NEW BENNI - Manual de Servicio

Part 1
Engine
Section Title Page
Chapter II Engine Cooling System................................................................................................ 4
Chapter III Electronic Control System .......................................................................................... 6
Oxygen Sensor Assembly ..................................................................................................... 6
Knock Sensor ....................................................................................................................... 7
Crankshaft Position Sensor Assembly ................................................................................... 9
Camshaft Position Sensor Assembly ................................................................................... 10
Coolant Temperature Sensor Assembly............................................................................... 12
Oil Pressure Alarm Assembly ............................................................................................. 14
Intake Air Temperature/Pressure Sensor ............................................................................. 15
Electronic Throttle Body Assembly .................................................................................... 17
Fuel Manifold Assembly ..................................................................................................... 19
Starter Assembly................................................................................................................. 21
Integral AC Generator Assembly ........................................................................................ 27
Ignition System................................................................................................................... 35
Chapter IV Mechanical Maintenance of Engine .......................................................................... 40
Inspection of Cylinder Pressure........................................................................................... 40
Inspection of Oil Pressure ................................................................................................... 41
Inspection and Adjustment of Valve Clearance ................................................................... 43
Cylinder Head Cover Assembly .......................................................................................... 45
Oil Pan Assembly, Oil Filter Assembly and Oil Strainer Assembly ..................................... 47
Front Gear Train ................................................................................................................. 49
Timing Mechanism ............................................................................................................. 51
Water Pump Assembly ....................................................................................................... 54
Oil Pump Front Housing ..................................................................................................... 56
Camshaft ............................................................................................................................ 58
Valve and Cylinder Head .................................................................................................... 62
Valve .................................................................................................................................. 64
Cylinder Head ..................................................................................................................... 66
Valve Spring ....................................................................................................................... 67
Cylinder Gasket Assembly .................................................................................................. 69
Piston, Piston Ring, Connecting Rod and Cylinder.............................................................. 71
Crank Pin and Connecting Rod Bearing Bush ..................................................................... 75
Chapter V Air Inlet System......................................................................................................... 77
Air Cleaner Element ........................................................................................................... 77
Throttle Body and Inlet Manifold ........................................................................................ 78
Chapter VI Exhaust System ........................................................................................................ 79
Chapter VII Clutch ..................................................................................................................... 82
Chapter VIII Transmission Maintenance..................................................................................... 86
Transmission Structure ....................................................................................................... 86
Operation and Maintenance Method.................................................................................... 92
Disassembly and Assembly of Transmission ....................................................................... 94
Transmission Maintenance.................................................................................................. 98
Oil Replacement ................................................................................................................. 98
Replacement of Left and Right Oil Seals of Differential...................................................... 98
Chapter IX Final Assembly .......................................................................................................101
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Installation or Connection ..................................................................................................102

Chapter V Heavy Repair ............................................................................................................104
Engine Assembly ...............................................................................................................104
Main Bearing Bush, Crankshaft and Cylinder Block ..........................................................105
Installation and Inspection of Conrod Bearing Bush...........................................................111
Flywheel Ring Gear Assembly...........................................................................................112
Attached Tables .................................................................................................................114
Special Tools .....................................................................................................................117
After-sales Repair Materials ......................................................................................................120
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Chapter I Overview
JL473Q1 engine (EA14FF) is the first transverse VVT engine of Changan EA series,
with high power, high quality and low fuel consumption. JL473Q1 gasoline engine is a new
design engine with advanced combustion system, inlet system, exhaust system, admirable
NVH performance, etc. possessing competitive edges on price and performance in domestic
market. It adopts double overhead camshafts (DOHC), inlet VVT (i-VVT), four valves, low-
tension piston ring, offset crankshaft, low-load valve spring, mute valve drive chain, oil pan
and transmission housing combination, aluminum-enclosed thin-wall cylinder barrel and other
technologies, with power per liter of 54kW/L, meeting national Phase III fuel standard and
reaching requirements of National IV Emission Regulation. Through repeated and strict bench
tests, high-intensity road tests (8 times of 40,000km test and 4 times of 100,000km test per set)
and tests under high temperature, frigid climate and ultimate plateau conditions, the results
prove and guarantee effective service life and quality of the engine.
EA series engine is researched and developed independently by Changan with input of
over RMB 2 billion and 3 years, and EA14FF is the first transverse VVT model of this series.
EA14FF has power per liter of over 50kW/L, surpassing definition of energy-saving and
environmentally friendly - 50kW, and possess over 50 technology patents, being in an
advanced level in similar engine field of China.
The engine has the following advantages:
Configuration of double overhead camshafts (DOHC), inlet VVT and four valves
enhances inlet and exhaust efficiency, improves engine reliability and reduces fuel
consumption rate and maintenance rate;
Timing system of the engine adopts a service-free mute timing chain which is durable in
use and difficult to have faults and can be free of maintenance for a lifetime compared with a
timing belt used for an engine of a traditional microcar. Moreover, the chain can reduce noise
and provide a quiet and comfortable riding environment;
The engine is adopted with high-performance combustion chamber and air passage
which organize airflow reasonably with charging efficiency nearly up to 100%, guaranteeing
high performance of the engine;
Three technologies – hollow camshaft, direct drive valve and low-load valve spring
make the engine configuration more compact and reduce mechanical loss of the engine, so as
to improve fuel economy of the engine;
The engine piston is of advanced high-temperature aluminium alloy, which makes the
piston lighter and the engine running easier, reduces unnecessary loss and consumption and is
helpful to improve efficiency and reduce fuel consumption. High-quality material and
advanced processing technology are adopted for the piston ring, which minimizes frictional
loss of the piston group;
Adopted with gantry structure and made of aluminium completely, the cylinder block is
of sunken structure design on each different end face, so as to reduce its mass, and it is
adopted with short water jacket design to reduce combustion energy loss of the engine,
improve fuel availability, shorten start-up and warm-up time of the engine and reduce
pollutant emission by the engine;
The engine is adopted with offset crankshaft, so as to reduce lateral force of the piston
against the cylinder block during combustion and expansion travel and reduce frictional loss
between the piston group and cylinder wall.
Note: oil seal, cylinder gasket, metallic and non-metallic sealing gasket and non-metallic
seal ring shall not be used repeatedly during maintenance.
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Chapter II Engine Cooling System
S/N Comp/part No. Comp/part Name

