone
1.25 (12.8)
0.14 (1.5)
1.32 (13.5) Pressure on High
Pressure Side
MPa (kgf/cm2)
0.5 (5.0) 1.0 (10.0) 1.5 (15.0) 2.0 (20.0)
ALI025G
Replacement
1. Recycle refrigerant from refrigeration system
(a) Turn the A/C switch on.
(b) Operating the compressor at the engine speed of approx. 1,000 rpm for 5 to 6 minutes, circulate the refrigerant
and collect compressor oil remaining in each component into the compressor as much as possible.
(c) Stop the engine.
(d) Recycle refrigerant with special tool.
2. Add refrigerant
(a) Purify refrigerant system with vacuum pump.
(b) Add refrigerant, HFC-134a (R134a).
Standard: 500 ± 20 g
3. Warm up engine
4. Inspect leakage of refrigerant

Refrigerant Line
Components
Compressor Suction Pipe Assembly
Condenser Outlet Pipe
Compressor Discharge Pipe Assembly
ALI026G

A/C Controller Assembly No.1

Replacement
1. Remove A/C control knob
(a) Remove the 3 A/C control knobs.
ALI027G
2. Remove center console panel body

(b) Using molding remover, disengage 6 claws and 6 clips, then
remove center console panel body.
(c) Disconnect 3 connectors.
::6 Clips :: 6 Claws ALI028G
3. Remove A/C controller assembly No.1

(a) Disengage 3 claws and disconnect A/C controller assembly
No.1.
:：
3 Claws ALI029G
(b) Using a screwdriver, open the claw of the cable clamp and
disconnect the temperature damper cable.
Notice:
• Be careful not to bend the cable wire.
• If the cable wire bends, the temperature damper
cable operation may be affected.
Hint:
Tape the screwdriver tip before use.
ALI030G

(c) Using a screwdriver, open the claw of the cable clamp and
disconnect the position damper cable.
Notice:
• If the cable wire bends, the position damper cable
operation may be affected.
ALI031G
(d) Using a screwdriver, open the claw of the cable clamp and
disconnect the air intake damper cable.
Notice:
• If the cable wire bends, the air intake damper cable
(e) Remove A/C controller assembly No.1.
Hint:
ALI032G Tape the screwdriver tip before use.
4. Remove air inlet damper control lever

(a) Disengage the claw, and remove the air inlet damper control
lever.
5. Install air inlet damper control lever
:：Claw ALI033G
6. Install A/C controller assembly No.1

(a) Install the inner cable end of the position damper cable on
the lever.
(b) Install the outer cable of the position damper cable on the
cable clamp.
Notice:
• If the cable wire bends, the position damper cable
ALI034G operation may be affected.
Hint:
• Operating the air flow position control knob, check that
it properly stops at both ends of FACE and DEF.
• Check that the outer cable is not disengaged ( moved ) from
the A/C controller assembly when the cable is pulled.

(c) Install the inner cable end of the temperature damper cable
on the temperature control lever.
(d) Install the outer cable of the temperature damper cable on the
cable clamp.
Notice:
• If the cable wire bends, the temperature damper
cable operation may be affected.
ALI035G Hint:
• Operating the temperature control knob, check that it
properly stops at both ends of MAX COOL and MAX
HOT.
• Check that the outer cable is not disengaged ( moved )
from the A/C controller assembly No.1 when the cable is
pulled.
(e) Install the inner cable end of the air intake damper cable to
the air intake damper control lever.
(f) Install the outer cable of the air intake damper cable on the
cable clamp.
Notice:
• If the cable wire bends, the air intake damper cable
ALI036G
Hint:
• Operating the circulation control knob, check that it
properly stops at both ends of inner circulation and outer
circulation.
• Check that the outer cable is not disengaged ( moved )
from the A/C controller assembly No.1 when the cable is
pulled.
(g) Connect connector and install A/C controller assembly No.1.


Overhaul
Hint:
verse order.
ALI027G

(b) Using molding remover, disengage 6 claws and 6 clips, then
remove center console panel body.
(c) Disconnect 3 connectors.
::6 Clips :: 6 Claws ALI028G
3. Remove A/C controller assembly No.2

(b) Release 3 claws and remove A/C controller assembly No.2.
: 3 Claws ALI037G
4. Remove A/C switch

(a) Disengage 3 claws and remove A/C switch.
: 3 Claws ALI038G
5. Remove hazard warning light switch

(a) Disengage 3 claws and remove hazard warning light switch.
: 3 Claws ALI039G

6. Remove rear defogger switch

(a) Disengage 3 claws and remove rear defogger switch.
: 3 Claws ALI040G
7. Remove light guide strip

(a) Disengage 2 claws and remove light guide strip.
: 2 Claws ALI041G

A/C Assembly
Components
Air Intake
Air Intake Sponge
Inner-Outer Cycle
Ventilator Louver
Inner-Outer
Cycle Damper
Ventilation Baffle
Upper Case
Expansion Valve Sponge

Heater Core
Heater Water
Inlet Pipe Protector
A/C Air Filter Assembly
Defrost Damper
Blower Assembly
Blower Speed Regulating

Main Outlet Damper Resistor
Evaporator Core
Lower Air Vent Cool/Hot
Damper Drain Pipe
Lower Case
ALI042G

Overhaul
Hint:
reverse order. However, only installation procedures requiring ad-
ditional information are included.
1. Recycle refrigerant from refrigeration system (See page
AC-17)
2. Remove compressor suction pipe assembly and con-
denser outlet pipe
(a) Remove 1 bolt and disconnect compressor suction pipe as-
sembly and condenser outlet pipe from expansion valve.
ALI043G
3. Disconnect heater inlet water hose and outlet water

hose
(a) Engage the claw of the clip with pliers, slip the clip and dis-
connect heater inlet water hose and outlet water hose.
4. Remove A/C controller knob (See page AC-19)
5. Remove center console panel body (See page AC-19)
6. Remove upper instrument panel body
Hint:
ALI044G For the removal of the upper instrument panel body, refer to
the relative description.
7. Remove lower instrument panel body w/instrument
panel reinforcement member (See page IR-35)
Hint:
For the removal of the lower instrument panel body w/instru-
ment panel reinforcement member, refer to relative descrip-
tion.
8. Remove A/C assembly
(a) Disconnect the connector.
(b) Remove position damper cable
(1) Disconnect outer cable.
(2) Disconnect inner cable and remove position damper
cable.
ALI045G

(c) Remove temperature damper cable.

(2) Disconnect inner cable and remove temperature damper
cable.
(d) Remove air intake damper cable.
(2) Disconnect inner cable and remove temperature damper
cable.
ALI046G
(e) Remove central defroster duct assembly.

(1) Remove the clip.
(2) Disengage 2 claws and remove central defroster duct
assembly.
: 2 Claws ALI047G
(f) Disconnect rear lower air duct LH and rear lower air duct
RH.
Rear lower air Rear lower air
duct LH duct RH
ALI048G
(g) Remove 7 bolts and A/C assembly.
ALI049G
9. Remove A/C air filter assembly

(a) Release 2 claws joint surface and remove A/C air filter as-
sembly.
: 2 Claws ALI050G

10. Remove blower speed regulating resistor

(b) Remove 2 screws and blower speed regulating resistor.
ALI051G
11. Remove blower assembly

(b) Remove 3 screws and blower assembly.
ALI052G
12. Remove expansion valve

(a) Remove 2 bolts and expansion valve.
ALI053G
13. Remove heater core

: Clip
(a) Remove screw and bracket.
(b) Remove clip and disconnect connector.
(c) Remove heater core.
ALI054G
14. Remove A/C upper case

(a) Remove screws and A/C upper case.
ALI055G

15. Remove evaporator thermistor

(a) Disengage 2 claws and remove evaporator thermistor.
:: 2 Claws ALI056G
16. Remove evaporator sub-assembly

(a) Remove evaporator sub-assembly.
(b) Remove 2 O-rings from evaporator sub-assembly.
ALI057G
17. Install position damper cable

(a) Set the arm to the FACE position.
(b) Install inner cable end to the control lever when the arm in
the FACE position.
(c) Install the outer cable to the cable clamp while slightly press-
ing it in the direction of the arrow.
FACE DEF Notice:
ALI058G • If the cable wire bends, the A/C controller assembly
No.1 operation may be affected.
Hint:
Operating the mode control lever, check that it properly stops
at both ends of FACE and DEF.

18. Install temperature damper cable

(a) Set the arm in the MAX COOL position.
MAX HOT (b) Install the inner cable end to the control lever with the arm in
the MAX COOL position.
MAX (c) Install the outer cable to the cable clamp while slightly press-
COOL ing it in the direction of the arrow.
Notice:
ALI059G • If the cable wire bends, the A/C controller assembly
No.1 operation may be affected.
Hint:
Operating the mode control lever, check that it properly stops
at both ends of MAX HOT and MAX COOL.
19. Install air intake damper cable
20. Install lower instrument panel body w/instrument panel
reinforcement member
21. Install upper instrument panel body
22. Install center console panel body
23. Install A/C control knob
24. Install compressor suction pipe assembly and condens-
er outlet pipe
(a) Install compressor suction pipe assembly and condenser out-
let pipe to expansion valve with 1 bolt.
Torque: 10 N·m (102 kgf·cm, 90 in.·lbf)
ALI043G
25. Install heater inlet water hose and outlet water hose
26. Add engine coolant (See page EG-10)
27. Charge refrigerant (See page AC-17)
Specified amount: 500 ± 20 g
28. Warm up engine
29. Check for engine coolant leaks (See page EG-6)
ALI044G

Compressor Assembly
Replacement
AC-17)
2. Remove deflector panel assembly of engine LH and RH.
3. Remove fan and generator drive belt
4. Disconnect compressor discharge pipe assembly
(a) Remove the bolt and disconnect compressor discharge pipe
assembly from compressor assembly.
(b) Remove the O-ring from compressor discharge pipe assem-
bly.
Notice:
Seal the opening of the disconnected parts by vinyl
tape to prevent moisture and foreign matter from enter-
ALI060G ing.
5. Disconnect compressor suction pipe assembly

(a) Remove the bolt and disconnect compressor suction pipe as-
sembly from compressor assembly.
(b) Remove the O-ring from compressor suction pipe assembly.
Notice:
ing.
ALI061G
6. Remove compressor assembly

(b) Remove 4 bolts and compressor assembly.
7. Inspect compressor oil
(a) When replacing compressor assembly with a new one, after
gradually discharging the refrigerant gas from the service
valve, drain the following amount of oil from the new com-
pressor assembly before installation.
ALI062G Standard:
(Oil capacity inside new compressor: 200 ml) - (Re-
maining oil amount in the removed compressor ) = (Oil
amount to be discharged when replacing)
Notice:
• When checking the compressor oil level, observe the
precautions for compressor removal or installation.
• Because compressor oil remains in the pipes of the
vehicle, if a new compressor is installed without dis-
charging some of the remaining oil, the oil amount
becomes too much, preventing heat exchange in the
refrigerant cycle and causing refrigerant failure.

• If the remaining oil in the removed compressor is

too small in volume, check for oil leakage.
• Be sure to use ND-OIL 8 for compressor oil.
8. Install compressor assembly

(a) Install the compressor assembly with the 4 bolts.
Notice:
Tighten the bolts in the order as shown in the illustra-
tion to install the compressor assembly.
(b) Connect the connectors.
ALI062G
9. Install compressor suction pipe assembly

(a) Remove the wound vinyl tape from the hose.
(b) Apply a sufficient amount of compressor oil to a new O-ring
and fit surface of the compressor assembly.
Compressor oil: ND-OIL 8 or equivalent
(c) Install the O-ring to compressor suction pipe assembly.
(d) Install the suction hose sub-assembly on the compressor as-
sembly with the bolt.
ALI061G Torque: 10 N·m (102 kgf·cm, 90 in.·lbf)
10. Install compressor discharge pipe assembly

(a) Remove the wound vinyl tape from the hose.
(b) Apply a sufficient amount of compressor oil to a new O-ring
and fit surface of the compressor assembly.
(c) Install the O-ring to the compressor discharge pipe assembly,
and then install it to the compressor assembly with the bolt.
ALI060G 11. Install generator and connecting belt of steering oil pump
12. Adjust belt tension by adjusting generator position
14. Warm up engine
Super-cooling Type Condenser Assembly

On-vehicle inspection
1. Inspect super-cooling type condenser assembly
(a) If the fin of the super-cooling condenser assembly is dirty,
clean it with water and dry it with compressed air.
Notice:
Be careful not to damage the fin of the super-cooling
condenser assembly.
(b) If the fin of the super-cooling condenser assembly is bent,
use a screwdriver or pliers to straighten it.

2. Inspect condenser for leakage of refrigerant

(a) Using a halogen leak detector, check the pipe joints for gas
leakage.
(b) If gas leakage is detected in a joint, check the torque of the
joint.
Components
9.8 (100, 87 in.·lbf)
Condenser Upper Mount Assembly

3.9 (40, 35 in.·lbf)
9.8 (100, 87 in.·lbf)
3.9 (40, 35 in.·lbf)
Dryer
l O-ring
2.9 (29, 25 in.·lbf)
10 (102, 90 in.·lbf)
l O-ring
Compressor Discharge Pipe Assembly
l O-ring Super-Cooling Type Condenser Assembly
Condenser Outlet Pipe

10 (102, 90 in.·lbf)
torque
N·m (kgf·cm, ft·lbf) : Specified Torque
l Non-reusable
● Non-reusable part
Parts
ALI063G
Overhaul
Hint:
Components: See page AC-32
AC-17)
BO-38)

4. Disconnect compressor discharge pipe assembly

(a) Remove the bolt and disconnect compressor discharge pipe
assembly from super-cooling condenser assembly.
(b) Remove the O-ring from compressor discharge pipe assem-
bly.
Notice:
ALI064G ing.
5. Disconnect condenser outlet pipe

(a) Remove condenser outlet pipe from super-cooling condenser
assembly.
(b) Remove O-ring from condenser outlet pipe.
Notice:
ing.
ALI065G (c) Disconnect outlet tube from condenser outlet pipe bracket.
6. Remove super-cooling type condenser assembly

(a) Remove 2 bolts and super-cooling condenser assembly.
ALI066G
7. Remove condenser upper mount assembly

(a) Remove 2 bolts and 2 condenser upper mount assembly.
ALI067G

8. Remove dryer
(a) Remove the cap from the adjuster with 10 mm (0.55 in.)
socket hexagon wrench.
ALI068G
(b) Remove O-rings from the cap.
ALI069G
(c) Remove dryer with pliers.
ALI070G
9. Install dryer
(a) Install dryer with pliers.
ALI070G
(b) Install new O-rings to the cap.

(c) Apply a sufficient amount of compressor oil to the new
O-rings and fit surface of the cap.
ALI071G

(d) Install the cap to the adjuster with 10 mm (0.55 in.) socket
hexagon wrench.
ALI068G
10. Install condenser upper mount assembly

(a) Install 2 bolts and 2 condenser upper mount assembly.
ALI067G
11. Install super-cooling type condenser assembly

(a) Install super-cooling condenser with 2 bolts.
12. Install condenser outlet pipe
(a) Remove the wound vinyl tape from the condenser outlet pipe
and super-cooling condenser assembly.
(b) Apply a sufficient amount of compressor oil to the new
O-ring and the joint of the hose.
ALI066G Compressor oil: ND-OIL 8 or equivalent
(c) Install the O-ring to condenser outlet pipe.
(d) Fix the condenser outlet tube to the bracket.
(e) Install condenser outlet pipe to super-cooling condenser as-
sembly with bolt.
14. Warm up engine
ALI065G

MEMO

RS-
SAFETY SUPPLEMENTAL
RESTRAINT SYSTEM
SUPPLEMENTAL RESTRAINT SYSTEM
Precaution......................................................................... RS-2
SRS Airbag System Diagnosis.......................................... RS-10
On-vehicle Inspection....................................................... RS-25
Driver Airbag Assembly..................................................... RS-28
Clock Spring Sub-assembly.............................................. RS-37
Passenger Airbag Assembly............................................. RS-39
Airbag ECU Assembly....................................................... RS-47
SEAT BELT
Seat Belt Warning System................................................ RS-49
Front Seat Belt.................................................................. RS-51
Rear Seat Belt................................................................... RS-60
RS
10-SAFETY SUPPLEMENTAL RESTRAINT1 1 2008-10-21 8:40:38

RS- GREAT WALL COOL BEAR REPAIR MANUAL
SUPPLEMENTAL RESTRAINT SYSTEM

Precaution
Caution:
• This vehicle is equipped with SRS, which consists of the driver airbag, passenger airbag and seat belt.
Failure to carry out service operations in the correct sequence could cause the SRS to unexpectedly de-
ploy during servicing, possibly leading to serious accident. Further, if a mistake is made in servicing the
SRS, it is possible that the SRS may fail to operate when required. Before performing servicing (including
removal or installation of parts, inspection or replacement), be sure to read the following items carefully,
then follow the correct procedures indicated in the repair manual.
• Wait at least 90 seconds after the ignition switch is turned to the “LOCK” position and the negative (-)
terminal cable is disconnected from the battery. (The SRS is equipped with a back-up power source, so
that if work is started within 90 seconds after disconnecting the negative (-) terminal cable of the battery,
the SRS may be deployed)
• Do not expose the driver airbag assembly, passenger airbag assembly, airbag ECU assembly directly to
hot air or flames.
Notice:
• Malfunction symptoms of the SRS are difficult to confirm, so DTCs are the most important source of
information when troubleshooting. When troubleshooting the SRS, always inspect DTCs before discon-
necting the battery.
• Even in the case of a minor collision when the SRS does not deploy, the driver airbag assembly, pas-
senger airbag assembly, airbag ECU assembly must be inspected (See page RS-25).
• Before repair work, remove the airbag ECU assembly if any kind of shock is likely to occur to the as-
sembly during operation.
• Never use the SRS parts from another vehicle. When replacing the parts, replace them with new ones.
• Never disassemble nor repair the driver airbag assembly, passenger airbag assembly, airbag ECU as-
sembly in order to reuse it.
• If the driver airbag assembly, passenger airbag assembly, airbag ECU assembly has been dropped, or if
there are any cracks, dents or other defects in the case, bracket or connector, replace it with a new one.
• Use a X-431 tester for troubleshooting the electrical circuits.
• Information labels are attached to the periphery of the SRS components. Follow the instructions in the
notice.
• After work on the SRS is completed, perform the SRS warning light check.
• When the negative (-) terminal cable is disconnected from the battery, the memory of the clock and au-
dio system will be canceled. So before starting work, make a record of the contents memorized in the
audio memory system. When work is finished, reset the audio systems as they were before and adjust
the clock. To avoid erasing the memory in each memory system, never use a back-up power supply
from outside the vehicle.
• If the vehicle is equipped with a mobile communication system, refer to the precaution in the “Introduction”
section.

SAFETY SUPPLEMENTAL RESTRAINT SYSTEM RS-
1. SRS connectors
1
Passenger Side
Seat Belt Assembly
(Squib)
2
3
Passenger Airbag
Assembly (Squib)
4
Airbag ECU
5 7
Clock Spring Driver Airbag
Sub-assembly Assembly (Squib)
6 8
9
Driver Side Seat Belt
Assembly (Squib)
10
ALJ001G
No. Item Application

(1) twin-lock mechanism Connectors 2, 3, 5
(2) prevention mechanism Connectors 4, 6, 8, 10
(3) lock mechanism Connectors 1, 7, 9

Spacer (a) All connectors in the SRS are colored in yellow to distin-
guish them from other connectors.
Housing The connectors having special functions and specifically
designed for the SRS are used in the locations shown on the
previous page to ensure high reliability. These connectors use
durable gold-plated terminals.
(1) Terminal twin-lock mechanism:
Female
Male Each connector has a two-piece component consisting
ALJ002G of a housing and a spacer. This design enables the ter-
minal to be locked securely by two locking devices (the
retainer and the lance) to prevent terminals from com-
ing out.
(2) Activation prevention mechanism:
Each connector contains a short spring plate. When the
connector is disconnected, the short spring plate auto-
matically connects positive (+) terminal and negative (-)
terminal of the squib.
When connector is connected When connector is disconnected
Short Spring Plate
Short Spring Plate

Housing
Contacting Male Terminal
Housing
Short Spring Plate ON
Terminal
Short Squib
Connectors Closed Circuit
Spring Squib
Plate
ALJ003G
Hint:
The type of connector is shown in the diagram on the
previous page.

(3) Half connection prevention mechanism:

If the connector is not completely connected, the connector is disconnected due to the spring operation to
the extent that no continuity exists.
Slider Stopper
Locking Arm Spring
Locking Part Rebounded by Slider
Stopper (Spring)
ALJ004G
(4) Connector lock mechanism:

Locking the connector lock button connects the connector securely.
Lock Button
Claw
Groove
ALJ005G
(5) Connector position assurance mechanism:

Only when the housing lock (white part) is completely engaged, the CPA (yellow part) slides, which com-
pletes the connector engagement.
Housing Lock
(White Part)
Housing Lock
(White Part)
CPA (Yellow Part) CPA (Yellow Part)

ALJ006G

Fig.1 (b) When the vehicle is involved in a frontal collision in the

hatched area (Fig.1) and the shock is larger than the prede-
termined level, the SRS is activated automatically. The saf-
ing sensor is designed to go on at a smaller deceleration rate
Fig.2 Power Source
than the airbag sensor. As illustrated in the Fig.2, ignition is
caused when current flows to the squib, which happens when
Safing Squib the safing sensor and the deceleration sensor go on simul-
Sensor
taneously. When a deceleration force acts on the sensors, 2
Deceleration Sensor ALJ007G squibs in the driver airbag and front passenger airbag ignite
and generate gas. The bags are deployed. Then the bags de-
flate as the gas is discharged through discharge holes at the
bag’s rear or side.
2. Disconnection of connectors for driver airbag assembly
Hint:
(a) Release the lock button (yellow part) of the connector by a screwdriver.
(b) Insert a screwdriver tip between the connector and the base, and then raise the connector.
Lock Button (Yellow)

(a) Lock Button (Yellow) (b)
Marks
ALJ008G

3. Connection of connectors for driver airbag assembly

(a) Connect the connectors.
(b) Push down securely on the lock button (yellow part) of the connector.
Lock Button (Yellow)
ALJ009G
4. Disconnection of connector for airbag ECU assembly

(a) Push down the housing lock (white part) and slide the CPA (yellow part). (At this time, the connector cannot be
disconnected yet)
(b) Push down the housing lock (white part) again and disconnect the connector.
Hint:
Do not push down the A part shown in the illustration when disconnecting.
Housing Lock (White Part)
Connector
lock is
released
CPA (Yellow Part)
ALJ010G

(c) After disconnecting the connector, check that the position of the housing lock (the white part) is as shown in the
illustration.
ALJ011G
5. Connection of connector for airbag ECU assembly

(a) Before connecting the connectors, check that the position of the housing lock (the white part) is as shown in the
illustration.
ALJ012G

(b) Be sure to engage the connectors until they are locked. (When locking, make sure that a click sound can be
heard)
Hint:
When connecting them, the housing lock (white part) slides. Be sure not to hold the housing lock (white part)
and A part, as it may result in an insecure fit.
A
Housing Lock (White Part)
CPA (Yellow Part)
Connection
is completed
ALJ013G

RS-10 GREAT WALL COOL BEAR REPAIR MANUAL
SRS Airbag System Diagnosis

1. Airbag ECU
Passenger Airbag
Assembly
Driver Airbag Airbag ECU Assembly
Malfunction Diagnosis Connector
Dotted line in the figure is the wire harness schematic drawing.
Driver Side Seat Belt Pretensioner

Passenger Side Seat Belt Pretensioner ALJ014G
For safe operation, read the precaution for maintenance below before operation.
(a) When performing airbag maintenance, it should be operated as the order and cautions indicated in this
chapter.
(b) Always operate with experimental instruments and special tools indicated in this chapter.
(c) When repair the parts below, if the parts have malfunction, always replace with a new one.
(1) Airbag ECU
(2) Clock spring sub-assembly
(3) Driver airbag assembly
(4) Passenger airbag assembly
(5) Driver side seat belt pretensioner
(6) Passenger side seat belt pretensioner
(7) Airbag wire harness
(d) Wait 90 seconds after disconnection of negative terminal to prevent airbag from deploying.
2. Airbag ECU terminal
25
25 11 10 9 8 7 6 5 4 3 2 1
46 30
26
50
ALJ015G

SAFETY SUPPLEMENTAL RESTRAINT SYSTEM RS-11
Terminal No. Symbol Description

1 DRV A/B+ Driver airbag, Positive
2 DRV A/B- Driver airbag, Negative
3 PSG A/B+ Passenger airbag, Positive
4 PSG A/B- Passenger airbag, Negative
7 PSG PRETENSIONER- Passenger side seat belt pretensioner, Negative
8 DRV PRETENSIONER+ Driver side seat belt pretensioner, Positive
9 DRV PRETENSIONER- Driver side seat belt pretensioner, Negative
10 WARNING LAMP Malfunction lamp
11 GND Ground wire
25 BPT Hi Battery voltage
30 PSG PRETENSIONER- Passenger side seat belt pretensioner, positive
46 K-LINE Diagnosis serial data I/O (K line)
3. Airbag troubleshooting
(a) Using X-431 tester diagnosis malfunction
Malfunction type of airbag ECU divides into two kinds by time: current malfunction and history malfunction;
and by nature: outer malfunction and inner malfunction.
Current malfunction code and history malfunction code may exist at the same time; outer malfunction code can
be eliminated by using diagnosis tester, inner malfunction code cannot be eliminated, but replace airbag ECU.
Caution:
After installing new airbag system electrical control unit, airbag system warning light turn off after light-
ing 6 ~ 7 seconds when the ignition switch is ON, which means that airbag system operation normal.
At this time, it is not necessary to service, but for the others except this, it should perform system di-
agnosis and service.
Using the diagnosis
Warning light Find the Perform
tester and K line Clear trouble code
status is abnormal malfunction area troubleshooting
connect scan tool ECU
Inspection for airbag warning light
(1) When turning the ignition switch to “ON” position, check the warning light remains on for 6 ~ 7 sec-
onds.
(2) If the warning light turns off after 6 ~ 7 seconds, it is normal.
(3) Except for above, it is necessary to perform diagnosis inspection.
System diagnosis
Airbag ECU will perform a list of cycle diagnosis test to check if the airbag system function is ready. This
test will prevent restraint system from deploying unexpectedly and be sure to make necessary deployment
in collision. If malfunction is found, airbag ECU will store a proper trouble code and turn on warning light
to indicate a malfunction condition for maintenance.
603 418 (b) Malfunction judgment
Or-B1 W-P (1) Malfunction record (trouble code storage)
0.5 0.5
Diagnosis After ECU determines malfunction by cycle diagnosis
Interface test, airbag ECU will store corresponding code, first
9 K 16
judgment time, last judgment time and the times in EE-
1 905 905A 7 8
PROM.
B B Only 16 trouble codes can be stored in airbag ECU.
0.5 0.5
ALJ016G

Certified trouble code for airbag ECU:

Type Trouble
No. Description Troubleshooting
code code
1 (Passenger side seat belt pretensioner), connected to 03H 01H OK
power source
2 (Driver side seat belt pretensioner), connect to power 03H 02H OK
source
3 (Driver front airbag), connect to power source 03H 03H OK
4 (Passenger airbag), connect to power source 03H 04H OK
5 (Passenger side seat belt pretensioner), ground 02H 01H OK
6 (Driver side seat belt pretensioner), ground 02H 02H OK
7 (Driver front airbag), ground 02H 03H OK
8 (Passenger airbag), ground 02H 04H OK
9 (Passenger side seat belt pretensioner), the resistance is 01H 01H OK
too high or circuit is open
10 (Driver side seat belt pretensioner), the resistance is too 01H 02H OK
high or circuit is open
11 (Driver front airbag), the resistance is too high or circuit 01H 03H OK
is open
12 (Passenger airbag), the resistance is too high or circuit is 01H 04H OK
open
13 (Passenger side seat belt pretensioner), the resistance is 0CH 01H OK
too low or circuit is short
14 (Driver side seat belt pretensioner), the resistance is too 0CH 02H OK
low or circuit is short
15 (Driver front airbag), the resistance is too low or circuit 0CH 03H OK
is short
16 (Passenger airbag), the resistance is too low or circuit is 0CH 04H OK
short
17 Voltage of power source is out of range (high voltage or 12H 42H OK
low voltage)
18 Power source line trouble in contact 11H 42H OK
19 Warning light malfunction - connect to power source or 03H 40H OK
bulb is short
20 Warning light malfunction - ground or filament is open 02H 41H OK
21 Configuration error 06H 44H OK
22 Inner malfunction 0DH >80H Cannot troubleshoot
(Replace Airbag ECU)
Transmission of trouble code is completed by airbag ECU through maintenance procedure serial data inter-
face transmitting to specified diagnosis tester (X-431 diagnosis tester).
(c) Clear trouble code
Description:
Trouble code in ECU is cleared when ECU receive the order of “clear trouble code” by the serial interface from
X-431 diagnosis tester. However, it does not perform the order if a inner trouble code or collision is recorded.

4. Warning light troubleshooting

(a) Warning light does not come on or remains on.
Symptom Possible cause
Airbag system warning light dose Airbag system warning circuit has malfunction.
not come on.
Airbag system warning light remains Airbag system warning circuit malfunction or outer malfunction.
on.
(b) Airbag system warning light dose not come on.
Airbag system warning light dose Airbag system warning circuit has malfunction.
not come on. • Voltage disappeared (fuse open)
• Combination meter malfunction
• Wire malfunction between combination meter and ECU unit
Diagnosis procedure
Hint:
When performing the first malfunction detection, it is recommended that you shake the wire and connector to
check for trouble in contact timely, if the problem exists, check if the connector, terminal and wire connect cor-
rectly and is undamaged, if not, go on as the follow procedures.
Procedure Detection Operation
1 Detect other wires and instrument lamp. Yes Turn the ignition switch the “LOCK”
• Turn the ignition switch to “ON” position position, go to next step for operation.
• Other warning light and lamp on or not No Detect instrument power supply system
and ground system (fuse), then go to the
step 5.
2 Check bulb Yes Go to the next step for operation.
Caution:
Failure to carry out airbag system element in the
correct way could cause the airbag and belt pre-
tensioner to unexpectedly deploy, possibly leading
to serious accident. Read airbag system service
warning before carrying out airbag element.
• Turn the ignition switch to “LOCK” position No Replace the warning light bulb.
• Disconnect battery negative terminal and keep
for at least 90 seconds
• Remove instrument
• Check the airbag warning light corresponding
two terminals for continuity
3 Detect connection for wires between ECU unit Yes Go to the next step for operation.
and instrument.
• Turn the ignition switch to “LOCK” position
• Disconnect battery negative terminal
• Disconnect instrument connector No Replace the wire, then go to the step 5.
• Check for continuity of warning light circuit
corresponding line

(c) Airbag system warning light remains on.

Airbag system warning light remains • Battery is low
on. • ECU inner malfunction
• Combination meter airbag warning light malfunction
• ECU connector connects incorrectly
• Combination meter connector connects incorrectly
• ECU power supply fuse is open or connects incorrectly
• ECU connector terminals connect incorrectly
• The wires between ECU connector terminals and the ground connect
incorrectly
• Driver side airbag or passenger side airbag malfunction
• Driver side and passenger side seat belt pretensioner malfunction
Diagnosis procedure
Hint:
Using the special diagnostic equipment (X-431 diagnostic tester) communicates with the ECU before inspec-
tions to identify the reasons for failure, if not communicate, perform the following further checks.
1 Check the battery Yes Go to the next step for operation.
• Measure the battery voltage No Battery voltage is low
• Check the battery voltage is higher than 9 V. Check charge/discharge system, then go
to the step 5.
2 Check bulb Yes Go to the next step for operation.
• Disconnect battery negative
• Open instrument panel lower socket
• Disconnect instrument connector
• Connect battery negative No Check the circuit, and then go to the
• Turn the ignition switch to “ON” position step 5 after being repaired.
• Check the voltage between the instrument cor-
responding connector terminals is 12 V (power
supply and instrument wire)
3 • Turn the ignition switch to “LOCK” position Yes Go to the next step for operation.
• Check the continuity between the instrument
corresponding terminals and the diagnose in- No Replace the wire, then go to the step 5.
terface (at both ends of K Line)
4 Make sure to disconnect battery negative terminal Yes Go to the next step for operation.
and keep for at least 90 seconds
• Disconnect ECU connector
• Disconnect instrument connector
No Replace the wire, then go to the step 5.
• Check the continuity between the ECU con-
nector terminals 25, 10, 46 and the instrument
connector
5 Remove ECU and check if the terminal is good, Yes Replace the ECU
short spring plate is broken No Reconnect the ECU connector, then go
to the next step for operation.
next page


6 Check the problem symptom does not exist after Yes Explain the repair procedure to the cus-
being repaired. tomer after troubleshooting.
• Disconnect battery negative terminal and keep
for at least 90 seconds
• Connect all ECU connectors
• Connect the driver side airbag assembly con-
nector
• Connect the passenger side airbag assembly No Check the problem symptom again, if
connector the trouble occurs again, repeat the pro-
• Connect the driver and passenger side seat belt cedure from the step 1.
pretensioner connector
• Connect the clock spring connector
• Connect battery negative terminal
• Turn the ignition switch to “ON” position
• Check the airbag warning indicator is operat-
ing normally
5. Inner malfunction
Type code Airbag system unit inner malfunction
0D
Trouble code
>80
Detection Caution
condition • The detection condition of this malfunction is that the trouble code may not occur before
checking, perform DTC checking, which may cause injury or damage the system due to the
operating error during the inspection. Thus, before checking, perform preparation before
work.
• Airbag system electronic control unit inner circuit malfunction.
Possible Airbag system unit inner malfunction
cause
Operation
Replace airbag system unit, refer to the airbag system, removal/installation of the airbag system unit.

6. Power source
Trouble code The power voltage of airbag system electronic control unit exceeds the standard voltage range.
12
Trouble code
42
Detection Caution
condition • The detection condition of this malfunction is that the trouble code may not occur before
checking, perform DTC checking, which may cause injury or damage the system due to the
operating error during the inspection. Thus, before checking, perform preparation before
work.
• The voltage between terminal 5 and 6 of airbag system unit connector is lower than 9 V.
Possible • Battery voltage is too low
cause • The wires between the battery and airbag system electronic control unit have malfunctions.
Procedure Inspection Operation

1 • Check the battery Yes Go to the next step for operation.
• Measure the battery voltage
No The battery voltage is too low, check the
• Check the battery voltage is higher than 9 V.
charge and discharge system
2 • Check the wire harnesses between the battery Yes Go to the next step for operation.
and fuse block
• Remove the fuse block and turn the ignition
switch to “ON” position with the connector
No Check the wire harness
connected.
• Measure the voltage between the two fuse
block terminals and the voltage is higher than
9V
next page

Procedure Inspection Operation

3 Check the wire harness between the fuse block Yes Go to the next step for operation.
and airbag system unit
Caution
• If the handling is incorrect, the airbag modules
and seat belt pretensioner may be deployed and
tightened, resulting in serious personal injury,
therefore, read the repair warnings carefully
before operating. Refer to airbag system repair
warnings.
• Disconnect battery negative cable and wait
more than 90 s
• Remove the combination switch cover No Check the wire harness
• Disconnect the clock spring connector
• Remove the glove box body
• Disconnect the passenger airbag module con-
nector
• Remove the instrument panel lower socket
• Disconnect all airbag system unit connectors
• Connect the battery negative cable, turn the
ignition switch to “ON” position, and measure
the voltage between the terminals 25 and 11
(ground) of the airbag system unit connector,
the voltage is higher than 9 V
4 • Turn the ignition switch to “LOCK” position Yes [Current trouble codes]
• Disconnect battery negative cable and wait Replace the airbag system unit
more than 90 s Refer to airbag system
• Remove the inner trim panel LH removal/installation of airbag system
• Disconnect airbag system unit adaptor connec- unit
tor [History trouble codes]
• Connect the battery negative cable, turn the Malfunction diagnosis is finished
ignition switch to “ON” position, and measure No Replace the wire harness
the voltage between the adaptor connector and
ground, the voltage is higher than 9 V

7. Drive side malfunction

Trouble code Driver airbag malfunction (Resistance is too large or too small, short, etc.)
02
Trouble code
01, 02, 03
Detection Caution
condition • If the handling is incorrect, the airbag modules and seat belt pretensioner may be deployed
and tightened, resulting in serious personal injury, therefore, read the repair warning carefully
before operating. Refer to airbag system repair warnings.
• The resistance value between terminals of airbag system unit connector is not as specified.
• A short or open circuit occurs in the wiring harness related to the driver airbag of airbag sys-
tem
Possible • Driver airbag module malfunction
cause • Clock spring inner malfunction
• Connectors malfunction in the circuit between the clock spring and airbag system electronic
control unit
• A short or open circuit occurs in the wiring harness between the clock spring and airbag sys-
tem electronic control unit
• The connectors of driver airbag in the airbag system do not insert well

1 Check the clock spring OK Go to the next step for operation.
Caution
• If the handling is incorrect, the airbag modules
and seat belt pretensioner may be deployed and
tightened, resulting in serious personal injury,
therefore, read the repair warning carefully
NG Replace the clock spring
warnings.
Refer to airbag system, removal/instal-
• Check the clock spring and its related parts
lation of the clock spring
are normal, (The connections between the ter-
minals are normal, no short, open circuit phe-
nomenon, etc.) if necessary, replace the clock
spring with a new one.
2 • Make sure there is malfunctions in driver air- Yes Replace driver airbag module
bag module or in other parts. Refer to airbag system, removal/instal-
• Replace a good DAB module lation of the driver airbag module
• Connect battery negative cable No Go to the next step for operation.
• Whether the trouble code is display, or cleared
next page


3 • Check the clock spring wire harness connector OK Go to the next step for operation.
more than 90 s
NG Replace the wire harness
• Remove the combination switch cover
• Whether the clock spring connector is normal
4 • Turn the ignition switch to “LOCK” position Yes [Current trouble codes]
• Disconnect battery negative cable and wait Replace the airbag system unit
more than 90 s Refer to airbag system
• Remove the inner trim panel LH removal/installation of airbag system
• Disconnect airbag system unit adaptor connec- unit
tor [History trouble codes]
• Connect the battery negative cable, turn the Malfunction diagnosis is finished
ignition switch to “ON” position, and measure No Replace the wire harness
the voltage between the adaptor connector and
ground, the voltage is higher than 9 V
5 • Check the wire harness between the clock OK Replace the airbag system unit
spring and airbag system electronic control Refer to airbag system
unit removal/installation of airbag system
• Turn the ignition switch to “LOCK” position unit
more than 90 s
nector
• Disconnect all airbag system unit connectors NG Replace the wire harness
• Check the wire harness between the airbag
system unit connector terminals and the clock
spring connector terminals, and the terminals
of the airbag system unit connector and the
clock spring connector:
(1) Ground
(2) Short to +B
(3) Open
Whether the wire harness is normal
6 • Check the clock spring connector OK Go to the next step for operation.
NG Replace the wire harness or connector
next page


7 • Check the clock spring OK Go to the next step for operation.
• Remove the clock spring
• Refer to airbag system, removal/installation of
the clock spring
NG Replace the clock spring
• Check the clock spring
• Refer to airbag system, check the clock spring
lation of the clock spring
8 • Check the wire harness between the clock OK Replace driver airbag module
spring and airbag system electronic control Refer to airbag system
unit removal/installation of the driver airbag
• Turn the ignition switch to “LOCK” position module
more than 90 s
nector
• Remove the instrument panel lower socket NG Replace the wire harness
• Disconnect all airbag system unit connectors
• Check the wire harness between the airbag
system unit connector terminals and the clock
spring connector terminals, and the terminals
of the airbag system unit connector and the
clock spring connector:
(1) Ground
(2) Short to +B
(3) Open

8. Passenger side malfunction

Type code Passenger side airbag module (Resistance is too large or too small, short, etc.)
02
Trouble code
01, 02, 03
Detection Caution
condition • If the handling is incorrect, the airbag modules and seat belt pretensioner may be deployed
and tightened, resulting in serious personal injury, therefore, read the repair warning carefully
before operating. Refer to airbag system repair warnings.
• The resistance value between terminals 3 and 4 of airbag system unit connector is not as spec-
ified.
• Wire harness between the airbag system unit terminals 3 and 4 has short circuit
Possible • Passenger airbag module malfunction
cause • The connector malfunction between the passenger airbag module and the airbag system elec-
tronic control unit
• The connector malfunction between the airbag system electronic control unit and the ground
• The circuit between the passenger airbag module and the airbag system electronic control unit
is open or short
• The circuit between the airbag system electronic control unit and the ground is open or short
• Airbag system unit malfunction

1 Whether the vehicle is equipped with passenger Yes Go to the next step for operation.
airbag module No -
2 Check the passenger airbag module connector OK [Current trouble codes]
• If the handling is incorrect, the airbag modules Go to the next step for operation.
and seat belt pretensioner may be deployed and [History trouble codes]
tightened, resulting in serious personal injury, Go to the next step for operation.
therefore, read the repair warning carefully
warnings.
NG Replace the wire harness
more than 90 s
• Remove the glove compartment body
nector
• Whether the passenger airbag connector is nor-
mal
3 • Make sure there is malfunction in passenger Yes Go to the next step for operation.
airbag module or in other parts.
• Connect a good module to the passenger air-
bag module connector terminal A and B
No Replace the passenger airbag module
• Connect battery negative cable
lation of the passenger airbag module
• Whether the trouble code is displayed
next page


4 Check the wire harness between passenger airbag OK [Current trouble codes]
module and airbag system electronic control unit Replace the airbag system unit
• Turn the ignition switch to “LOCK” position Refer to airbag system
• Disconnect battery negative cable and wait removal/installation of airbag system
more than 90 s unit
• Remove the combination switch cover [History trouble codes]
• Disconnect the clock spring connector Malfunction diagnosis is finished
• Disconnect the driver and passenger airbag
module connector
• Disconnect all airbag system unit connectors NG Replace the related wire harness
• Check the circuit between the airbag system
unit connector terminals and the passenger
airbag module connector terminals, and the
terminals of the airbag system unit connector
and the passenger airbag module connector:
(1) Ground
(2) Short to +B
(3) Open
Whether the wire harness is normal

9. Diagnosis for vehicle involved in collision

Whether the airbag is deployed or not, check and mainte-
nance procedures for the vehicle involved in collision are as
follows.
(a) Check the ECU diagnosis signal
(1) Connect (X-431 diagnosis tester) diagnosis connector.
(2) Read the diagnosis result with (X-431 diagnosis tester).
Caution:
Because the impact and the battery power short-
age, the instrument cannot communicate with the
airbag ECU, thus, use an external power supply
during the check and maintenance of the instru-
ment panel.
(b) Repair order
(1) When the airbag is deployed
Replace the following parts with new ones:
• Driver airbag module
• Passenger airbag module
• Airbag ECU
• Driver side and passenger side seat belt pretensioner
Check the following parts, replace it with a new one if
it is abnormal:
• Clock spring
• Steering wheel, steering column, steering axis
The installation conditions of driver airbag module for
steering wheel.
• Check for abnormal noise of steering wheel, and
the movement and clearance is normal.
• Check for the damage of wire harness and the dis-
tortion of terminals.
(c) Airbag ECU
AUTOLIV ELECTRONIC
(1) Check the airbag ECU is dented, cracked, deformed,
etc.
(2) Check for the damage of connector and the distortion of
terminals.
(3) Check the installation condition of the airbag ECU
XY 21610232-8
bracket.
• Check the cover is dented, cracked, deformed, etc.
ALJ017G
• Check for the damage of connector, the distortion
of terminals, and the pinch of wire harness.
• Check the airbag assembly is dented, cracked de-
formed, etc.
• Check the direction of the arrow is the same with
the vehicle.
(4) Check the installation condition of airbag module.

(d) Check driver airbag module

(e) Clock spring
(1) Check for the damage of connector, protect tube, the
distortion of terminals.
(2) Check the distortion of case
(f) Steering wheel, steering column and axis
(1) Check the installation condition of driver airbag
module.
(2) Check for abnormal noise of steering wheel, and the
clearance is normal.
(g) Check the wire harness connector (instrument panel wire
harness)
(h) Check wire harness for firmly installed, connector for
damage, terminal for deformation.
10. Test method for airbag without tester
Airbag indicator alarming
Check for airbag ECU connector looseness

and alarming continuously after installing.
No
Disconnect driver airbag wire harness, substitute Yes

the airbag alarm indicator with 2 ohmmeter Check the clock spring for continuity
resistance, check for coming on continually.
No
No
Disconnect passenger airbag wire harness, Yes

substitute the airbag alarm indicator with 2 Check for alarming continually
ohmmeter resistance, check for coming on when replace the clock spring
continually.
No
Disconnect driver airbag harness, substitute the

airbag alarm indicator with 2 ohmmeter
No
Disconnect driver airbag harness, substitute the

airbag alarm indicator with 2 ohmmeter
No
Perform checking at
the specialized repair station.

1. Driver airbag assembly (vehicles not involved in colli-
sion)
(a) Perform a diagnostic system check.
(b) Perform a visual check which includes the following items
with the driver airbag assembly installed in the vehicle:
Cuts, minute cracks or marked discoloration on the driver
airbag assembly top surface and in the grooved portion.
ALJ018G
2. Driver airbag assembly (vehicle involved in collision

and airbag is not deployed)
with the driver airbag assembly removed from the vehicle:
• Cuts, minute cracks or marked discoloration on the driver
airbag assembly top surface and in the grooved portion.
• Cracks or other damage in the connectors.
ALJ019G • Deformation of the horn button contact plate of the steer-
ing wheel assembly.
Hint:
• If the horn button contact plate of the driver airbag as-
sembly is deformed, never repair it. Always replace the
driver airbag assembly with a new one.
• There should be no interference between the driver air-
bag assembly and steering wheel assembly, and the clear-
ance should be uniform all the way around when the new
driver airbag assembly is installed on the steering wheel
ALJ020G assembly.
Caution:
For removal and installation procedures of the driver
airbag assembly, refer to “REPLACEMENT” on page
RS-26, and be sure to follow the correct procedure.
ALJ021G

3. Passenger airbag assembly (vehicles not involved in

collision)
with the passenger airbag assembly installed in the vehicle:
Cuts, minute cracks or marked discoloration on the instru-
ment panel around the passenger airbag assembly.
ALJ022G
4. Passenger airbag assembly (vehicle involved in colli-

sion and airbag is not deployed)
with the passenger airbag assembly removed from the ve-
hicle:
• Cuts, minute cracks or marked discoloration around the
passenger airbag assembly.
ALJ023G • Cuts and cracks in wire harness, and chips in connector.
• Deformation or cracks on the instrument panel and in-
strument panel reinforcement.
Hint:
• If the instrument panel or instrument panel reinforcement
is deformed or cracked, never repair it. Always replace it
with a new one.
• There should be no interference between the instrument
panel body upper and the passenger airbag assembly.
ALJ024G
Caution:
For removal and installation procedures of the pas-
senger airbag assembly, refer to “REPLACEMENT” on
page RS-35, and be sure to follow the correct proce-
dure.
ALJ025G

5. Airbag ECU assembly (vehicles not involved in colli-

sion)
6. Airbag ECU assembly (vehicle involved in collision and
airbag is not deployed)
7. Airbag ECU assembly (vehicle involved in collision and
airbag is deployed)
(a) Replace the airbag ECU assembly (See page RS-48).
8. Wire harness and connector (vehicle not involved in
collision)
9. Wire harness and connector (vehicle involved in colli-
sion)
(b) Check for breaks in all wires of the SRS wire harness, and
exposed conductor.
(c) Check if the SRS wire harness connectors are cracked or
chipped.
Hint:
The SRS wire harness is integrated with the engine room
main wire, instrument panel wire, floor wire, harness assem-
bly.


Components
Torx Screw
Torx Screw 8.8 (90, 78 in.·lbf)
8.8 (90, 78 in.·lbf)
Combination Switch Upper Cover
Steering Wheel Assembly
Clock Spring Sub-assembly 50 (510, 37)
Combination Switch Lower Cover
N·m (kgf·cm, ft·lbf) : Specified torque Driver Airbag Assembly

ALJ026G

Replacement
1. Precaution (See page RS-2)
3. Remove driver airbag assembly
(a) Place the front wheels facing straight ahead.
(b) Using a torx socket wrench (T30), loosen the 2 torx screws
until the groove along the screw circumference catches on
the screw case. Harness assembly is integrated.
ALJ027G
(c) Pull out the driver airbag assembly from the steering wheel
assembly and support the airbag assembly with one hand as
Notice:
When removing the driver airbag assembly, do not pull
the airbag wire harness.
(d) Using a screwdriver, disconnect the driver airbag assembly
connectors.
ALJ028G (e) Disconnect the airbag connector.
(f) Remove the driver airbag assembly.
4. Install driver airbag assembly
(a) Support the driver airbag assembly with one hand as shown
(b) Connect the driver airbag assembly connectors.
(c) Connect the airbag connector.
(d) Confirm that the circumference groove of the torx screw fits
in the screw case, and place the driver airbag assembly onto
the steering wheel assembly.
ALJ029G (e) Using a torx socket wrench (T 30), install the 2 screws.
5. Inspect driver airbag assembly
(a) Perform a visual check which includes the following items
with the driver airbag assembly installed in the vehicle:
Cuts, minute cracks or marked discoloration on the driver
airbag assembly top surface or in the grooved portion.
6. Inspect SRS warning light
ALJ018G

Disposal
Hint:
When scrapping a vehicle equipped with the SRS or disposing of
the driver airbag assembly, be sure to deploy the airbag first in ac-
cordance with the procedure described below.
Caution:
• Never dispose of the driver airbag assembly that has an
undeployed airbag.
• The airbag produces an exploding sound when it is de-
SST
ployed, so perform the operation outdoors where it will
SRS AJRBAG DEPLOYMENT TOOL
not create a nuisance to nearby residents.
CAUTNON
• When deploying the airbag, always use the specified SST

(airbag deployment tool). Perform the operation in a place
ALJ030G away from electrical noise.
• When deploying the airbag, perform the operation at least
10 m (33 ft.) away from the driver airbag assembly.
• The driver airbag assembly is extremely hot when the
airbag is deployed, so do not touch it within at least 30
minutes after deployment.
• Use gloves and safety glasses when handling the driver
airbag assembly with the deployed airbag.
• Do not apply water etc. to the driver airbag assembly with
the deployed airbag.
• Always wash your hands with water after completing the
operation.
1. Dispose of driver airbag assembly (when scrapping ve-
hicle deployment method)
Hint:
Prepare a battery as the power source to deploy the airbag.
(a) Check the function of the SST.
Caution:
When deploying the airbag, always use the specified
SST: Airbag Deployment Tool.
SST
SST 09082-00700
CAUTNON
ALJ030G
(1) Connect the SST to the battery.

Connect the red clip of the SST to the battery positive
(+) terminal and the black clip of the SST to the battery
negative (-) terminal.
Battery Hint:
Do not connect the yellow connector of the SST which
SST
is to be connected with SRS.
ALJ031G

(2) Check the function of the SST.

Press the SST activation switch, and check that the
LED of the SST activation switch comes on.
Caution:
If the LED comes on when the activation switch is
not being pressed, SST malfunction is possible, so
SST be sure not to use the SST.
(3) Disconnect the SST from the battery.
ALJ032G
Airbag (b) Install the SST.

Connector Caution:
Check that there is no looseness in the steering wheel
assembly and driver airbag assembly.
(1) While turning the steering wheel assembly to the right
and left, remove the 3 screws and combination switch
cover.
(2) Disconnect the airbag connector of the clock spring
ALJ033G sub-assembly.
(3) Connect the connector of the SST to the airbag connec-

tor of the clock spring sub-assembly.
SST 09082-00700, 09082-00780
Notice:
To avoid damaging the SST connector and wire
harness, do not lock the secondary lock of the twin
lock.
SST ALJ034G
(4) Move the SST at least 10 m (33 ft.) away from the front
of the vehicle.
(5) Close vehicle doors and windows.
Battery Notice:
Take care not to damage the SST wire harness.
SST (6) Connect the red clip of the SST to the battery positive
10 m (33 ft.) or more
ALJ035G

(c) Deploy the airbag.

(1) Check that no one is inside the vehicle or within a 10 m
(33 ft.) radius of the vehicle.
(2) Press the activation switch of the SST and deploy the
airbag.
Hint:
The airbag is deployed as the LED of the SST activa-
tion switch comes on.
(d) Dispose of the driver airbag assembly.
Caution:
• The driver airbag assembly is extremely hot when
the airbag is deployed, so do not touch it within at
least 30 minutes after deployment.
• Use gloves and safety glasses when handling the
driver airbag assembly with the deployed airbag.
• Always wash your hands with water after complet-
ing the operation.
• Do not apply water etc. to the driver airbag assem-
bly with the deployed airbag.
2. Dispose of driver airbag assembly (when disposing of
airbag assembly deployment method)
Battery Notice:
• When disposing of the driver airbag assembly only,
never use the customer’s vehicle to deploy the air-
bag.
SST
• Be sure to follow the procedure detailed below
when deploying the airbag.
ALJ031G Hint:
(a) Check the function of the SST (See step 1-(a)).
(b) Remove the driver airbag assembly (See page RS-29).
Caution:
• When removing the driver airbag assembly, work
must be started 90 seconds after the ignition switch
is turned to the “LOCK” position and the negative (-)
terminal cable is disconnected from the battery.
• When storing the driver airbag assembly, keep the
upper surface of the airbag deployment side facing
upward.

(c) Using a service-purpose wire harness for the vehicle, tie

down the driver airbag assembly to the disc wheel.
Wire Harness Diameter
Wire harness: Stripped wire harness section 1.25 mm2 or
more (0.0019 in.2 or more)
Caution:
If a wire harness which is too thin or an alternative
Square of the Stripped Wire object is used to tie down the driver airbag assembly,
Harness Section
it may be snapped by the shock when the airbag is
ALJ036G deployed. This is highly dangerous. Always use a wire
harness for vehicle use which has a diameter of at least
1.25 mm2 (0.0019 in.2).
Hint:
To calculate the square of the stripped wire harness section:
Square = 3.14 × (Diameter)2/4
(1) Install the 2 bolts with washers in the 2 bolt holes of the
driver airbag assembly.
L Bolt:
L: 35.0 mm (1.378 in.), M: 6.0 mm (0.236 in.)
M Pitch: 1.0 mm (0.039 in.)
Notice:
• Tighten the bolts by hand until the bolts be-
come difficult to turn.
ALJ037G • Do not tighten the bolts too much.
(2) After connecting the SST below to each other, connect

SST them to the driver airbag assembly.
SST 09082-00802 (09082-10801, 09082-30801)
ALJ038G
(3) Using 3 wire harnesses, wind each wire harness at least

2 times each around the bolts installed on the left and
right sides of the driver airbag assembly.
Caution:
2 times or more
• Tightly wind the wire harness around the bolts
so that there is no slack.
• If there is slack in the wire harness, the driver
airbag assembly may become loose due to
ALJ039G the shock when the airbag is deployed. This is
highly dangerous.

(4) Face the upper surface of the driver airbag assembly

upward.
Separately tie the left and right sides of the driver airbag
assembly to the disc wheel through the hub nut holes.
Position the SST connector so that it hangs downward
through a hub hole in the disc wheel.
Caution:
• Make sure that the wire harness is tight. It is
SST
ALJ040G highly dangerous when looseness in the wire
harness results in the driver airbag assembly
coming free due to the shock resulted from the
airbag deployment.
• Always tie down the driver airbag assembly
with the pad side facing upward. It is highly
dangerous if the driver airbag assembly is tied
down with the metal surface facing upward
as the wire harness will be cut by the shock
caused by the airbag deployment and the driv-
er airbag assembly will be thrown into the air.
Notice:
The disc wheel will be marked by the airbag de-
ployment, so use a redundant disc wheel.
(d) Install the SST.
Caution:
Place the disc wheel on the level ground.
SST
(1) Connect the connector of the SST.
SST 09082-00700
Notice:
ALJ041G lock. Also, secure some slack for the SST wire
harness inside the disc wheel.
(2) Move the SST to at least 10 m (33 ft.) away from the
driver airbag assembly tied down to the disc wheel.
Battery

ALJ042G

(e) Cover the driver airbag assembly with a cardboard box or

Y
tires.
(1) Covering method using a cardboard box:
Y Cover the driver airbag assembly with the cardboard
X
box and place the weights on the cardboard box in 4
places with at least 190 N (20 kg, 44 lb).
Size of cardboard box:
Must exceed the following dimensions:
Weight ALJ043G X = 460 mm (18.11 in.)
Y = 650 mm (25.59 in.)
Notice:
• When the dimension Y of the cardboard
box exceeds the diameter of the disc wheel
with tire to which the driver airbag assem-
bly is tied, X should be the following size:
X = 460 mm (18.11 in.) + width of tire
• If a cardboard box which is smaller than the
specified size is used, the cardboard box will
be broken by the shock from the airbag de-
ployment.
Inner Diameter (2) Covering method using tires:
Place at least 3 tires with no disc wheels on top of the
Width tire with disc wheel to which the driver airbag assembly
Tires
(3 or is tied.
More) Tire size: Must exceed the following dimensions
Width: 185 mm (7.28 in.)
Caution:
ALJ044G Do not use tires with disc wheels.
Notice:
• The tires may be marked by the airbag deploy-
ment, so use redundant tires.
• Do not place the SST connector under the tire
because the SST connector could be dam-
aged.
(f) Deploy the airbag.
(1) Connect the red clip of the SST to the battery positive
Battery (+) terminal and the black clip of the SST to the battery
(2) Check that no one is within a 10 m (33 ft.) radius of the
disc wheel to which the driver airbag assembly is tied.
airbag.
ALJ042G Hint:

(g) Dispose of the driver airbag assembly.

Caution:
• The driver airbag assembly is extremely hot when
the airbag is deployed, so do not touch it within at
least 30 minutes after deployment.
driver airbag assembly with the deployed airbag.
• Do not apply water etc. to the driver airbag assem-
ALJ045G bly with the deployed airbag.
ing the operation.
(1) Remove the driver airbag assembly from the disc
wheel.
(2) Place the driver airbag assembly in a plastic bag, tie it
tightly and dispose of it as other general parts disposal.

Clock Spring Sub-assembly

Replacement
Hint:
Components: See page RS-28
4. Remove dirver airbag assembly (See page RS-29)
5. Remove steering wheel assembly (See page SR-7)
SST 09950-50013 (09951-05010, 09952-05010,
09953-05020, 09954-05021)
6. Remove combination switch cover
(a) Remove the 3 screws and the combination switch cover.
ALJ046G
7. Remove clock spring sub-assembly

(a) Disconnect the airbag connector and the clock spring sub-
assembly connector.
(b) Disengage the 3 claws and remove the clock spring sub-
assembly.
Airbag Connector
8. Check clock spring sub-assembly
(a) If the following condition is identified, replace the clock
spring sub-assembly with a new one.
: Claw ALJ047G Condition:
• Scratches or cracks on the connector
• Cracks, dents or chips in the clock spring sub-assembly.
(a) Check that the front wheels are facing straight ahead.

10. Install clock spring sub-assembly

(a) Set the turn signal switch to the neutral position.
Notice:
Make sure that the turn signal switch is in the neutral
position since the pin of the turn signal switch may be
snapped.
(b) Engage the 3 claws and install the clock spring sub-assembly.
Notice:
When replacing the clock spring sub-assembly with
a new one, remove the lock pin before installing the
steering wheel assembly.
(c) Connect the airbag connector and the clock spring sub-
assembly connector.
(d) Install the combination switch cover with the 3 screws.
11. Adjust clock spring sub-assembly
(a) Check that the ignition switch is OFF.
(b) Check that the battery negative terminal is disconnected.
Notice:
Do not start the operation for 90 seconds after remov-
ing the terminal.
(c) Turn the clock spring sub-assembly counterclockwise slowly
by hand until it feels firm.
ALJ048G
(d) Then rotate the spiral cable sub-assembly clockwise about 3.5
Marks
turns to align the marks.
Hint:
The clock spring will rotate about 3.5 turns to both left and
right of the center.
12. Install steering wheel assembly (See page SR-10)
13. Inspect steering wheel center point
14. Install driver airbag assembly (See page RS-29)
ALJ049G 15. Inspect driver airbag assembly (See page RS-29)

Passenger Airbag Assembly

Components
Front Tweeter Shield RH
Front Tweeter Shield LH
Upper Instrument Panel Body
ALJ050G
Replacement
3. Remove front tweeter assembly RH (See page AV-6)
4. Remove front tweeter assembly LH (See page AV-6)
5. Disconnect passenger airbag assembly connector
(a) Remove the passenger airbag connector clip.
(b) Disconnect the passenger airbag connector.
Notice:
When handling the airbag connector, take care not to
damage the airbag wire harness.
6. Remove upper instrument panel body w/passenger air-
bag assembly (See page IR-31)
ALJ051G

7. Remove passenger airbag assembly

(a) Remove the 2 nuts.
ALJ052G
(b) Disengage the 12 claws of the passenger airbag assembly,

and then remove the passenger airbag assembly from the up-
per instrument panel body.
8. Install passenger airbag assembly
(a) Install the passenger airbag with 2 nuts.
9. Check passenger airbag assembly (See page RS-26).
10. Install upper instrument panel body w/passenger airbag
: Claw ALJ053G assembly
11. Connect driver airbag assembly connectors

Disposal
Hint:
• When scrapping a vehicle equipped with the SRS or disposing
of the passenger airbag assembly, be sure to deploy the airbag
first in accordance with the procedure described below.
• If any abnormality occurs with the airbag deployment, contact
the after-sales service department of Great Wall Motor Com-
pany.
Caution:
• Never dispose of the passenger airbag assembly that has
an undeployed airbag.
• The airbag produces an extremely exploding sound when
SST
it is deployed, so perform the operation outdoors where it
will not create a nuisance to nearby residents.
CAUTNON
• When deploying the airbag, always use the specified SST

(Airbag Deployment Tool). Perform the operation in a
ALJ030G place away from electrical noise.
• When deploying the airbag, perform the operation at least
10 m (33 ft.) away from the driver airbag assembly.
• The passenger airbag assembly is extremely hot when
the airbag is deployed, so do not touch it within at least
30 minutes after deployment.
• Use gloves and safety glasses when handling the pas-
senger airbag assembly with the deployed airbag.
• Do not apply water etc. to the passenger airbag assembly
with the deployed airbag.
• Always wash your hands with water after completing the
operation.
1. Dispose of passenger airbag assembly (when scrap-
ping vehicle deployment method)
Hint:
(a) Check the function of the SST (See page RS-30, step 1-(a)).
Battery
SST
ALJ031G

(b) Disconnect the passenger airbag connector.

(1) Remove the glove box body (See page IR-35).
Notice:
When handling the airbag connector, take care not
to damage the airbag wire harness.
(2) Disconnect passenger airbag assembly connector.
ALJ051G
(c) Install the SST.

(1) Connect the connector of the SST to the passenger air-
bag assembly connector.
SST 09082-00700, 09082-00780
Notice:
SST lock.
ALJ054G
(2) Move the SST at least 10 m (33 ft.) away from the front
of the vehicle.
(3) Close vehicle doors and windows.
Battery Notice:
SST (4) Connect the red clip of the SST to the battery positive
10 m (33 ft.) or more (+) terminal and the black clip of the SST to the battery
ALJ035G (d) Deploy the airbag.
(1) Check that no one is inside the vehicle or within a 10 m
(33 ft.) radius of the vehicle.
airbag.
Hint:

(e) Dispose of the passenger airbag assembly.

Caution:
• The passenger airbag assembly is extremely hot
when the airbag is deployed, so do not touch it
within at least 30 minutes after deployment.
passenger airbag assembly with the deployed air-
bag.
• Do not apply water etc. to the passenger airbag as-
sembly with the deployed airbag.
ing the operation.
2. Dispose of passenger airbag assembly (when scrap-
ping airbag assembly deployment method)
Notice:
• When disposing of the passenger airbag assembly
only, never use the customer’s vehicle to deploy the
airbag.
• Be sure to follow the procedure detailed below
when deploying the airbag.
Hint:
(a) Check the function of the SST (See page RS-30, step 1-(a)).
Battery
SST
ALJ031G
(b) Remove the passenger airbag assembly (See page RS-40).

Caution:
• When removing the passenger airbag assembly,
work must be started 90 seconds after the ignition
switch is turned to the “LOCK” position and the
negative (-) terminal cable is disconnected from the
battery.
• When storing the passenger airbag assembly, keep
ALJ023G the upper surface of the airbag deployment side
facing upward.

(c) Using a service-purpose wire harness for the vehicle, tie

down the passenger airbag assembly to the disc wheel.
Wire Harness Diameter
Wire harness: square of the stripped wire harness section
1.25 mm2 or more (0.0019 in.2 or more)
Caution:
• If a wire harness which is too thin or an alternative
Square of the Stripped object is used to tie down the passenger airbag as-
Wire Harness Section
sembly, it may be snapped by the shock when the
ALJ036G airbag is deployed.
• This is highly dangerous. Always use a wire har-
ness for vehicle use which has a diameter of at
least 1.25 mm2 (0.0019 in.2).
Hint:
To calculate the square of the stripped wire harness section:
Square = 3.14 × (Diameter)2/4
Position the passenger airbag assembly inside the tire with
the airbag deployment side facing inside.
Tire size: must exceed the following dimensions
Width: 185 mm (7.28 in.)
Caution:
• Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the passenger airbag assembly coming free
due to the shock from the airbag deployment.
• Always tie down the passenger airbag assembly
with the airbag deployment side facing inside the
tire.
Notice:
The tires may be marked by the airbag deployment, so
use redundant tires.
Inner Diameter
Width Tires
ALJ055G

(d) Install the SST.

Connect the connector of the SST to the passenger airbag as-
sembly.
SST 09082-00780
SST
ALJ056G
(e) Place tires.

(1) Place at least 2 tires under the tire to which the passen-
ger airbag assembly is tied.
Tires
(2) Place at least 2 tires upper the tire to which the passen-
(5 or More) ger airbag assembly is tied. The top tire should have the
disc wheel installed.
Notice:
Do not place the SST connector under the tire be-
ALJ057G cause the SST connector could be damaged.
(3) Tie the tires together with 2 wire harnesses.

Caution:
Make sure that the wire harness is tight. It is highly
dangerous when looseness in the wire harness re-
sults in the tires coming free due to the shock from
SST
the airbag deployment.
Hint:
Place the SST connector and the wire harness inside
ALJ058G tires. Secure at least 1 m (3 ft.) of slack for the wire har-
ness.

(f) Install the SST.

Connect the connector of the SST.
SST 09082-00700
Battery Notice:
To avoid damaging the SST connector and wire har-
SST ness, do not lock the secondary lock of the twin lock.
Also, secure some slack for the SST wire harness in-
side the tire.
ALJ059G (g) Deploy the airbag.
(1) Connect the red clip of the SST to the battery positive
(2) Check that no one is within a 10 m (33 ft.) radius of the
tire to which the passenger airbag assembly is tied.
airbag.
Hint:
(h) Dispose of the passenger airbag assembly.
Caution:
• The passenger airbag assembly is extremely hot
when the airbag is deployed, so do not touch it for
at least 30 minutes after deployment.
passenger airbag assembly with the deployed air-
bag.
ALJ060G • Do not apply water etc. to the passenger airbag as-
sembly with the deployed airbag.
ing the operation.
(1) Remove the passenger airbag assembly from the tire.
(2) Place the passenger airbag assembly in a plastic bag,
tie it tightly and dispose of it as other general parts dis-
posal.

Airbag ECU Assembly

Components
20 (200, 14)
Airbag ECU Assembly
Instrument Panel Lower Shield

ALJ061G

Replacement
3. Remove instrument panel lower shield (See page
IR-35)
4. Remove airbag ECU assembly
(a) Disconnect the connectors from the airbag ECU assembly.
(b) Using a socket wrench, remove the 3 screws and airbag ECU
assembly.
5. Install airbag ECU assembly
(a) Check that the ignition switch is OFF.
(b) Check that the battery negative (-) terminal is disconnected.
Notice:
ALJ062G After removing the terminal wait for at least 90 seconds
before starting the operation.
(c) Using a socket wrench, install the airbag ECU assembly with
the 3 screws.
Notice:
• If the airbag ECU assembly has been dropped, or
there are any cracks, dents or other defects in the
case, bracket or connector, replace the airbag ECU
assembly with a new one.
• When installing the airbag ECU assembly, take care
that the SRS wiring does not interfere with other
parts and is not pinched between other parts.
(d) Tighten the 3 screws to the specified torque.
(e) Connect the connectors to the airbag ECU assembly.
(f) Check that there is no looseness in the installation parts of
the airbag ECU assembly.
(g) Check that the water-proof sheet is properly set.

SEAT BELT
Seat Belt Warning System
Parts location
Combination Meter
(Driver Seat Belt Warning Indicator)
Passenger Seat Belt
Warning Indicator
Driver Seat Belt Buckle Assembly
Passenger Seat Belt Buckle Assembly
ALJ063G

Problem symptoms table

Driver seat belt warning indicator does not 2. Combination meter IR-41
come on 3. Driver seat belt buckle assembly RS-51
4. Wire harness -
Driver seat belt warning indicator does not go
2. Driver seat belt buckle assembly RS-51
off
3. Wire harness -
2. Center console panel body IR-30
Passenger seat belt warning indicator does
3. Passenger seat belt buckle assembly RS-50
not come on
5. Wire harness -
1. Center console panel body IR-30
Passenger seat belt warning indicator does 2. Passenger seat belt buckle assembly RS-50
not go off 3. Combination meter IR-41
4. Wire harness -
Inspection
A 1. Inspect passenger seat belt buckle assembly
Connector A
(a) Check the buckle switch.
(1) Fasten the seat belt (Buckle switch is ON).
(2) Check the resistance between the terminals.
1 2 Standard:
A-1 - A-2 Below 1 W
ALJ064G
(3) Release the seat belt (Buckle switch is OFF).
Standard:
A-1 - A-2 10 kW or higher
If the result is not as specified, replace the seat belt buckle
assembly.

2. Inspect driver seat belt buckle assembly

A (a) Check the buckle switch.
(1) Fasten the seat belt (Buckle switch is ON).
Connector A
Standard:
1 2 Tester connection Specified condition
A-1 - A-2 Below 1 W
(3) Release the seat belt (Buckle switch is OFF).
ALJ064G (4) Check the resistance between the terminals.
Standard:
A-1 - A-2 10 kW or higher
If the result is not as specified, replace the seat belt buckle
assembly.
Front Seat Belt

Precaution
Caution:
Replace the faulty parts of the seat belt systems (outer belt,
seat belt buckle assembly, bolts, nuts, seat belt adjuster as-
sembly, tether anchor hardware, sill-bar, etc.)
Seat belt systems not in use at the time of a collision should
also be inspected and replaced if found to be damaged or
working improperly.
1. Running test
(a) Fasten the front seat belts.
(b) Drive the vehicle at 16 km/h (10 mph) and slam on the
brakes. Check that the belt locks and cannot be extended at
this time.
Hint:
Conduct this test in a safe area. If the belt does not lock, re-
move the belt assembly and perform the inspections. Also
ALJ065G whenever installing a new belt assembly, verify the proper
operation before installation.

Components
B Pillar Upper Trim RH
Seat Belt Adjuster Assembly 38 (388,29)
Front Door Sealing Strip RH
Rear Door Sealing

Strip RH
38 (388,29)
Rear Rocker
Trim RH
Guide Ring Trim

Cover RH
Passenger Seat
Outer Belt Assembly
Cowl Side Trim
Board RH Front Rocker
Trim RH 38 (388,29)
B Pillar Lower
Trim Panel RH
Driver Seat Rear 38 (388,29) 38 (388,29)

Mounting Bolt Cover LH End Plate Cover
Passenger Seat
Assembly
Driver Seat Rear
Mounting Bolt Cover LH
Passenger Seat Belt

Buckle Assembly
42 (430, 31)
ALJ066G

Replacement
Hint:
• The installation procedures are the removal procedures in the
reverse order. However, only installation procedures requiring
additional information are included.
• Use the same procedures for the RH side and LH side.
2. Remove passenger seat assembly RH (See page
IR-67)
3. Remove passenger seat belt buckle assembly
4. Remove front rocker trim RH (See page IR-62)
5. Remove rear rocker trim RH (See page IR-63)
6. Remove front door sealing strip RH
7. Remove rear door sealing strip RH
8. Remove B pillar lower trim RH (See page IR-63)
9. Remove passenger seat outer belt assembly
Notice:
• Removal operation concerning the seat belt with
the pretensioner must be started when 90 seconds
or more time has passed after the ignition switch is
turned OFF and the battery negative terminal is dis-
connected.
• Carefully read the notices for the “pretensioner” in
the SRS airbag system section and the front seat
outer belt section.
(a) Remove the end plate cover.
(b) Remove bolt on the plate side and the outer belt.
(c) Remove guide ring trim cover RH.
(d) Remove bolt on the guide ring side and the outer belt.
(e) Disconnect the pretensioner connector as shown in the illus-
tration.
(f) Remove the 2 bolts on the retractor side and remove the
outer belt completely.
10. Remove seat belt adjuster assembly
R (a) Remove the bolt and the seat belt adjuster assembly.
11. Install seat belt adjuster assembly
(a) Install the seat belt adjuster assembly with the bolt.
ALJ067G

Unlock 12. Install passenger seat outer belt assembly

45°
Notice:
Do not disassemble the retractor.
(a) Check the degree of tilt when beginning to lock the retractor.
Lock
(1) Check that the belt does not lock within 15° of tilt in all
directions but locks with over 45° of tilt when gently
moving the retractor.
Retractor
If operation is not as specified, replace the outer belt as-
ALJ068G sembly.
(b) Install the outer belt with the 2 bolts on the retractor side.
Torque:
5.5 N·m (51 kgf·cm, 4.0 ft·lbf) for upper bolt
38 N·m (388 kgf·cm, 29 ft·lbf) for lower bolt
(c) Connect the pretensioner connector as shown in the illustra-
tion.
(d) Install the seat outer belt with the bolt on the guide ring side.
Torque:
38 N·m (388 kgf·cm, 29 ft·lbf)
R (e) Install guide ring trim cover.
(f) Install the seat outer belt with the bolt on the end plate side.
ALJ067G
(g) Install the end plate cover.
(h) Check retractor lock.
Notice:
The check should be performed with the assembly in-
stalled.
(1) Check that the belt locks by pulling it out quickly after
installation.
If operation is not as specified, replace the outer belt as-
sembly.
(i) Check the fastening function of the child restraint system.
Notice:
stalled.
(1) Check that the belt cannot be pulled out any more but
rewinds after being pulled out fully.
(2) Check that the belt can be pulled out and rewound after
it has been fully rewound.
If the operation is not as specified, replace the belt as-
sembly.
13. Install passenger seat belt buckle assembly
(a) Install the buckle with the bolt.
14. Install passenger seat assembly

Disposal
Hint:
When scrapping of vehicles equipped with a seat belt pretensioner
or a front seat outer belt (w/seat belt pretensioner), always first ac-
tivate the seat belt pretensioner in accordance with the procedures
described below. When disposing of a front seat outer belt assem-
bly (w/seat belt pretensioner) that was activated in a collision, fol-
low the same procedures listed in step 1-(e) in “DISPOSAL”.
Caution:
• Never dispose of a front seat outer belt assembly with an
inactivated pretensioner.
• The seat belt pretensioner produces a sizeable exploding
SST sound when it activates, so perform the operation out-
doors so as not to disturb nearby residents.
• When activating a front seat outer belt (w/seat belt pre-
tensioner), control operation at least 10 m (33 ft.) away
ALJ069G from the front seat outer belt.
• Use gloves and safety glasses when handling a front seat
belt with an activated pretensioner.
• Always wash your hands with water after completing acti-
vation.
• Do not apply water, etc. to a front seat outer belt with an
activated pretensioner.
• When activating the seat belt pretensioner, always use
the specified SST (SRS airbag deployment tool). Perform
operation in a place away from electrical interference.
SST 09082-00700
1. Dispose of passenger seat outer belt assembly (When
installed in vehicle)
Hint:
Check that the battery positive voltage is above 12 V.
ALJ070G
(a) Check the function of SST.

Caution:
When activating the seat belt pretensioner, always use
the specified SST.
SST SST 09082-00700, 09082-00770
ALJ069G

(1) Connect the SST red clip to the battery positive (+)
terminal and the black clip to the battery negative (-)
terminal.
Battery
Hint:
Do not connect the yellow connector which will be con-
nected to the seat belt pretensioner.
SST
ALJ031G
(2) Press the SST activation switch, and check that the
LED of the SST activation switch comes on.
SST Caution:
If the LED comes on when the activation switch is
not pressed, the SST may have a malfunction, in
which case that SST should not be used.
(b) Disconnect the SST from the battery.
(c) Disconnect the pretensioner connector.
ALJ071G (d) Disconnect the battery negative (-) terminal.
(e) Check the SRS airbag system (See page RS-25).
(f) Remove front rocker trim RH (See page IR-62)
(g) Remove rear rocker trim RH (See page IR-63)
(h) Remove the front door sealing strip RH.
(i) Remove the rear door sealing strip RH.
(j) Remove B pillar lower trim RH (See page IR-63)
(1) Disconnect the pretensioner connector as shown in the
illustration.
(k) Connect SST.
(1) Install the end plate of the seat belt.
ALJ067G
(2) Connect SST, then connect them to the seat belt preten-
sioner.
SST 09082-00700, 09082-00770
Notice:
SST SST
lock.
ALJ072G

(3) Move the SST at least 10 m or more (33 ft.) away from
the front of the vehicle.
(4) Close all the doors and windows of the vehicle.
Notice:
10 m or more
terminal.
ALJ073G (l) Activate the seat belt pretensioner.
(1) Confirm that no one is inside the vehicle or within 10 m
(33 ft.) of the vehicle.
(2) Press the SST activation switch and activate the seat
belt pretensioner.
Hint:
The seat belt pretensioner operates simultaneously with
the LED light for the SST activation switch.
(m) Dispose of the outer belt (w/the seat belt pretensioner).
Caution:
• The outer belt is very hot when the seat belt preten-
sioner is activated, so leave it untouched for at least
30 minutes after it has been activated.
• Use gloves and safety glasses when handling an
outer belt with a pretensioner that has been acti-
vated.
ing activation.
• Do not apply water, etc. to the outer belt assembly
with a pretensioner that has been activated.
Hint:
When scrapping a vehicle, activate the seat belt pretensioner,
and then scrap the vehicle with the activated outer belt in-
stalled.
2. Dispose of passenger seat outer belt assembly (when
not installed in vehicle)
Notice:
• When disposing of the front seat outer belt (w/the
seat belt pretensioner) only, never use the custom-
er’s vehicle to activate the seat belt pretensioner.
• Be sure to follow the procedures listed below when
activating the seat belt pretensioner.
(a) Remove the outer belt (See page RS-53).
Hint:
Cut the belt near the seat belt retractor.

(b) Check the function of SST (See step 1-(a)).

SST 09082-00700, 09082-00770
Battery
SST
ALJ031G
(c) Connect SST.

(1) Connect SST, then connect them to the seat belt preten-
sioner.
SST 09082-00700, 09082-00770
SST SST Notice:
lock.
ALJ072G
(2) Place the outer belt on the ground and cover it with a
tire and wheel.
Notice:
Set the front seat outer belt assembly as shown in
the illustration.
(3) Move the SST at least 10 m or more (33 ft.) away from
the front of the vehicle.
SST SST Notice:
ALJ074G Take care not to damage the SST wire harness.
(d) Activate the seat belt pretensioner.

terminal.
(2) Check that no one is within 10 m (33 ft.) of the wheel.
(3) Press the SST activation switch and activate the seat
10 m or more belt pretensioner.
Hint:
ALJ075G The seat belt pretensioner operates simultaneously with
the LED light for the SST activation switch.

(e) Dispose of the outer belt (w/the seat belt pretensioner).

Caution:
• The outer belt assembly is very hot when the seat
belt pretensioner is activated, so leave it untouched
for at least 30 minutes after it has been activated.
• Use gloves and safety glasses when handling an
outer belt assembly with a pretensioner that has
been activated.
ALJ076G • Always wash your hands with water after complet-
ing activation.
• Do not apply water, etc. to the outer belt assembly
with a pretensioner that has been activated.
(1) Remove the wheel and SST.
(2) Place the outer belt in a plastic bag, tie the end tightly
and dispose of it in the same way as other general parts.

Rear Seat Belt

Components
Rear Door Sealing Strip RH C Pillar Upper Trim

Panel Assembly RH
Back Door Sealing Strip
38 (388, 29)
C Pillar Lower
Trim Panel
Assembly RH
Rear Seat 3 Point Type

Outer Belt Assembly
Back Door
38 (388, 29) Rocker Shield
64 (653, 48)
Center Rear Seat
Outer Belt Assembly
Deck Board No.2
Rear Rocker Rear Seat
Trim RH Shoulder Belt Cover Deck Board No.1
38 (388, 29)
Deck Floor Box RH
Spare Tire Bracket Assembly
Rear Seat
Assembly
23 (235,17)
Rear Seat Setting Cross

Rear Seat Member Assembly
Buckle w/
Center Belt Rear Seat Buckle w/Center
Assembly RH Belt Assembly LH

ALJ077G

Replacement
Hint:
1. Remove rear rocker trim RH (See page IR-63)
3. Remove deck board No.1
5. Remove spare tire bracket assembly
6. Remove deck floor box RH
7. Remove rear seat assembly (See page IR-72)
9. Remove back door rocker trim
10. Remove C pillar lower trim panel assembly RH (See
page IR-64)
11. Remove roof inner trim panel RH
12. Remove rear seat 3 point type outer belt assembly
(a) Remove the bolt on the guide ring side and the belt.
(b) Remove the bolt on the retractor side, and remove the seat
belt completely.
13. Remove center rear seat outer belt assembly
(a) Remove the seatback board (See page IR-72).
(b) Remove the shoulder belt cover (See page IR-73).
(c) Remove the bolt and the seat belt at the end plate side.
(d) Remove the bolt and nut on the retractor side, and remove
the belt completely.
14. Remove rear seat buckle w/center belt assembly RH
(a) Remove the bolt and buckle.
15. Remove rear seat buckle w/center belt assembly LH
(a) Remove the bolt and buckle.
16. Remove rear seat setting cross member assembly
(a) Remove the 4 bolts and the setting cross member bracket.
17. Install rear seat setting cross member assembly
(a) Install the setting cross member bracket with the 4 bolts.
18. Install rear seat buckle w/center belt assembly LH
Protrusion Part (a) Install the end plate and the belt with the bolt as shown in the
illustration.
Notice:
Make sure that the end plate part does not run onto the
Front protrusion part of the floor panel.
Protrusion Part
ALJ078G

19. Install rear seat buckle w/center belt assembly RH

Protrusion Part (a) Install the end plate and the belt with the bolt as shown in the
illustration.
Notice:
Front protrusion part of the floor panel.
Protrusion Part
ALJ078G
20. Install center rear seat outer belt assembly

Unlock 45°
(a) Install the belt on the retractor side with the nut.
Lock
(b) Install shoulder belt cover.
(c) Install the center seatback board.
(d) Check the degree of tilt when the belt begins to lock the re-
tractor.
ALJ079G directions but locks with over 45° of tilt when gently
moving the retractor.
sembly.
(e) Install the belt with the bolt.
(f) Check retractor lock.
Notice:
stalled.
installation.
Hint:
The seat belt does not lock when it is pulled out to a
length of 955 mm (37.60 in.) or less.
sembly.
(g) Check the fastening function of the child restraint system.
Notice:
stalled.
sembly.

21. Remove rear seat 3 point type outer belt assembly

(a) Install the belt with the bolt on the retractor side.
(b) Check the degree of tilt when the belt begins to lock the re-
Unlock 45° tractor.
directions but locks with over 45° of tilt when gently
Lock moving the retractor.
sembly.
(c) Install the seat belt with the bolt on the end plate side.
ALJ080G Torque: 38 N·m (388 kgf·cm, 29 ft·lbf)
Notice:
protrusion part of the floor panel.
installation.
sembly.
(d) Check retractor lock.
Notice:
stalled.
installation.
sembly.
(e) Check the fastening function of the child restraint system.
Notice:
stalled.
sembly.
22. Install rear seat assembly

MEMO

IR-
VEHICLE INTERIOR
LIGHTING SYSTEM
Precaution......................................................................... IR-3
Problem Symptoms Table................................................. IR-3
On-vehicle Inspection....................................................... IR-5
Inspection.......................................................................... IR-6
Combination Headlamp Assembly LH.............................. IR-10
Rear Combination Lamp Assembly LH............................. IR-14
High-mounted Brake Lamp Assembly............................... IR-15
License Plate Lamp Assembly.......................................... IR-16
Combination Switch Assembly LH.................................... IR-16
Front Fog Lamp Assembly LH.......................................... IR-17
Back-up Lamp Assembly.................................................. IR-18
IGNITION SWITCH
Replacement..................................................................... IR-19
Inspection.......................................................................... IR-19
COMBINATION SWITCH
Replacement..................................................................... IR-20
COMBINATION METER
Problem Symptoms Table................................................. IR-21
On-vehicle Inspection....................................................... IR-23
Instrument Panel/Instrument............................................. IR-25
Upper Instrument Panel Body........................................... IR-29
Lower Instrument Panel Body........................................... IR-35 IR
Combination Meter Assembly........................................... IR-41
BACK-UP RADAR
System Description........................................................... IR-42
Function Description......................................................... IR-43
Electrical Wiring Diagram.................................................. IR-44
Technical Parameter......................................................... IR-45
Connector Terminals Definition......................................... IR-45
Components...................................................................... IR-47
11-VEHICLE INTERIOR.indd 1 2008-10-21 9:50:57

IR-
Back-up Radar Buzzer...................................................... IR-47

Back-up Radar ECU......................................................... IR-48
THEFT DETERRENT SYSTEM

System Description........................................................... IR-49
Function Description......................................................... IR-49
Components...................................................................... IR-50
Theft Deterrent ECU Terminals Definition......................... IR-50
DOOR LOCK
Electric Door Lock Control System................................... IR-52
Wireless Door Lock Control System................................. IR-57
Transmitter Battery............................................................ IR-58
Door Control Transmitter................................................... IR-59
ROOF HEADLINING
Components...................................................................... IR-61
Replacement..................................................................... IR-62
SEAT
Front Seat Assembly......................................................... IR-66
Rear Seat Assembly......................................................... IR-71

VEHICLE INTERIOR IR-
LIGHTING SYSTEM
Precaution
1. Precaution for headlamp bulb replacement
(a) If the surface of halogen lamp bulb (headlamp) is coated with oil, lamp service life is shortened because of the
heat generated when the lamp is on.
(b) Since the internal pressure of the halogen lamp bulb (headlamp) is high, operate carefully. It may injure others if
dropped.
(c) Try not to touch the lens with your fingers when changing the lamp because it could cause the lens dirty or wet.
Always have the replacement bulb prepared before starting the installation.
(d) Always replace the bulb with one that has the same wattage.
(e) Avoid wetting the lens with moisture or water.
(f) In order to avoid the lens wet or leakage, firmly reinstall the socket after bulb replacement.

Hint:
1. Headlamp and rear position lamp
1. Bulb -
“LO-Beam” does not come on (One side).
2. Wire harness -
1. Low-beam fuse -
2. Low-beam relay -
“LO-Beam” does not come on (All). 3. Combination switch assembly LH SR-7
4. Bulb -
5. Wire harness -
1. Bulb -
“HI-Beam” does not come on (One side).
2. Wire harness -
1. High-beam fuse -
2. High-beam relay -
“HI-Beam” does not come on (All). 3. Combination switch assembly LH SR-7
4. Bulb -
5. Wire harness -
1. Fuse -
“Flash” does not come on (All). 2. Combination switch assembly LH SR-7
3. Wire harness -
1. Bulb -
Headlamp is dark.
2. Wire harness -
1. LED lamp -
Only one rear position lamp comes on.
2. Wire harness -
Both rear position lamps do not come on 1. LED lamp -
(Front position lamps are normal). 2. Wire harness -
1. Position lamp fuse -
2. Position lamp relay -
Both rear position lamps do not come on
3. Combination switch assembly LH SR-7
(Front position lamps do not come on).
4. LED lamp -
5. Wire harness -

IR- GREAT WALL COOL BEAR REPAIR MANUAL
2. Fog lamp
1. Fog lamp fuse -
2. Fog lamp relay -
All fog lamps do not come on. 3. Fog lamp switch assembly -
4. Bulb -
5. Wire harness -
1. Fog lamp switch assembly -
Fog lamp always remains on.
2. Wire harness -
1. Bulb -
Fog lamp does not come on (One side).
2. Wire harness -
3. Turn signal light and hazard warning system

1. Hazard warning fuse -
“Hazard warning lamp” and “turn signal 2. Turn signal lamp fuse -
light” do not come on. 3. Flasher relay -
4. Wire harness -
Hazard warning lamp does not come on (Turn 1. Hazard warning fuse -
signal lamp is normal). 2. Wire harness -
Turn signal lamp does not come on (Hazard 1. Turn signal lamp switch IR-6
warning lamp is normal). 2. Wire harness -
1. Turn signal lamp switch IR-6
Turn signal lamp does not come on in one di- 2. Flasher relay -
rection. 3. Bulb -
4. Wire harness -
1. Bulb -
Only one bulb comes on.
2. Wire harness -
4. Brake lamp system

1. Brake lamp fuse -
Both brake lamps do not come on. 2. Brake lamp switch assembly IR-7
3. Wire harness -
1. Brake lamp switch assembly IR-7
Brake lamp always remains on.
2. Wire harness -
1. LED lamp -
Brake lamp does not come on (One side).
2. Wire harness -
5. Back-up lamp system

1. Bulb -
2. Fuse -
Back-up lamp does not come on.
3. Back-up lamp switch assembly IR-7
4. Wire harness -
1. Back-up lamp switch assembly IR-7
Back-up lamp always remains on.
2. Wire harness -

6. Ceiling lamp system

1. Bulb -
Ceiling lamp does not come on. 2. Fuse -
3. Wire harness -
1. Bulb -
Reading lamp does not come on. 2. Fuse -
3. Wire harness -
Ceiling lamp and reading lamp do not come
1. Fuse -
on (All).
Wire Harness View:

1. Inspect turn signal flasher assembly
(a) Disconnect the connector from the turn signal flasher as-
1 2 3 sembly and inspect the connector on the wire harness side as
shown in the table below.
4 5 6 7 8
Standard:
Specified
Tester connection Condition
condition
ALK001G
1 (IG) - Ground Ignition switch ON Battery voltage
Ignition switch
1 (IG) - Ground No voltage
LOCK
30 (IG) - Ground Always Battery voltage
7 (31) - Ground Always Continuity
(b) Connect the connector to the turn signal flasher assembly and
15R 15L 30 IG
inspect the connector on the wire harness side from the back
as shown in the table below.
Standard:
31 Flasher Relay Specified
Tester connection Condition
condition
L R HWS Hazard warning 0 V → 0 Û 9 V (60
2 (R) - Ground switch to 120 times per
ALK002G OFF → ON minute)
Turn signal lamp 0 V → 0 Û 9 V (60
Turn Signal Flasher Assembly
6 (15R) - Ground switch (Right turn) to 120 times per
Connector Front View: OFF → ON minute)
Hazard warning 0 V → 0 Û 9 V (60
3 (L) - Ground switch to 120 times per
3 2 1
OFF → ON minute)
8 7 6 5 4
Turn signal lamp 0 V → 0 Û 9 V (60
5 (15L) - Ground switch (Left turn) to 120 times per
OFF → ON minute)
ALK003G Turn signal lamp
5 (15L) - Ground switch (Left turn) Above 9 V → 0 V
ON → OFF

Turn signal lamp

6 (15R) - Ground switch (Right turn) Above 9 V → 0 V
ON → OFF
Hazard warning
8 (HWS) - Ground switch Above 9 V → 0 V
ON → OFF
2. Delay function of ceiling lamp (When the interior light
switch is in the DOOR position)
(a) Open any door and then close, the ceiling lamp will be on for
10 seconds. If the ceiling lamp detects that the vehicle key is
inserted into the ignition switch again or any door is closed
within 10 seconds, it will change from bright to dark and
fade out gradually.
(b) When removing the vehicle key from the ignition switch, the
ceiling lamp comes on. If the key is inserted into the ignition
switch again or any door is closed, the ceiling lamp will go
off. When there is not any operation, the ceiling lamp will
change from bright to dark and fade out gradually after 1
minute.
(c) When the vehicle key is in the ignition switch, the ceiling
lamp will not come on whether the door is open or closed.
HI BEAM Inspection
HEAD
TAIL 1. Combination switch assembly LH
(a) Inspect the light control switch continuity.
OFF
FLASH
table below.
Combination Switch
4 Standard:
Assembly LH
Connector Specified
Front View: Switch operation Tester connection
5 6 7 8 9 condition
ALK004G
OFF 4-5-6-7 10 kΩ or higher
TAIL 4-7 Below 1 Ω
HEAD 4-7 Below 1 Ω
HEAD 5-6 Below 1 Ω
Replace the switch as necessary.
(b) Inspect the combination switch LH continuity.
table below.
Standard:
Specified
Switch operation Tester connection
condition
FLASH 5-6-8 Below 1 Ω
LOW BEAM 5-6-9 Below 1 Ω
HI BEAM 5-6-8 Below 1 Ω
Hint:
Turn the combination switch LH to the HEAD position
when checking “LOW BEAM” and “HI BEAM”.

Right turn (c) Inspect the turn signal lamp switch continuity.
table below.
Standard:
Left turn Specified
Combination Switch Switch operation Tester connection
condition
Assembly LH
Connector Right turn 10 - 11 Below 1 Ω
Front View: 101112 Neutral 10 - 11 - 12 10 kΩ or higher
ALK005G Left turn 11 - 12 Below 1 Ω
2. Back-up lamp switch assembly
(a) Inspect the back-up lamp switch assembly continuity.
table below.
Standard:
Specified
ON condition
ON 1-2 Below 1 Ω
OFF OFF 1-2 10 kΩ or higher
ALK006G

3. Brake lamp switch assembly
Free Pushed in (a) Inspect the brake lamp switch assembly continuity.
2 1
table below.
Standard:
Specified
condition
Switch pin pushed
1-2 10 kΩ or higher
ALK007G in (Pedal released)
Switch pin free
1-2 Below 1 Ω
(Pedal depressed)
4. A/C controller assembly No.2
Connector Front View: (a) Inspect the hazard warning signal switch continuity.
A/C
table below.
Standard:
Specified
condition
ON 1-2 Below 1 Ω
2 1
ALK008G OFF 1-2 10 kΩ or higher
If the value is not as specified, replace the integration
control & panel assembly.

5. Front door courtesy lamp switch assembly

Front Door Courtesy ON
(a) Inspect the front door courtesy lamp switch assembly conti-
Lamp Switch Assembly
OFF nuity.
table below.
Standard:
Specified
condition
ALK009G ON 1 - Body ground Below 1 Ω
OFF 1 - Body ground 10 kΩ or higher
6. Rear door courtesy lamp switch assembly
(a) Inspect the rear door courtesy lamp switch assembly continu-
ity.
(1) Check the rear door courtesy lamp switch assembly us-
ing the same procedures as for the front door courtesy
lamp switch assembly.
Standard: Same as the front door.
7. Back door courtesy lamp switch assembly
Back Door Lock Assembly
Connector Front View: (a) Inspect the back door courtesy lamp switch assembly conti-
nuity.
table below.
Standard:
1 2
Specified
condition
ALK010G ON (Unlock) 1-2 Below 1 Ω
OFF (Lock) 1-2 10 kΩ or higher
8. Reading lamp assembly
2
(a) Inspect the reading lamp assembly continuity.
ON OFF DOOR
(b) Measure the resistance according to the value(s) in the table

below.
Standard:
1
Ω Specified
- + condition
ON 1-2 Below 1 Ω
ALK011G DOOR 1-2 Below 1 Ω
OFF 1-2 10 kΩ or higher
Replace the lamp as necessary.

9. High-beam headlamp relay

(a) Inspect the high-beam headlamp relay continuity.
(b) Measure the resistance according to the value(s) in the table
3 3
5 below.
5 Standard:
1 2 Tester connection Specified condition
2 1
3-5 10 kΩ or higher
Below 1 Ω
ALK012G 3-5 (When battery voltage is ap-
plied to terminals 1 and 2)
Replace the relay as necessary.
10. Low-beam headlamp relay
(a) Inspect the low-beam headlamp relay continuity.
(1) Check the low-beam headlamp relay using the same
procedures as for the high-beam headlamp relay.
Standard: Same as the high-beam headlamp relay.
Replace the relay as necessary.

IR-10 GREAT WALL COOL BEAR REPAIR MANUAL
Combination Headlamp Assembly LH

Components
Front Position Lamp Bulb
High-beam Lamp Bulb
Low-beam Lamp Bulb

Turn Signal Lamp
Bulb LH
ALK013G

VEHICLE INTERIOR IR-11
Replacement
Hint:
Remove the combination headlamp LH by following the same or-
der as for the RH side.
Components: See page IR-9
BO-38)
2. Remove front fender lining LH (See page BO-38)
3. Remove front fender lining RH (See page BO-38)
4. Remove front bumper connecting bracket LH (See
page BO-38)
5. Remove front bumper connecting bracket RH (See
page BO-38)
7. Remove front bumper lower grille body (See page
BO-39)
8. Remove headlamp assembly LH
(b) Disconnect the connectors and remove the headlamp assem-
bly LH.
ALK014G
9. Remove high-beam headlamp socket cover

(a) Turn the high-beam headlamp socket cover counterclockwise
to remove it as shown in the illustration.
ALK015G
10. Remove high-beam headlamp bulb

(a) Remove the high-beam headlamp bulb as shown in the illus-
tration.
(b) Remove the front position lamp bulb.
ALK016G

11. Remove low-beam headlamp socket cover

(a) Turn the low-beam headlamp socket cover counterclockwise
12. Remove low-beam headlamp bulb
(a) Remove the low-beam headlamp socket cover and the low-
beam headlamp bulb.
13. Remove turn signal lamp socket LH and turn signal
lamp bulb LH
ALK017G 14. Install headlamp assembly
Hint:
reverse order.
15. High-beam headlamp aim only
Adjustment
1. High-beam headlamp aim only
Hint:
• Perform aiming adjustment with high-beam headlamp.
• Use the same method to adjust the low-beam lamp.
(a) Prepare vehicle in the following conditions.
• Check that any damage or deformation does not exist on
the body around the headlamps.
• Fuel tank is full.
• The tire pressure is within the specified range. (See page
SP-37)
• Vehicle is parked at a level surface.
• A person having an average weight (68 kg (149.14 lb))
sits in the driver’s seat.
• Vehicle is bounced up and down to stabilize the suspen-
sion to the normal position.
(b) Prepare a thick white paper (Draw base lines).
Hint:
V LH Line V Line V RH Line
• Stand the paper perpendicular as against a wall.
• The base lines differ for “Low-beam inspection” and
H Line
“High-beam inspection”.
(1) V line (Vehicle center position)
Draw a vertical line down the center of the paper in or-
Ground der to align it with the center of the vehicle.
ALK018G (2) H line (Headlamp height)
Draw horizontal line across the paper at the same height
from the ground as the center mark for the high-beam
lamps.
(3) V LH line, V RH line (Center mark position of right
and left headlamps)
Draw vertical lines, for left & right, at the same posi-
tion as the center mark for the high-beam lamps.
Hint:
Follow the same procedures when adjusting the low-
beam lamps.

(c) Check the high-beam headlamp aiming.

(1) Align the position of the paper and vehicle.
V RH Line • Make the distance of 3 m (9.84 ft) between the
headlamps and the paper, and put the paper on the
90° V Line
wall with the H line being at the same height as the
3 m (9.84 ft) center mark.
V LH Line • Align the center of the vehicle with the V line on
the paper, and ensure that the paper is at a 90° angle
ALK019G in accordance with the V line.
(2) Start the engine.
(3) Turn on the headlamps and check that the aim is within
LO-Beam: V LH Line
V RH Line the specified values as shown in the illustration.
40 mm
(1.57 in.) Notice:
The headlamp lens is made of synthetic resin, so
H Line it is easy to be damaged.
40 mm Hint:
(1.57 in.) When checking the aiming of the high-beam, shut off
40 mm 40 mm the low-beam or disconnect the low-beam headlamp
(1.57 in.) (1.57 in.)
ALK020G connector.
HI-Beam: V LH Line
V RH Line
40 mm
(1.57 in.)
H Line
40 mm
(1.57 in.)
40 mm 40 mm
(1.57 in.) (1.57 in.)
ALK021G
(d) Adjust the aiming in the vertical direction:

Using a screwdriver, adjust the high-beam headlamp aim
within the specified range by turning the aiming screw A.
Notice:
• Adjust the high-beam headlamp aim by turning the
screw in the tightening direction.
• When the screw is tightened excessively, loosen it
once and retighten it to adjust the high-beam head-
ALK022G lamp aim.
Hint:
The optical axis aim moves downward when turning the
screwdriver clockwise, and it moves upward when turning
the screwdriver counterclockwise.

Rear Combination Lamp Assembly LH

Replacement
1. Remove C pillar lower trim panel assembly LH

(a) Remove the 2 bolts and the hook.
Claw
(b) Remove the bolts and the seatback hinge.
(c) Remove the bolts on the end plate cover side and the belt.
(d) Using a screwdriver, disengage the 3 claws and the 5 clips,
Clip and remove the C pillar lower trim panel assembly LH.
ALK023G
2. Remove rear combination lamp assembly LH

(b) Remove the 2 nuts and the rear combination lamp assembly
LH.
ALK024G
3. Remove rear turn signal lamp bulb

(a) Remove the turn signal lamp bulb, turn signal lamp socket
and the wire sub-assembly as shown in the illustration.
ALK025G
4. Remove rear brake lamp assembly

(a) Remove the 4 screws as shown in the illustration.
(b) Remove the LED lamp cover.
(c) Remove the 6 screws and the LED lamp.
5. Install rear combination lamp assembly LH
Hint:
reverse order.
ALK026G

High-mounted Brake Lamp Assembly

Replacement
1. Remove high-mounted brake lamp screw cover

(a) Remove the high-mounted brake lamp screw cover by hand
: 2 Screw Covers ALK027G
2. Remove high-mounted brake lamp assembly

(b) Disconnect the connector and remove the high-mounted
brake lamp assembly.
ALK028G
(c) Remove the 3 screws and the LED lamp lens as shown in the
illustration.
ALK029G
(d) Remove the 3 screws and replace the LED lamp assembly as
ALK030G

License Plate Lamp Assembly

Replacement
1. Remove back door shield (See page BO-33)
2. Remove license plate lamp trim panel assembly (See
page BO-44)
3. Remove license plate lamp assembly
(a) Remove the 4 screws and the license plate lamp assembly.
ALK031G
4. Remove license plate lamp bulb

(a) Remove the license plate lamp bulb and socket as shown in
the illustration.
(b) Remove the license plate lamp bulb from the socket.
5. Remove license plate lamp body
6. Install license plate lamp assembly
Hint:
ALK032G reverse order.
Combination Switch Assembly LH

Replacement
1. Remove combination switch cover (See page SR-7)
2. Remove combination switch assembly LH
(b) Using a screwdriver, disengage the claw and pull out the
combination switch assembly LH.
Hint:
3. Install combination switch assembly LH
4. Install combination switch cover (See page SR-10)
: Claw
ALK033G

Front Fog Lamp Assembly LH

Replacement
Hint:
Remove the front fog lamp assembly LH by following the same
procedure as for the RH side.
BO-38)
2. Remove front fender lining LH (See page BO-38)
3. Remove front fender lining RH (See page BO-38)
4. Remove front bumper connecting bracket LH (See
page BO-38)
5. Remove front bumper connecting bracket RH (See
page BO-38)
ALK034G 6. Remove front bumper lower grille body (See page
BO-39)
7. Remove front bumper body
(a) Remove the clip and the 2 bolts from the upper side of the
bumper body.
(b) Using a screwdriver, disengage the 2 claws and remove the 2
bolts and the 6 screws.
ALK035G
8. Remove front fog lamp assembly LH

(b) Disconnect the connector and remove the front fog lamlp as-
sembly LH from the front bumper body.
9. Remove front fog lamp socket and bulb LH
10. Replace front fog lamp bulb LH
11. Install front fog lamp bulb LH
12. Install front fog lamp assembly LH
ALK036G (a) Install the front fog lamp assembly LH to the front bumper
body with the 3 screws.
(b) Connect the connector.
Hint:
reverse order.

Back-up Lamp Assembly

Replacement
Hint:
Remove the back-up lamp assembly by following the same order
for the rear fog lamp assembly.
1. Remove rear bumper mud guard LH
(a) Using a screwdriver, disengage the claw and remove the
screw and the 2 clips.
2. Remove rear bumper mud guard RH
3. Remove rear bumper body
(a) Using a screwdriver, disengage the 2 claws and remove the 7
bolts and the bumper body.
(b) Disconnect the wire harness, the connector and the clamp.
ALK037G
4. Remove back-up lamp assembly

(b) Remove the back-up lamp assembly from the rear bumper
body.
5. Remove back-up lamp socket and bulb
6. Install back-up lamp bulb
7. Install back-up lamp assembly
(a) Install the back-up lamp assembly to the rear bumper body
ALK038G with the 3 screws.
8. Install rear bumper
Hint:
reverse order.

IGNITION SWITCH
Replacement
Hint:
verse order.
1. Remove driver airbag assembly (See page RS-29)
2. Remove steering wheel (See page SR-7)
3. Remove combination switch lower cover and upper
cover (See page SR-7)
4. Remove ignition switch assembly
(a) Disconnect the ignition switch and unlock warning switch
connectors.
(b) Remove the clamp.
(c) Remove the 2 screws and ignition switch.
ALK039G
LOCK
ACC
Inspection
1. Inspect ignition switch assembly
ON (a) Check the resistance of the switch.
Standard:
START
Tester
Switch condition Specified condition
connection
3 2 1 1-3 ACC
6 5 4
1-2
ALK040G
1-3 ON
5-6 Below 1 W
1-2
4-5 START
5-6
If the result is not as specified, replace the switch assembly.

COMBINATION SWITCH
Replacement
Hint:
verse order.
3. Remove combination switch lower cover and upper
cover (See page SR-7)
4. Remove combination switch assembly LH
(a) Disconnect the connector and remove the combination switch
assembly LH.
5. Remove combination switch assembly RH
(a) Disconnect the connector and remove the combination switch
assembly RH.
ALK041G

COMBINATION METER
Indicator:
Front fog lamp indicator does not come on. 2. Front fog lamp switch -
3. Combination meter assembly IR-41
Rear fog lamp indicator does not come on. 2. Rear fog lamp switch -
HI-Beam indicator does not come on. 2. Combination switch assembly LH IR-16
Turn signal indicator does not come on. 2. Turn signal and hazard warning system -
Open door warning indicator does not come
2. Door courtesy lamp switch IR-8
on.
Charge indicator does not come on. 2. Generator MA-7
Parking brake indicator does not come on. 2. Parking brake switch BR-48
Airbag malfunction indicator does not come
2. Airbag ECU assembly RS-48
on.
Seat belt reminder indicator does not come
2. Buckle switch RS-50
on.
Brake system malfunction indicator does not 2. Parking brake switch BR-47
come on. 3. Brake fluid level warning switch IR-24
ABS malfunction indicator does not come on.
Oil pressure warning indicator does not come
2. Oil pressure switch -
on.
Fuel warning indicator does not come on. 2. Fuel gauge sensor -


Engine system malfunction indicator does not
2. ECM -
come on.
2. O/D main switch line -
O/D switch indicator does not come on.
3. ECM -
2. Service reminder indicator switch -
Engine service indicator does not come on.
3. Sensor -
2. Parking brake switch BR-47
EBD indicator does not come on.
3. Brake fluid level warning switch IR-24
Engine water temperature warning indicator
2. ECM -
does not come on.
Engine pre-heating indicator does not come
2. Pre-heating sensor -
on.
Light main switch indicator does not come
2. Light main switch -
on.
Rear defogger/defroster indicator does not
2. Rear defroster/defogger switch -
come on.
Oil water separator warning indicator does
2. Water level sensor -
not come on.
120 km/h warning indicator* does not come
2. Speed sensor -
on.
* For Middle East and G.C.C. Countries.

1. Inspect speed meter
(1) Using a speed meter tester, inspect the speed meter for allowable indication error, and check the operation
of the odometer.
Standard indication (km/h) Allowable range (km/h)
20 (17 to 23)
40 (36 to 40)
60 (55 to 60)
80 (75 to 80)
100 (95 to 100)
120 (114 to 120)
140 (133 to 140)
160 (152 to 160)
180 (171 to 180)
Note 1: The basic error of speedometer at a higher speed should be determined by customer and producer.
Note 2: No assessment on limit speed error.
Note 3: When users have special requirements, the basic error can be checked in accordance with corporate
standards approved through established procedures and user’s requirements.
Notice:
Tire wear and tire over or under inflation will increase the indication error.
2. Inspect tachometer
(1) Connect a tune-up test tachometer, and start the engine.
Notice:
• Reversing the connection of the tachometer will damage the transistors and the diodes in-
side.
• When removing or installing the tachometer, be careful not to drop it or give it heavy shocks.
(2) Compare the test result with the tachometer indications.
DC 13.5 V, at 25°C (77°F).
Allowable range
Standard indication
(Percentage of speed at checked point, %)
Low engine speed ± 10
Middle, high engine speed ±5
Note 1: The low speed is less than or equal to 30% of the limit of the dial scale.
Note 2: The middle and high speed is more than 30% of the limit of the dial scale.
Note 3: When users have special requirements, the basic error can be checked in accordance with corporate
standards approved through established procedures and user’s requirements.
Fuel Gauge Sensor:

3. Inspect fuel gauge sensor
(a) Inspect the circuit.
F14 (1) Disconnect fuel gauge sensor connector.
(2) Turn the ignition switch to the ON position, then check
the position of the fuel gauge needle.
1 2 3
Needle position: EMPTY
4 5 (3) Connect the positive (+) lead from the three 1.5 V dry
batteries to terminal 2 and its negative (-) lead to termi-
ALK042G nal 3.

(4) Disconnect the negative (-) terminal from the battery and wait at least 60 seconds.
(5) Connect the negative (-) terminal to the battery and turn the ignition switch to the ON position, then check
the position of the fuel gauge needle.
Needle position: FULL
4. Inspect fuel warning indicator
(1) Disconnect fuel gauge sensor connector.
(2) Turn the ignition switch to the ON position, and check that the fuel level needle indicates EMPTY and the
fuel warning indicator comes on.
5. Inspect seat belt reminder indicator (Driver seat)
(1) Turn the ignition switch to the ON position, and check that the indicator comes on.
(2) Fasten the outer belt to the seat belt buckle, and check that the indicator goes off.
(3) Disconnect the buckle switch connector, and ground the terminal on the wire harness side connector.
6. Inspect oil pressure warning indicator
(1) Disconnect low oil pressure switch connector.
(2) Turn the ignition switch to the ON position.
(3) Connect the terminal on the wire harness side connector and ground, then check that the low oil pressure
warning indicator comes on.
7. Inspect parking brake indicator
(a) Inspect the parking brake indicator.
(1) Disconnect the parking brake switch connector, and ground the terminal on the wire harness side connec-
tor.
8. Inspect brake fluid level warning switch
(a) Inspect the continuity
(1) Remove the reservoir cap and the strainer.
(2) Disconnect the connector.
(3) Measure the resistance according to the value(s) below.
Float up (switch OFF): 10 kΩ or more
(4) Use a syphon, etc., to take fluid out of the reservoir.
(5) Measure the resistance according to the value(s) below.
Float down (switch ON): Below 1 Ω
(6) Refill the reservoir with brake fluid.
9. Inspect driver seat belt warning buzzer
(a) Inspect warning buzzer function.
(1) Turn the ignition switch to the ON position, and check that the driver seat belt warning buzzer sounds if
the driver seat belt is not fastened.
(2) Check that the buzzer stops approximately 4 to 8 seconds later.
10. Inspect key reminder warning buzzer
(a) Inspect warning buzzer function.
(1) Turn the ignition switch off, and check that the key reminder warning buzzer sounds when the ignition key
is inserted into the key cylinder and the driver side door is opened.

Instrument Panel/Instrument
Components
Wind Tunnel Assembly RH

Wind Tunnel Assembly LH
A Pillar Upper Trim

A/C Air Vent Ball Assembly RH Panel Assembly RH
A/C Air Vent Ball Assembly LH

Passenger Airbag
Assembly
A Pillar Upper Trim Panel Assembly LH
Instrument End
Trim Panel
Front Tweeter RH
Instrument Panel Front
Damping Sealing
Sponge Bar
Upper Instrument
Panel Body
Front Tweeter LH
Instrument Panel
Hole Cover No.3 Front Tweeter Shield RH
Front Tweeter Shield LH

Center Console Panel Body A/C Control Knob
Combination Meter Assembly
Combination Meter
Trim Cover

ALK043G

Steering Column Dust Cover

28 (286, 21)
Glove Box Body
CD Player w/Bracket Assembly A Pillar Lower
Trim Panel
Steering Shaft Assembly
Steering Column Front Rocker Trim RH
28 (286, 21)
A Pillar Lower Combination Switch

Trim Panel Assembly RH
Assembly 25 (255, 19) Small Glove Box Body
Clock Spring
Sub-assembly
Instrument Panel
Lower Shield
Combination Switch
Assembly LH
Front Rocker Trim LH Shift Lever Knob Sub-assembly
Steering Wheel Assembly
50 (510, 37)
Combination Switch Cover
8.8 (90, 78 in.·lbf)

Driver Airbag
N·m (kgf·cm, ft·lbf ) : Specified torque
ALK044G

Instrument Panel
Reinforcement Member
20 (204, 15)
20 (204, 15)
Instrument Panel Brace

Sub-assembly No.1
20 (204, 15)
Instrument Panel Mounting

Bracket No.1
Lower Instrument
Panel Insert LH
Central Wind Tunnel
Glove Box Striker
Coin Box
Fuse Block Opening Cover
ALK045G

Combination Meter Cover
Combination Meter
Assembly
Combination Meter Glass
ALK046G
Precaution
1. Precaution for vehicle with SRS airbag and seat belt pretensioner
(a) Some operations in this section may affect the SRS airbags. Prior to performing the corresponding operations,
read the SRS airbag PRECAUTION (See page RS-2).


Replacement
2. Remove combination meter trim cover
(a) Remove the clip.
(b) Disengage the 7 claws and the 3 clips, and remove the com-
bination meter trim cover.
: 7 Claws
: 3 Clips ALK047G
3. Remove combination meter assembly

(b) Disconnect the connector, and then remove the combination
meter assembly.
ALK048G
4. Remove front tweeter shield LH

(a) Using a moulding remover, disengage the 5 claws and re-
move the tweeter shield.
: 5 Claws ALK049G
5. Remove front tweeter shield RH

6. Remove front tweeter assembly LH and RH (See page
AV-6).
ALK050G


ALK051G
(b) Disengage the 8 clips and the 6 claws, and remove the center
console panel body.
: 6 Claws
: 8 Clips ALK052G
9. Remove CD player w/bracket assembly (See page

AV-4)
ALK053G
10. Remove A pillar upper trim assembly LH

(a) Disengage the 2 clips, and remove the A pillar upper trim as-
sembly LH.
11. Remove A pillar upper trim assembly RH
: 2 Clips ALK054G
12. Remove instrument panel hole cover No.3

(a) Disengage the 4 claws, and remove the instrument panel hole
cover No.3.
13. Disconnect passenger airbag connector (See page
RS-39)
: 4 Claws
ALK055G


bag assembly
(a) Remove the bolt.
(b) Remove the 6 screws.
(c) Disengage the 7 clips and the 3 claws.
(d) Disconnect the connector.
(e) Pull the upper instrument panel body w/passenger airbag as-
sembly and remove it.
ALK056G
: 3 Claws
: 7 Clips ALK057G
15. Remove wind tunnel assembly LH

(a) Using nippers etc., cut off the ultrasonic welding portion as
shown in the illustration to remove the wind tunnel assembly
LH from the upper instrument panel body.
ALK058G

Ultrasonic Welding Portion

Cut Line
Wind Tunnel
Assembly LH
ALK059G
16. Remove wind tunnel assembly RH

shown in the illustration to remove the wind tunnel assembly
RH from the upper instrument panel body.
ALK060G

Cut Line
Wind Tunnel
Assembly RH
ALK059G
17. Remove A/C air vent ball assembly

shown in the illustration to remove the A/C air vent ball as-
sembly from the upper instrument panel body.
ALK061G

Cut Line
A/c Air Vent Ball

Assembly RH
ALK059G

18. Remove instrument end trim panel

(b) Disengage the 2 claws, and remove the instrument end trim
panel.
19. Remove passenger airbag assembly (See page RS-40)
20. Remove instrument panel front damping sealing
sponge bar
(a) Remove the instrument panel front damping sealing sponge
: 2 Claws
ALK062G bar from the upper instrument panel body.
21. Remove upper instrument panel body
22. Install wind tunnel assembly LH
Cut Line
Boss (a) When replacing the upper instrument panel body with a new
one, cut the boss off by nippers, etc. as shown in the illustra-
tion.
Notice:
When reusing the upper instrument panel body, start
Nippers Wind Tunnel from step (b).
Assembly LH
ALK063G
Wind Tunnel Assembly LH (b) Using a screw, install the wind tunnel assembly LH to the
upper instrument panel body.

ALK064G
23. Install wind tunnel assembly RH

Cut Line
Boss (a) When replacing the upper instrument panel body with a new
tion.
Notice:
When reusing the upper instrument panel body, start
Nippers Wind Tunnel from step (b).
Assembly RH
ALK063G

Wind Tunnel Assembly RH (b) Using a screw, install the wind tunnel assembly RH to the
upper instrument panel body.
24. Install upper instrument panel body w/passenger airbag
assembly
(a) Install the upper instrument panel body w/passenger airbag
assembly with the 6 screws.

ALK064G
: 3 Claws
: 7 Clips ALK065G
(b) Using a torque wrench, install the bolt.

ALK056G

Lower Instrument Panel Body

Replacement
2. Remove upper instrument panel body w/passenger airbag assembly (See page IR-31)
SST 09950-50013 (09951-05010, 09952-05010, 09953-05020, 09954-05021)
6. Remove combination switch assembly LH (See page SR-7)
7. Remove combination switch assembly RH (See page SR-7)
8. Remove front rocker trim LH (See page IR-62)
9. Remove front rocker trim RH (See page IR-62)
10. Remove A pillar lower trim panel assembly LH (See page IR-63)
11. Remove A pillar lower trim panel assembly RH (See page IR-63)
12. Remove A/C controller assembly No.1 (See page AC-19)
13. Remove small glove box body
(a) Disengage the 2 claws and the 2 clips.
(b) Disconnect the connectors, and then remove the small glove
box body.
: 2 Claws
: 2 Clips
ALK066G
14. Remove instrument panel lower shield

(a) Using a clip remover, remove the clip.
(b) Disengage the 3 claws, and remove the instrument panel
lower shield.
: 3 Claws
ALK067G
15. Remove glove box body

(a) Push the right side wall, and then push the left side wall to
release the stoppers.
: 2 Stoppers
ALK068G

(b) Pull the glove box rearward to remove it.
: 2 Claws
ALK069G

17. Separate steering column and steering shaft (See page
SR-8)
18. Remove steering column (See page SR-8)
19. Remove steering column dust cover (See page SR-8)
20. Spearate steering shaft and steering connecting shaft
(See page SR-8)
21. Remove antenna cord sub-assembly
22. Remove lower instrument panel w/instrument panel re-
inforcement member
(a) Remove the 2 bolts.
ALK070G
(b) Remove the 3 bolts.
ALK071G
(c) Using a clip remover, remove the clip.
ALK072G

(d) Remove the 3 bolts.
ALK073G
(e) Remove the bolt and the instrument panel mounting bracket
No.1.
ALK074G
(f) Remove the screw.

(g) Disconnect the connector, and remove the door control re-
ceiver.
ALK075G
(h) Remove the bolt.

(i) Disconnect the engine hood lock control cable.
(j) Remove the 2 bolts, 2 nuts and the 2 screws
(k) Remove the 2 screws and the 3 nuts, and separate the instru-
ment panel J/B assembly.
(l) Disconnect the connectors, and then remove the lower instru-
ment panel w/instrument panel reinforcement member.
ALK076G

ALK077G
23. Remove instrument panel reinforcement member

(a) Using a clip remover, remove the 2 clips.
ALK078G
(b) Remove the screw.
ALK079G

(c) Remove the 3 bolts and the lower instrument panel insert
LH.
ALK080G
(d) Remove the nut and the instrument panel brace sub-assembly
No.1.
24. Remove fuse block opening cover
ALK081G
25. Remove central wind tunnel

shown in the illustration to remove the central wind tunnel
from the upper instrument panel body.
ALK082G

Cut Line
Central Wind
Tunnel
ALK059G
26. Remove glove box striker

(a) Remove the screw and the glove box striker.
27. Remove coin box
28. Remove lower instrument panel body
ALK083G

29. Install central wind tunnel

Cut Line
Boss (a) When replacing the lower instrument panel body with a new
tion.
Notice:
When reusing the lower instrument panel body, start
Nippers Central Wind Tunnel from step (b).
ALK063G
Central Wind Tunnel (b) Using a screw, install the central wind tunnel.
Lower Instrument Panel Body

ALK064G
30. Connect steering shaft and steering connecting shaft

(See page SR-9)
31. Install steering column (See page SR-9)
32. Connect steering column and steering shaft (See page
SR-10)
33. Install upper instrument panel w/passenger airbag as-
sembly (See page IR-34)
34. Adjust clock spring sub-assembly
35. Install steering wheel (See page SR-10)
36. Install driver airbag assembly (See page RS-29)
37. Inspect driver airbag assembly (See page RS-29)

Combination Meter Assembly

Overhaul
Notice:
When disassembling combination meter assembly, mea-
sures should be taken to prevent static electricity from dam-
aging the system.
1. Remove combination meter trim cover
(a) Remove the clip.
(b) Disengage the 7 claws and the 3 clips, and remove the com-
bination meter trim cover.
: 7 Claws
: 3 Clips ALK047G
2. Remove combination meter assembly

(b) Disconnect the connector, and then remove the combination
meter assembly.
ALK048G
3. Remove combination meter glass

(a) Disengage the 3 claws, and remove the combination meter
glass.
4. Remove combination meter cover
(a) Disengage the 6 claws, and remove the combination meter
cover.
: 3 Claws ALK084G

BACK-UP RADAR*
System Description
ALK085G
Back-up radar system components contains 1 ECU, 4 sensors and 1 warning buzzer.
ECU calculates the distance between vehicle and detected object base on the time difference when the signal is sent
and received.
*: For models equipped with back-up radar system

Function Description
1. Self-check function
The system will delay 0.3s and begin to self-check when turning the power switch to ACC and switching shift lever
to R. If all sensors operate normally, the buzzer will sound twice; if malfunction occurs in any of sensors, the buzzer
will sound three times, and the normal sensors will go on operating. For specific malfunction warning specifications
see the table below:
500 ms
100 ms 100 ms
All the sensors are normal Buzzer ON
OFF
Sensor malfunction occurs Buzzer

ON
OFF
Malfunction Warning Specifications Description
ALK086G
2. Normal use function

(a) The system operates when the shift lever is switched to R; The system stops operating when the shift lever is
switched to other positions.
(b) When normal operating
(1) The warning signal is sent by the system, when the ultrasonic sensor receives the reflected wave in the de-
tection range.
(2) See the table below for the sensor detected distance and buzzer warning time.
(3) When the object is detected by more than one sensors, the system will be activated by the sensor which de-
tects the nearest object.
Distance from the object Response method of buzzer
Corner sensor Center sensor Within 150 to 90 cm
——— 150 cm - 90 cm ON: 75 ± 7.5 ms/OFF: 225 ± 22.5 ms
60 cm - 45 cm 90 cm - 45 cm ON: 75 ± 7.5 ms/OFF: 75 ± 7.5 ms
Within 45 cm Within 45 cm ON: Continuous/OFF: 0 ms
(4) Three different warning sounds will be performed according to the distance between the sensor on the
bumper and the object. The warning buzzer will not sound if the objects is beyond the detecting scope.
Three different warning sound:
Sound Corner sensor Center sensor Mark on the table blow
Slow, and intermittent
Within 150 to 90 cm
beep
Quick, and intermittent
Within 60 to 45 cm Within 90 to 45 cm
beep
Continuous beep Within 45 cm Within 45 cm

Corner Sensor Corner Sensor

Center Sensor Center Sensor
<45 cm
cm <45
60- <45 cm
45 c cm
45
m 60-
90-45 cm
150-90 cm
The data above is to distinguish the sensor detecting range, it is not the accurate detecting data.
ALK087G
Electrical Wiring Diagram
2 11
Corner
1 3
Sensor LH
12
Corner 2 8
Sensor RH 1
Center 2 10 Buzzer
Sensor LH 1
24
Center 2 9 GND
Sensor RH 1
Back-up Light 13
Power Supply 1A
ECU
ALK088G

Technical Parameter
1. ECU
Standard voltage DC 13.5 V
Operating voltage DC 9 ~ 16 V
Static current 0 mA (Operate only when turning to ON and START)
Operating temperature -30 ~ +80°C
Storage temperature -40 ~ +85°C
2. Sensor
Connecting types with ECU 2 solid wires
Standard voltage DC 12 V
Operating voltage DC 8 ~ 15 V
Operating frequency 48 ± 1.5 KHZ
Sensor model Twin angle, flat type, f14 mm
150 cm ± 5 cm (Center sensor)
Farthest distance detection
(Use plywood with width 30 cm × Height 1 m for test)
3. Warning buzzer
Warning frequency 2.8 KHZ ± 0.7 KHZ
Warning sound pressure 90 dB (min)/30 cm
Operating mode Built-in driver buzzer
Connector Terminals Definition

1. ECU connector terminals definition
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
ALK089G

Termi- Terminal Termi- Terminal

Condition 4 Sensors Condition 4 Sensors
nal No. names nal No. names
Back-up
Output termi-
1 NC NC 13 light power To apply
nal
supply
2 NC NC 14 NC NC
3 Sensor GND Output terminal To apply 15 NC NC
4 NC NC 16 NC NC
5 NC NC 17 NC NC
6 NC NC 18 NC NC
7 NC NC 19 NC NC
Input/Output
8 Corner sensor R To apply 20 NC NC
terminal
Input/Output
9 Corner sensor R To apply 21 NC NC
terminal
Input/Output
10 Corner sensor L To apply 22 NC NC
terminal
Input/Output
11 Corner sensor L To apply 23 NC NC
terminal
Input/Output Output termi-
12 BUZ To apply 24 NC To apply
terminal nal
2. Sensor connector terminals definition

1 2
Lead wire Terminal
Terminal No. Condition
color names
1 Black GND Input terminal
Sensor power
Input/Output
2 White supply and
terminal
signal
ALK090G
3. Buzzer connector terminals definition

Terminal No. Wire position definition
1
1 Buzzer positive
2 Buzzer negative
ALK091G

Components
Back-up Radar ECU
Sensor
Back-up Radar Buzzer
ALK092G
Back-up Radar Buzzer

Hint:
verse order.
bag assembly (See page IR-29)
3. Remove back-up radar buzzer
(a) Disconnect back-up radar buzzer connector.
(b) Remove the bolt from the instrument panel reinforcement
member and remove the back-up radar buzzer.
ALK093G

Back-up Radar ECU

Hint:
verse order.
2. Remove C pillar upper trim panel assembly RH (See
page IR-64)
3. Remove back-up radar ECU
(a) Disconnect back-up radar ECU connector.
(b) Remove the 2 bolts form D pillar RH and remove the back-
up radar ECU.
ALK094G

THEFT DETERRENT SYSTEM

System Description
Theft deterrent system components contains: theft deterrent ECU assembly, theft deterrent coil assembly and convert-
er assembly.
The main purposes that the vehicle is equipped with the theft deterrent system are: 1 Prevent vehicle
from missing; 2 Prevent strangers from breaking in illegally; 3 Prevent vehicle from driving illegally;
4 Help to monitor and search for the missing vehicle and so on.
Function Description
The following illustration is the theft deterrent system components as well as the mount standard parts.
Theft Deterrent
ECU Assembly
Bolt, Spring Washer

& Plate Washer Kit
Theft Deterrent Converter
Assembly
Theft Deterrent
Theft Deterrent Coil Indicator
Assembly
ALK095G
Theft deterrent converter assembly is embedded in each key, when inserting a key into the lock cylinder and turning it
to “ON”,the communication between the theft deterrent ECU assembly and theft deterrent converter assembly in the
key is progressing by radio waves. If the key is confirmed to be correct, the theft deterrent ECU assembly and engine
ECU assembly will perform code verification, if the verification passes, the electronic theft deterrent system will al-
low engine to start. If any of the two kinds of code verifications fails, the engine will not be allowed to start.

Components
Other components of the theft deterrent system are assembled on the complete vehicle, except the theft deterrent con-
verter assembly contained in the key. They communicate via the wire harness connection. The following illustration
described each component’s location in the complete vehicle.
Theft Deterrent Converter Assembly

(In the key)
Theft Deterrent Coil Assembly

Hollow Beam
Theft Deterrent
ECU Assembly
Ignition Switch
ALK096G
Theft Deterrent ECU Terminals Definition

The theft deterrent control ECU contains two connectors, connector A is 8 - Pin connector, connector B is 4 - Pin con-
nector. Front view for connectors is as below:
7 5 3 1
4 3 2 1
8 6 4 2
Front View for the Theft Deterrent Control ECU Connector A Front View for the Theft Deterrent
Control ECU Connector B
ALK107G

Each terminal definition is in the table below:

Port Signal name Signal definition Port Signal name Signal definition
A1 Battery/KL.30 Battery positive B1 GND/KL.31 Ground
A2 GND/KL.31 Ground B2 Coil positive Coil positive
A3 Status LED State lamp B3 Coil negative Coil negative
A4 Ignition/KL.15 Ignition switch B4 GND/KL.31 Ground
A5 R - Line R Line
A6 Reservation
Communication
A7 K - Line
diagnosis interface
Engine certification
A8 W - Line
interface

DOOR LOCK
Electric Door Lock Control System
On-vehicle inspection
1. Check operation of the eletric door lock
(a) Lock front door with key
(1) When locking the front door, turn the key counterclockwise. When unlocking the door, turn the key clock-
wise.
(2) Other doors will be locked or unlocked as you lock or unlock front door LH.
(b) Locking the door without key
(1) Front door LH
Front door LH cannot be locked if there is no key outside the vehicle. This is to avoid locking the door ac-
cidentally when the key is left the vehicle.
Caution:
If the front door lock LH is in LOCK status, and the handle is pulled up when closing the door,
then the door will be locked.
(2) Other doors
Press the control knob to the lock position and then close the door, the door can be locked without key out-
side.
(c) Automatic door lock
(1) Using automatic door lock system, you can lock the front door LH and RH at the same time.
(2) All the doors can be locked or unlocked by operating the lock switch of front door LH.
(d) Rear door “Child Protection” lock
Child protection lock can prevent the door from unlocking accidentally, especially when child is seating on the
back seat. Every rear door has a lock lever.
(1) If the lock lever is set on the LOCK position, you cannot open the door using the inner handle. If you need
to open the door when using the child protection lock, use outer handle please.
(2) The child protection lock has no effect if the lock bar is set on RELEASE position.
(e) Back door
(1) Open back door
Pull out the key from the ignition switch cylinder, press the back door opening button, then press the back
door opener switch button within 60 s and pull up the back door handle.
(2) Close back door
Pull the back door handle down, and release the back door handle before the back door closed fully. Push
the back door from the back lightly to close it fully.
2. Check lighting
(a) Check door unlock lighting system.
Hint:
“All the doors” means: front door LH, front door RH, rear door LH, rear door RH and back door.
(1) Press the LOCK button once after closing all the doors, the lamp will flash once and then 5 doors will be
locked.
(2) Press the UNLOCK button in the LOCK status, the lamp will flash twice and then 4 doors will be opened.
(b) Check on-vehicle Lighting System.
Hint:
“All the doors” means: front door LH, front door RH, rear door LH, rear door RH and back door. “Any of the
door”means any of the 5 doors.
(1) Set the roof lamp switch to DOOR position.

(2) Open any door and then close, the ceiling lamp will be on for 10 seconds. If the ceiling lamp detects that
the vehicle key is inserted into the ignition switch again or any door is closed within 10 seconds, it will
change from bright to dark and fade out gradually.
(3) When removing the vehicle key from the ignition switch, the ceiling lamp comes on. If the key is inserted
into the ignition switch again or any door is closed, the ceiling lamp will go off. When there is not any
operation, the ceiling lamp will change from bright to dark and fade out gradually after 1 minute.
(4) When the vehicle key is in the ignition switch, the ceiling lamp will not come on whether the door is open
or closed.
Hint:
• If the roof lamp remains on for 20 minutes, the roof lamp will enter the battery electricity-save mode
and go off automatically.
• The battery electricity-save mode timer will be reset when the following condition is met: 1) Insert the
key into the ignition switch cylinder, or 2) Open or close any of the door.
3. Back door independent open function
(a) Press the button of back door lock on the remote control, the back door actuator will operate after turning on
the back door opener switch (That is, 14 pin outputs positive voltage), then the back door can be opened. If the
back door is still closed within 60 s, the back door actuator cannot operate after turning on the back door opener
switch (That is, 14 pin does not output positive voltage).
(b) When the button of the back door lock on the remote control is not pressed, or the back door does not open after
60 s when the button is pressed, The actuator cannot operate after turning on the back door opener switch (That
is, 14 pin does not output positive voltage).
Lock
Inspection
Unlock
1. Inspect front door lock actuator assembly LH
(a) Apply battery voltage to the actuator terminals and check op-
eration of the door lock motor.
Standard:
Measurement condition Specified condition
Battery positive (+) →
Terminal 1
Lock
ALK098G
Battery negative (-) →
Terminal 4
Terminal 4
Unlock
Terminal 1
If the result is not as specified, replace the door lock assem-
bly.

(b) Check the resistance between different actuators.

Standard:
Specified
Tester connection Switch condition
condition
1-4 OFF Below 1 W
Hint:
The detection way of different actuators is the same.
(c) Check the resistance of the control switch.
Standard:
Specified
Tester Switch condition
condition
ON 10 kW or higher
8-7
OFF 1W
ON 10 kW or higher
10 - 7
OFF 1W
ON 10 kW or higher
9-7
OFF 1W
bly.
2. Inspect front door lock actuator assebly RH
Unlock Lock
Standard:
Terminal 1
Lock
ALK099G Terminal 4
Terminal 4
Unlock
Terminal 1
bly.
(b) Check the resistance between different actuators.
Standard:
Specified
condition
1-4 OFF Below 1 W
Hint:
The detection way of different actuators is the same.

(c) Check the resistance of the control switch.

Standard:
Specified
Tester Switch condition
condition
ON 10 kW or higher
8-7
OFF 1W
ON 10 kW or higher
10 - 7
OFF 1W
ON 10 kW or higher
9-7
OFF 1W
bly.
3. Inspect rear door lock actuator assembly LH
Standard:
Unlock Measurement condition Specified condition
Terminal 1
Lock
Lock Battery negative (-) →
ALK100G Terminal 4
Terminal 4
Unlock
Terminal 1
bly.
4. Inspect rear door lock actuator assembly RH
Standard:
Unlock Measurement condition Specified condition
Terminal 1
Lock
Lock Battery negative (-) →
ALK101G Terminal 4
Terminal 4
Unlock
Terminal 1
bly.

5. Inspect back door lock assembly

(a) Check operation of the door lock.
21
43 (1) Using a screwdriver, move the latch to the full-latch po-
sition.
Position (2) Apply battery voltage to the door lock terminals and
check operation of the latch.
Full-latch
Standard:
Open-latch Measurement condition Specified condition
ALK102G Battery positive (+) →
Terminal 1 Latch turns to open-latch
Battery negative (-) → position
Terminal 2
bly.
(b) Check the back door control switch resistance.
Standard:
Door lock latch Specified
Tester connection
condition condition
Open-latch Below 1 W
1-2
Full-latch 10 kW or higher
bly.
Lock 6. Inspect door control switch assembly

(a) Check the resistance of the door control switch.
Standard:
Unlock
Specified
condition
L-E Lock
Below 1 W
UL - E Unlock
ALK103G
7. Inspect back door opener switch assembly

1 2 (a) Check the resistance of the switch.
Standard:
Specified
condition
Not pushed 10 kW or higher
1-2
Pushed Below 1 W
Pushed
Not Pushed
ALK104G

Wireless Door Lock Control System

Precaution
Precautions when checking
(a) Power door LOCK/UNLOCK function:
The wireless remote control function operates only when the following 3 conditions are met.
(1) No key is inserted into the ignition key cylinder.
(2) All the doors are closed.
(3) The power door lock system operates normally.
Hint:
• The UNLOCK function operates even when a door is open.
• The UNLOCK function operates even when the key is inserted into the ignition key cylinder, however,
it must be in the LOCK position.
(b) Remote function:
The wireless remote control function operates only when the key is not in the ignition switch cylinder.
(c) The wireless door lock remote control operation area differs depending on the situation.
(1) The operation area differs depending on the operators and the holding way of the transmitter.
(2) In certain areas, the remote control function will only operate partially for the operation area will be re-
duced due to the vehicle body shape and the influence of the surrounding environment.
(3) Since the transmitter uses faint electric waves, strong electric waves or noise in the frequency used may
reduce the operation area or the remote control may not function.
(4) When the battery weakens, the operation area is reduced or the remote control may not function.
Hint:
If the door control transmitter is left in a place where it is exposed to the direct sunlight, such as on the in-
strument panel, it may cause the battery weaken or other relative problems.
Check wireless door lock control functions
(a) Lock function
(b) Unlock function
(c) Seeking function
Press LOCK button on the remote control once in door LOCK condition, the lamp will flash quickly 10 times.
Press UNLOCK button to withdraw seeking function.
(d) Automatic returning function
Press UNLOCK button on the remote control in door LOCK condition, if the door is not opened, then the door
will automatically lock after 30s.
(e) Automatical window close function
(1) After pressing LOCK button on the remote control, quarter window close negative output will last 10s (For
jam protection glass regulator)
(2) After pulling out the key, roof window close negative output will last 60s (For the vehicle equipped with
roof window)
(f) Remote control function pause
When inserting the key into the ignition switch cylinder, the remote control will not work, however, host ma-
chine can work normally.

(g) Clearing or registering remote control remote learn function

(1) Under normal condition, open front door LH (do not close), insert the key into ignition switch cylinder, and
press the key switch (ON-LOCK) 5 times within 5 s, stop at ON after the fifth time, the warning buzzer
sounds once and the lamp flashes once, then the remote control enters into the study status.
(2) Press any of the buttons on the remote control within 10 s, the warning buzzer sounds twice and the lamp
flashes twice, then the first remote control learn is finished. After that, press any of the buttons on the
second remote control, the warning buzzer sounds twice and the lamp flashes twice, then the second remote
control learn is finished (Four remote controls should be learnt).
(3) After finishing learn, close the key button and withdraw the learn status. If any of the buttons is not pressed
within 10s, the system will withdraw learn status after 10 s and the remote control will keep as it was.
Transmitter Battery
Replacement
1. Remove transmitter battery
Notice:
Special caution should be taken for handling each com-
ponent as they are precision electronic components.
(a) Remove the bolt and take the case from the key.
ALK105G
(b) Remove the battery (Lithium battery).

Notice:
• Do not push the terminals with your finger.
• Prying up the battery (Lithium battery) forcibly to re-
move it will cause deformation of the terminals.
• Do not touch the battery with wet hands. Water may
cause unexpected rust.
• Do not touch or move any components inside the
ALK106G transmitter as it may interfere with proper operation.

2. Install transmitter battery

(a) Install a new battery (Lithium battery) with the positive (+)
side facing upward, as shown in the illustration (Model:
CR2016).
Notice:
• Be sure that the positive side and the negative side
of the transmitter battery are matched-up correctly.
• Be careful not to bend the electrode of the transmit-
ALK107G ter battery insertion.
• Be careful that dust or oil does not adhere to the
transmitter case.
(b) Install the case securely.
Door Control Transmitter

Inspection
1. Inspect door control transmitter
(a) Inspect operation of the transmitter.
(1) Remove the battery (Lithium battery) from the trans-
mitter
(2) Install a new or normal battery (Lithium battery).
(3) In a location where is approx. 1 m (3.28 ft) away from
the driver side outside door handle in the right direction,
point the key plate of the transmitter at the vehicle
and check operation of the transmitter by pressing the
transmission switch on the transmitter body.
Standard:
The door lock can be operated via the remote
control.
Hint:
• The minimum operation distance differs depending
on the operator, the holding way of the transmitter
and the location.
• Since the transmitter uses faint electric waves, the
operation distance might be shortened if noise or
strong electric wave occurs in the area where the
frequency is used.
(4) Install the battery (Lithium battery).
(b) Inspect the battery capacity.

Hint:
• The capacity of the battery can be determined only when
the battery is installed in the transmitter. For a lithium
battery used in the transmitter, a voltage of more than 2.5
V is shown on the tester until the energy is completely
consumed, or no battery is installed in the transmitter.
Therefore, it is necessary to measure the voltage while
the battery is installed in the transmitter (A resistance
of 1.2 W is applied to the battery), when checking the
amount of energy left in the battery.
• If the transmitter is faulty, the amount of energy left in
the battery might not be checked correctly.
(1) Remove the battery (Lithium battery) from the trans-
mitter
(2) Connect the lead to the negative (-) terminal of the
transmitter and install the battery.
(3) Connect the tester positive (+) probe to the positive
Lead (+) battery (Lithium battery) and the tester negative (-)
probe to the lead respectively.
(4) Press one of the transmission switches on the transmit-
ter for approx. 1 second.
(5) Press the transmission switch on the transmitter again
ALK108G
to check the voltage.
Standard:
2.2 V or higher
Hint:
• When the temperature of the battery is low, the in-
spection cannot be performed correctly.
• When the outcome of the test is less than 2.2 V,
conduct the test again after leaving the battery in a
place with a temperature of 18°C (64°F) for more
than 30 minutes.
• The automatic power-off function causes the volt-
age of the battery to be 2.5 V or more (voltage
with no resistance applied to the battery) when 0.8
seconds have passed after the switch is pressed.
Therefore, make sure to read the voltage just after
the switch is pressed.
• Because high voltage might be shown once or twice
after the battery returns to the specified tempera-
ture, the inspection should be made with the voltage
shown after the switch is pressed at least 3 times.
(6) Disconnect the lead.
(7) Install the battery (Lithium battery).

ROOF HEADLINING
Components
Rear Door Sealing Strip RH 38 (388, 29) Guild Ring Cover

C Pillar Upper Trim
Panel Assembly RH Back Door
B Pillar Upper Trim Sealing Strip
Assembly RH
Front Door Sealing

Strip RH
A Pillar Upper C Pillar Lower Trim
Trim Panel Panel Assembly RH
Assembly RH
Seatback Hinge
Rear Rocker 38 (388, 29)

Trim RH
Deck Board No.2
B Pillar Lower Trim Back Door
Panel RH Rocker Shield
Front Rocker Trim RH Deck Board No.1

A Pillar Lower Trim
Panel Assembly RH Spare Tire Bracket Assembly
Deck Floor Box RH
B Pillar Upper Trim Panel Assembly LH Rear Door Sealing

Strip LH
Front Guild Ring Cover LH
38 (388, 29)
Front Door Sealing Strip LH C Pillar Upper Trim

Panel Assembly LH
A Pillar Upper Trim

Panel Assembly LH
C Pillar Lower Trim

Panel Assembly LH
B Pillar Lower
Trim Panel LH Rear Rocker Trim LH
A Pillar Lower Trim Front Rocker
Panel Assembly LH Trim LH
38 (388, 29)
Seatback Hinge
ALK109G

Roof Rear Handle Assembly
Roof Headlining
Roof Front Handle Assembly
Passenger Sun Visor Body Assembly
Roof Rear Handle

Holder Cover Assembly
Ceiling Lamp
Assembly
Roof Front Handle Assembly
Ceiling Lamp Lens Cover
Passenger Inner Rear

Sun Visor View Mirror
Bracket Assembly
Driver Sun Visor Body Assembly
Driver Sun Visor Bracket
ALK110G
Replacement
Hint:
verse order.
1. Remove front rocker trim RH
(a) Using a screwdriver, disengage the 2 claws and the 3 clips
and remove the front rocker trim RH.
Claw
Clip Hint:
ALK111G
2. Remove front rocker trim LH
Hint:
Follow the same procedures described for the RH side.

3. Remove rear rocker trim RH

(a) Using a screwdriver, disengage the 2 claws and the 2 clips
Clip and remove the rear rocker trim RH.
Hint:
4. Remove rear rocker trim LH
Hint:
Claw Follow the same procedures described for the RH side.
ALK112G
5. Remove A pillar lower trim assembly RH

(a) Using a screwdriver, disengage the 2 clips and remove the A
pillar lower trim assembly RH.
Hint:
6. Remove A pillar lower trim assembly LH
Hint:
Clip Follow the same procedures described for the RH side.
ALK113G 7. Remove front door sealing strip RH
8. Remove front door sealing strip LH
10. Remove rear door sealing strip LH
11. Remove B pillar lower trim RH
(a) Remove the end plate cover.
(b) Remove the bolt and the front outer seat belt at the end plate
side.
(c) Remove the B pillar lower trim RH.
12. Remove B pillar lower trim LH
Hint:
ALK114G
13. Remove B pillar upper trim assembly RH

(a) Remove the guild ring cover.
Clip
(b) Remove the bolt and the front seat belt at the guild ring cover
side.
(c) Disengage the clip and remove the B pillar upper trim panel
assembly RH by pulling it up.
14. Remove B pillar upper trim panel assembly LH
Hint:
Claw
ALK115G Follow the same procedures described for the RH side.
17. Remove spare tire bracket assembly
18. Remove deck floor box RH
19. Remove rear seat assembly (See page IR-72)

21. Remove back door rocker shield

(a) Using a remover tool, disengage the 2 clips.
(b) Using a screwdriver, disengage the 4 clips and remove the
back door rocker shield.
Hint:
ALK116G
22. Remove C pillar lower trim assembly RH

(a) Remove the 2 bolts and the hook.
Claw
(b) Remove the bolts and the seatback hinge.
(c) Remove the bolt and the seat belt at the end plate side.
(d) Using a screwdriver, disengage the 3 claws and 5 clips and
Clip remove the C pillar lower trim assembly RH.
Hint:
ALK117G 23. Remove C pillar lower trim panel assembly LH
Hint:
Claw 24. Remove C pillar upper trim panel assembly RH
(a) Remove the guild ring cover.
(b) Remove the bolt and the seat belt at the guild ring cover side.
Clip
(c) Using a screwdriver, disengage the claws and 5 clips and re-
move the C pillar upper trim assembly RH.
Hint:
25. Remove C pillar upper trim assembly LH
ALK118G Hint:
26. Remove A pillar upper trim assembly RH
(a) Using a screwdriver, disengage the 2 claws and 2 clips and
remove the A pillar upper trim assembly RH.
Clip
Hint:
27. Remove A pillar upper trim assembly LH
Hint:
Claw Follow the same procedures described for the RH side.
ALK119G

Claw 28. Remove inner rear view mirror assembly

(a) Using a screwdriver, disengage the 2 clips and remove the
holder cover.
Hint:
(b) Remove the 2 screws and rear view mirror.
29. Remove passenger sun visor body assembly
(a) Remove the 2 screws and the sun visor.
ALK120G 30. Remove driver sun visor body assembly
(a) Remove the 2 screws and the sun visor.
31. Remove ceiling lamp assembly
(a) Using a screwdriver, disengage the 4 claws and remove the
lens cover.
Claw Hint:
Claw
(b) Remove the 2 screws.
(c) Disconnect connector and remove the lamp.
ALK121G
32. Remove passenger sun visor bracket

(b) Using a molding remover, disengage the 3 clips and remove
the bracket.
33. Remove driver sun visor bracket
Hint:
ALK122G
34. Remove roof handle assembly

Claw (a) Using a screwdriver, disengage the 2 claws and remove the
roof handle cover.
Hint:
(b) Remove the 2 bolts and the roof handle.
ALK123G
Clip
35. Remove roof headlining assembly
(a) Using a clip remover, disengage the 4 clips and remove the
roof headlining.
ALK124G

SEAT
Front Seat Assembly
Components
Front Seat Headrest Assembly
Front Seat Headrest Assembly

Front Seatback Cover
l Hog Ring Front Seatback
Hook
Front Seat Cushion Cover
Front Seatback
Spring Assem-
bly
l Hog Ring
Front Seat Cushion Pad Front Seatback Pad

Front Seat Buckle Assembly 43 (440, 32)
41 (418, 30)
Passenger Seatback Reclining
Adjuster Inner Cover
Driver Seatback
Reclining Adjuster
Inner Cover
Driver Seat
Cushion Inner
Shield
Driver Seat Rear

64 (653, 48) Mounting Bolt Cover LH
Driver Seat Rear Mounting

Bolt Cover RH
Driver Seatback
：规定扭矩 Reclining Adjuster
Driver Seat Cushion Shield
Release Handle
� Non-reusable
l 不可重复使用零件 part
ALK125G

Replacement
Hint:
• Use the same procedure for the driver seat and passenger seat.
Caution:
• Wear safety gloves because the cutting surface of the
seatback frame and seat adjuster may injure your hand.
• Operation must be started more than 90 seconds after
the ignition switch is turned to the LOCK position and the
negative (-) terminal cable is disconnected from the bat-
tery. (The SRS is equipped with a back-up power source.
If operation is started within 90 seconds from disconnect-
ing the negative (-) terminal cable of the battery, the SRS
may deploy)
1. Remove driver seat assembly
(a) Remove the driver seat rear mounting bolt cover and 5 bolts.
(b) Disconnect the connector.
(c) Remove the seat.
2. Remove driver seat headrest assembly
3. Remove driver seat buckle assembly
(a) Disconnect the wire harness of the buckle from the seat ad-
juster.
ALK126G (b) Remove the bolt and buckle.
4. Remove driver seat cushion inner shield

(a) Remove the clip and the screw.
(b) Disengage the claw and remove the seat cushion inner shield.
Screw
ALK127G
5. Remove driver seatback reclining adjuster release han-

Adhesive Tape dle
(a) Using a screwdriver, remove the seatback reclining adjuster
release handle.
Hint:
ALK128G

6. Remove driver seat cushion shield

(b) Disengage the 2 claws and remove the seat cushion shield.
ALK129G
7. Remove driver seatback hook

(a) Remove screw and seatback hook.
ALK130G
8. Remove driver seatback assembly

(a) Remove the hog rings.
ALK131G
(b) Lift up the seatback cover and remove the hog rings.
ALK132G
(c) Disconnect the clips.

(d) Remove the 4 bolts and the seatback.
ALK133G

9. Remove driver seat headrest support

(a) Lift up the seatback cover to the top, then disengage the 4
claws and remove the 2 headrest supports.
ALK134G
10. Remove driver seatback spring assembly

(a) Remove the hog ring and the seatback spring.
11. Remove driver seatback cover
(a) Remove the hog rings and the seatback cover.
(2)
(1)
ALK135G
12. Remove driver seat cushion cover

(a) Remove the hog rings.
(b) Disengage the claw of the front part of the seat adjuster.
(c) Disengage the hook and remove the seat cushion cover (w/
pad).
(d) Remove the hog rings and seat cushion cover.
ALK136G
13. Remove driver seatback reclining adjuster inner cover

Slip
(a) Remove the screws and the adjuster inner cover.
14. Remove passenger seatback reclining adjuster inner
cover
(a) Remove the screws and the adjuster inner cover.
ALK137G

15. Install driver seat cushion cover

(a) Install the seat cushion cover to the seat cushion pad with
Hog Ring Pliers
new hog rings.
(b) Install the seat cushion cover (w/pad) to the seat adjuster.
Notice:
Do not damage or contaminate the seat cushion cover.
Hint:
When installing the hog rings, take care to prevent wrinkles
ALK138G as much as possible.
16. Install passenger seatback cover
(a) Install the seat cushion cover to the seat cushion pad with
new hog rings.
(b) Install the seatback cover (w/pad) to the front seatback
frame.
Hog Ring Pliers
Notice:
Do not damage or contaminate the seat cushion cover.
Hint:
When installing the hog rings, take care to prevent wrinkles
as much as possible.
(c) Install the 2 headrest supports.
ALK138G
17. Install driver seatback assembly

(a) Install the seatback with the 4 bolts.
(b) Install new hog rings to the backside of the seatback.
(c) Install the headrest.
18. Install driver seat buckle assembly
ALK133G
19. Install driver seat assembly

(a) Put the seat in the cabin.
(c) Install the 5 bolts.
(d) Install driver seat rear mounting bolt cover.
ALK126G

Rear Seat Assembly

Components
Rear Seat Shoulder Belt Cover Center Rear Seat Outer Belt Assembly
Rear Seat Headrest Assembly
Rear Seatback Lock
Release Button
Rear Seatback Lock
Button Gasket
Rear Seatback RH
Lock Assembly 38 (388, 29)
Tether Anchor Cover

Rear Seatback
Buckle RH
Rear Seat Headrest Support

Clip
Rear Seatback Lock
Clip Release Button
Rear Seatback
Lock Button Gasket
Rear Seat LH
Rear Seatback Hinge RH Seatback Lock
Assembly
64 (653, 48))
23 (235,17)
Rear Seatback RH
Rear Seatback LH
Rear Seatback Buckle LH

Rear Seat Setting Cross
Member Assembly
64 (653, 48)
Rear Seatback Hinge LH
Rear Seat Cushion w/Cover

Pad Sub-assembly
N·m (kgf·cm, ft·lbf ) :：规定扭矩
Specified torque
ALK139G

Replacement
Hint:
Caution:
Wear gloves because cutting surface of the seat cushion
frame and seat adjuster may injure your hand.
1. Remove rear seat cushion w/cover pad sub-assembly
(a) Pull up the 2 seat bracket of the seat cushion, then remove it.
Notice:
In this case, hold the base of the clip up to prevent the
cushion frame from being distorted.
A: 100 mm (3.94 in.)

or less.
ALK140G
2. Remove rear seatback assembly LH

(a) Tilt down the seatback toward the front of the vehicle.
(b) Turn up the seatback cover as shown in the illustration.
(c) Remove the 2 bolts and seatback.
1 2
1
2
ALK141G
3. Remove rear seatback assembly RH

Hint:
Follow the same procedures as for the LH side.
4. Remove rear seatback buckle LH
2 (a) Remove the 2 bolts and rear seatback buckle LH.
1
1 5. Remove rear seatback buckle RH
(a) Remove the nut, 2 bolts and rear seatback buckle RH.
2 6. Remove rear seatback hinge sub-assembly LH
ALK142G (a) Remove the bolts and seatback hinge.
7. Remove rear seatback hinge sub-assembly RH
(a) Remove the bolts and seatback hinge.
8. Remove rear seat setting cross member assembly
(a) Remove the bolts and setting cross member assembly.
9. Remove rear seat headrest assembly
(a) Remove the headrest.
10. Remove rear seatback lock release button

11. Only rightside:

Remove rear seat shoulder belt cover
(a) Using a screwdriver, remove the shoulder belt cover.
ALK143G
Tether Anchor Cover 12. Remove tether anchor cover

(a) Using a screwdriver, remove the 3 tether anchor covers.
: 4 Claws
ALK144G
Clip 13. Remove rear seat headrest support

Notice:
If clips are damaged during removal, replace them.
(b) Remove the hog rings.
ALK145G
(c) Disengage the claws and remove the seat headrest support.
Hint:
When performing this step, position yourself between the
seatback frame and the seatback cover (w/pad).
ALK146G
14. Remove rear seatback lock button gasket

(a) Disengage the claws and remove the seatback lock button
gasket.
Hint:
When performing this step, position yourself between the
seatback frame and the seatback cover (w/pad).
ALK147G

15. Remove rear seatback cover w/pad LH

(a) Remove the seatback cover (w/pad) from the rear seatback
frame.
16. Remove rear seatback cover w/pad RH
(a) Remove the seatback cover (w/pad) from the rear seatback
frame.
17. Remove rear seatback lock assembly LH
(a) Remove the 2 bolts and seatback lock.
18. Remove rear seatback lock RH assembly
(a) Remove the 2 bolts and seatback lock.
19. Remove center rear seat outer belt assembly
(a) Remove the nut and seat belt.
20. Install center rear seat outer belt assembly
(a) Install the seat belt with nuts.
ALK148G Torque: 38 N·m (388 kgf·cm, 29 ft·lbf)
21. Install rear seatback cover w/pad LH
(a) Install the seatback cover (w/pad) to the front seatback
frame.
Notice:
Do not damage or contaminate the seatback cover (w/
pad).
22. Install rear seatback cover w/pad RH
Hint:
23. Install rear seat setting cross member assembly
(a) Install the setting cross member assembly with bolts.
24. Install rear seatback hinge sub-assembly LH
(a) Install the seatback hinge with the bolts.
25. Install rear seatback hinge sub-assembly RH
(a) Install the seatback hinge with the bolts.
26. Install rear seatback buckle LH
(a) Install the seatback buckle with the 2 bolts.
27. Install rear seatback buckle RH
(a) Install the seatback buckle RH with the 2 bolts and 1 nut.
28. Install rear seatback LH
29. Install rear seatback RH

ET-
VEHICLE EXTERIOR
WIPER AND WASHER SYSTEM

Problem Symptoms Table................................................. ET-2
On-vehicle Inspection....................................................... ET-3
Inspection.......................................................................... ET-3
Windshield Wiper Motor Assembly................................... ET-6
Rear Wiper Motor Assembly............................................. ET-9
Wiper Rubber LH.............................................................. ET-11
Rear Wiper Rubber........................................................... ET-12
Combination Switch Assembly RH.................................... ET-13
Washer Nozzle.................................................................. ET-14
WINDSHIELD/WINDOW GLASS/MIRROR
Power Window Control System ....................................... ET-16
Windshield........................................................................ ET-22
Quarter Window Assembly RH......................................... ET-27
Back Door Glass............................................................... ET-32
Window Defogger System ............................................... ET-37
Power Mirror Control System............................................ ET-41
ELECTRIC HORN SYSTEM

Parts Location................................................................... ET-46
Inspection.......................................................................... ET-47
Low Tone Electric Horn Assembly..................................... ET-48
High Tone Electric Horn Assembly.................................... ET-48
SLIDING ROOF
Components...................................................................... ET-49 ET
Disassembly...................................................................... ET-51
Reassembly...................................................................... ET-52
Installation......................................................................... ET-53
12-VEHICLE EXTERIOR.indd 1 2008-10-21 9:41:55

ET- GREAT WALL COOL BEAR REPAIR MANUAL
WIPER AND WASHER SYSTEM

Hint:
1. Wiper and washer system
1. Wiper fuse -
2. Combination switch assembly RH IR-20
Front wipers do not operate.
3. Windshield wiper motor assembly ET-4
4. Wire harness -
Front wipers do not operate in the LO or HI
position.
3. Wire harness -
Front wipers do not operate in the INT
position.
3. Wire harness -
1. Washer fuse -
Front washer motor does not operate.
3. Washer motor ET-3
4. Wire harness -
Front wipers do not operate when washer switch
is in the ON position.
3. Wire harness -
1. Wiper fuse
-
2. Rear wiper switch
Rear wiper and washers do not operate. ET-3
3. Wire harness
-
4. Rear wiper relay
1. Washer fuse -
2. Rear washer switch -
Rear washer motor does not operate.
3. Washer motor ET-3
4. Wire harness -
1. Rear wiper switch ET-3
Rear wipers do not operate when washer
2. Rear wiper motor ET-5
switch is in the ON position.
3. Wire harness -
Washer fluid does not flow. 1. Washer hose and nozzle -
• When the wiper switch is OFF, the wiper 1. Windshield wiper motor assembly ET-4
blade does not retract or retracts to the (Wiper arm and blade set position)
wrong position.
• The wiper blade is in contact with the
body.

VEHICLE EXTERIOR ET-
1. Washer motor
(a) Operation check
(1) Pour water into the washer jar.
(2) Connect the battery positive cable to terminal 2 of the
front windshield washer motor and pump assembly, the
battery negative cable to terminal 1 of the front wind-
Front Side shield washer motor and pump assembly. Check that
the water comes out from the washer jar.
2
ALL001G

rear windshield washer motor and pump assembly, the
battery negative cable to terminal 1 of the rear wind-
Rear Side shield washer motor and pump assembly. Check that
the water comes out from the washer jar.
ALL002G
Inspection
1. Combination switch assembly RH
Combination Switch Assembly (a) Continuity check
RH Connector Front View :
table below.
Front wiper switch
10 9 8 7 6 5 4 3 2 1
Switch position Tester connection Specified condition
MIST 3-4 Below 1 Ω
OFF 3-2-4 10 kΩ or higher
ALL003G INT 3-4 Below 1 Ω
LO 3-4 Below 1 Ω
HI 3-2 Below 1 Ω
Front washer switch
OFF 7-6 10 kΩ or higher
ON 7-6 Below 1 Ω
Rear wiper switch
WASH 8-6 Below 1 Ω
OFF - 10 kΩ or higher
ON 9-6 Below 1 Ω
ON + WASH 9-8-6 Below 1 Ω

(b) Intermittent operation check

(1) Connect the voltmeter positive terminal to terminal 3
of the connector and the voltmeter negative terminal to
terminal 4.
connector and the battery negative cable to terminal 4.
(3) Turn the wiper switch to the INT position.
connector for 5 seconds.
(5) Connect the battery negative cable to terminal 4 of the
connector. Operate the intermittent wiper relay and
check voltage between terminals 3 and 4.
Fast: Connect the battery negative Slow: Connect the battery negative
cable to terminal 4 cable to terminal 4
10 to 14 V
3 <=> 4
Voltage between the terminals
0V
1.6 ± 1 sec. 10.7 ± 5 sec.
ALL004G
(c) Operation check (front washer)

(1) Turn the wiper switch off.
Washer ON
Switch OFF connector and the battery negative cable to terminal 4.
10 to 14 V (3) Connect the voltmeter positive terminal to terminal 3
3 <=> 4
of the connector and the voltmeter negative terminal to
0V
Voltage between Approx. Approx. terminal 4.
the terminals 0.3 sec. 2.2 sec. Turn the washer switch on and off, and check voltage
ALL005G between terminals 3 and 4.
Windshield Wiper Motor Assembly

2. Windshield wiper motor assembly
Connector Front View: (a) LO operation check
connector and the battery negative cable to terminal 4,
3 2 1
and check that the motor operates at low speed (LO).
5 4 (b) HI operation check
connector and the battery negative cable to terminal 4,
ALL006G and check that the motor operates at high speed (HI).

(c) Automatic stop operation check

connector and the battery negative cable to terminal 4.
With the motor operating at low speed (LO), disconnect
terminal 5 to stop the wiper motor operation at any
position other than the automatic stop position.
(2) Using SST, connect terminal 5 or 1 and the battery
positive cable to terminal 2 to restart motor operation at
low speed.
SST 09843-18040
(3) Check the automatic stop position.

Standard: Refer to the illustration.
SST 09843-18040
7°~20°
ALL007G
3. Rear wiper motor assembly

Rear Wiper Motor Assembly Connector
Front View: (a) Operation check
connector and the battery negative cable to motor case,
and check that the rear wiper motor operates.
1 2 3
Notice:
The body earth should be connected.
ALL008G
(b) Automatic stop position operation check

Blade Position Mark (1) Connect the battery positive cable to terminal 1 of the
connector and the battery negative cable to motor case.
Notice:
The body earth should be connected.
(2) With the motor rotating, disconnect terminal 1 or 3 to
stop the motor operation at any position other than the
automatic stop position.
ALL009G (3) Connect the battery positive cable to terminal 1. Check
that the motor is restarted and automatically stops.

Windshield Wiper Motor Assembly

Replacement
1. Remove windshield wiper arm bolt cover
2. Remove front wiper arm & blade assembly RH
3. Remove front wiper arm & blade assembly LH
4. Remove cowl ventilation cover plate sealing strip
(a) Using a clip remover, disconnect the 9 clips and remove the
cowl ventilation cover plate sealing strip.
: 9 Clips ALL010G
5. Remove cowl top ventilation cover plate RH

(b) Disengage the 5 claws and remove the cowl top ventilation
cover plate RH.
: 5 Claws ALL011G
6. Remove cowl top ventilation cover plate LH

(b) Disengage the 5 claws and remove the cowl top ventilation
cover plate LH.
: 5 Claws
ALL012G
7. Remove windshield wiper motor & link assembly

(b) Remove the 3 bolts and the windshield wiper motor & link
assembly.
ALL013G

8. Remove windshield wiper motor assembly

(a) Using a screwdriver, disconnect the 2 rods at the crank arm
pivot of the windshield wiper motor assembly.
Hint:
ALL014G
ALL015G
(b) Remove the 3 bolts and the windshield wiper motor assem-
bly.
ALL016G
9. Install windshield wiper motor assembly

(a) Install the windshield wiper motor assembly with the 3 bolts.
(b) Apply MP grease to the crank arm pivot of the windshield
wiper motor assembly.
(c) Install the 2 rods to the windshield wiper motor assembly.
ALL016G
10. Install windshield wiper motor & link assembly

(a) Install the windshield wiper motor & link assembly with the
3 bolts.
ALL013G

11. Install cowl top ventilation cover plate LH

(a) Engage the 5 claws and install the cowl top ventilation cover
plate LH.
(b) Install the 4 clips.
: 5 Claws
ALL012G
12. Install cowl top ventilation cover plate RH

(a) Engage the 5 claws and install the cowl top ventilation cover
plate RH.
(b) Install the 4 clips.
: 5 Claws ALL011G
13. Install cowl ventilation cover plate sealing strip

(a) Install the cowl ventilation cover plate sealing strip with the
9 clips.
: 9 Clips ALL010G
14. Install front wiper arm & blade assembly LH

Wiper Arm Serration (a) Operate the wiper and stop the windshield wiper motor as-
sembly in the automatic stop position.
(b) Clear the foreign matter in the wiper arm serration with trian-
Wiper Pivot Serration gular file or hacksaw blade.
Wire Brush (c) Use wire brush to clean the wiper pivot serration.
ALL017G
(d) Install the front wiper arm & blade assembly LH with nuts in
the position shown in the illustration.
Installation Position Mark:
Installation Position Mark 25 to 40 mm (0.98 to 1.57 in.)
25 to 40 mm Hint:
(0.98 to 1.57 in.)
Hold the wiper arm by hand to fasten the nut.
ALL018G

(e) Operate the wiper while spraying water or washer fluid on

the window, and check the wiping condition and that the
wiper does not hit against the vehicle’s body.
15. Install front wiper arm & blade assembly RH

Wiper Arm Serration (a) Clear the foreign matter in the wiper arm serration with trian-
gular file or hacksaw blade.
(b) Use wire brush to clean the wiper pivot serration.
Wiper Pivot Serration
Wire Brush
ALL017G
(c) Install the front wiper arm & blade assembly RH with nuts in
the position shown in the illustration.
Installation Position Mark Installation Position Mark:
29 to 44 mm (1.14 to 1.73 in.)
29 to 44 mm
(1.14 to 1.73 in.) Hint:
Hold the arm hinge by hand to fasten the nut.
16. Install windshield wiper arm bolt cap
ALL019G
Rear Wiper Motor Assembly

Replacement
2. Remove rear wiper arm cover
3. Remove rear wiper arm & blade assembly
4. Remove rear wiper motor grommet
5. Remove rear wiper motor assembly
(b) Remove the 3 bolts and rear wiper motor assembly.
ALL020G
6. Install rear wiper motor assembly

(a) Install the rear wiper motor assembly with the 3 bolts.
ALL020G

ET-10 GREAT WALL COOL BEAR REPAIR MANUAL
7. Install rear wiper motor grommet

Installation Position Mark (a) Install the rear wiper motor grommet in the position as
8. Install rear wiper arm & blade assembly
(a) Operate the wiper and stop the windshield wiper motor as-
sembly in the automatic stop position.
ALL021G
(b) Clear the foreign matter in the wiper arm serration with trian-
Wiper Arm Serration gular file or hacksaw blade.
(c) Use wire brush to clean the wiper pivot serration.
Wiper Pivot Serration

Wire Brush
ALL017G
(d) Install the rear wiper arm & blade assembly with nuts in the
Blade Position Mark position shown in the illustration.
Hint:
Hold the wiper arm by hand to fasten the nut.
(e) Operate the wiper while spraying water or washer fluid on
the window, and check the wiping condition and that the rear
wiper does not hit against the vehicle’s body.
ALL030G

VEHICLE EXTERIOR ET-11
Wiper Rubber LH
Replacement
1. Remove front wiper blade LH
(a) Remove the front wiper blade LH from the front wiper arm
LH.
Notice:
Do not bend the front wiper arm when removing the
front wiper blade from it.
2. Remove wiper rubber LH
(a) Remove the wiper rubber from the front wiper blade LH.
Bending (b) Remove the 2 wiper rubber backing plates from the wiper
rubber LH.
ALL022G
3. Install wiper rubber LH

(a) Install the 2 wiper rubber backing plates to the wiper rubber
Bending
LH.
Notice:
Be sure to install the wiper rubber backing plates in the
correct direction.
ALL022G
(b) Install the wiper rubber LH so that the head part (longer side)
of the wiper rubber faces the arm axle side.
Notice:
• Push the front wiper blade into the grooves of the
wiper rubber to engage them completely.
• Put back the wiper arm of the passenger side be-
fore putting back that of the driver’s side.
ALL023G

Rear Wiper Rubber

Replacement
1. Remove rear wiper rubber
(a) Raise the rear wiper blade to the position as shown in the il-
lustration so that the meshing of the claw can be disengaged
(1)
with a clicking sound.
(2) Notice:
Be careful not to damage the claw.
(b) Pull the rear wiper blade straight from the wiper arm toward
the left side of the vehicle.
ALL024G
Notice:
Do not fold the rear wiper arm without the rear wiper
blade.
(c) Pull the end of the rubber protruded from the blade stopper
Push Notice:
Do not forcibly pull out the wiper rubber. Otherwise, the
backing plates will be deformed or the blade claw will
be damaged.
Pull
Hint:
Push the position close to the middle of the blade to raise the
Stopper
ALL025G rubber, which makes it easier to pull the rubber out.
2. Install rear wiper rubber

Bending (a) Install the 2 wiper rubber backing plates to the rear wiper
rubber.
Notice:
Be sure to install the wiper rubber backing plates in the
correct direction.
ALL022G
(b) Insert the rear wiper rubber from the claw side in the middle
of the rear wiper blade end position.
ALL026G

(c) After passing the rear wiper rubber through the rear end side
claw, extend it from the rear end stopper and pass it through
the front end side claw.
ALL027G
Combination Switch Assembly RH

Replacement
2. Remove combination switch assembly RH
(b) Using a screwdriver, disengage the claw and pull out the
combination switch assembly RH.
Hint:
3. Install combination switch assembly RH
: Claw 4. Install combination switch cover (See page SR-10)
ALL028G

Washer Nozzle
Adjustment
1. Inspect washer nozzle
(a) With the engine running, turn on the washer nozzle switch, check that the area where the washer fluid sprays on
the windshield and the rear window is within the range as shown in the illustration.
Front:
The range of washer nozzle fluid spraying

ALL029G
Rear:
The range of washer nozzle fluid spraying
ALL030G

2. Adjust washer nozzle

(a) Using a pin, adjust the direction of the washer nozzle.
Notice:
Use a pin of which the end is not sharp to adjust the di-
rection of the washer nozzle.
ALL031G

WINDSHIELD/WINDOW GLASS/MIRROR
Power Window Control System
Parts Location
Front Glass Regulator

Motor Assembly RH
Front Window Main Front Window Switch
Instrument Panel Switch Assembly LH Assembly RH
Junction Block Assembly
l Power Source Relay
Front Door Glass
l Instrument Fuse
Regulator Sub-assembly RH
Rear Window Switch
Front Glass Regulator Assembly RH
Motor Assembly LH
Front Door Glass Regulator

Sub-assembly LH
Rear Window
Switch Assembly LH
Rear Door Glass Regulator Rear Glass Regulator

Sub-assembly LH Motor Assembly RH
Rear Glass Regulator
Sub-assembly RH
Rear Glass Regulator

Motor Assembly LH
ALL032G

1. Check window lock switch
(a) Check that operation of the power windows except the driver
side power window is disabled when the window lock switch
of the power window main switch is pressed.
(b) Check that the power windows can operate when the window
lock switch is pressed again.
ALL033G
2. Check manual UP/DOWN function

(a) Check that each power window switch can operate each power window as follows:
Standard:
Condition Switch Switch operation Power window
Pulled up UP
FL
Pushed down DOWN
Pulled up UP
FR
• Ignition switch ON Pushed down DOWN
• Window lock switch OFF Pulled up UP
RL
Pushed down DOWN
Pulled up UP
RR
Pushed down DOWN
3. Check UP/DOWN function of main switch

(a) Check that the front window main switch LH can operate all other power windows besides the FL side power
window as follows:
Standard:
Condition Main switch Switch operation Power window
Pulled up UP
FR
Pushed down DOWN
• Ignition switch ON Pulled up UP
RL
• Window lock switch OFF Pushed down DOWN
Pulled up UP
RR
Pushed down DOWN

2. Power source relay -
No power window operates
3. Ignition switch IR-18
4. Wire harness -
1. Front window main switch assembly LH ET-17
2. Window switch assembly ET-17
Only one power window does not operate.
3. Glass regulator motor assembly ET-17
4. Wire harness -
Window lock system does not operate 1. Front window main switch assembly LH ET-17

Inspection
1. Glass regulator system circuit
30c
15a
905 60A 60A

B R R S/B2
0.5 0.5 0.5
30A
E B+ B+
Driver Side Window Switch
Window Lock Switch
Front Window Switch RH
Rear Window Switch LH
Rear Window Switch RH

L E UL
U B D U B D U B D U B D
UP UP UP UP
Closed Closed Closed Closed
Down Down Down Down
LOCK
L UL U1 D1 OUT U2 D2 U3 D3 U4 D4
4/16 C13 12/16 C13 10/16 C13 11/16 C13
284A 283A 305 306 302 309 310 307 308 311 312
Br-W G-W R G BI BI-W BI-B R-Y G-Y R-B Lg
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
10/22 C16 6/20 C15
7/16 C13 7/20 C15
C14
Front Window Switch RH
03/14 12/22 C16 12/22 C16 2/8 C21

7/16 C18 1/10 C21
Rear Window Switch LH

3/10 C20 3/10 C21
Rear Window Switch RH

U B D U B D U B D
UP UP UP
Closed Closed Closed
Down Down Down 303
U B D U B D U B D BI-W
2.0
284B 283B 05/16 C13
Br-W G-W 309 310 13/16 C13 307 308 311 312
02/10 C20
0.5 0.5 05/16 C18 BI-W BI-B R-Y G-Y R-B Lg
C19 0.5 0.5 02/16 C18 0.5 0.5 0.5 0.5
10/14 03/14
13/22 C16 13/22 C16
02/16 C13 02/16 C18
07/08 C20 07/08 C21
L E UL
UP DOWN +BAT UP DOWN +BAT UP DOWN +BAT UP DOWN +BAT
1 6 3 1 6 3 1 6 3 1 6 3
Front Window Jam Front Window Jam Rear Window Jam Rear Window Jam
Protection Motor LH Protection Motor RH Protection Motor LH Protection Motor RH
4 GND 4 GND 4 GND 4 GND
288A 288B 288C 288D
Gr-W Gr-W Gr-W Gr-W
0.5 0.5 0.5 0.5
905 905 985 986 987 988

B B B B B B
0.5 0.5 2.0 2.0 2.0 2.0
ALL034G
Window Lock Switch 2. Check front window main switch LH

(a) Check the resistance between each terminal of the connector
Front Window
Switch RH when the switch is operated.
Rear
Window
Switch RH
Front Window
Switch LH
Rear Window
Switch LH
ALL035G

Standard:
Front window switch LH
Window lock switch Window switch
condition condition
1-4
UP
B+ -1
Constant
1-4
(OFF/ON) OFF Below 1 W
4-6
4-6
DOWN
B+ - 6
Front window switch RH

condition condition
1-4
UP
B+ -1
1-4
OFF OFF
4-6
4-6
DOWN
B+ - 6
Below 1 W
1-4
UP
B+ -1
1-4
ON OFF
4-6
4-6
DOWN
B+ - 6
Rear window switch LH

condition condition
1-4
UP
B+ -1
1-4
OFF OFF
4-6
4-6
DOWN
B+ - 6 Below 1 W
1-4
UP
B+ -1
ON 1-4
OFF
4-6
DOWN 4-6

Rear window switch RH

condition condition
1-4
UP
B+ -1
1-4
OFF OFF
4-6
4-6
DOWN
B+ - 6
Below 1 W
1-4
UP
B+ -1
1-4
ON OFF
4-6
4-6
DOWN
B+ - 6
If the result is not as specified, replace the main switch assembly.
3. Inspect front glass regulator motor assembly LH

Motor Gear (a) Check operation of the regulator motor.
UP DOWN +BAT
1 6 3
(1) Apply battery voltage to the motor terminals.
4 GND
(2) Check that the motor rotates smoothly.
Standard:
Counterclockwise
Clockwise Battery positive (+) → 1
Motor gear rotates clockwise
Battery negative (-) → 4
ALL036G Battery positive (+) → 6 Motor gear rotates
Battery negative (-) → 4 counterclockwise
If the result is not as specified, replace the motor assembly.

(b) Check operation of the PTC inside the regulator motor.

Notice:
The work must be performed with the glass regulator
and glass installed in the vehicle.
(1) Fully close the window glass by operating the window
switch and keep the door glass there for approx. 60 sec-
onds.
(2) Try to operate the power window to past the fully
closed position using the window switch and measure
the time until the electrical current changes into 1 A
from 16 to 34 A (Inspection of current shut-off).
Standard: 4 to 90 seconds
(3) Check that the window glass goes down when the glass
regulator switch is pushed down.
If the result is not as specified, replace the motor as-
sembly.
Hint:
The inspection procedure for other glass regulator mo-
tors assembly is the same as that for the front glass
regulator motor assembly LH.

Windshield
Components
Roof Handle Assembly Ceiling Lamp Assembly

Passenger Sun Visor Body
Front Door Sealing Strip RH Ceiling Lamp

Holder Cover Lens Cover
Passenger Sun
Visor Bracket Driver Sun Visor Body
A Pillar
Upper Trim Inner Rear View Mirror Assembly
Panel
Assembly l Windshield Outside Moulding
RH l Window Glass Adhesive Dam
Driver Sun Visor Bracket
l Front Windshield Glass Stopper
Ventilation Cover
Windshield
Plate Body RH
A Pillar Upper Trim

Panel Assembly LH
Front Wiper Ventilation Cover

Arm RH Plate Body LH
Front Ventilation Cover
Plate Sealing Strip
Wiper Arm Bolt Cover RH

Wiper Arm Bolt Cover LH Front Wiper Arm LH
20 (204, 15)
Front Door Sealing

N·m (kgf·cm, ft·lbf) : Specified torque Strip LH
l Non-reusable part
ALL037G

Replacement
Hint:
The installation procedures are the removal procedures in reverse order. However, only installation procedures requir-
ing additional information are included.
1. Remove roof headlining
(a) Remove the front door sealing strip LH and RH.
(b) Remove the A pillar trim panel assembly LH and RH.
(c) Remove the driver sun visor body and passenger sun visor body.
(d) Remove the roof handle assembly.
(e) Remove the driver sun visor bracket and passenger sun visor bracket.
(f) Remove the ceiling lamp lens cover.
(g) Remove the ceiling lamp
(h) Remove the roof headlining partially so that the windshield glass can be removed.
2. Remove inner rear view mirror assembly (See page IR-65)
3. Remove ventilation cover plate body LH and RH
(a) Remove the wiper arm bolt cover LH and RH.
(b) Remove the front wiper arm LH and RH.
(c) Remove the front ventilation cover plate sealing strip.
(d) Remove ventilation cover plate body LH and RH.
4. Remove windshield glass

(a) From the interior, insert piano wire between the vehicle body
and glass, as shown in the illustration.
(b) Tie objects that can serve as handles (for example, wooden
Stopper
blocks) to all wire ends.
Piano Wire
ALL038G
Plastic Sheet
Hint:
Apply protective tape to the outer surface of the vehicle to
prevent its surface from being scratched.
Notice:
• When separating the glass from the vehicle, take
care not to damage the vehicle paint, the interior
and exterior ornaments.
Protective Tape • To prevent instrument panel’s safety pad from being
ALL039G scratched when removing the glass, place a plastic
sheet between the piano wire and safety pad.
(c) Cut the glass by pulling the piano wires around the glass.
(d) Disengage the stoppers.
(e) Using a suction cup, remove the glass.

5. Clean windshield glass

(a) Using a scraper, remove the damaged stoppers, dam and ad-
hesive sticking to the glass.
(b) Clean the outer circumference of the glass with white gaso-
line.
Notice:
• Do not touch the glass surface after cleaning it.
• Be careful not to damage the glass.
ALL040G • Even if using new glass, clean the glass with white
gasoline.
6. Install 2 stoppers
Backside:
A 7. Install window glass adhesive dam
A (a) Coat the installation part of the adhesive dam with primer.
A A Notice:
B • Allow the primer coating to dry for 3 minutes or
B more.
A-A a
• Throw away any leftover primer.
• Do not apply too much primer.
B-B b (b) Install a new dam, apply double-sided tape all the way
ALL041G around the glass except where the dam is installed, as shown
Specification:
Area Measurement
a 7.0 mm (0.276 in.)
b 23.5 mm (0.925 in.)
8. Install windshield glass

Adhesive (a) Clean and shape the contact surface of the vehicle body.
(1) Using a knife, cut away any excess or unneeded adhe-
Adhesive sive on the contact surface.
(2) Clean the contact surface of the vehicle body with a
piece of shop rag saturated with cleaner.
Hint:
Even if all the adhesive is removed, you should clean
ALL042G the vehicle body still.
(b) Position the glass.

(1) Using a suction cup, place the glass in the correct posi-
tion.
Mark (2) Check that the whole contact surface of the glass rim is
perfectly even.
(3) Place reference marks between the glass and vehicle
body.
Notice:
ALL043G Check that the stoppers are attached to the ve-
hicle body correctly.
Hint:
When reusing the glass, check and correct the reference
mark positions.

(4) Remove the glass.

Primer M (c) Using a brush, coat the contact surface of the vehicle body
Correct
on the vehicle side with Primer M.
Notice:
Wrong
• Allow the primer coating to dry for 3 minutes or
Primer M
Adhesive more.
• Do not coat the adhesive with Primer M.
• Throw away any leftover Primer M.
: Primer M ALL044G
Backside:
A (d) Using a brush or sponge, coat the edge of the glass and the
A contact surface with primer, as shown in the illustration.
A A Specification:
B
Area Measurement
B
A-A a a 7.0 mm (0.276 in.)
b 23.5 mm (0.925 in.)
B-B b Hint:
If the primer is accidentally applied to another part of the
Primer ALL045G vehicle, wipe off the primer with a clean shop rag before it
dries.
Notice:
more.
• Do not coat the adhesive with primer.
Backside: A (e) Apply adhesive.

A (1) Cut off the tip of the cartridge nozzle, as shown in the
A A illustration.
B Hint:
B After cutting off the tip, use all adhesive within the time
A-A a
b described in the table below.
b Usage timeframe
a a B-B
b Temperature Usage timeframe
ALL046G 35°C (95°F) 15 minutes
20°C (68°F) 1 hour and 40 minutes
5°C (41°F) 8 hours
(2) Load the sealer gun with the cartridge.
(3) Coat the glass with adhesive, as shown in the illustra-
tion.
Specification:
Area Measurement
a 8.0 mm (0.315 in.)
b 12.0 mm (0.472 in.)

(f) Install the glass.

(1) Using a suction cup, position the glass so that the
reference marks are aligned. Press it gently along the
rim.
Notice:
more.
• Check that the stoppers are attached to the
ALL047G vehicle body correctly.
• Check the clearance between the vehicle body
and glass.
(2) Lightly press the front surface of the glass to ensure a
close fit.
(3) Using a scraper, remove any excess or protruding
adhesive.
Adhesive
ALL048G
Windshield Hint:
Apply adhesive onto the glass rim.
Sealing Notice:
Strips
Take care not to drive the vehicle for the time
described in the table below.
Minimum time:
Temperature Minimum time prior to driving
Adhesive
35°C (95°F) 1 hour and a half
ALL049G 20°C (68°F) 5 hours
5°C (41°F) 24 hours
9. Check for leaks and repair
(a) Conduct a leak test after the adhesive has hardened
completely.
(b) Seal any leaks with auto glass sealer.

Quarter Window Assembly RH

Components
l Quarter Window Spacer
C Pillar Upper Trim Panel

Assembly RH
Quarter Window
Assembly RH
l Quarter Window Guide Pin No.1
C Pillar Lower Trim

Panel Assembly RH
Rear Door
Sealing Strip RH
Back Door Rocker Shield
42 (428, 31)
Rear Rocker Trim RH

42 (428, 31)
Deck Board No.2
Deck Board No.1
Deck Floor Box RH
Spare Tire
Bracket Assembly
l Non-reusable part
ALL050G

Replacement
Hint:
• The installation procedures are the removal procedures in the reverse order. However, only installation procedures
requiring additional information are included.
1. Remove rear seatback RH (See page IR-74)
2. Remove rear seatback LH (See page IR-74)
3. Remove rear seat cushion with cover pad sub-assembly (See page IR-74)
4. Remove rear seat setting cross member assembly (See page RS-61)
5. Remove rear seatback hinge sub-assembly RH (See page IR-72)
6. Remove C pillar upper trim panel assembly RH
(a) Remove the rear rocker trim RH
(b) Remove the the rear door sealing strip RH.
(c) Remove the deck board No.2
(d) Remove the deck board No.1
(e) Remove the back door rocker shield.
(f) Remove the deck floor box RH and the spare tire bracket assembly.
(g) Remove the deck board trim panel RH
(h) Remove the C pillar upper trim panel assembly RH.
7. Remove quarter window RH
Moulding
(a) Using a knife, cut off the moulding, as shown in the
Cut
illustration.
Notice:
Do not damage the body with the knife.
(b) Remove the remaining moulding.
Quarter Window Hint:
Cut
Make a partial cut in the moulding. Then, pull and remove it
ALL051G by hand.
Piano Wire
(c) From the interior, insert piano wire between the vehicle body
(d) Tie objects that can serve as handles (for example, wooden
Spacer
Pin
ALL052G
Hint:
Protective Tape
Apply protective tape to the outer surface of the vehicle to
Notice:
When separating the glass from the vehicle, take
care not to damage the vehicle paint, the interior and
exterior ornaments.
(e) Cut the glass by pulling the piano wires around the glass.
ALL053G (f) Remove the glass.

8. Clean quarter window RH

(a) Clean the outer circumference of the glass with white
gasoline.
Notice:
ALL054G
Backside: 9. Install quarter window guild pin No.1

(a) Using a brush or sponge, coat the edge of the glass and the
Pin contact surface with primer.
(b) Install new pins.
Notice:
a c
e f
more.
b d • Throw away any leftover primer.
ALL055G • Do not apply too much primer.
Specification:
Area Measurement
a 40.0 mm (1.575 in.)
b 40.0 mm (1.575 in.)
c 37.0 mm (1.457 in.)
d 42.0 mm (1.654 in.)
e 11°
f 46.4°
Backside: 10. Install quarter window spacer

Spacer
contact surface with primer.
(b) Install new spacers.
a e
Notice:
b f
j • Allow the primer coating to dry for 3 minutes or
i
more.
g • Throw away any leftover primer.
c
d h ALL056G • Do not apply too much primer.
Specification:
Area Measurement
a 41.0 mm (1.614 in.)
b 19.0 mm (0.748 in.)
c 20.0 mm (0.787 in.)
d 45.0 mm (1.772 in.)
e 28.0 mm (1.102 in.)
f 23.0 mm (0.906 in.)
g 63.0 mm (2.480 in.)
h 21.0 mm (0.827 in.)
i 4°
j 31°

11. Install quarter window moulding RH

Notice:
more.
• Do not coat the adhesive with primer.
(b) Install the moulding.
12. Install quarter window assembly RH
(1) Using a knife, cut away any excess or unneeded
Adhesive adhesive on the contact surface.
Hint:
Even if all the adhesive is removed, you should clean
ALL042G the vehicle body still.
(b) Using a brush, coat the contact surface of the vehicle body
with Primer M.
Primer M Correct
Notice:
more.
Primer M • Do not coat the adhesive with Primer M.
Wrong • Throw away any leftover Primer M.
Adhesive
: Primer ALL057G
B (c) Using a brush or sponge, coat the edge of the glass and the
Backside:
B contact surface with primer.
AA
CC Specification:
E E
D Item Measurement
D a 14.0 mm (0.551 in.)
A-A
A-A Primer b 8.6 mm (0.338 in.)
B-B
C-C
a 14.0 mm (0.551 in.)
B-B
D-D b 5.0 mm (0.197 in.)
E-E b a ALL058G a 14.0 mm (0.551 in.)
C - C, D - D
b 6.0 mm (0.236 in.)
a 22.0 mm (0.866 in.)
E-E
b 8.6 mm (0.339 in.)

Hint:
If the primer is accidentally applied to another part of the
vehicle, wipe off the primer with a clean shop rag before it
dries.
Notice:
more.
Backside:
B (d) Apply adhesive.
B
C C
(1) Cut off the tip of the cartridge nozzle, as shown in the
A A
E E illustration.
D
D
Hint:
a B-B A-A
a
After cutting off the tip, use all adhesive within the time
b
b c
d
b a a D-D a C-C
Usage Timeframe:
b b Temperature Usage timeframe
e f ALL059G 35°C (95°F) 15 minutes
20°C (68°F) 100 minutes
5°C (41°F) 8 hours
(3) Coat the glass with adhesive, as shown in the
illustration.
Specification:
Area Measurement
a 8.0 mm (0.315 in.)
b 12.0 mm (0.472 in.)
c 13.0 mm (0.512 in.)
d 12.0 mm (0.472 in.)
e 13.0 mm (0.512 in.)
f 15.5 mm (0.610 in.)
(e) Install the glass to the body.
(1) Hold the quarter window glass assembly in place
securely with protective tape or equivalent until the
adhesive hardens.
Notice:
more.
• Check that the clips are installed to the vehicle
body correctly.
and glass.
close fit.

(3) Using a scraper, remove any excess or protruding

adhesive.
Hint:
Notice:
Take care not to drive the vehicle for the time
Adhesive
Minimum time:
ALL048G Temperature Minimum time prior to driving
20°C (68°F) 5 hours
5°C (41°F) 24 hours
13. Water-leak check and repair
(a) Conduct a leak test after the adhesive has hardened
completely.
Back Door Glass

Replacement
Hint:
1. Remove back door glass
Piano Wire (a) From the interior, insert piano wire between the vehicle body
(b) Tie objects that can serve as handles (for example, wooden
Clip
ALL060G
Protective Tape Hint:

Apply protective tape to the outer surface to the vehicle to
Notice:
When separating the glass from the vehicle, take
care not to damage the vehicle paint, the interior and
exterior ornaments.
(c) Cut the glass by pulling the piano wires around the glass.
ALL061G Notice:
If the back door glass will be reused, be careful not to
damage the clip attached to the glass when you cut off
the adhesive.
(d) Using a suction cup, remove the glass.

2. Clean back door glass

(a) Clean the outer circumference of the glass with white gaso-
line.
Notice:
ALL054G
Backside: 3. Install back window glass clip

R L
(b) Install the new clips.
b a a b Notice:
more.
ALL062G • Do not apply too much primer.
Specification:
Area Measurement
a 528.8 mm (20.819 in.)
b 35.8 mm (1.409 in.)
Backside: 4. Install back door glass spacer

a (a) Using a brush or sponge, coat the edge of the glass and the
b b contact surface with primer.
(b) Install new spacers.
Notice:
c c more.
d ALL063G • Do not apply too much primer.
Specification:
Area Measurement
a 15.0 mm (0.591 in.)
b 220 mm (8.661 in.)
c 220 mm (8.661 in.)
d 18.0 mm (0.709 in.)

Backside:
5. Install back door outside moulding
(a) Coat the installation part of the window glass adhesive dam
A A B B with primer.
Notice:
A-A
B-B
more.
a
ALL064G (b) Install a new dam, apply double-sided tape all the way
around the glass except where the dam is installed, as shown
Specification:
Area Measurement
a 3.0 mm (0.118 in.)
6. Install back door glass

(1) Using a knife, cut away any rough adhesive on the con-
Adhesive tact surface of the vehicle body to ensure the appropri-
ate surface shape.
Hint:
ALL042G Even if all the adhesive is removed, you should clean
the vehicle body still.
Primer M Correct (b) Using a brush, coat the exposed part of the vehicle body with
Primer M.
Notice:
Wrong
Primer M • Allow the primer coating to dry for 3 minutes or
Adhesive more.
• Do not coat the adhesive with Primer M.
• Throw away any leftover Primer M.
: Primer M ALL065G

Backside:
A (c) Using a brush or sponge, coat the edge of the glass and the
A
C
C
B D D Hint:
B If the primer is accidentally applied to another part of the
A-A B-B
a a
vehicle, wipe off the primer with a clean shop rag before it
dries.
b c
C-C a e D-D Notice:
d f ALL066G more.
Specification:
Area Measurement
a 14.0 mm (0.551 in.)
b 10.0 mm (0.394 in.)
c 12.8 mm (0.504 in.)
d 30.0 mm (1.181 in.)
e 22.0 mm (0.866 in.)
f 38.0 mm (1.496 in.)
Backside:
A (d) Apply adhesive.
A
C
C
(1) Cut off the tip of the cartridge nozzle, as shown in the
B D D illustration.
B Hint:
A-A B-B
a a
After cutting off the tip, use all adhesive within the time
b b
c d
b a
C-C
a a
D-D Usage Timeframe:
b b Temperature Usage timeframe
e f ALL067G 35°C (95°F) 15 minutes
20°C (68°F) 1 hour and 40 minutes
5°C (41°F) 8 hours

(3) Coat the glass with adhesive, as shown in the illustra-
tion.
Specification:
Area Measurement
a 8.0 mm (0.315 in.)
b 12.5 mm (0.492 in.)
c 10.0 mm (0.394 in.)
d 12.8 mm (0.504 in.)
e 30.0 mm (1.181 in.)
f 30.0 mm (1.181 in.)

(e) Install the glass to the body.

(1) Hold the back door glass in place securely with tape or
equivalent to the vehicle body until the adhesive hard-
ens.
Notice:
more.
• Check that the clips are installed to the vehicle
body correctly.
and glass.
close fit.
(3) Using a scraper, remove any excess or protruding adhe-
sive.
Hint:
Notice:
Take care not to drive the vehicle for the time de-
scribed in the table below.
Adhesive
Minimum time:
ALL048G Temperature Minimum time prior to driving
20°C (68°F) 5 hours
5°C (41°F) 24 hours
7. Water-leak check and repair
(a) Conduct a leak test after the adhesive has hardened com-
pletely.

Window Defogger System

Parts Location
Instrument Panel Junction Block Assembly

l Defogger High Current Fuse
l Instrument Fuse
Defogger Wire
l Rear Window Defogger Switch
Defogger Relay
ALL068G


2. Defogger high current fuse -
Rear window defogger does not operate.
3. Defogger relay ET-40
(Indicator ON)
4. Rear window defogger wire ET-38
5. Wire harness -
2. Defogger high current fuse -
Rear window defogger does not operate. 3. Defogger relay ET-40
(Indicator OFF) 4. A/C controller assembly No.2 -
5. Rear window defogger wire ET-38
6. Wire harness -
1.4 W Test Bulb Inspection

1. Inspect A/C controller assembly No.2
4 3 2
A/C (a) Check operation of the defogger timer.
(1) Connect the positive (+) lead from the battery to termi-
nal 3 and the negative (-) lead to terminal 4.
(2) Connect the positive (+) lead from the battery to termi-
nal 2 through a 1.4 W test bulb.
1
(3) Turn on the rear window defogger switch, check that
ALL069G the switch and the test bulb illuminates for 12 to 18 sec-
onds, and then go off.
If the result is not as specified, replace the module
switch.
2. Inspect back door glass (defogger wire)
Notice:
Defogger Wire
• When cleaning the glass, wipe the glass along the
Tester Probe wire by a soft and dry cloth. Take care not to dam-
age the wires.
• Do not use detergents or glass cleaners including
abrasive ingredients.
Tinfoil
• When measuring voltage, wrap a piece of tinfoil
ALL070G around the tip of the negative tester probe and
press the foil against the wire with your finger, as

At Center (a) Turn the ignition switch ON.

(b) Turn the defogger switch ON.
(c) Check the voltage at the center of each defogger wire, as
v shown in the illustration.
Standard:
Voltage Standard
Approx. 5 V Wire is not broken
Approx. 10 or 0 V Wire is broken
ALL071G
Hint:
If there is approximately 10 V, the wire may be faulty be-
tween the center of the wire and the wire end on the battery
side. If there is no voltage, the wire may be faulty between
the center of the wire and the wire end on the ground side.
Foil Strip (d) Connect the voltmeter positive (+) lead to the defogger wire
on the battery side.
0 V Below 10 V
(e) Connect the voltmeter negative (-) lead with the foil strip to
Broken the wire on the ground side.
Wire
(f) Slide the positive (+) lead from the battery side to the ground
V side.
Ground Side Battery
± Side (g) The point where the voltage jumps from approximately 10 V
to 0 V is the position where the defogger wire is broken.
ALL072G Hint:
If the defogger wire is not broken, the voltmeter will indicate
0 V at the positive (+) end of the defogger wire and gradually
increase to approximately 12 V as the meter probe moves to
the other end.
(h) If necessary, repair the defogger wire.
Repair Point (1) Clean the broken wire tips with grease, wax and sili-
cone remover.
(2) Place the masking tape along both sides of the wire.
(3) Thoroughly mix the repair agent (Dupont paste No.
4817).
Broken
Wire
Masking Tape
ALL073G

(4) Using a fine tip brush, apply a small amount of the

agent to the wire.
(5) After a few minutes, remove the masking tape.
Notice:
Do not repair the defogger wire again for at least
24 hours.
3. Inspect defogger relay
(a) Check the resistance.
ALL074G Standard:
Terminal No. Specified condition
10 kW or higher
Below 1 W
85 - 86
(When battery voltage is applied to
terminals 30 and 87)
If the result is not as specified, replace the relay.

Power Mirror Control System

Parts Location
Outside Rear View Mirror Assembly RH
Outside Rear View Mirror Assembly LH
Outside Rear View Mirror

Adjustment Switch
ALL075G


1. Outside Rear View Mirror Adjustment Switch ET-42
Mirror does not operate 2. Outside Rear View Mirror Assembly ET-44
3. Wire harness -
1. Outside Rear View Mirror Adjustment Switch ET-42
Mirror operates abnormally 2. Outside Rear View Mirror Assembly ET-44
3. Wire harness -
LEFT RIGHT Inspection

Left/Right Mirror Fold Switch
Select Switch
L R
(Elite model) 1. Check outside rear view mirror adjustment switch
Rear View Mirror (a) The L side of the left/right select switch: Check the mirror
MIRROR
UP Switch switch resistance.

LEFT OFF RIGHT
DOWN Standard (Left side):
Terminal Specified
Switch condition
2 3 4 5 6 7 8 9 10 connection condition
Connect with Rear View 4-8
Mirror Adjustment Switch
UP
ALL076G 6-7
4-7
DOWN
6-8
Below 1 W
5-8
LEFT
6-7
5-7
RIGHT
6-8
(b) The R side of the left/right select switch: Check the mirror
switch resistance.
Standard (Right side):
Terminal Specified
Switch condition
connection condition
3-8
UP
6-7
3-7
DOWN
6-8
Below 1 W
2-8
LEFT
6-7
2-7
RIGHT
6-8

2. Inspect outer rear view mirror assembly LH

(A) (a) Disconnect the mirror connector.
(C) (D) (b) Apply battery voltage to the mirror terminals and check op-
(B) eration of the mirror face, as shown in the table and illustra-
tion.
Standard:
6 5 4 3 2 1
Measurement condition Mirror operation
9 8 7
Battery positive (+) → 9
UP (A)
Outside Power Mirror LH ALL077G Battery negative (-) → 8
DOWN (B)
LEFT (C)
RIGHT (D)
If the result is not as specified, replace the mirror assembly.
3. Inspect outer rear view mirror assembly RH
(A) (a) Disconnect the mirror connector.
(C) (D)
(b) Apply battery voltage to the mirror terminals and check op-
(B)
eration of the mirror face, as shown in the table and illustra-
tion.
6 5 4 3 2 1
Standard:
9 8 7
Measurement condition Mirror operation
Outside Power Mirror RH UP (A)
ALL078G Battery negative (-) → 8
DOWN (B)
LEFT (C)
RIGHT (D)
If the result is not as specified, replace the mirror assembly.

Outside Rear View Mirror Assembly LH

Replacement
Hint:
1. Remove front door waterproof membrane LH
(a) Remove the front door triangular trim.
(b) Remove the front door inside pull handle.
(c) Remove the glass regulator main switch.
(d) Remove the front door trim panel.
(e) Remove the front door inside handle
(f) Remove the front door trim panel bracket.
(g) Remove the front door waterproof membrane.
2. Remove outside rear view mirror assembly LH

(b) Remove the 3 nuts and mirror.
ALL079G
3. Install outside rear view mirror assembly LH

(a) Install the mirror with the 3 nuts.
Torque: 8.0 N·m (61 kgf·cm, 71 in·lbf)
ALL079G

Inner Rear View Mirror Assembly

Replacement
Hint:
reverse order.
1. Remove inner rear view mirror assembly
(a) Using a screwdriver, disengage the claws and mirror cover.
Hint:
(b) Remove the 2 screws and rear view mirror.
ALL080G

ELECTRIC HORN SYSTEM

Parts Location
Electric Horn Button Switch
Low Tone Electric Horn Assembly
Engine Room Fuse

Block
High Tone Electric Horn Assembly
ALL081G


1. Electric horn button switch -
2. High tone electric horn assembly ET-47
3. Low tone electric horn assembly ET-47
Electric horn does not sound
4. Electric horn fuse -
5. Electric horn relay assembly ET-47
6. Wire harness -
Inspection
1. Inspect low tone electric horn assembly
(a) Apply battery voltage to the electric horn and check
operation of the electric horn.
Standard:
Battery positive (+) → Terminal 1
Electric horn sounds
Battery positive (-) → Electric horn body
ALL082G
If the result is not as specified, replace the electric horn
assembly.
2. Inspect high tone electric horn assembly
(a) Apply battery voltage to the electric horn and check
operation of the electric horn.
Standard:
Battery positive (+) → Terminal 1
Electric horn sounds
Battery positive (-) → Electric horn body
If the result is not as specified, replace the electric horn
ALL083G assembly.
3. Inspect electric horn relay assembly

1 2 (a) Remove the electric horn relay from engine room fuse block.
(b) Inspect electric horn relay resistance.
3 5 Standard:
5
2 1 10 W or higher
Below 1 W
3
3-5 (When battery
ALL084G voltage is applied to
terminals 3 and 5)
If the result is not as specified, replace the relay assembly.

Low Tone Electric Horn Assembly

Replacement
Hint:
1. Remove low tone electric horn assembly
(a) Remove the front bumper upper grille.
(c) Remove the bolts, the located pad and the electric horn.
2. Install the low tone electric horn assembly
(a) Attach the electric horn stay to the body panel and then in-
stall the electric horn with the bolts.
Torque: 19.5 N·m (199 kgf·cm, 14 ft·lbf)
ALL085G (b) Connect the connectors.
High Tone Electric Horn Assembly

Replacement
Hint:
1. Remove high tone electric horn assembly
(a) Remove the front bumper lower grille.
(c) Remove the bolts and the electric horn.
2. Install the high tone electric horn assembly
(a) Attach the electric horn stay to the body panel with located
pad and then install the electric horn with the bolts.
ALL086G

SLIDING ROOF
Components
26 18
28 27
25
21
30
23 22
18 19 19 24
18
20
29 18
17
16
7 14
5 11 9 12 8 12 13 15
10
9 17
5
4 6
5
3
2
1
ALL087G
Cable Protector Locating Block Rear Drain Pipe

1 Bolt 7 13 19 Stopper Plate 25
RH LH RH
Sliding Roof Locating Block Guide Groove
2 Motor 8 14 20 26 Sun Visor
Housing RH LH
Sliding Roof
Connecting Guide Groove
3 Cables 9 15 Lock Attachment 21 27 Rear Drip
Rod RH
Plate LH
Front Sun Sliding Roof
Linked Mecha-
4 Baffle Plate 10 Visor Stopper 16 Lock Attachment 22 28 Roof Glass
nism LH
LH Plate RH
Front Sun Linked
5 Hinge Screw 11 Visor Stopper 17 Sealing Strips 23 Mechanism 29 Screw
RH RH
Cable Protector Rear Drain Jam Protection
6 12 Screw 18 Screw 24 30
LH Pipe LH Trim Cover


Foreign material in roof track Remove the blocked material
Roof cannot operate misplaced parts in the track Install the parts correctly
(Motor operates) The locations of the roof parts are interfered Correct the interfered parts
Wrong installation of the cable Install them correctly
Fuse damage in the system Replace the fuse
Check the line according to the roof
Roof switch malfunction
switch description
Roof cannot operate
(Motor does not operate) Motor malfunction
motor description
Controller error
controller description
1. Remove roof headlining

(a) Remove the roof headlining
2. Remove rear roof air duct
(a) Detach the 2 clips and remove the air duct.
ALL088G
3. Remove sliding roof side garnish LH

(a) Detach the 5 claws and remove the side garnish.
4. Remove sliding roof side garnish RH
Hint:
Use the same procedures described for the LH side.
ALL089G
5. Remove sliding roof glass

(a) Using a screwdriver, remove the 4 screws and glass.
6. Remove sliding roof weatherstrip
7. Remove sliding roof housing sub-assembly
(a) Disconnect the sliding roof drain pipes.
(b) Remove the bolts, nuts and housing.
ALL090G

Disassembly
1. Remove sliding roof lock catch plate LH
2. Remove sliding roof motor
(a) Detach the bracket claw and remove the bracket.
(b) Remove the 3 bolts and sliding roof motor.
ALL091G
3. Remove sunshade trim sub-assembly

Rearward (a) Remove the 2 screws.
(b) Detach the 4 claws and remove the sliding roof piece LH and
RH.
(c) Slide and remove the trim.
ALL092G
4. Remove sliding roof sunshade stopper LH

(a) Remove the stopper.
5. Remove sliding roof sunshade stopper RH
Hint:
ALL093G
6. Remove sliding roof drive cable sub-assembly

Notice:
Do not disassemble the sliding roof drive cable sub-
assembly except when replacing it.
(a) Remove the 2 screws and 2 stoppers.
(b) Using a screwdriver, detach the 2 claws and slide the rear
roof drip channel rearward to remove it.
Hint:
ALL094G Tape the screwdriver tip before use.
(c) Hold down the window deflector.
ALL095G

Matchmark A (d) Place matchmarks on the sliding roof drive cable sub-assem-
Matchmark B
bly at locations A and B as shown in the illustration.
ALL096G
(e) Using a screwdriver, slide the sliding roof drive cable sub-
Protective Tape assembly in the direction indicated by the arrow in the illus-
tration to remove it.
Hint:
ALL097G
Reassembly
1. Install sliding roof drive cable sub-assembly
(a) Hold down the window deflector.
Notice:
Make sure that the spring indicated by the arrow in the
illustration is securely installed.
ALL098G
(b) Using a screwdriver, slide the drive cable in the direction in-
Protective Tape dicated by the arrow in the illustration to install it.
Installation
Hint:
ALL099G
(c) Slide the rear roof drip channel forward and attach the 2
claws to install it.
Forward
ALL100G

(d) Install the 2 stoppers with the 2 screws.
ALL101G
Matchmark A 2. Adjust sliding roof drive cable sub-assembly

(a) Using a screwdriver, align the matchmarks by sliding the
Matchmark B
drive cable in the directions indicated by the arrow in the il-
Protective Tape
lustration.
Hint:
ALL102G
3. Install sliding roof sunshade stopper LH

(a) Install the stopper.
4. Install sliding roof sunshade stopper RH
Hint:
ALL093G
5. Install sunshade trim sub-assembly

Forward (a) Insert the sunshade trim into the sliding roof housing.
(b) Attach the 4 claws to install the sliding roof piece LH and
RH.
(c) Install the 2 screws.
6. Install sliding roof motor
(a) Install the sliding roof motor with the bolts.
(b) Attach the bracket claw to install the bracket.
ALL103G 7. Install sliding roof lock catch plate LH
Installation
1. Install sliding roof housing sub-assembly
(a) Temporarily install the housing with the bolts (vehicle body
side) and nuts.
(b) Tighten the 8 nuts.
(c) Tighten the 8 bolts.
(d) Connect the 4 sliding roof drain pipes.
ALL104G

2. Install sliding roof weatherstrip

(a) Install the sliding roof weatherstrip as follows.
(1) Attach each corner of the weatherstrip so that each
weatherstrip mark is aligned with the sliding roof glass
center mark. After attaching the entire weatherstrip,
check that all weatherstrip marks are within the sliding
roof glass end marks.
(2) Make sure the weatherstrip cutout is toward the rear
side of the vehicle and centered.
(3) Make sure the weatherstrip is securely installed as
ALL105G
3. Install sliding roof glass sub-assembly

(a) Using a screwdriver, temporarily install the glass with the 4
screws.
(b) Perform a level check.
(1) Check the difference in the level between the roof panel
and the upper surface of the weatherstrip when the slid-
ing roof glass is fully closed.
(2) Perform a gap check. Check the gap between the roof
ALL090G panel and roof glass.
Notice:
The gap must be even all around.
4. Check for water leak
(a) After adjusting the sliding roof glass sub-assembly, check for
water leaks. If there are any leaks, readjust the sliding roof
glass sub-assembly.
5. Install sliding roof side garnish LH
(a) Attach the 5 claws to install the sliding roof side garnish.
6. Install sliding roof side garnish RH
Hint:
ALL089G

7. Install rear roof air duct

8. Install roof headlining
(a) Install roof headlining
ALL088G

MEMO

BO-
BODY
ENGINE HOOD
Engine Hood..................................................................... BO-2
Engine Hood Lock Release Cable.................................... BO-4
DOOR
Front Door......................................................................... BO-5
Rear Door......................................................................... BO-18
Back Door......................................................................... BO-31
BUMPER
Front Bumper.................................................................... BO-37
Rear Bumper..................................................................... BO-40
DOOR OUTER WEATHERSTRIP

Front Door Outer Weatherstrip LH.................................... BO-42
Rear Door Outer Weatherstrip LH.................................... BO-42
TRIM STRIP
Roof Panel Trim Strip LH.................................................. BO-43
Rocker Trim Panel LH....................................................... BO-43
License Plate Lamp Trim Panel........................................ BO-44
FUEL TANK DOOR

Fuel Tank Door Cable....................................................... BO-45
BO
13-BODY.indd 1 2008-10-21 9:17:20

BO- GREAT WALL COOL BEAR REPAIR MANUAL
ENGINE HOOD
Engine Hood
Adjustment
Hint:
Centering bolts are used to mount the engine hood hinge and en-
gine hood lock. The engine hood and engine hood lock cannot be
Centering Bolt Standard Bolt
adjusted with the centering bolts on. Substitute the centering bolts
ALM001G with standard bolts (w/washers) when making adjustments.
1. Inspect engine hood sub-assembly

(a) Check that the clearance is within the standard range.
ALM002G
Standard:
Area Measurement
A 4.0 mm (0.157 in.)
B 0 mm (0. in.)
2. Adjust engine hood sub-assembly

(a) Horizontally and vertically adjust the engine hood.
(1) Loosen the 4 hinge bolts on the engine hood side.
ALM003G
13-BODY.indd 2 2008-10-21 9:17:21

BODY BO-
(2) Adjust the clearance by moving the engine hood so that

it is in the standard range.
Standard range (A): 4.0 mm (0.157 in.)
(3) Tighten the engine hood side hinge bolts after the ad-
justment.
ALM004G
(b) Adjust the height of the engine hood front end by the adjust-
ing block.
(1) Turn the adjusting block so that the engine hood and the
fender are aligned.
Hint:
Raise and lower the adjusting block by turning it.
(c) Adjust the engine hood lock.
(1) Remove the clips and grille.
ALM005G
(2) Adjust the engine hood lock position so that the striker
can enter smoothly.
(3) Tighten the engine hood lock bolts after the adjustment.
ALM006G
13-BODY.indd 3 2008-10-21 9:17:22

Engine Hood Lock Release Cable

Replacement
1. Remove engine hood lock release cable
(a) Open the engine hood.
(b) Remove the engine hood lock release handle from the instru-
ment panel.
(c) Remove the cable from the engine hood lock release handle.
(d) Remove the bolts and engine hood lock bolt release mecha-
nism assembly.
(e) Remove the cable from engine hood lock bolt release mecha-
ALM007G nism assembly.
2. Install engine hood lock release cable
Hint:
The contact of different metals can speed up the corrosion.
You must use the right fastener to avoid early corrosion.
(a) Install the cable on the engine hood lock bolt release mecha-
nism assembly.
(b) Install engine hood lock bolt release mechanism assembly
with the bolts.
(c) Install the cable on the engine hood lock bolt release handle.
(d) Install the engine hood lock release handle on the instrument
panel.
(e) Close the engine hood.
13-BODY.indd 4 2008-10-21 9:17:22

BODY BO-
DOOR
Front Door
Components
Front Door Glass Sealing Strip LH
Front Door Glass LH
6.2 (63, 55 in.·lbf)
l Front Door Waterproof

Front Door Rear Lower Frame Sub-assembly LH Membrane LH
Front Door Triangular Trim LH
8.0 (82, 71 in.·lbf) Front Door Glass Regulator Sub-assembly LH
Front Door Inner Weatherstrip LH
8.0 (82, 71 in.·lbf)
5.4 (55, 48 in.·lbf)
Front Glass Regulator Motor Assembly LH
Front Door Inside Pull Handle LH

Front Window Main
Switch Panel LH
Front Door
Trim Panel Plastic Clip
LH
Front Window Main Switch Assembly LH
Front Door Trim

Panel Bracket LH
Plastic Clip
l Non-reusable part
ALM008G
13-BODY.indd 5 2008-10-21 9:17:22

Front Door Outside Handle and Frame LH
Front Door Outside Rear

View Mirror LH
Front Door Sealing Strip LH Turn Signal

Light
Front Door Outer 8.0 (82, 71 in.·lbf)

Weatherstrip LH
Front Door Upper Hinge LH
23 (235, 17)
5.5 (56, 49 in.·lbf)
Front Door Check LH

30 (306, 22)
Cushion Plate
Front Door Lower Hinge LH

23 (235, 17)
Front Door Lock Control Knob
Front Door Lock
Control Knob Clip
5.0 (51, 44 in.·lbf) Front Door Lock Cable Mounting Clip

Front Door Inside Handle Assembly LH
Front Door Open Cable LH

Front Door Lock Body Assembly LH
Front Door Lock Actuator Assembly LH

Precoated parts
ALM009G
13-BODY.indd 6 2008-10-21 9:17:23

BODY BO-
Adjustment
Hint:
• Centering bolts are used to mount the door hinge to the vehicle
body and door. The door cannot be adjusted with the centering
bolts on. Substitute the centering bolts with standard bolts (w/
washers) when making adjustments.
ALM001G
1. Inspect front door panel sub-assembly LH

160 mm (6.30 in.)*
A
D
C
E
*: 160 mm (6.30 in.) from the end of the window frame, check the clearances A and B as illustrated in the cross section.
ALM010G
Standard:
Area Measurement
A 5.0 mm (0.197 in.)
B 6.5 mm (0.256 in.)
C 3.8 mm (0.149 in.)
D 3.8 mm (0.149 in.)
E 6 mm (0.236 in.)
F 6 mm (0.236 in.)
2. Adjust front door panel sub-assembly LH

(a) Using SST, adjust the door horizontally and vertically by
loosening the door side hinge bolts.
SST 09812-00010, 09812-00020
(b) Tighten the door side hinge bolts after the adjustment.
ALM011G
13-BODY.indd 7 2008-10-21 9:17:24

(c) As shown in the illustration, horizontally and vertically ad-

just the door by loosening the body side hinge bolts.
(d) Tighten the body side hinge bolts after the adjustment.
ALM012G
(e) Adjust the striker position by slightly loosening the striker

mounting screws and hitting the striker with a plastic-faced
hammer.
(f) Tighten the striker mounting screws after the adjustment.
ALM013G
Overhaul
Hint:
Clip 1. Remove front door triangular trim LH
(a) Using a screwdriver, disengage the clip and claw, and re-
move the triangular trim.
Hint:
Claw
ALM014G
2. Remove front door inside pull handle LH

(a) Remove the screw and remove the inside pull handle.
ALM015G
13-BODY.indd 8 2008-10-21 9:17:25

BODY BO-
3. Remove front window main switch assembly LH

(a) Using a screwdriver, disengage the clip and claw, and re-
Clip
move the front window main switch panel LH together with
the main switch.
Hint:
(b) Disconnect the switch connector.
(c) Remove the 3 screws and the switch from the front window
Claw
ALM016G main switch panel LH.
Protective Tape Clip A 4. Remove front door trim panel LH

(a) Remove the screw and clip A as shown in the illustration.
(b) Using a screwdriver, disengage the 7 clips.
Hint:
Screw (c) Remove the trim panel upward.
Hint:
In order to prevent the door panel from being damaged, use
: Clip ALM017G protective tape to cover the areas indicated by the arrow
marks in the illustration.
(d) Using a screwdriver, disengage the clips and remove the in-
ner weatherstrip.
Hint:
5. Remove front door inside handle assembly LH
Claw A (a) Using a screwdriver, disengage the claw A as shown in the il-
1
lustration.
2 Hint:
(b) Move the inside handle in the direction indicated by the ar-
row mark in the illustration.
(c) Disconnect the cable from the inside handle.
: Claw
ALM018G
6. Remove front door waterproof membrane LH

(a) Remove the 2 screws and bracket.
ALM019G
13-BODY.indd 9 2008-10-21 9:17:25

BO-10 GREAT WALL COOL BEAR REPAIR MANUAL
(b) Remove the waterproof membrane.

Notice:
Remove the remaining tape on the door side.
Butyl Tape
ALM020G
7. Remove front door outside rear view mirror LH

(a) Disconnect the mirror connector.
(b) Remove the 3 nuts and mirror.
Notice:
Be careful when removing the nuts as the mirror may
fall and become damaged.
ALM021G
8. Remove front door outer weatherstrip LH (See page

BO-42)
9. Remove front door speaker assembly LH
(b) Remove the speaker.
(c) Disconnect the speaker connector.
ALM022G
10. Remove front door glass LH

Hint:
Insert a shop rag inside the door panel to prevent the glass
from being scratched.
(a) Move the door glass until the bolts appear in the service
holes.
(b) Remove the 2 bolts holding the door glass to the glass regu-
lator.
ALM023G Notice:
Be careful when removing the bolts as the glass may
fall and become damaged.
13-BODY.indd 10 2008-10-21 9:17:26

BODY BO-11
(c) Remove the door glass in the direction indicated by the white
2 arrow marks in the illustration.
1 Notice:
Be careful not to damage the glass.
(d) Remove the glass sealing strip.
ALM024G
11. Remove front door glass regulator sub-assembly LH

(a) Disconnect the glass regulator connector.
(b) Remove the 6 bolts and glass regulator.
Notice:
Be careful when removing the bolts as the glass regula-
tor may fall and become damaged.
Hint:
Remove the glass regulator through the service hole.
ALM025G
12. Remove front glass regulator motor assembly LH

(a) Using a torx driver, remove the 3 screws and motor.
ALM026G
13. Remove front door rear lower frame sub-assembly LH

(a) Remove the bolt and frame.
Hint:
Remove the frame through the service hole.
ALM027G
14. Remove front door lock body assembly LH

(a) Disconnect the clip and outside locking link from the outside
handle.
(b) Disconnect the clip and lock open rod from the outside han-
dle.
13-BODY.indd 11 2008-10-21 9:17:27

(c) Turn the control knob and remove it, as shown in the illustra-
Control Knob
tion.
(d) Using a screwdriver, disengage the 2 claws and remove the
clip.
Hint:
Clip
Claw
ALM028G
(e) Remove the bolt.

(f) Using a torx socket wrench, remove the 3 screws and door
lock.
Notice:
Be careful not to drop the door lock as it may become
damaged.
Hint:
Remove the door lock through the service hole.
Bolt
ALM029G (g) Remove the cable from the lock.
(h) Remove the 2 screws and actuator.
ALM030G
15. Remove front door outside handle LH

(a) Remove the 2 bolts and handle and the cylinder.
Notice:
Be careful when removing the bolts as the outside han-
dle may fall and become damaged.
(b) Unlock the cylinder by turning it.
(c) Remove the cylinder.
ALM031G
16. Remove front door check LH

(a) Remove the 3 screws and door check.
Hint:
Remove the door check through the service hole.
ALM032G
13-BODY.indd 12 2008-10-21 9:17:28

BODY BO-13
17. Remove front door sealing strip LH

(a) Using a clip remover, disengage the clips and remove the
sealing strip.
Hint:
18. Install front door check LH
(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 bolts.
(c) Apply adhesive to the threads of the bolt.
(d) Install the check to the door panel with the bolts.
Adhesive Torque: 30 N·m (305 kgf·cm, 22 ft·lbf)
ALM033G
19. Install front door outside handle LH

(a) Install the cylinder to the handle.
(b) Lock the cylinder by turning it.
(c) Install the handle and the cylinder with the 2 bolts.
ALM031G
20. Install front door lock body assembly LH

(a) Install the actuator with the 2 screws.
ALM030G
(b) Apply MP grease to the sliding and rotating areas of the door
lock.
ALM034G
13-BODY.indd 13 2008-10-21 9:17:29

(c) Install the bolt.

Adhesive
(d) Apply adhesive to the threads of the 3 screws.
(e) Using a torx socket wrench, install the door lock with the 3
screws.
(f) Connect the door lock connector.
Adhesive
ALM035G
(g) Install the lock open rod and outside locking link.
(h) Install the clip.
Control Knob
(i) Attach the control knob in the direction indicated by the
white arrow mark in the illustration.
Clip Hint:
After attaching the control knob, rotate it 90 degrees in the
direction indicated by the arrow marks in the illustration.
ALM036G
21. Install front door rear lower frame sub-assembly LH

(a) Install the frame with the bolt.
ALM027G
22. Install front glass regulator motor assembly LH

(a) Using a torx driver, install the 3 screws and motor.
ALM026G
13-BODY.indd 14 2008-10-21 9:17:29

BODY BO-15
23. Install front door glass regulator sub-assembly LH

(a) Apply MP grease to the sliding and rotating areas of the glass
regulator.
Notice:
Do not apply grease to the spring of the glass regulator.
ALM037G
(b) Install the glass regulator with the 6 bolts.

Notice:
Be careful not to drop the glass regulator as it may be-
come damaged.
(c) Connect the glass regulator connector.
ALM025G
24. Install front door glass LH

(a) Install the glass sealing strip.
Notice:
(b) Insert the door glass into the door panel along the glass seal-
2 ing strips as indicated in the illustration.
ALM038G
(c) Install the door glass to the glass regulator with the 2 bolts.
(d) Check the operation of the power window.
(1) Connect the power window switch to the wire harness
and turn the ignition switch ON.
(2) Use the UP and DOWN function several times.
ALM023G
13-BODY.indd 15 2008-10-21 9:17:30

25. Install front door speaker assembly LH

(a) Connect the speaker connector.
(b) Install the speaker.
ALM022G
26. Install front door outside rear view mirror LH

(a) Install the mirror with the 3 nuts.
Torque: 8 N·m (82 kgf·cm, 71 in·lbf)
(b) Connect the mirror connector.
ALM021G
27. Install front door waterproof membrane LH

(a) Apply butyl tape to the door as shown in the illustration.
(b) Install a new waterproof membrane.
Hint:
Butyl Tape
• When installing the waterproof membrane, pull out the
links and connectors through the waterproof membrane.
• There should be no wrinkles or folds after attaching the
waterproof membrane.
ALM039G • After attaching the waterproof membrane, check the
sealing quality.
(c) Install the bracket with the 2 bolts.
ALM019G
28. Install front door inside handle assembly LH

Claw A (a) Install the cable to the inside handle.
1
2 row mark in the illustration.
(c) Attach the claw A.
: Claw
ALM018G
13-BODY.indd 16 2008-10-21 9:17:30

BODY BO-17
Protective Tape Clip A 29. Install front door trim panel LH

(a) Install the inner weatherstrip and attach the clips.
(b) Install the trim panel.
(c) Attach the 7 clips.
(b) Install the screw and clip A as shown in the illustration.
Screw
: Clip
ALM017G
30. Install front window main switch assembly LH

(a) Using the 3 screws to install the switch to the front window
Snap
main switch panel.
(b) Connect the switch connector.
(c) Attach the clip and claw to install the window main switch.
Claw
ALM016G
31. Install front door inside pull handle LH

(a) Install the front door inside pull handle and fix it with the
screw.
ALM015G
Clip 32. Install front door triangular trim LH

(a) Attach the clip and claw to install the triangular trim.
Claw
ALM014G
13-BODY.indd 17 2008-10-21 9:17:31

Rear Door
Components
5.0 (51, 44 in.·Ibf)
Rear Door Quarter Window Glass LH
Rear Door Glass LH
5.4 (55, 48 in.·Ibf)
Rear Quarter Window 8.0 (82, 71 in.·Ibf)

Glass Sealing Strip LH
5.0 (51, 44 in.·Ibf) Rear Door Glass

LH Sealing Strip LH
5.0 (51, 44 in.·Ibf)
Rear Door Window Division

Bar Sub-assembly LH Rear Door Glass Regulator
Motor Assembly LH Rear Door Glass Regulator
Rear Door Inside Pull
Handle LH Rear Door Inner Weatherstrip LH Sub-assembly LH
l Rear Door Waterproof Membrane LH
Rear Door Trim Panel Bracket

Rear Door Window
Switch Panel LH
Rear Window Switch Assembly LH
Rear Door Trim Panel LH
Plastic Clip
l Non-reusable part
ALM040G
13-BODY.indd 18 2008-10-21 9:17:31

BODY BO-19
Rear Door Outside Handle and Frame LH
Rear Door Sealing Strip LH
Rear Door Outer Weatherstrip LH
Rear Door Upper Hinge LH
Rear Door Check 23 (235, 17)
5.0 (51, 44 in.·lbf) 5.5 (56, 49 in.·lbf)
30 (306, 22)
Rear Door Open Cable LH 23 (235, 17)
Rear Door Inside Handle Assembly LH
Rear Door Lock Body Assembly LH

Rear Door Lower Hinge LH
Rear Door Actuator Assembly LH
Rear Door Lock Control Knob

Rear Door Control Link Assembly No.2 LH Rear Door Woofer Assembly LH
Rear Door Lock
Control Knob Clip
Rear Door Rod Assembly LH

Door Link Control Bellcrank

Precoated parts
ALM041G
13-BODY.indd 19 2008-10-21 9:17:31

Adjustment
Hint:

ALM001G
1. Inspect rear door panel sub-assembly LH

160 mm (6.30 in.)*
A
D
C
E
*: 160 mm (6.30 in.) from the end of the window frame, check the clearances A and B as illustrated in the cross section.
ALM010G
Standard:
Area Measurement
A 5.0 mm (0.197 in.)
B 6.5 mm (0.256 in.)
C 3.8 mm (0.149 in.)
D 3.8 mm (0.149 in.)
E 6 mm (0.236 in.)
F 6 mm (0.236 in.)
2. Adjust rear door panel sub-assembly LH

(a) Remove the lower garnish.
(b) As shown in the illustration, horizontally and vertically ad-
just the door by loosening the body side hinge nuts.
(c) Tighten the body side hinge nuts after the adjustment.
ALM042G
13-BODY.indd 20 2008-10-21 9:17:32

BODY BO-21
(d) Horizontally and vertically adjust the door by loosening the

door side hinge bolts.
(e) Tighten the door side hinge bolts after the adjustment.
ALM043G
(f) Adjust the striker position by slightly loosening the striker

hammer.
(g) Tighten the striker mounting screws after the adjustment.
ALM044G
Overhaul
Hint:
1. Remove rear door inside pull handle LH
(a) Remove the screw and remove the inside pull handle.
ALM015G
2. Remove rear window switch assembly LH

(a) Using a screwdriver, disengage the 2 claws labeled A in the
illustration. Remove the rear window switch panel and the
A A
switch.
(b) Disengage the 2 claws labeled B in the illustration. Remove
the switch.
B B
ALM045G
13-BODY.indd 21 2008-10-21 9:17:32

Protective Tape 3. Remove rear door trim panel LH

(a) Remove the screw as shown in the illustration.
(b) Using a clip remover, disengage the 7 clips.
(c) Remove the trim panel upward.
Screw Hint:
In order to prevent the door panel from being damaged, use
protective tape to cover the areas indicated by the arrow
marks in the illustration.
: Clip
ALM046G (d) Using a screwdriver, disengage the claws and remove the in-
ner weatherstrip.
Hint:
4. Remove rear door inside handle assembly LH
Claw A
(a) Using a screwdriver, disengage the claw A as shown in the il-
1
lustration.
2 Hint:
row mark in the illustration.
(c) Disconnect the cable from the inside handle.
: Claw
ALM018G
5. Remove rear door waterproof membrane LH

(a) Remove the 2 screws and bracket.
ALM019G
(b) Remove the waterproof membrane.

Notice:
Remove the remaining tape on the door side.
Butyl Tape
ALM047G
6. Remove rear door outer weatherstrip LH (See page

BO-42)
13-BODY.indd 22 2008-10-21 9:17:33

BODY BO-23
7. Remove rear door woofer assembly LH

(b) Remove the woofer.
(c) Disconnect the woofer connector.
ALM022G
8. Remove rear door window division bar sub-assembly

LH
Hint:
Insert a shop rag inside the door panel to prevent the glass
from being scratched.
Notice:
(a) Lower the glass as far as it can.
ALM048G (b) Remove the glass sealing strip.
(c) Remove the 2 bolts and screw.
(d) Rotate the division bar and remove it, as shown in the illus-
3
tration.
2
1
ALM049G
9. Remove rear door quarter window glass LH

(a) Remove the window glass in the direction indicated by the
Notice:
(b) Remove the quarter window glass sealing strip.
ALM050G
10. Remove rear door glass LH

(a) Carefully pull up the door glass out of the door panel.
Hint:
Insert a shop rag inside the door panel to prevent the door
glass from being scratched.
13-BODY.indd 23 2008-10-21 9:17:34

11. Remove rear door glass regulator sub-assembly LH

(a) Disconnect the glass regulator connector.
(b) Remove the 4 bolts and glass regulator.
Notice:
Be careful when removing the bolts as the glass regula-
tor may fall and become damaged.
Hint:
Remove the glass regulator through the service hole.
ALM051G
12. Remove rear glass regulator motor assembly LH

(a) Using a torx driver, remove the 3 screws and motor.
ALM052G
13. Remove rear door lock body assembly LH

Remote Control Rod No.2 (a) Disconnect the snap and remote control rod No.2 in the di-
Clip rection indicated by the white arrow marks in the illustration.
ALM053G
(b) Turn the control knob and remove it, as shown in the illustra-
Control Knob
tion.
(c) Using a screwdriver, disengage the 2 claws and remove the
clip.
Hint:
Clip
Claw
ALM028G
(d) Using a screwdriver, disengage the 4 claws and remove the

Remote Control
Rod No.2
bellcrank, the remote control rod and remote control rod
No.2.
Hint:
Claw
(e) Remove the remote control rod and remote control rod No.2.
Remote Control Rod Bellcrank

ALM054G
13-BODY.indd 24 2008-10-21 9:17:35

BODY BO-25
(f) Using a torx socket wrench, remove the 3 screws and door
lock.
Notice:
Be careful when removing the bolts as the door lock
may fall and become damaged.
Hint:
ALM055G
(g) Remove the 2 screws and actuator.
ALM056G
14. Remove rear door outside handle LH

(a) Remove the bolt, nut and outside handle frame.
Nut
(b) Remove the bolt and handle.
Bolt
Notice:
Be careful when removing the bolts as the outside han-
dle may fall and become damaged.
ALM057G
15. Remove rear door check LH

(a) Remove the 3 screws and door check.
Hint:
Remove the door check through the service hole.
ALM058G
16. Remove rear door sealing strip LH

(a) Using a clip remover, disengage the clips and remove the
sealing strip.
Hint:
13-BODY.indd 25 2008-10-21 9:17:36

17. Install rear door check LH

(a) Apply MP grease to the sliding areas of the check.
(b) Install the check to the door panel with the 2 bolts.
(c) Apply adhesive to the threads of the bolts.
(d) Install the check to the door panel with the bolts.
Adhesive
ALM059G
18. Install rear door outside handle LH

(a) Install the handle with the bolt.
(b) Install the outside handle with the bolt and nut.
Bolt Nut
ALM057G
19. Install rear door lock body assembly LH

(a) Install the actuator with the 2 screws.
ALM056G
(b) Apply MP grease to the sliding and rotating areas of the door
lock.
ALM060G
13-BODY.indd 26 2008-10-21 9:17:36

BODY BO-27
(c) Apply adhesive to the threads of the 3 screws.

(d) Using a torx socket wrench, install the door lock with the 3
screws.
(e) Connect the door lock connector.
ALM055G
(f) Install the bellcrank, the remote control rod and remote con-
Remote Control
Rod No.2 trol rod No. 2.
Remote Control Rod Bellcrank

ALM061G
Control Knob
(g) Install the clip.
(h) Attach the control knob in the direction indicated by the
Clip Hint:
After attaching the control knob, rotate it 90 degrees in the
direction indicated by the arrow marks in the illustration.
ALM036G
(i) Connect the remote control rod No.2 in the direction indi-
Remote Control cated by the arrow marks in the illustration.
Snap Rod No.2
ALM053G
20. Install rear glass regulator motor assembly LH

(a) Using a torx driver, install the 3 screws and motor.
ALM052G
13-BODY.indd 27 2008-10-21 9:17:37

21. Install rear door glass regulator sub-assembly LH

(a) Apply MP grease to the sliding and rotating areas of the glass
regulator.
Notice:
Do not apply grease to the spring of the glass regulator.
ALM062G
(b) Install the glass regulator with the 4 bolts.

(c) Connect the glass regulator connector.
Notice:
Be careful not to drop the glass regulator as it may be-
come damaged.
ALM051G
22. Install rear door glass LH

Notice:
(a) Install the door glass into the door panel.
Hint:
Insert a shop rag inside the door panel to prevent the door
glass from being scratched.
23. Install rear door quarter window glass LH
(a) Install the quarter window glass sealing strip to the glass.
Notice:
(b) Install the quarter window glass in the direction indicated by
the white arrow mark in the illustration.
(c) Mount the door glass to the window regulator along the glass
weatherstrip.
ALM063G
24. Install rear door window division bar sub-assembly LH

3 1 (a) Insert the division bar into the door panel and then rotate it
90 degrees, as shown in the illustration.
2 Torque: 8.0 N·m (82 kgf·cm, 71 in·lbf)
ALM064G
13-BODY.indd 28 2008-10-21 9:17:38

BODY BO-29
(b) Install the division bar with the 2 bolts and screw.
(c) Install the glass sealing strip.
(d) Check the operation of the power window.
(1) Connect the power window switch to the wire harness
and turn the ignition switch ON.
(2) Use the UP and DOWN function several times.
ALM048G
25. Install rear door woofer assembly LH

(a) Connect the woofer connector.
(b) Install the woofer.
ALM022G
26. Install rear door waterproof membrane LH

(a) Apply butyl tape to the door as shown in the illustration.
(b) Install a new waterproof membrane.
Hint:
Butyl Tape
• When installing the waterproof membrane, pull out the
links and connectors through the waterproof membrane.
• There should be no wrinkles or folds after attaching the
waterproof membrane.
ALM065G • After attaching the waterproof membrane, check the
sealing quality.
(c) Install the bracket with the 2 bolts.
ALM019G
13-BODY.indd 29 2008-10-21 9:17:38

27. Install rear door inside handle assembly LH

Claw A
(a) Install the cable to the inside handle.
1
2 row mark in the illustration.
(c) Attach the claw A as shown in the illustration.
: Claw
ALM018G
Protective Tape 28. Install rear door trim panel LH

(a) Install the inner weatherstrip and attach the claws.
(b) Install the trim panel downward.
(c) Attach the 7 clips.
Screw (d) Install the screw as shown in the illustration.
: Clip
ALM046G
29. Install rear window switch assembly LH

(a) Attach the 2 claws labeled B in the illustration to install the
switch to the switch panel.
A A
(b) Attach the 2 claws labeled A in the illustration to install the
window switch assembly.
B B
ALM045G
30. Install rear door inside pull handle

(a) Install the rear door inside pull handle and fix it with the
screw.
ALM015G
13-BODY.indd 30 2008-10-21 9:17:38

BODY BO-31
Back Door
Components
High-mounted Brake Lamp Assembly
Back Door Hinge Assembly RH
Back Door Hinge Assembly LH
23 (235, 17)
26 (265, 19)
26 (265, 19)
23 (235, 17) 8.0 (82, 71 in.·lbf)
l Back Door Window
Glass Groove RH
l Back Door Window Glass Groove LH
Back Door Air Spring RH
8.0 (82, 71 in.·lbf)

22 (224, 16)
Back Door Air Spring LH Back Door Lower 12.5 (112, 9)
Stopper RH
Door Pull Handle
22 (224, 16)
Back Door Lower Stopper LH

12.5 (112, 9) License Plate Lamp
Trim Panel Assembly
Rear Wiper Assembly
Back Door Outside Handle

Switch Assembly
Rear Wiper Motor 5.5 (56, 49 in.·lbf) 11.5 (117, 8)

Assembly
Back Door Striker Assembly

Back Door Lock Assembly
Back Door Shield 12.5 (112, 9)

l Non-reusable part
ALM066G
13-BODY.indd 31 2008-10-21 9:17:39

Adjustment
Hint:
ALM001G
1. Inspect back door panel sub-assembly

A
B
ALM067G
Standard:
Area Measurement
A 7 mm (0.275 in.)
B 0 mm (0 in.)
C 5 mm (0.197 in.)
D 3 mm (0.118 in.)
E 5 mm (0.197 in.)
F 10 mm (0.393 in.)
2. Adjust back door panel sub-assembly

(a) Remove the roof headlining (See page IR-65).
(b) As shown in the illustration, horizontally and vertically ad-
just the door by loosening the body side hinge nuts.
(c) Tighten the body side hinge nuts after the adjustment.
ALM068G
13-BODY.indd 32 2008-10-21 9:17:40

BODY BO-33
(d) Horizontally and vertically adjust the back door by loosening

the back door side hinge bolts.
(e) Tighten the back door side hinge bolts after the adjustment.
ALM069G
(f) Remove the back door rocker shield (See page IR-64).
(g) Adjust the striker position by slightly loosening the striker
hammer.
(h) Tighten the striker mounting screws after the adjustment.
ALM070G
Overhaul
Hint:
1. Remove back door shield
(a) Using a clip remover, remove the 13 clips and cover.
2. Remove license plate lamp trim panel assembly (See
page BO-44)
3. Remove high-mounted brake lamp assembly (See
page IR-15)
4. Remove rear wiper motor assembly (See page ET-9)
5. Remove back door lock assembly
(a) Disconnect the lock connector.
(b) Remove the 3 bolts and lock.
Hint:
ALM071G
13-BODY.indd 33 2008-10-21 9:17:41

6. Remove back door window glass groove LH

(b) Using a heat light, heat the glass groove.
Heating temperature: 20 to 30°C (68 to 86°F)
Notice:
Do not heat the body and groove excessively.
(c) Using a screwdriver, remove the groove.
Hint:
7. Remove back door window glass groove RH
(a) Use the same procedures for the RH side and LH side.
8. Remove door pull handle
(a) Using a screwdriver, disengage the 4 claws and remove the
pull handle.
Hint:
: Claw ALM072G
9. Remove back door air spring assembly LH (See page

BO-35)
10. Remove back door air spring assembly RH (See page
BO-35)
11. Remove back door stopper lower
(a) Remove the bolts, left side and right side stoppers.
12. Install back door stopper lower
(a) Install the left side and right side stoppers with the bolts.
13. Install back door window glass groove LH
(a) Clean the contact surface of the door with shop rag saturated
with white gasoline.
(b) Using a heat light, heat the door and groove.
Heating temperature:
Item Temperature
Door 40 to 60°C (104 to 140°F)
Glass Groove 20 to 30°C (68 to 86°F)
Notice:
Do not heat the door and groove excessively.
(c) Remove peeling paper from the glass groove face.
(d) Install the glass groove and 2 clips.
14. Install back door window glass groove RH
(a) Use the same procedures for the RH side and LH side.
13-BODY.indd 34 2008-10-21 9:17:41

BODY BO-35
15. Install back door lock assembly

(a) Install the door lock with the 3 bolts.
(b) Connect the door lock connector.
ALM071G
Back Door Air Spring

Replacement
Hint:
1. Remove back door air spring assembly LH
A
(a) Remove the bolt A from the back door panel.
Hint:
Support the back door with hands when removing the back
door spring.
(b) Remove the 2 bolts B and air spring from the body panel.
B
ALM073G
2. Install back door air spring assembly LH

(a) Install the air spring with the bolts.
Torque:
22.0 N·m (224 kgf·cm, 16 ft·lbf) for bolt A
8.0N·m (82 kgf·cm, 71 in.·lbf) for bolt B
13-BODY.indd 35 2008-10-21 9:17:42

Disposal
Hint:
Use the same procedures for the RH side and LH side.
1. Dispose of back door air spring assembly LH
(a) Horizontally fix the air spring in a vise, with the piston-rod
pulled out.
(b) Wearing safety glasses, gradually cut the part between A and
B as shown in the illustration by a metal saw to gradually re-
a b
lease the gas.
A B Specification:
Area Measurement
ALM074G a 80 mm (3.15 in.)
b 20 mm (0.80 in.)
Notice:
Be careful to cover the area that is being cut as there is
a possibility that metal debris could be blown out by the
gas. (The gas is colorless, odorless and harmless)
13-BODY.indd 36 2008-10-21 9:17:42

BODY BO-37
BUMPER
Front Bumper
Components
Front Bumper Body
Front Bumper Upper Grille Body

Front Bumper Body
Connecting Bracket RH
Connecting Bracket LH
Hook Cover Plate
Front Bumper Lower Grille
ALM075G
13-BODY.indd 37 2008-10-21 9:17:42

Replacement
Hint:
verse order.
1. Remove front bumper upper grille body

(a) Remove the 1 clip and 2 screws, and remove the front bum-
per upper grille body.
ALM076G
2. Remove front fender lining LH

(b) Partially remove the fender lining.
Hint:
Partially remove the fender lining, and then remove the front
bumper body.
3. Remove front fender lining RH
Hint:
ALM077G Use the same procedures for the RH side and LH side.
4. Remove front bumper connecting bracket LH

(a) Remove connecting bracket LH by a screwdriver.
5. Remove front bumper connecting bracket RH
Hint:
ALM078G
6. Remove front bumper body

(a) Disconnect the fog lamp connector.
(b) Remove the clip and the 2 bolts from the upper side of the
bumper body.
(c) Using a screwdriver, disengage the 2 claws and remove the 2
bolts, 6 screws and bumper body.
Hint:
Apply protective tape to the front fender.
ALM079G
13-BODY.indd 38 2008-10-21 9:17:46

BODY BO-39
7. Remove front bumper lower grille

bumper lower grille.
Hint:
ALM080G
8. Remove front fog lamp assembly LH

(a) Remove the 3 screws and then remove the front fog lamp as-
sembly LH.
9. Remove front fog lamp assembly RH
(a) Remove the 3 screws and then remove the front fog lamp as-
sembly RH.
ALM081G
10. Remove front bumper cross member assembly

(a) Remove the 2 nuts from the front bumper bracket LH.
(b) Remove the 2 nuts from the front bumper bracket RH.
(c) Remove the front cross member from the front bumper
bracket LH and the front bumper bracket RH.
ALM082G
13-BODY.indd 39 2008-10-21 9:17:48

Rear Bumper
Components
Rear Bumper Body
Rear Bumper Buffer Block Rear Mounting Bracket
Hook Cover
Plate
Rear Exhaust Shield Trim Panel

Front Mounting Bracket
Rear Exhaust Upper Shield
Rear Bumper Body
Rear Exhaust Lower Shield

Rear Exhaust Lower Bracket
ALM083G
13-BODY.indd 40 2008-10-21 9:17:48

BODY BO-41
Replacement
Hint:
The installation procedures are the removal procedures in reverse
order.
1. Remove rear bumper mud guard LH

Hint:
2. Remove rear bumper mud guard RH
Hint:
: Claw
ALM084G
3. Remove rear bumper body

Protective Tape
(a) Using a screwdriver, disengage the 2 claws and remove the 6
bolts and the bumper body.
Hint:
(b) Disconnect the harness of rear lamp and back-up lamp, con-
Claw nector and clip.
: Claw
ALM085G
4. Remove back-up lamp assembly (See page IR-18)

5. Remove rear fog lamp assembly
(a) Remove the screws and the rear fog lamp.
ALM086G
6. Remove rear bumper cross member assembly

(a) Remove the 3 nuts from the rear bumper bracket LH.
(b) Remove the 3 nuts from the rear bumper bracket RH.
(c) Remove the rear cross member from the rear bumper bracket
LH and the rear bumper bracket RH.
ALM087G
13-BODY.indd 41 2008-10-21 9:17:51

DOOR OUTER WEATHERSTRIP

Front Door Outer Weatherstrip LH
Replacement
Hint:
reverse order.
1. Remove front door outer weatherstrip LH

(a) Apply protective tape under the outer weatherstrip.
(b) Using a moulding remover, pry out the weatherstrip as shown
Protective Hint:
Moulding Tape Tape the remover tip before use.
Remover
Adhesive Tape ALM088G
Rear Door Outer Weatherstrip LH

Replacement
Hint:
reverse order.
1. Remove rear door outer weatherstrip LH

(a) Apply protective tape under the outer weatherstrip.
(b) Using a moulding remover, pry out the weatherstrip as shown
Protective Hint:
M o u l d i n g Tape
Remover Tape the remover tip before use.
Adhesive Tape ALM089G
13-BODY.indd 42 2008-10-21 9:17:51

BODY BO-43
TRIM STRIP
Roof Panel Trim Strip LH
Replacement
Hint:
Use the same procedures for the RH side and LH side.
Mount 1. Remove roof panel trim strip LH

(a) Apply the protective tape to the circumference of the trim
strip.
(b) Using a moulding remover, disengage the supporting seat
both in the front and rear ends of the trim strip, and then re-
move the trim strip.
Adhesive Tape 2. Install roof panel trim strip LH
(a) Remove the tape that remains on the mounting surface of the
ALM090G body, and then clean the surface with white gasoline.
(b) Using a heat light, heat the supporting seat installation sur-
faces of the body and the trim strip.
Heating temperature:
Item Temperature
Body 40 to 60°C (104 to 140°F)
Trim strip 20 to 30°C (68 to 86°F)
Notice:
Do not heat the trim strip and body excessively.
Front Side
(c) Set the supplied clips in the positions as shown in the illus-
14 (0.551) tration and press-fit those clips by hand to install them.
Notice:
The installation of the trim strip should be carried out
when 30 minutes or more have passed after press-
Rear Side
21 (0.827) fitting the clips.
Hint:
mm (in.)
• Initial hardening time: 30 minutes
ALM091G • Perfect hardening time: 24 hours
Rocker Trim Panel LH

Replacement
Hint:
reverse order.
13-BODY.indd 43 2008-10-21 9:17:52

1. Remove rocker trim panel body LH

(b) Remove front cover and rear cover of the rocker trim panel
LH and the 2 bolts.
(c) Disengage the 6 clips and remove the moulding.
ALM092G
License Plate Lamp Trim Panel

Replacement
Hint:
verse order.
2. Remove license plate lamp trim panel assembly
(a) Remove the 2 nuts, 2 clips and 1 connecting bolt.
ALM093G
(b) Remove the 4 screws and back door opener switch and the 2
license lamps.
ALM094G
13-BODY.indd 44 2008-10-21 9:17:53

BODY BO-45
FUEL TANK DOOR

Fuel Tank Door Cable
Removal:
1. Open the luggage room.
2. Remove the luggage room trim panel.
3. Disconnect the cable from the filler cap.
4. Remove the B pillar lower seat belt bolt and the fixture.
5. Remove the clip of the fuel tank door cable.
6. Remove the bolt of the fuel tank door cable handle.
7. Disconnect the cable from the handle.
ALM095G 8. Remove the driver seat.
9. Remove the front and rear door trim panel LH and the
B pillar lower garnish LH.
10. Move the carpet LH away.
11. Remove the cable.
Installation:
1. Pull the cable through the luggage room to the passen-
ger room.
2. Put the carpet LH back.
3. Install the front and rear door trim panel LH and the B
pillar lower garnish LH.
4. Install the driver seat.
5. Connect the cable to the handle. Pay special attention
that the contact of different metals can speed up the
corrosion. Use the right fastener to avoid early corro-
sion.
6. Install the bolt of the fuel tank door cable handle.
7. Install the clip of the fuel tank door cable.
8. Install the B pillar lower seat belt fixture with the bolt.
Tighten the bolt of the lower B pillar seat belt fixture.
9. Connect the cable to the filler cap.
10. Install the luggage room trim panel.
11. Close the luggage room.
13-BODY.indd 45 2008-10-21 9:17:53

MEMO
13-BODY.indd 46 2008-10-21 9:17:53

EWD-
ELECTRICAL WIRING DIAGRAM
GENERAL INFORMATION OF ELECTRICAL SYSTEM

Glossary of Terms and Symbols....................................... EWD-3
Illustrations Description for Electrical System................... EWD-6
Precaution for Circuit Checking and Repairing................. EWD-8
Circuit Checking and Repairing Procedure....................... EWD-8
GROUND POINT
Ground Point Definition and Position Diagram................. EWD-9
MAIN ELECTRICAL ELEMENT MODULE

Main Electrical Element Module Position Diagram........... EWD-11
Driver Cab Fuse Block (No.1 Fuse Block)........................ EWD-13
Engine Room Fuse Block (No.2 Fuse Block).................... EWD-14
WIRING DIAGRAM
Engine Room Wire Harness............................................. EWD-15
Instrument Wire Harness.................................................. EWD-16
Back Door Wire Harness.................................................. EWD-17
Front Door Wire Harness LH............................................ EWD-18
Rear Door Wire Harness LH............................................. EWD-18
Floor Wire Harness........................................................... EWD-19
Vehicle Body Wire Harness.............................................. EWD-20
CONNECTORS
Wire Connector and Connector Number Diagram............ EWD-21
Wire Connector Terminal Function Diagram..................... EWD-23
Connector List................................................................... EWD-29
EWD
1-ELECTRICAL WIRING DIAGRAM.indd1 1 2008-10-21 10:39:25

EWD-
OVERALL ELECTRICAL WIRING DIAGRAM

Power Source and Starter Circuit..................................... EWD-35
Airbag Circuit.................................................................... EWD-36
ABS Circuit ...................................................................... EWD-37
Combination Meter Circuit................................................ EWD-38
Air Conditioner, Defogger System Circuit ........................ EWD-39
Wiper, Washer Motor System Circuit................................ EWD-40
Power Mirror Circuit ......................................................... EWD-41
CD System Circuit............................................................. EWD-42
Electric Injection ECU Control System Circuit ................. EWD-43
Lights, Signal Alarm System Circuit.................................. EWD-44
Central Control Lock,
Glass Regulator System Circuit........................................ EWD-45

ELECTRICAL WIRING DIAGRAM EWD-
GENERAL INFORMATION OF ELECTRICAL SYSTEM

Glossary of Terms and Symbols
Great Wall vehicle wiring diagram uses these symbols as shown in the illustration below.
Battery Ground
Stores chemical energy The point at which the
and converts it into electri- power source negative
cal energy. Provides direct lead connected to the body,
current for the various cir- thereby providing a return
cuits of vehicle. path for the circuit; without
a ground, current cannot
flow.
Capacitor (Condenser) Engine speed sensor
A small holding unit for Detects the speed of the
temporary storage of elec- crankshaft and provides
tricity. ignition timing and work
sequence as standard sig-
nal to ECU.
Cigarette lighter Knock sensor
An electric resistance heat- The knock sensor mounted
ing element. on cylinder block detects
engine knocking and sends
it to ECU. ECU adjusts the
angle of ignition advance
according to this signal.
Circuit breaker Horn
Basically a reusable An electric device which
switch, a circuit breaker sounds a loud audible sig-
will heat and open if nal.
too much current flows
through it. Some units
automatically reset when
cool, others must be manu-
ally reset.
Diode Ignition coil
A semiconductor which Converts low-voltage DC
allows current flow in only current into high-voltage
one direction. ignition current for firing
the spark plugs.
Zener diode Light
A diode which allows cur- Current flowing through
rent flow in one direction a filament causes the fila-
but blocks reverse flow ment to heat up and emit
only up to a specific volt- the light.
age. Above that potential,
it passes the excess volt-
age. It acts as a simple
voltage regulator.

EWD- GREAT WALL COOL BEAR REPAIR MANUAL
Photodiode LED (light emitting diode)

The photodiode is a semi- Upon current flow, these
conductor which controls diodes emit light without
the current flow according producing the heat of a
to the strength of light. comparable light, which
is different from the other
lights.
Pump Analog meter
A device for sucking and Current flow activates a
discharging gas or liquid. magnetic coil which causes
a needle to move, thereby
providing a relative dis-
play against a background
calibration.
Fuse Digital meter
A thin metal strip which Current flow activates one
burns through when or many LED’s, LCD’s, or
too much current flows fluorescent displays, which
FUEL
through it, thereby stop- provide a relative or digital
ping current flow and display.
(For Medium Current protecting a circuit from
Fuse) damage.
Fusible link Motor
A heavy-gauge wire placed A power unit which con-
in high amperage circuits verts electrical energy into
which burns through on M
mechanical energy, espe-
(For High Current Fuse overload to protect the cir- cially for rotation.
or Fusible Link) cuit. The numbers indicate
the cross section surface
area of the wires.
Relay Speaker
Basically, an electrically An electromechanical de-
1. Normally operated switch which vice which creates sound
closed may be normally closed (1) waves from current flow.
or opened (2).
Current flowing through a Manual switch
2. Normally
small coil creates a mag- Opens and closes circuits,
open
netic field which either thereby stopping (1) or al-
opens or closes an attached 1. Normally open lowing (2) current flow.
switch.
Double throw relay
A relay which passes cur-
rent through one set of 2. Normally closed
contacts or the other.

Resistor Double throw switch

An electrical component A switch which continuous-
with a fixed resistance, ly passes current through
placed in a circuit to re- one set of contacts or the
duce voltage to a specific other.
value.
Tapped resistor Ignition switch
A resistor which supplies A key operated switch with
two or more different non several positions which
adjustable resistance val- allows various circuits,
ues. particularly the primary
Variable resistor or rheostat ignition circuit, to become
A controllable resistor operational.
with a variable rate of re-
sistance.
Also called a potentiom-
eter or rheostat.
Sensor (thermistor) Wiper park switch
A resistor which varies its Automatically returns wip-
resistance with tempera- ers to the stop position
ture. when the wiper switch is
turned off.
Speed sensor Transistor
Changes according to the A solidstate device typi-
1 2 shape of the teeth by the cally used as an electronic
field magnetic flux of the relay; stops or passes cur-
induction coil, so induces rent depending on the volt-
alternate signal on the in- age applied at “base”.
duction coil.
Short pin Wires
Used to provide an unbro- Wires are always drawn
ken connection within a as straight lines on wiring
junction block. (1) Not connected diagrams.
Crossed wires (1) without
Solenoid Valve a black dot at the junction
An electromagnetic coil are not joined.
which forms a magnetic Crossed wires (2) with a
field when current flows. (2) Spliced black dot or octagonal ()
mark at the junction are
spliced (joined) connec-
tions.

Illustrations Description for Electrical System

1. Configuration instructions
There are three configurations for the Great Wall COOL BEAR vehicle: Comfort, Luxury and Elite model. The
wire harness is divided into 2 types, The one is called non-jam-protection comfortable model for comfort and
luxury model, and the other is called elite type for elite type. These two configurations are commonly used in the
most content of the manual. The part contents only for non-jam-protection comfortable model has been marked
in the manual, please note the difference when repairing.
2. Fuse block and power source description
30
30a
30b
X
15a
8A
W
0.5 IG1
Theft 85 30
Deterrent
ECU6
Relay
F04 8C
W
F33 86 87
To ABS 15A 0.5 15A 908E
ECU#1 7
B
0.5
15
11 8 6 10 Br
RG W G Y 2.0 15b
1.25 1.25 0.5 2.0
Terminal 1 2 3 4 5 6
F24 F30
AM1 1G1 ACC ST2 AM2 IG2
Ignition Switch
Position 10A 25A

LOCK
4 600 3 5
R R R R ACC
8.0 4.0 8.0 10.0 ON
ABS F29
START
Motor 30A
12
WG
40A 0.5
ALN001G
The left fuse block inside instrument panel is driver cab fuse block, and the left fuse block inside engine room is
engine room fuse block.
• 30a stands for normal power wire, which comes from battery positive fuse block — 60 A.
• 30b stands for normal power wire, which comes from battery positive fuse block — 120 A.
• 30c stands for normal power wire, which comes from battery positive fuse block — 120 A.
• 15a stands for small-capacity electrical power wire, which is supplied by IG relay when ignition switch is
“ON”.
• 15b stands for small-capacity electrical power wire, which is supplied directly by ignition switch IG2 when
ignition switch is “ON”.
• X stands for small-capacity electrical power wire, which is supplied by ACC relay when ignition switch is
“ACC”.

3. Connector terminal
The connector terminal number is based on cord and the plug-ins towards wire intering direction. Plugs are
numbered from left to right, and socket are from right to left.
2
1 Protector View 1
2
Protector View
3
4 Direction 3
4
Direction
Connector Terminal Number Connector Terminal Number

ALN002G
4. Disconnection of the connector

Only pull the connector itself to disconnect the connector and do not pull the wire harness.
Hint:
First check which type of connectors to be disconnected before disconnection.
ALN003G
5. The color and section of lead (mm2)

B—Black W—White R—Red Bl—Blue Br—Brown Y—Yellow
G—Green P—Pink Or—Orange V—Purple Lg—Aqua Gr—Gray
In addition: Double-Color wire is indicated by adding a tilted line (/) between the letters which stand for two
colors. The letter before (/) indicates main color, and the one behind (/) indicates assistant color.
For example: 0.5 Bl/R indicates that the main color of the lead is blue and the assistant color is red. Sectional
area is 0.5 mm2.

Precaution for Circuit Checking and Repairing

1. Always set the ignition switch in LOCK position, and then disconnect the negative battery cable before
operating any electrical equipment or when the tools and repair equipments easily contact the electri-
cal terminal. Disconnecting this cable can avoid injuring or damaging the vehicle. When ignition switch
is in ON position, do not remove the battery connecting wire or pull the power fuse off whether the en-
gine is running or not. Otherwise, the microelectronic device such as ECU and other correlative sen-
sors may be severely damaged.
2. When replacing the fuse, make sure the new fuse has the right rated current value, and do not exceed
or under this rated value.
3. Only specified tester and lead can be used when repairing airbag and pretensioner wire.
4. Before repairing the wire, the factors, which can cause damage, such as sharp edge of body, dam-
aged or rusty electrical devices must be eliminated firstly.
5. Shielded lead is not allowed to be repaired, but renewed wholly when damaged.
6. ECU and sensor cannot be tested with needle type multimeter unless it is specially indicated while
testing. It should be tested with a high impedance digital multimeter (Internal resistance ≥ 10 kΩ) or
vehicle-use multimeter.
7. When checking the connector with a digital multimeter, remove the waterproof rubber boot on the con-
nector, and insert the meter pen along the wiring terminal. Do not apply excessive force in order to
prevent the damage of connector.
Circuit Checking and Repairing Procedure
The essential point of troubleshooting is the confirmation of “Potential cause”. The checked components can be limit-
ed in those components which have relationship with the potential cause as soon as the potential cause is determined.
The confirmation of potential cause should be based on the theory and facts, but not only by intuition. If trying to
solve the problem but not take proper troubleshooting procedure, the symptom may become more complex, thereby
the cause cannot be properly determined, and repair cannot be done accurately. Follow the 4 procedures bellow dur-
ing troubleshooting:
1. Observe the symptom carefully, and check whether other abnormal symptom exists and take note.
2. The circuit diagram must be researched when determining the potential cause, in order to analyze
properly it is necessary to learn the circuit as a system, master the knowledge of switch, relay and
other electrical element.
3. Troubleshooting by checking step by step until the reason is found out.
4. After troubleshooting, make sure the checked system works normally, and check whether new prob-
lems has been caused or not due to repairing.

GROUND POINT
Ground Point Definition and Position Diagram
Body ground point is the position where ground wire and body connected. The bolt fixes the ground wire to body
steel plate through the hole on the end of ground wire and the nut on body steel plate.
The position of ground point is shown as the diagram:
G02 G01 G03
G05 G04
G06
G07
G08
ALN004G

EWD-10 GREAT WALL COOL BEAR REPAIR MANUAL
G09
ALN005G
No. Ground position Note

G01, G02 Engine room fender LH inside Engine room wire harness
G03 Engine room fender RH inside Engine room wire harness
G04, G05 Below A pillar wire holder RH Engine, instrument panel wire
harness
G06 Below A pillar wire holder LH Instrument wire harness
G06 Above instrument panel reinforcement member Instrument wire harness
G07 Rear fender trim LH Vehicle body wire harness
G08 Rear fender trim RH Vehicle body wire harness
G09 Near rear wiper motor Back door wiring harness assembly

ELECTRICAL WIRING DIAGRAM EWD-11
MAIN ELECTRICAL ELEMENT MODULE

Main Electrical Element Module Position Diagram
Main electrical element module contains driver cab fuse block, engine room fuse block, engine ECU, airbag ECU,
theft deterrent ECU, central lock controller and back-up radar ECU. The position of main electrical element module is
shown in the diagram:
ABS ECU Anode Fuse Block

Engine
Room
Fuse
Block
ALN006G

Central Lock Controller
Theft Deterrent
ECU
Engine ECU
No.1 Fuse Block
Airbag ECU
ALN007G
Back-up Radar ECU
ALN008G

Driver Cab Fuse Block (No.1 Fuse Block)

Fuse block: There are more and more various relays and fuses as the electrical equipments increase gradually. Various
relays and fuses are installed on one or a few switchboards, which has plugs on its face, and has connection socket on
its backside. And such switchboard and its cover are called fuse block.
J01 J02 J04 J05 J06 J07

Horn Relay J03
Position Light Relay Blower High-speed Relay Reserved Door Window Relay Blower Relay
(Reserved) Flasher Relay
Hazard Warning
Position Light
Turn Light
Reserved
Reserved
S/B1 S/B2 S/B3 S/B4

AM1
Horn
F01
F02
F03
F04
F05
F06
F07
Reserved Door Window Reserved Blower

Front Fog Rear Fog
Light Relay Light Relay Compressor Relay ACC Relay IG Relay Rear Wiper Relay Defrosting Relay
Rear Fog Light
Front Fog Light
Compressor
Rear Wiper
Defrosting
J08 J09 J10 J11 J12 J13 J14
F08
F09
F10
F12
F11
Rear View Mirror
Cigarette Lighter
Back-up Lamp
Combination
Control Lock
Reserved
Brake Lamp
Seat Heater
Front Wiper
Illumination
Instrument
CD Player
Reserved
Reserved
Charging
Central
Interior
S/B5
Airbag
Roof
ABS
F13
F14
F15
F16
F17
F18
F19
F20
F21
F22
F23
F24
F25
F26
F27
F28
ALN009G
Number Name Fusing current Number Name Fusing current Number Name Fusing current
J1 Horn relay F03 Position light 10 A F19 Reserved
J2 Position light relay F04 AM1 15 A F20 Reserved
J3 Flasher relay F05 Reserved F21 Cigarette lighter 25 A
J4 Blower high-speed relay F06 Hazard Warning 15 A F22 Rear view mirror 15 A
J5 Rear A/C relay F07 Turn light 10 A F23 Front wiper 15 A
J6 Door window relay F08 Front fog light 15 A F24 Charging 10 A
J7 Blower relay F09 Rear fog light 10 A F25 ABS 10 A
J8 Front fog light relay F10 Compressor 10 A F26 Airbag 10 A
J9 Rear fog light relay F11 Rear wiper 10 A F27 Seat heater 20 A
J10 Compressor relay F12 Defrosting 25 A F28 Back-up lamp 10 A
J11 ACC relay F13 Combination instrument 10 A S/B1 Reserved
J12 IG relay F14 Interior illumination 10 A S/B2 Door window 30 A
J13 Rear wiper relay F15 Central control lock 20 A S/B3 Reserved
J14 Defrosting relay F16 Brake lamp 10 A S/B4 Blower 40 A
F01 Horn 15 A F17 CD player 15 A S/B5 Reserved
F02 Reserved F18 Roof 15 A

Engine Room Fuse Block (No.2 Fuse Block)
86 86
86 402
BrB1 30 87 97
0.5
30 87 212
WR
GB
0.5
213 214 0.5 95 96
87a 401
400 B1 WB1 Br GrB
30 BR RW 87 0.85 0.85 1.25 1.25
2.0 2.0
401G 95A
RW Br
0.5 0.5
400
85 BR 85 85
0.5
Main Relay Oil Pump Relay Horn Relay
86
86 30 87 427
YG
10A Back-up 15A Back-up 25A Back-up 0.5
424 425
R RG
30 87 424 467 3.0 3.0
213 95 601
R RB1
87a B1 BrR RB
3.0 3.0
401H
0.85 1.25 2.5 RW
0.5
10A 15A 25A Reversed Reversed 30A
3 85
R
Low-speed Fan Relay
Engine 8.0
85 F31 F35 F39 F32 F34
Room Low-speed High-speed
Oil Pump Horn ABS
Power 2 Fan Relay Fan Relay
Back-up
Main High Low Engine 86

Starter Relay AM2
Relay Beam Beam ECU 30 87
F29 426
F40 F30 F36 F37 F38 OrB1
4 467 428 0.5
R RB1 WR
8.0 3.0 3.0
Engine Room 30A Blank 15A 25A 15A 15A 10A
Power 1 401I
RW
17 10 400 400A 30 31 418
BR Y RW RB1 R 0.5
BR + BR
2.0 2.0 2.0 0.5 2.0 2.0 0.85 85
High-speed Fan Relay
A12 A5 86 86 85 86 85 86 87a 85
66 426 402
A16 RB1 OrB1 A9 BrB1 A1
0.5 0.5 15 0.5
30 87 13 34 30A 35 31A
WV RY RW RG RB1
Bw
212 0.5 0.5 0.5 0.5 0.5
2.0 17 15
GB
0.5 BR BW 32 33
67D 214 418 2.0 2.0 87 R 87 RB 87
GV WB1 R 12 2.0 2.0
401
0.5 0.85 0.85 WG
RW 30 31
0.5
400A 421 2.0 13A 427 30 RW 30 RB1 30
A19 BR BrG WV YG A4 85 2.0 2.0
0.5 0.5 A11 0.5 0.5
A22 A20 Starter Relay Starter Relay Low Beam Relay Back-up
To Engine Wire Harness
ALN010G
Fusing Fusing Fusing

Number Name current Number Name current Number Name current
J1 Main relay J9 Low beam relay F36 High beam 15 A
J2 Oil pump relay J10 Back-up relay F37 Low beam 15 A
J3 Horn relay F29 Starter relay 30 A F38 Engine ECU 10 A
J4 Back-up relay F30 Main relay 25 A F39 ABS 25 A
J5 Low-speed fan relay F31 Oil pump 15 A F40 AM2 15 A
J6 High-speed fan relay F32 Low-speed fan relay 30 A F41 Back-up 10 A
J7 Starter relay F34 High-speed fan relay 30 A F42 Back-up 15 A
J8 High beam relay F35 Horn 15 A F43 Back-up 25 A

WIRING DIAGRAM
Wiring diagram is the circuit diagram which is drawn according to the layout of the vehicle wiring harness on the
vehicle and the concrete connection condition of each branch lead end. Wiring diagram is mainly used to indicate the
connection position of each electrical devices and the shape and position of the connectors.
Engine Room Wire Harness
Brake Fluid Level Switch Front Wiper Motor to Body Wire

Brake Lamp Switch Instrument Wire Harness A Harness
Instrument Wire
Harness B
Right Ground Point

to Battery
Positive Lead
Clutch Switch
Front Speed
Sensor RH Combination
Combination Headlamp LH
Headlamp RH
Front Turn
Front Turn Light LH
Light RH
ABS ECU
Headlight Height
Adjusting Motor RH
Headlight Height
Low Pitched Horn
Adjusting Motor LH
Rear Washer Motor
Front Washer Motor
Front Fog Light RH Condenser Fan Radiator Fan High Pitched Horn Front Fog Light LH
ALN011G

10:39:43
2008-10-21
ALN012G
CD Player Combination Instrument
Reading Theft Deterrent
Ignition Switch Lamp Indicator Antenna HAVC1 Passenger Airbag Front Tweeter
No.1 Fuse Block
Assembly B18
Ground Point
Outside Power
Mirror Switch
Engine Wire
Harness No.1
GREAT WALL COOL BEAR REPAIR MANUAL
A Pillar Tweeter
Interior Illumination Engine Wire
Instrument Wire Harness
Switch Harness No.2

No.1 Fuse Block
Assembly E8
Outside Power
Mirror Switch HAVC2
No.1 Fuse Block
Assembly H
No.1 Fuse
Block Assembly D16
Front Door
No.1 Fuse Wire Harness
Block Assembly A20
Theft Deterrent ECU Ground
Point
Combination
Switch LH Electronic
Accelerator
Combination
Switch RH
Airbag ECU
Diagnosis
Connector
Backup
16
Clock Spring Power
1-ELECTRICAL WIRING DIAGRAM.indd16

Front Ground Ignition Switch A/C Controller Cigarette Lighter Cigarette Lighter
EWD-16
Door LH Point Illumination No. 2 Illumination

A/C Controller A/C Controller
No.1 No.3
Back Door Wire Harness

to Body Wire Harness B to High-mounted Brake Lamp
Body Wire Harness A to Defroster Positive Pole to Defroster Negative Pole
to Back Door Lock Ground Point Ground Point

to Rear Wiper to License Plate Lamp and Back Door Open Switch to Back Door Open Switch
ALN013G

Front Door Wire Harness LH

to Front Window Switch LH to Outside Power Mirror LH
to Front Door to Front Door to Front Door to Instrument Panel to Instrument Panel Wire
Lock LH Glass Regulator LH Speak LH Wire Harness B Harness A ALN014G
Rear Door Wire Harness LH
to Rear Window
Switch
to Rear Door Glass

Regulator LH
to Rear Door
Lock Motor LH
to Body Wire Harness
ALN015G

to Front Door Light Switch LH Body Wire Harness Assembly

to Rear Door Wire Harness LH Ceiling Lamp to Belt Switch to Instrument Panel Wire Harness
to Driver Side
19
Belt Pretensioner
to Engine Room
Wire Harness
to Rear Door
Light Switch LH
to Back-up Radar
Controller
Ground Point
to Rear Speed
Sensor LH
to Seat Heater
Switch LH or RH
to Rear Combination
Lamp LH
Floor Wire Harness
ELECTRICAL WIRING DIAGRAM
to Parking Brake Switch to Belt Switch
to Rear Door Light

Switch RH
to Back Door Wire Harness LH to Rear Door Wire

Harness RH
to Rear Body Wire Harness

to Seat Belt
Pretensioner
to Rear Combination Lamp RH Ground Point to Rear Speed Sensor RH
Oil Pump D Pillar Mid-Low Tone Speaker to Rear Door Light Switch LH or RH
ALN016G
EWD-19
2008-10-21
10:39:45
10:39:47
2008-10-21
ALN017G
Rear Door Wire Harness Back Door Wire Harness Assembly
Assembly RH
Defroster Positive Pole
Wire Harness Assembly
Instrument Panel
Wire Harness Assembly Rear Body Wire
Harness
GREAT WALL COOL BEAR REPAIR MANUAL
Front Door Wire

Vehicle Body Wire Harness
Harness Assembly LH
Defroster Ground Wire
Harness Assembly
Engine Wire
Harness Assembly
20
EWD-20
Battery Ground Wire Engine Room Wire Front Door Wire Body Wire Harness Rear Door Wire Harness
Harness Assembly Harness Assembly Harness Assembly LH Assembly Assembly LH
Condenser Fan Motor
to Low Tone
to Combination
Horn
21
Headlamp LH to High Tone Horn
Radiator Fan Motor
to Front Turn Light RH
to Front Fog Light LH Engine Ground
to Front Turn
Light LH Battery Negative Pole to Combination Headlamp RH to Front Fog Light RH
Body Ground to Generator
Battery to Generator Output
to Compressor to Rear Washer Motor
Battery Positive Pole to Back-up Switch
Front Oxygen Sensor Rear Oxygen
Sensor Oil Pressure Switch
to A/C Pressure Switch
Generator to Battery to Front Washer Motor
to Front Speed Positive Pole
to Ignition Coil to Intake Air Temperature to Phase Sensor
C01
Sensor LH to Coolant Temperature Pressure Sensor
Sensor
Starter to Battery Positive Pole to Front Speed Sensor RH
to Injection Nozzle for
Cylinder No.4
to ABS ECU to Injection Nozzle for Cylinder No.2 Right Ground
to Engine Speed Sensor to Knock
to Injection
to Injection Nozzle for Cylinder No.1
Sensor 接第1缸喷油嘴
Left Ground to Vehicle Speed Sensor Nozzle for
Cylinder No.3 to Starter Excitation
to Electronic Throttle
to Clutch Canister Control Valve
C02
to Brake Switch to Brake Fluid Level Warning Switch to Starter
Lamp Switch
to Combination Instrument A
to Theft Deterrent Indicator to Central Lock Controller
(White) to Ground P1#
C10
C09
to CD Player to Ground P2#
C12
C11
C03
C04
C05
C06
C07
C08
to Front Wiper Motor to Antenna
to Engine ECU
Theft Deterrent ECU 1 to A/C Switch

to Ignition Switch Illumination Light
to Brightness to Ignition Switch (White) to A/C Temperature Passenger Airbag
Adjustment Switch
Sensor
C14
C13
C18
C19
to Outside Rear View Key Insert Detect Switch

Mirror Adjustment Combination Switch
Ground
Switch (White) RH (Wiper) to Accelerator Pedal Diagnosis to A/C Speed Regulator and Passenger
Connector Plate 3
Ground Plate 2 Seat Belt Reminder Indicator
Combination to Speed Regulating Resistor,
Ground Plate 1 Switch LH (Lamp)
Blower
C17
Ground Plate 4
C16
C15
to Main Airbag, Horn Switch
to Airbag ECU (Yellow)
Front Tweeter LH
Front Tweeter RH
Outside Power Front Door Glass
Mirror LH Regulator Motor LH to Cigarette Lighter (Illumination)
Front Door Glass
Regulator Motor RH Outside Power Mirror RH
to Glove Box Illumination light
Passenger Seat Belt Switch Front Door Glass

Regulator Switch RH
Front Mid-Low Tone
Speaker LH Driver Seat Belt Switch
Glass Regulator Main Switch,
to Cigarette Lighter Front Mid-Low Tone
Central Control Lock Main Switch
Passenger Central Speaker RH
Control Lock Switch
Front Door
Light Switch RH
to Parking Brake Switch
Front Door Lock Motor LH

Front Door Light Front Door Lock Motor RH
Switch LH C21
C20 Passenger Seat Belt Pretensioner
CONNECTORS
Driver Seat Belt Pretensioner

Rear Door Glass
Regulator Motor RH
Rear Door Glass

Regulator Motor LH
Rear Mid-Low Tone

Speaker RH
Rear Door Glass

Rear Mid-low Regulator Switch RH
Wire Connector and Connector Number Diagram
Tone Speaker LH Rear Door Glass

Regulator Switch LH
Rear Speed Sensor RH
Rear Speed Sensor LH
Rear Door Light Switch RH

Rear Door Lock Motor LH
Rear Door Light Switch LH
Rear Door Lock Motor RH
Ground Point A Fuel Pump, Fuel Sensor
Capacitor Ground Point B

Rear Room Inside Ceiling Lamp
On-board Power
Rear Combination
Light LH
C23
C22
to Left Sensor to Mid-left to Mid-right to Right Sensor

Rear Fog Light LH Sensor Sensor
Rear Combination Light RH
High-mounted Brake Lamp
Rear Wiper Motor

Rear Windshield Defroster "-"
Ground Point
Back Door Lock Motor

Rear Windshield Defroster "+"
License Plate Lamp and Back Door Open Switch

EWD-21
2008-10-21
10:03:06
Wire Connector Terminal Function Diagram
Terminal Function Diagram 1
C01
A5 A12
412 402 426 66
A1 WB1 BrB1 OrB1 RB1 A16 A12 A5
66 426 402 412
0.5 0.5 0.5 0.5 A9
15 A16 RB1 OrB1 BrB1 WB1 A1
BW 0.5 0.5 15 0.5 0.5
2.0 BW
A9 2.0
67D 418
418 67D GV R
401
R GV 0.5 0.85
RW
0.85 0.5 400A 421 13A 427
2.0
A19 BR BrG WV YG A4
427 13A 401 421 400A 0.5 0.5 A11 0.5 0.5
YG WV RW BrG BR
0.5 0.5 2.0 0.5 0.5
A4 A11 A19 A22 A20
A20 A22
to Engine Room Wire Harness to Engine Room Wire Harness
C02
5 5
R R
10.0 10.0
to Driver Cab Fuse Block to Engine Room Wire Harness
C03
46 80 42 464 41 41 464 42 80 46
A1 B1W B1Y B1 RW RB1 A8 A8 RB1 RW B1 B1Y B1W A1
0.5 0.85 0.5 0.75 1.25 1.25 0.75 0.5 0.85 0.5
280 47 47 280
A9 R B1R A20 A20 B1R R A9
2.0 0.5 0.5 2.0
A13 A13
to Driver Cab Fuse Block A-20 to Instrument Panel Wire Harness
C04
8A 908F 100 6 412 412 6 100 908F 8A

B1 W B P
303 90
G WB1 B7 B7 WB1 G
90 303
P B W B1
0.5 0.5 1.25 0.5 0.5 0.5 0.5 1.25 0.5 0.5
B1W RB1 RB1 B1W
160 908E 2.0 2.0 60 60 908E 160
B8 B1W B R B18 B18 R
2.0 2.0
B B1W B8
1.25 0.5 1.25 1.25 0.5 1.25
B11 B11
to Driver Cab Fuse Block B-18 to Instrument Panel Wire Harness

C05
202 251 385 166 602 602 166 385 251 202
C1 B1V WB1 R B1B PB C5 C5 PB B1B R WB1 B1V C1
0.5 0.5 252 0.75 0.5 0.85 0.85 0.5 0.75 252 0.5 0.5
RB1 RB1
164A 168 3.0 350A 169 169 350A 3.0 168 164A
C6 RG RB1 WR RY C14 C14 RY WR RB1 RG C6
0.85 0.85 0.75 0.85 0.85 0.75 0.85 0.85
C8 C8
to Driver Cab Fuse Block C-14 to Instrument Panel Wire Harness
C06
56 53 54 906E 52 52 906E 54 53 56
D1 GB GB1 GY B BY D6 D6 BY B GY GB1 GB D1
0.5 0.5 0.85 72 71 0.5 0.5 0.5 0.5 71 72 0.85 0.5 0.5
RW GW GW RW
55 11 0.5 0.85 0.85 0.5 11 55
D7 GB RG D16 D16 RG GB D7
0.85 1.25 1.25 0.85
D10 D10
to Driver Cab Fuse Block D-16 to Instrument Panel Wire Harness
C07
65 101 214
214 101 65
RW RW WB1
E1 WB1 RW RW E4 E4 0.85 1.25 0.85
E1
0.85 1.25 0.85
E5 E8 E8 E5
to Driver Cab Fuse Block E-8 to Instrument Panel Wire Harness
C08
5 5
R R
10.0 10.0
to Driver Cab Fuse Block H-1 to Instrument Panel Wire Harness

C09
55 54 603 65 602 32 352

1 GB GY YW RW RY R GB1 9 352 32 602 65 603 54 55
0.5 0.5 0.5 0.85 0.85 0.5 0.5 9 GB1 R RY RW YW GY GB 1
0.5 0.5 0.85 0.85 0.5 0.5 0.5
418 605 604 8E 41 71
10 R B1W YR W RB1 GW 18 71 41 8 604 605 418
0.5 0.5 0.5 0.5 1.25 0.5 18 GW RB1 W YR B1W R 10
0.5 1.25 0.5 0.5 0.5 0.5
to Instrument Panel Wire Harness A to Engine Room Wire Harness A
C10
162 161 160B 10 12 97

97 12 10 160B 161 162 8 B1R B1Y B1W Y WG WR 1
1 WR WG Y B1W B1Y B1R 8 1.25 1.25 1.25 2.0 0.5 0.5
0.5 0.5 2.0 1.25 0.85 1.25
413 35 34 165 167 163
163 167 165 34 35 413
16 B1 RG RY B1G B1Y WG 9
9 WG B1Y B1G RY RG B1 16 1.25 0.5 0.5 0.5 0.5 1.25
1.25 0.5 0.5 0.5 0.5 1.25
to Instrument Panel Wire Harness B to Engine Room Wire Harness B
C11
206 420 419 353 353 419 420 206

1 PY B1 P YB 4 4 YB P B1 PY 1
0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5
16 423 422 8 7C 60 60 7 8B 422 423 16

WB PB1 VB W Br R R Br W VB P WB
5 0.5 0.5 0.5 1.25 2.0 0.85 10 10 0.85 2.0 1.25 0.5 0.5 0.5 5
to Instrument Panel Wire Harness A to Instrument Panel Wire Harness A (White)
C12
214 465 357 350 355 61 909

909 61 355 350 357A 465 214 8 WB1 B1Or YB1 WR BrGr RW B 1
1 B RW BrGr WR YB1 B1Or WB1 8 0.85 0.5 0.5 0.5 0.5 0.5 1.25
1.25 0.85 0.5 0.5 0.5 0.5 0.85
212 207 430 439A 442 440 434A 441
441 434A 440 442C 439A 430C 207 212 16 GB RG Y BR RY BrY GrB1 VB 9
9 V GrB1 BrY RY BR Y YP GB 16 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5
0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.5
to Instrument Panel Wire Harness B to Engine Wire Harness B

C13
60 303 288A 307 309 302 282 282 302 309 307 288A 303 60
1 R B1W GrW RY B1W B1 B1R
8 8 B1R B1 B1W RY GrW B1W R
1
0.85 2.0 0.5 0.5 0.5 0.5 1.25 1.25 0.5 0.5 0.5 0.5 2.0 0.85
281 311 312 308 310 310 308 312 311 281
9 B1W RB Lg GY B1B 16 16 B1B GY Lg RB B1W 9
1.25 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 1.25
to Instrument Panel Wire Harness A to Front Door Wire Harness LH A (White)
C14
286 55B 283A 105 106 900

1 B1Y GB GW B1R B1W B 7 908 106 105 283A 55B 286
0.5 0.5 0.5 0.5 0.5 2.0 7 B B1W B1R GW GB B1Y 1
2.0 0.5 0.5 0.5 0.5 0.5
157B 158B 284 252A 153 151 154
OrG Or BrW RB1 PG PB PBr
8 0.5 0.5 0.5 0.5 0.5 0.5 0.5 14 154 151 153 252A 284A 158B 157B
14 PBr PB PG RB1 BrW Or OrG 8
0.5 0.5 0.5 0.5 0.5 0.5 0.5
to Instrument Panel Wire Harness to Front Door Wire Harness LH B
C15
61 115 288C 312 311 282C 116

1 RW B1G GrW Lg RB B1R B1B 10
0.5 0.5 0.5 0.5 0.5 1.25 0.5 82C 116 282C 311 312 80 288C 115 61
10 B1R B1B B1R RB Br-Gr B1Y GrW B1G RW 1
391 392 117 118 281 71 46 55 54 0.5 0.5 1.25 0.5 0.5 0.5 0.5 0.5 0.5
Y YB B1Or B1Y B1W Lg B1W GB GY
11 0.5 0.5 0.5 0.5 1.25 0.5 0.5 0.5 0.5
20 54 55 46 71 281 118 117 392 391
GY GB B1W Lg B1W B1Y B1Or YB Y
20 0.5 0.5 0.5 0.5 1.25 0.5 0.5 0.5 0.5
11
to Instrument Panel Wire Harness A to Body Wire Harness

C16
307 308 361 168 169 164A 389 390 354 292 291
291 292 354 390 389 164A 169 168 361 308 307 11 RY GY WR RB1 RY RG G GB WB1 BB1 B1Y 1
1 B1Y BB1 WB1 GB G RG RY RB1 YR GY RY 11 0.5 0.5 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.5 1.25
1.25 0.5 0.5 0.5 0.5 0.85 0.85 0.85 0.85 0.5 0.5 654 351 252 413 356 84 83 350B 303A 302
RG WG RB1 B1 YW RW YG WR B1W B1
302 303A 350B 83 84 356 413 252 351 654 22 0.5 0.5 2.0 1.25 0.5 0.5 0.5 0.5 2.0 0.5
12
12 B1 B1W WR YG RW YW B1 RB1 WG RG 22
0.5 2.0 0.5 0.5 0.5 0.5 1.25 2.0 0.5 0.5
to Body Wire Harness A

to Instrument Panel Wire Harness B to Body Wire Harness B
C17
1 618 616 2
GV GR 2 616 618 1
GR GV
0.5 0.5
0.5 0.5
617 67 615 615 67 617
3 GB1 GV GB 6 6 GB GV GB1
3
0.5 0.5 0.5 0.5 0.5 0.5
to Body Wire Harness to Engine Room Wire Harness
C18
1 303 288B 309 302 282 8

B1W GrW B1W B1 B1R
8 282 302 309 288B 303 1
2.0 0.5 0.5 0.5 1.25 B1R B1 B1W GrW B1W
281 310 1.25 0.5 0.5 0.5 2.0
9 B1W B1B 16 310 281
1.25 0.5 16 B1B B1W 9
0.5 1.25
to Instrument Wire Harness A to Front Door Wire Harness RH A
C19
54B 283 107 108 908

157A 158A 284B 252B 153 155 152
1 GY GW B1 B1V B 7
0.5 0.5 0.5 0.5 2.0 8 OrG
0.5
Or
0.5
BrW
0.5
RB1
0.5
PG
0.5
PB1
0.5
PY
0.5
14
157A 158A 284B 252B 153 155 152
54B 283B 107 108 908
8 OrG Or BrW RB1 PG PB1 PY 14 GY GW B1 B1V B
0.5 0.5 0.5 0.5 0.5 0.5 0.5 1 0.5 0.5 0.5 0.5 2.0
7
to Instrument Wire Harness B to Front Door Wire Harness RH B

C20
302 308 307

3 B1 GY RY 1
307 308 302
1 RY GY B1 3 0.5 0.5 0.5
0.5 0.5 0.5 282 303 987 288C 281
281 288C 987 303 282 8 B1R B1W B GrW B1W

4
1.25 2.0 2.0 0.5 1.25
B1W GrW B B1W B1R
4 8
1.25 0.5 2.0 2.0 1.25
to Body Wire Harness to Rear Door Wire Harness LH
C21
3 302 312 311 1

B1 Lg RB
1 311 312 302 3 0.5 0.5 0.5
RB Lg B1
0.5 0.5 0.5
282 303 988 288D 281

281 288D 988 303 282 8 B1R B1W B GrW B1W 4
B1W GrW B B1W B1R 1.25 2.0 2.0 0.5 1.25
4 1.25 0.5 2.0 2.0 1.25
8
to Body Wire Harness to Rear Door Wire Harness RH
C22
169 168 84 164A

4 RY RB1 WR RG 1
164A 84 168 169 0.85 0.85 0.5 0.85
1 RG RW RB1 RY 4
0.85 0.5 0.85 0.85
to Body Wire Harness A to Back Door Wire Harness A
C23
900 291
291 900 B B1Y
1 B1Y B 2 2 1.25 1.25 1
1.25 1.25
71D 292 252 67E

67E 252 292 71D Lg BB1 RB1 GV
3 GV RB1 BB1 Lg 6 6 0.5 0.5 2.0 0.5 3
0.5 2.0 0.5 0.5
to Body Wire Harness B to Back Door Wire Harness B

Connector List
Power Source and Starter System
1 3
11 8 8A 6 16 8A 400A
1 RG W +W G 3 WB W BR
1.25 1.25 0.5 0.5 0.5 0.85 0.5
12 10 7
4 WG Y Br 6
0.5 2.0 2.0
Ignition Switch Engine Regulator
Airbag, ABS System
382 381 383 384 392 389 390 386 906 385
1 B1Y B1R B1W B1B YB G GB B1G B R 25
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.75 0.75
391 603 393
26 Y YW Br 50
0.5 0.5 0.5
Airbag ECU (Yellow)
612 611 614 613

2 YR YB 1 2 YW YB1 1
0.5 0.5
12 11 10 9 8 7 6 5 4 3 2 1
0.5 0.5
13 613 605
BrB1 B1Y 600
903
0.5 0.5 R
B 611 615 618 614 603 604 4.0 Front Speed Front Speed
4.0 24 BrB GB GW BrW YW YR 14
0.5 0.5 0.5 0.5 0.5 0.5
601
Sensor LH Sensor RH
903A 612 616 602 617 67A 421
RB
B BrR GR RY GB1 GV BrG
2.5
2.5 0.5 0.5 0.85 0.5 0.5 0.5
37 36 35 34 33 32 31 30 29 28 27 26 616 615 618 617
38 25 2 GR GB 1 2 GV GB1 1
0.5 0.5 0.5 0.5
ABS ECU Rear Speed Rear Speed

Sensor LH Sensor RH
389 390 391 392

905 905A 603
1 B B YW 8
1 G GY 2 1 Y YB 2
0.5 0.5 0.5 1 97 381 382 4 0.5 0.5 0.5 0.5
418 WR B1R B1Y
9 R 16 0.5 0.5 0.5
0.5
Main Airbag
Diagnosis Connector Driver Seat Belt Passenger Seat Belt

Pretensioner Pretensioner

Combination Meter
54C 422 32 252D 55C 41 605 352 16 423 386 354 81 351 604 353 46
GY VB RY R-B1 GB RG B1Y GB1 WB PB1 B1G WB1 RB1 WG YR YB B1W
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
906A 350A 464 906 358 603 420 357 419 356 355 73A 71F
B WR RW B BrB1 YW B1 YB1 P YW BrGr GB Lg
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
to Combination Meter A
1 2
352 911
1 2
GB1 B
354 911
0.5 0.5
WB1 B
0.5 0.5
Driver Seat Belt Switch Brake Fluid Level Warning Switch
Air Conditioner, Defogger System
1 3
1 4 906C
B
207
RG
201B
RB1
52 252C 906B 251 0.5 0.5 0.5
BY RB1 B WB1
0.5 0.5 0.5 0.5
906 202 361 73C

1 B B1V WR GB 5
3.0 0.5 0.5 0.5
Rear Defogger and

A/C Switch 6
204 205 203
10
Hazard Warning Switch B1Y
2.0
B1R
1.25
B1W
3.0
201A
1 2 1 RB1 2
3.0
to A/C Speed Regulator and Passenger
Seat Belt Reminder Indicator
350B 361
203 906A 205 204
WR WR
0.5 0.5
3 B1W B B1R B1Y 6
3.0 0.85 1.25 2.0
Passenger Seat Belt Switch to Speed Regulating Resistor, Blower

Electric Injection ECU Control System
404 405 419 418 8B 402 450 440 435 432 448 449 67D 206
6 B1W B1R P R W BrB1 PY BrY GrR Gr GrY B1Y GV PY

24 5 4
0.85 0.85 0.5 0.85 0.85 0.5 0.85 0.5 0.85 0.5 0.5 0.5 0.5 0.5
480 483
433 403 431 422 423 442 434 451 439 430 436 444 438 441 437 RB1 RG
25 WR B1G WB1 VB PB1 RY GrB1 B1Y BR Y BrR Lg B1V V VW 43 2.0 2.0
0.85 0.85 0.85 0.5 0.5 0.85 0.85 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5
913
B 3
2.0
401L 401M 407 406 479 427 915 916 443 429 211 66 357A 911
RW RW PY B1B W YG B B PB1 GrB1 B1R RB1 YB1 B 482 481
44 0.85 0.85 0.85 0.85 0.85 0.5 0.85 0.85 0.75 0.5 0.5 0.5 0.5 0.85
62 RW RB
2.0 2.0
401N 446A 446B 447A 447B 426 212 412 465 421 442A 13A 240 476 445 411 912
63 RW B1R B1R GrB GrB OrB1 GB WB1 B1Or BrG RY WV B1W PB BY B1B B 81 2 1
0.85 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.5 0.85 0.5 0.5 0.5 0.75 0.5 0.85
Engine ECU
1 2 1 2 1 2 1 2
401A 403 401B 404 401C 405 401D 406
RW B1G RW B1W RW B1R RW B1B
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85
Injection Nozzle for Cylinder No.1 Injection Nozzle for Cylinder No.2 Injection Nozzle for Cylinder No.3 Injection Nozzle for Cylinder No.4
1 2 1 2 3 4
1 4 1 ４ 401K 433 430B 432
435 437 434B 436 917 411 401F RW WR Y Gr
401E 407 0.85 0.85 0.5 0.5
GrR VW GrB1 BrR B B1B RW
RW PY
0.85 0.5 0.85 0.5 0.5 0.5 0.5
0.85 0.85
Intake Air Temperature Pressure Sensor Phase Sensor Canister Control Valve Front Oxygen Sensor
2
355 1 2
BrGr 1 2 3 4
0.5
448 449 401J 431 430A 429
439C 438 904B 425A RW WB1 Y GrB1
GrY B1Y
B RG
BR B1V 1 2.0 2.0
2 0.5 0.5 0.85 0.85 0.5 0.5
0.5 0.5
1 3
Coolant Temperature Sensor Condenser Fan Motor Knock Sensor Rear Oxygen Sensor
1 3 1 3 1 3 1 3
950 7D 480 960 7E 481 970 7F 482 980 7G 483
B Br RB1 B Br RB B Br RW B Br RG
2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0 2.0
to Ignition Coil to Ignition Coil to Ignition Coil to Ignition Coil

for Cylinder No.1 for Cylinder No.2 for Cylinder No.3 for Cylinder No.4
240
B1W 1 905 905A 603 465
356 907 0.5
1 YW B 1 B B YW B1Or 8
0.5 0.5
3 914 211 0.5 0.5 0.5 0.5
2 B B1R 3 418
413 907B 0.5 0.5
4 B1 B
5 9 R 16
207 0.5
1.25 1.25
YP 4
0.5
Fuel Pump, Fuel Sensor A/C Pressure Switch Diagnosis Connector
1 3 447 445 442B
350 901 357 1 2 1 GrB BY RY 3

0.75 0.75 0.5
WR B YB1 450 451 446 444 443
0.5 0.5 0.5 PY B1Y
0.85 0.85
4 B1R Lg PB1 6
0.75 0.5 0.75
Vehicle Speed Sensor Engine Speed Sensor Electronic Throttle

Wiper, Washer Motor System
1 3
160B 163 162
B1W WG B1R
1 166 165 167 905 163 161 160A 162 10 1.25 1.25 1.25
B1B B1G B1Y B WG B1Y B1W B1R
0.5 0.5 0.5 1.25 1.25 0.85 1.25 1.25 903D 161
B B1Y
4 1.25 0.85 5
Combination Switch RH (Wiper)
Front Wiper Motor
1 167 160C 2 165 160D 1 3

B1Y B1W 1 B1G B1W 2 164A 169 168
0.5 0.5 0.5 0.5 RG RY RB1
0.85 0.85 0.85
to Front Washer Motor to Rear Washer Motor Rear Wiper Motor
Power Mirror, CD System
1 1
906D 909A 158B 157B 55B 252A 906D 909A 158B 157B 55B 252A
6 B B Or OrG GB RB1 6 B B Or OrG GB RB1
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
152 153 155 151 153 154
PY PG PB1 PB PG PBr
12 0.5 0.5 0.5 7 12 0.5 0.5 0.5 7
Outside Power Mirror RH Outside Power Mirror LH
B7 B1
115 105 107 117 155 152 151 154 153 908B 100 157 158
B1G B1R B1 B1Or 1 PB1 PY PB PBr PG B P OrG Or 10
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
116 106 108 118
B1B B1W B1V B1Y
0.5 0.5 0.5 0.5 to Outside Rear View Mirror Adjustment Switch (White)
B8 B2
A7 A1 105 107
101 102 1 B1R 1 B1
50
RW B1 0.5 0.5
1.25 0.5
106 108
908D 73B 100A
2 B1W 2 B1V
B GB P
0.5 0.5
1.25 0.5 1.25
50 A8 A2
Front Tweeter LH Front Tweeter RH
CD Player
105 107 115 117

1 B1R 1 B1 1 B1G 1 B1Or
0.5 0.5 0.5 0.5
106 108 116 118
2 B1W 2 B1V 2 B1B 2 B1Y
0.5 0.5 0.5 0.5
Front Mid-Low Tone Front Mid-Low Tone Rear Mid-Low Tone Rear Mid-Low Tone
Speaker LH Speaker RH Speaker LH Speaker RH

Central Control Lock, Glass Regulator System
1 10 1 6
306 284A 302 905 305 310
32 54D 288 282 281 287 550 82 286 G BrW B1 B R B1B
R GY GrW B1R B1W B1Y GB B1R B1R 0.5 0.5 0.5 0.5 0.5 0.5
0.5 0.85 0.5 1.25 1.25 0.5 0.85 0.5 0.5 283A 311 308 60 60 307 312 309
358 60B 906A 219 292 280 393 81 284 283 283 84 GW RB GY R R RY Lg B1W
BrW R B B1Y BB1 R Br RB1 RrW GW VW RW 7 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 14
11 0.5 0.5 2.0 1.25 0.5 2.0 0.5 0.5 0.5 0.5 0.5 0.5 22
Glass Regulator Main Switch,

to Central Lock Controller (White)
Central Control Lock Main Switch
1 8 1 8
60 303 288A 307 309 302 282 303 288B 309 302 282
R B1W GrW RY B1W B1 B1R B1W BrW B1W B1 B1R
0.85 2.0 0.5 0.5 0.5 0.5 1.25 2.0 0.5 0.5 0.5 1.25
281 311 312 308 310 281 310
B1W RB Lg GY B1B B1W B1B
1.25 0.5 0.5 0.5 0.5 1.25 0.5
9 16 9 16
to Instrument Wire Harness A to Instrument Wire Harness A
1 6 1 5 1 6
306 985 985 288A 305 310 986 303 288B 309
G B B1W GrW R 310 309 302 B1B B B1W BrW B1W
0.5 2.0 2.0 0.5 0.5 B1G BG B1 0.5 2.0 2.0 0.5 0.5
0.5 0.5 0.5
Front Door Glass Front Door Glass Front Door Glass

Regulator Motor LH Regulator Switch RH Regulator Motor RH
1 282 281 4 1 282 281 4

B1R B1W B1R B1W 292 912C
1.25 1.25 1.25 1.25 1 84 912 2 BB1 B
905 286 284 283 RW B 0.5 0.5
5 B B1Y BrW GW 10 0.5 0.5
5 10
0.5 0.5 0.5 0.5 1 2
Front Door Lock Motor LH Front Door Lock Motor RH Back Door Back Door
Light Switch Open Switch
1 287 902 2
1 282 281 4 1 282 281 4 B1Y B
B1R B1W 291A 912A
B1R B1W 0.5 0.5
1.25 1.25 B1Y B
1.25 1.25 1.25 1.25
3 4 2
1
5 10 5 10
Rear Door Lock Motor LH Rear Door Lock Motor RH Key Insert Back Door
Detect Switch Lock Motor
83 84 84 84
YW RW RW RW
0.5 0.5 0.5 0.5
Front Door Front Door Rear Door Rear Door

Light Switch LH Light Switch RH Light Switch LH Light Switch RH

Light, Signal Warning System
33 32 904 33 32 903E
1 RB R B 3 1 RB R B 3
41A 903C 0.85 1.25 1.25 0.85 1.25 1.25
41B 904
1 2 1 RBL B 2
RBL B 71A 54 906D 71 54 906D
0.85 0.85 0.85 0.85 GW GY B GW GB B
4 0.5 0.5 0.5 6 4 0.5 0.5 0.5 6
Front Fog Light RH Front Fog Light LH Combination Headlamp RH Combination Headlamp LH
71B 67B 906D 71C 67C 906D

1 GW GV B 3 1 GW GV B 3
0.5 0.5 0.85 0.5 0.5 0.85
61A 55A 917 61B 54A 917 1 52 252C 906B 251 4
4 GW GB B 6 4 RW GY B 6 BY RB1 B WB1
0.5 0.5 1.25 0.5 0.5 1.25 0.5 0.5 0.5 0.5
Rear Combination Light LH Rear Combination Light RH Rear Defroster and Hazard Warning Switch
1 4
1 1
906D 909A 158B 157B 55B 252A 42 47 905F
906D 909A 158B 157B 54B 252A B1 B1R B
6 B B Or OrG GB RB1 6 B B Or OrG GB RB1 0.5 0.5 0.5
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 53 906D 56 35 34 72 905C 905B
151 153 154 152 153 155 GB1 B GB RG RY RW B B
PB PG PBr PY PG PB1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
12 0.5 0.5 0.5 7 12 0.5 0.5 0.5 7 5 13
Outside Power Mirror LH Outside Power Mirror RH Combination Switch LH

(Turn Signal Light LH) (Turn Signal Lamp Light RH) (Light)
1 2 1 2
96A 903G 96B 903H
97 381 382 GrB B GrB B
1 WR B1R B1Y 4
0.85 0.85 0.85 0.85
0.5 0.5 0.5
Horn Switch High Tone Horn Low Tone Horn

OVERALL ELECTRICAL WIRING DIAGRAM

Power Source and Starter Circuit
30a
30b
30c
15a
X
15b
Theft Deterrent
ECU6
8C
W
F04 0.5 F33
to ABS#1
15A 15A
11 8 6 10 7
R-G W G Y Br
1.25 1.25 0.5 2.0 2.0
Main Relay
Terminal 1 2 3 4 5 6
AM1 1G1 ACC ST2 AM2 IG2

Position
LOCK Ignition
4 600 3 5
ACC
Switch
R R R R
8.0 4.0 8.0 10.0
ON
ABS F29
START
30A
Motor 12
W-G
40A 0.5
17 12
B-R W-G
2.0 0.5
30 85
Starter
87 86
Relay
15 13 19/22
MAIN ALT B-W W-V C01
13A A28
60A 120A 2.0 0.5
W-V
0.5
Engine ECU Pin 74
C11
9/22 1
C01
Clutch 5/10 8/10
Switch
2 931
B
0.5
1 15 2 16 8D 400A
R B-W R W-B W B-R
20.0 2.0 15.0 0.5 0.85 0.5
C B +B L IG BATT
Battery
12V
60Ah Starter Engine
U>
M
900 E
B
15.0/15.0

Airbag Circuit
30a
30b A
15 B
15a C
to Engine ECU58# D
to Engine ECU58# E
F
G
F26
15A
SRS Indicator
3/14
C05
A19
WARNING LAMP
DIAGNOSTIC K
CRASH OUT
603 385 386 393

Y-W R B1-W Br
IG
0.5 0.85 0.5 0.5

46 25 10 48
Airbag Electronic Control Module
1 2 11 8 9 30 7
D PPB -
381 389 390 392

D PPB+
P PPB -
P PPB+
382 391
DAB -
DAB +
B1-Y B1-R G G-Y Y Y-B

0.5 0.5 0.5 0.5 0.5 0.5
C16 C15
05/22 04/22 11/20 12/20
4 3 1 2 1 2
9 Tester 16
1 905 905A 8
B B
0.5 0.5 Clock
Spring Driver Passenger
465 Seat Belt Seat Belt
W-LINE
B1-Or
0.5
Pretensioner Pretensioner
71 Driver Airbag 906
B
0.5

ABS Circuit
A
B
C
D F16
Brake Lamp Switch

E 10A
Central Control ECU#17
F
G
Theft Deterrent Controller A7 14/18
C19
16/22 8E 65
18/22
C01 W R-W
C01
F39 F25 0.5 0.85
25A 10A
66 67
R-B1 G-V
to Engine ECU Pin 72
0.5 0.85
EBD ABS
A30 A11
05/22
C01 05/14 03/18
C05 C09
EBD Warning Lamp
Brake Lamp Switch

ABS Warning Light
High-mounted Brake Lamp

Diagnostic K
MOTOR
421 600 601 602 603 604 605 67A

VALVE
Br-G R R-B R-Y Y-W Y-R B1-W G-V

IG
0.5 4.0 2.5 0.85 0.5 0.5 0.5 0.5 1 1

27 1 25 32 17 16 4 30
3 3
Brake Lamp LH
Brake Lamp RH
ABS Electronic Control Module 2
13 38 22 34 6 18 20 33 31 19
611 612 613 614 615 616 617 618
WS RR
WP RR
WS FR
WP FR
WS RL
WP RL
909
WS FL
WP FL
Y-B Y-R Y-B1 Y-W G-B G-R G-B1 G-V

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 B
0.5
C17
06/6 02/6 03/6 01/6
1 2 1 2 1 2 1 2
903 903A
B B Front Speed Front Speed Rear Speed Rear Speed
5.0 3.0 Sensor LH Sensor RH Sensor LH Sensor RH

Combination Meter Circuit
30c
15a
to Engine ECU #8
to Engine ECU #59 to Central
Control ECU#11
to Position
Lamp Relay
to Central
to Coolant
Control ECU#18
Temperature Sensor
F24 F13
10A 10A
73A 350A 355 420 419 464 358

G-B W-R Br-Gr B1 V R-W Br-W
0.5 0.75 0.5 0.5 0.5 0.75 0.5
A18 A23 A5 A6 A2 A22 A7
Temperature Warning
Low Water
Low Oil Pressure Indicator
Temperature Warning
High Water
Seat Belt Reminder Indicator
LCD Display
Brake Malfunction Indicator
Parking Brake Indicator
Instrument Lighting
P
V
Vehicle Speed
Low Fuel Level Warning IC Module Odometer
Q
Fuel Gauge
Tachometer
A16 A13 A14 A21 A1 A17 A4 A3

Brake Fluid Level Switch
Parking Brake Switch
Driver Seat Belt Switch
Vehicle Speed Sensor
354
Oil Pressure Switch
356
W-B1
Y-W
0.5
351 352 353 0.5 357
Fuel Sensor
W-G G-B1 Y-B Y-B1

0.5 1 0.5 0.5 1 2 3 0.5 350
W-R
Q V 0.5
1
2 2 2
3
911 911 906A 906 907 901

B B B B B B
0.5 0.5 0.5 0.5 0.5 0.5

Air Conditioner, Defogger System Circuit
30c
15a
to Position
Lamp Relay
to A/C Pressure
Adjustment Switch
F12 S/B4
25A 40A
15/16 C12 80E
Passenger Seat Belt Switch

B1-Y
0.5
A/C Panel Lighting

85 30 87 85
Defroster Blower
Relay Relay
86 87 30 86
201 202
R-B1 B1-V 73C 361
3.0 0.5 G-B W-R

207 201B
251 0.5 0.5
Defroster R-G R-B1
Passenger Seat Belt Reminder Indicator

W-B1
0.5 0.5
Switch 0.5
A/C Switch A/C Wind Speed Switch
Terminal Terminal Terminal
Position
B C D d e f Position
6 10 9 4 5 2 3
Position
ON OFF OFF
OFF ON LO
252C
M1
R-B1
0.5 M2
19/22 C16 11/14 C14 11/14 C19 4/40 C24 M3
252 252A 252B 252D
203 204 205 202
R-B1 R-B1 R-B1 R-B1
B1-W B1-Y B1-R B1-V
Rear Windshield Defroster
Mirror Defroster LH
1 0.5 1 0.5
Mirror Defroster RH
2.0 1.25
Outside Rear View
Outside Rear View
3.0 2.0 1.25 0.5

1
Capacitor
5 5
201A
906A
R-B1
B
1 3.0
6 5 0.85
Blower M 3 4
3 203 Speed Regulating

B1-W
3.0
Resistor
906B 912 909A 907A 909C 906C 906
B B B B B B B
0.5 2.0 0.5 0.5 1.25 0.5 3.0

Wiper, Washer Motor System Circuit
30c
15a
15a
183
16V33uF F23 F11
15A 10A
C1
623
753
303
T1
T2
J 164
D2 R-G
1.25
332
432
Rear Wiper Relay

16V220uF
85 87
C2
332 87a
203
D1 86 30
166 168 164A 169
B1-B R-B1 R-G R-Y
0.5 1.25 1.25 1.25
MIST
Front Wiper Switch
OFF
C16
INT
LO
HI 8/22 6/22 7/22
Front Washer
INT Adjustment
Time R
Rear Washer
Rear Wiper Switch
OFF
ON
Rear
Washer Wiper
Terminal 2 3 4 5 6 7 8 9 10
08/16 07/16 C12
C12 163 C10
W-G
162 160A 161 1.25 10/16 11/16
166
B1-R B1-W B1-Y
165 B1-B
1.25 1.25 1.25
B1-G 0.5
9/16 C10 1 0.5 3 1
Rear Washer Motor
Front Wiper Motor
5
Rear Wiper Motor
3 167
Front Washer Motor
B1-Y M
2 1 0.5
2 160
M 1 M 160D B1-W
M
B1-W 1.25
2 160C 0.5
2
B1-W
0.5
4
160B
B1-W
6/16 C10
1.25
903D 905
B B
1.25 1.25

Power Mirror Circuit

30c A
F22
15A
100
P
0.5
Outside Power Mirror Adjusting Switch
Terminal Terminal Terminal

Fold Switch
Adjustment Switch
Right/Left Selector Switch
7 8 9 10 8 7 6 2 3 4 5
E B F R B E M+ MV MH HR VR VL HL MH MV
Mirror Surface
Position Position Position

Reset Up Left
Fold Left OFF
157 158
Or-G Or OFF Right
0.5 0.5
Right
Down
08/14
08/14 C19
153 155 152 151 154
C14 P-G P-B1 P-Y P-B P-Br
157B 157A 0.5 0.5 0.5 0.5 0.5
Or-G Or-G
Fold Motor
3 0.5 3 0.5
12/14
M M C19 M
7 13/14 C19 14/14
8
4 4
M 9
158B 158A
Or Or 13/14 C10 14/14
0.5 0.5 Mirror Surface Adjustment
09/14
C14
09/14
C19
Motor RH
12/14
C14 9
M
8
7
M
Mirror Surface Adjustment

Motor LH
908B
B
0.5
D

CD System Circuit
to Position Lamp Relay
F17
15A
Antenna
Antenna Amplifier
100A 73B 101 102

P G-B R-W B1
1.25 0.5 1.25 0.5
Radio Receiver & CD Player Assembly
(+) 105 106 (-) (+) 115 116 (-) (+) 117 118 (-) (+) 107 108 (-)
B1-R B1-W B1-G B1-B B1-Or B1-Y B1 B1-V
0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
04/14 C14 05/14 02/20 C15 09/20 13/20 C15 14/20 04/14 C19 05/14
1 2
2 13/14 C20 14/14 13/14 C10 14/14

1
Front Tweeter LH Front Tweeter RH

1 2 1 2 1 2 1 2
Front Mid-Low Rear Mid-Low Rear Mid-Low Front Mid-Low

Tone Tone Tone Tone
Speaker LH Speaker LH Speaker RH Speaker RH
908D
B
1.25
D

Electric Injection ECU Control System Circuit
30a
30b
30c
15b
15a
F30 F31 F38

to Combination
25A 15A 10A Instrument
to Generator
to Combination Instrument
400 400 8A 8C 213 F10 F32 F34
to ABS
to Theft Deterrent Controller A3

B-R B-R W W B1-R 03/22 C01
Fuel Pump Relay

2.0 0.5 0.5 0.5 1.25 10A
30A 30A
Main Relay
30 85 85 30 85 30
IG1 Relay
Engine Malfunction Indicator

401H 424 467 401I
Ignition System
to Airbag
EOBD
High-speed Fan Relay

Low-speed Fan Relay
R-W R R-B1 R-W
Compressor Relay
87 86 86 87 86 87
Indicator 0.5 3.0 3.0 0.5
401 402 901 413
EOBD
R-W Br-B1 B B1 85 30 85 30 30 85
2.0 0.5 0.5 1.25 1 2 3 4
C11 A29 A12 401L
4 7C 86 87 87 86 R-W
401F 3 21 3 21 3 21 3 21 86 87
Fuel Pump
Br 3/10 2/10 0.85
to Theft Deterrent Controller A8

401E R-W 212 214 427 425 428 426 1
M 2.0 15/22 C01 603
11/22 C01 Injection Nozzle R-W
0.85
0.5 G-B W-B1 Y-G
0.5
R-G
3.0
W-R Or-B1
3.0 0.5
Y-W
0.5 0.85
Phase Sensor
3 1 VVT Valve 0.5
Canister Control Valve
5 7D 7E 7F 7G C11 2
425A 425B 418
3
Compressor Clutch
1 2 4 1 Br Br Br Br R-G R-G 2 R
919
2.0 2.0 2.0 2.0 7/10 6/10 2.0 2 2.0 0.5
2 1 2 1 2 1 2 1 B 16/16 C12 Tester
Condenser Fan
Radiator Fan
1 2 1.25 9 16
403 401A 404 401B 405 401C 406 401D
Engine Housing Ground

418 419 420 421 422 423 4/22 C01 M R M
12/22 C01
B1-G R-W B1-W R-W B1-R R-W B1-B R-W R P B1 Br-G V-B P-B1
2 401L 401M 401N 917 411 412 0.85 0.5 0.5 0.5 0.5 0.5
0.85 0.85 0.85 0.85 0.85 0.85 0.85 0.85 1 905 905A
1 B B 8
R-W R-W R-W B B1-B W-B1
926 0.5 0.5
0.85 0.85 0.85 0.5 0.5 0.5
B 925 7/16 C12
2.0 B 3
A.S.FAN1
A.S.FAN2
E.F.ZYHA
E.S.KL15
A.S.KOS
U.U.UBR
U.U.UBR
U.U.UBR
U.U.UBD
E.S.ABS
A.S.SVS
479 465
A.S.EKP
E.F.VFZ
A.S.MIL
A.T.TEV
402 407
A.T.EV1
A.T.EV4
A.T.EV2
A.T.EV3
8B 480 481 482 483
W-LINE
3.0
A.T.TN
Br-B1 P-Y R-G B1-Or
W R-B1 R-B R-W R-G
0.5 0.85 0.85 2.0 2.0 2.0 2.0 0.85 0.5
14 27 6 7 47 46 44 45 63 79 13 70 5 1 2 4 12 8 59 72 29 31 69 50 68 48 71
ME7.9.7.1 (1.1) Electronic Control Module
55 36 28 18 26 33 17 37 42 39 35 40 16 32 73 54 38 78 64 65 66 67 22 19 20 15 34 3 61 80 51 53 57 74 76 75 21 58
442C 442A 446A 446B 447A 447B 211 13A 476 240 67D 66
E.S.BR
M.R.SEN2
A.S.LSHK
E.A.LSHK
A.S.LSHVK
A.U.5V2
M.R.SEN1
E.A.DS
E.A.TMOT
M.R.SEN3
E.A.SP2S
E.A.SP1S
A.U.5V2
E.A.1P1S
E.A.1P2S
M.R.SEM
E.A.KS1A
E.A.KS1B
M.M.ZUE
M.M.ES1
M.M.ES2
M.M.EL2
M.M.EL1
E.S.PSW
E.S.PSW
E.S.AC
E.S.BL
E.A.TANS
F.A.LSHK
E.F.DGA
E.F.DGB
R-Y R-Y B1-R B1-R Gr-B Gr-B B1-R W-V PB B1-W G-V R-B1
0.85 0.5 0.75 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.5 0.85
18/22 16/22
Generator
C01 C01
A/C Pressure Adjustment Switch

Starter Relay 86
Power Steering Load

Medium-voltage Switch
430 441 434A 439A 440 442 443 442B 444 445 446 447 439B 206 448 449 450 451 1
to Brake Lamp Switch Pin 04

429 430A 431 432 430 433 434 435 436 437 438 355 439C
3
to ABS ECU
Gr-B1 Y W-B1 Gr Y WR Gr-B1 Gr-R Br-R V-W B1-V Br-Gr B-R Y V-B Br-B1 B-R Br-Y R-Y P-B1 R-Y Lg B-Y B1-R Gr-B B-R P-Y Gr-Y B1-Y P-Y B1-Y
0.5 0.5 0.85 0.5 0.5 0.85 0.85 0.85 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.85 0.75 0.75 0.5 0.75 0.75 0.75 0.5 0.5 0.5 0.5 0.85 0.85
4 3 4 3 3 1 4 2 2 3 1 5 6 1 3 4 2 6 3 5 2 4 1 1 2 1 2
4
401J 2
2 1
R-W M
0.85 1 2 401K 1 2 913 911 912 915 916 914
to A/C Switch
A/C Temperature B B B B B B
R-W
0.85 Intake Air Pressure Sensor 2.0 0.85 0.85 0.85 0.85 0.5
Rear Oxygen Sensor Front Oxygen Sensor Temperature Sensor Coolant Temperature Sensor Accelerator Pedal Module Electronic Throttle Body Knock Sensor Engine Speed Sensor
EWD-43

Lights, Signal Alarm System Circuit
30a
30c
15a
30b
to Central
Control ECU #1
F35 F08 F09 F36 F37 F03 F06 F07
15A 15A 5A 15A 15A 10A 15A 10A
30 31
R-W R-B1
Turn Light Switch

2.0 2.0 Terminal 11 10 12
Front Fog Light Relay
Rear Fog Light Relay

30A 31A
Turn Left
Position Light Relay

95A 95 R-W R-B1
High-beam Relay
Low-beam Relay
Br-R Br-R 0.5 0.5
0.5 1.25 OFF
30 85 85 30 30 85 85 30 85 30
Horn Relay
Turn Right
85 30
87 86 86 87 87 86 86 87 86 87
906D 56 53
86 87 41 42 47 46 32 34 35 33 72 71 B G-B G-B1
R-B1 B1 B1-R B1-W R R-Y R-G R-B R-W G-W 0.5 0.5 0.5
97 96 1.25 0.5 0.5 0.85 2.0 0.5 0.5 2.0 0.5 0.85 906E 15R 15L 30 IG
W-R Gr-B
B
0.5 1.25 C10 0.5
12/16 13/16 31 Flasher Relay
15/18 C09
2/16 C10 18/20 C15
L R HWS
4 5 6 7 8 9
Front Turn 55
OFF
Light LH G-B
3 5 0.5
97 42 47 Rear Turn 55A

W-R B1 B1-R
0.5 0.5 0.5
Light LH G-B
Low 6 5 0.5
Beam
Front Position Left-side
Horn Switch
1 ON High 71 55B
Beam G-W Light LH Turn Light G-B
0.5 4 3 6 2 0.5
Fog Light Switch
Overtake
Terminal 1 3 2
96A 96B
Gr-B Gr-B High 71A
Front Position Left-turn 55C
OFF
0.85 0.85 Beam G-W Light RH Indicator G-B
1 1
Front Fog OFF 0.5 4 3 A27 0.5
Light Low
Beam
Rear Fog
Light 71B Rear Position Front Turn 54
2 Overtake G-W Light
2 LH Light RH G-Y
High Tone Electric Horn
Low Tone Electric Horn
0.5 0.5
1 3 3 5
52
71C Rear Position Rear Turn 54A B-Y
41A 41B 41 46A 46
G-W Light RH Light RH G-Y 0.5
Hazard Warning Switch

R-B1 R-B1 R-B1 B1-W B1-W
High-beam Indicator
0.5 1 3 6 5 0.5
0.85 0.85 0.5 0.5 0.5 32 32 33 32 33
1 1 A32 2 A15
R R R-B R R-B
Light LH
Rear Fog
Light Indicator
Rear Fog
A25
0.5 1.25 0.85 1.25 0.85
71D License Plate
Right-side 54B Terminal
C
G-W Lamp LH
A
Right Headlamp
2 1 2 1 Turn Light
Left Headlamp
G-Y Position
2 2 1
Light LH
Front Fog
Light RH
Front Fog
Light Indicator
Front Fog
0.5 2 1 6 2 0.5
ON
A24
71E License Plate Right-turn 54C OFF
G-W Lamp RH Indicator G-Y
0.5 2 1 A260.5
3 3
903G 903H 903C 904 905F 907 905A 903E 905B 904 905C 906D 906B
B B B B B B B B B B B B B
0.85 0.85 0.85 0.85 0.5 0.5 0.5 1.25 0.5 1.25 0.5 0.5 0.5
EWD-44

Central Control Lock, Glass Regulator System Circuit
30c
to Combination
Instrument
15a
to Combination
Instrument
to Combination
Instrument
to High-beam Relay
905 60A 60C
to Airbag ECU B R R
F15 0.5 0.5 0.5 S/B2
to Combination
Instrument 20A Front Door Glass Regulator Main Control Switch LH 30A
Open Door
Vehicle Speed Signal

Indicator
E B+ B+
Power Switch
Turn Signal RH
Light Detection
Turn Signal LH
Driver Side
Door Window
Airbag Signal
Lock Switch
Front Door Power

A20
Rear Door Power

Rear Door Power
Central Control
Terminal
Switch RH
Switch RH
L E UL
Switch LH
Switch
Position U B D U B D U B D U B D
81C Locked Up Up Up Up
R-B1 Still OFF OFF OFF OFF
0.5
Unlocked Down Down Down Down
LOCK
L UL U1 D1 OUT U2 D2 U3 D3 U4 D4
81 358 393 55D 54D 280 60B 32
4/16 C13 12/16 C13 10/16 C13 11/16 C13
R-B1 Br-W Br G-B G-Y R R R 284A 283A
0.5 0.5 0.5 0.85 0.85 2.0 0.5 0.5 305 306 302 309 310 307 308 311 312
Br-W G-W R G B1 B1-W B1-B R-Y G-Y R-B Lg
18 11 17 8 2 16 12 1 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5
11/22 C16 10/22 C16 6/20 C15
C14 7/16 C13 7/20 C15
Central Controller Electronic Control Module 10/14 03/14 12/22 C16 12/22 C16 2/8 C21
7/16 C18 1/10 C10 1/10 C21 3/10 C21
3/10 C20
Front Door Switch RH
Rear Door Switch LH
Rear Door Switch RH

9 22 21 13 7 15 14 5 6 10 20 19 4 U B D U B D U B D
Delay Signal
82 84 83 287 292 291 282 281 286 283 284 288 Up Up Up

To Room B1-R R-W Y-W B1-Y B-B1 B1-Y B1-R B1-W B1-Y G-W Br-W Gr-W
OFF OFF OFF
Ceiling Lamp 0.5 0.5 0.5 0.5 0.5 1.25 1.25 1.25 0.5 0.5 0.5 0.5
Down Down Down 303
U B D U B D U B D B1-W
To Reading 02/22 C16 01/22 C16 284B 283B 2.0
Lamp C14 05/16 C13
Br-W G-W 309 31013/16 C13 307 308 311 312
01/14 03/14 10/14 02/10 C20
0.5 0.5 05/16 C18 B1-W B1-B R-Y G-Y R-B Lg
C16 01/06 C23 05/06 C23 0.5 0.5 02/16 C18 0.5 0.5 0.5 0.5
8 10 9 C19
Back Door Opening Switch
Back Door Lock Motor
16/22 16/22 16/22 16/22 15/22 10/14 03/14
Passenger Central
Lock Signal
1
Unlock
13/22 C16
Signal
02/16 C13 13/22 C16

1
Control Switch
1 4 02/16 C18
Inserted-key Detection Switch
07/08 C20 07/08 C21

M M Terminal
02/4C22 L E UL
Position UP DOWN +BAT UP DOWN +BAT UP DOWN +BAT UP DOWN +BAT
Front Door 1 6 3 1 6 3 1 6 3 1 6 3
2
2 Lock Body LH Lock
Front Door Jam Front Door Jam Rear Door Jam Rear Door Jam
1 4 7 Unlock
1
M
Protection Motor LH Protection Motor RH Protection Motor LH Protection Motor RH
Front Door 4 GND Global Close 4 GND Global Close 4 GND Global Close 4 GND Global Close
Lock Motor RH 288A 288B 288C 288D
1 M 4 Gr-W Gr-W Gr-W Gr-W
Back Door Light Switch
Rear Door Light Switch LH
Rear Door Light Switch RH
Front Door Light Switch RH
Front Door Light Switch LH
2
Rear Door 0.5 0.5 0.5 0.5
Lock Motor LH
1 M 4
Rear Door Lock

Motor RH
906A 912C 912A 905 905 905 985 986 987 988
B B B B B B B B B B
2.0 0.5 1.25 0.5 0.5 0.5 2.0 2.0 2.0 2.0
EWD-45


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FOREWORD

FOREWORD.indd 1 2008-10-21 9:48:07

ENGINE ACCESSORY SYSTEM EG

CONTENTS.indd 1 2008-10-7 8:14:33

01-GENERAL.indd 1 2008-10-21 9:46:08

Start and Charge ............................................................. GL-62

01-GENERAL.indd 2 2008-10-21 9:46:08

01-GENERAL.indd 3 2008-10-21 9:46:08

l Piston Dust Cover

Hole Plug Rear Brake Cylinder

l Cup Parking Brake Shoe Lever

Rear Brake Automatic Tension Spring

01-GENERAL.indd 4 2008-10-21 9:46:09

01-GENERAL.indd 5 2008-10-21 9:46:09

1. Vehicle identification number

2. Engine model and transmission model

01-GENERAL.indd 6 2008-10-21 9:46:10

• Always wear a clean uniform.

01-GENERAL.indd 7 2008-10-21 9:46:11

• Diagnose with a thorough understanding of the trouble phenomenon and per-

(b) Jacking up and supporting vehicle

01-GENERAL.indd 8 2008-10-21 9:46:11

Medium Current Fuse and High Current Fuse

Illustration Symbol Part name Abbreviation

Medium Current Fuse M-FUSE

High Current Fuse H-FUSE

01-GENERAL.indd 9 2008-10-21 9:46:12

Shape (Example) Removal/Installation

01-GENERAL.indd 10 2008-10-21 9:46:12

Shape (Example) Removal/Installation

01-GENERAL.indd 11 2008-10-21 9:46:12

(h) Removal and installation of vacuum hoses

(2) When disconnecting vacuum hoses, use tags to identify

(i) Torque when using torque wrench with extension tool

(3) Formula T’ = T × L2/(L1 + L2)

2. For vehicles equipped with SRS airbag and seat belt

01-GENERAL.indd 12 2008-10-21 9:46:14

(a) General notes

01-GENERAL.indd 13 2008-10-21 9:46:14

Mark (b) Clock spring (in combination switch)

(c) Driver airbag assembly (w/airbag)

01-GENERAL.indd 14 2008-10-21 9:46:14

(d) Passenger airbag assembly

01-GENERAL.indd 15 2008-10-21 9:46:15

(e) Seat belt pretensioner

(f) Airbag ECU assembly

01-GENERAL.indd 16 2008-10-21 9:46:15

01-GENERAL.indd 17 2008-10-21 9:46:16

4. Removal and installation of fuel control parts

01-GENERAL.indd 18 2008-10-21 9:46:16

6. Handling of hose clamps

7. For vehicles equipped with mobile communication sys-

01-GENERAL.indd 19 2008-10-21 9:46:17

Vehicle Lift and Support Locations

: Support Position, Pantograph Jack Position

: Center of Vehicle Gravity

01-GENERAL.indd 20 2008-10-21 9:46:18

4. Notice for using swing arm type lift

: Center of Vehicle Gravity

01-GENERAL.indd 21 2008-10-21 9:46:19

How To Troubleshoot ECU Controlled Systems

For using tester

How To Proceed With Troubleshooting