1 Q1860825 Hexagon flange bolt The cooling system of JL473Q1 engine is a
2 1008051-H03 Thermostat cover forced circulation water cooling system, and
3 1306010-H01 Thermostat assembly it mainly consists of compensation tank,
4 1008070-H05 Thermostat seat assembly
5 1008044-H02 Sealing gasket of thermostat
radiator, water pump, water jackets for
seat cylinder block and cylinder head, coolant
6 1000278-H04 Minor-cycle hose temperature sensor, thermostat and large and
7 1000371-A01 Water pipe clamp for throttle
body
small circulating pipes of the engine. Among
8 1000276-H03 Small return-water hose which, the compensation tank and radiator
9 1000098-01 Long stud of exhaust manifold are set on a complete vehicle. The crankshaft
10 1000322-H01 Hexagon flange nut drives the water pump through water pump
11 GB/T 5789 M8X35 Hexagon flange bolt
12 1307010-H03 Water pump assembly
belt and belt pulley to pump coolant from the
13 1009026-H01 O-ring of water inlet and outlet radiator to the cylinder block cooling
pipe channel, and then the coolant will flow to the
14 Q1860612 Hexagon flange bolt
cylinder head through the water jacket and
15 1303010-H03 Water inlet pipe assembly
cool the cylinder head. The coolant leaves the
cylinder head through water outlet pipe seat
on rear end of the cylinder head and returns
to the radiator through the circulating cooling
channel. When the temperature of the engine
is relatively low, the engine is cooled through
small cycle; when the engine coolant
temperature rises to certain degree, the
thermostat will be opened and the coolant
will circulate in large-cycle pipe to cool the
engine.
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Coolant pipe of engine is as shown in the

picture.
Notes:
Pay attention to the following matters during
maintenance and assembly of the engine
thermostat:
1. The thermostat shall not be omitted or
assembled incorrectly, and its upper bracket
shall face upward;
2. The seal ring on the thermostat shall not
fall off;
3. The minor-cycle seal ring on the
thermostat cover shall not fall off;
4. Pay attention to installation direction of the
thermostat assembly, and as shown in the
picture, auxiliary valve and small boss on the
thermostat assembly shall be aligned to each
other;
5. The thermostat cover must be screwed to
bottom;
6. Water outlet on the thermostat cover shall
be in opposite direction with HVAC water
outlet on the thermostat seat assembly.
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Chapter III Electronic Control System

The electronic control system of JL473Q1 engine mainly consists of control unit
assembly (ECU), fuel pipe assembly (incl. fuel injector), inlet pressure and temperature sensor,
electronic throttle body, crankshaft position sensor assembly, coolant temperature sensor
assembly, knock sensor assembly, camshaft position sensor assembly, oil pressure alarm
assembly, rear oxygen sensor, etc.
Inspect the electronic control system first and then inspect for mechanical faults in case
of engine faults such as unstable idling, start difficult, hot start difficult and other problems.
As for inspecting and eliminating electrical problems, first inspect each sensor for looseness,
poor contact, short circuit and open circuit; second, inspect the battery (battery voltage is
about 12V) for low voltage to eliminate problems caused by low battery; third, inspect spark
plug for normal ignition, which includes inspection for harness contact, spark plug ignition,
conductive voltage of spark plug, spark plug gap, advance angle of spark plug ignition,
continuous angle of spark plug ignition, electric conduction of ignition coil and normal
operation and breakdown crack of ignition coil; if any damage is found on the spark plug or
ignition coil, they shall be replaced immediately. Then, inspect fuel injection, which includes
inspection for electric conduction of fuel injector, normal voltage of fuel injector, fuel
pressure of fuel injector, damage of fuel injector distribution pipe and damage of fuel injector
nozzle; if any problem is found on the fuel injector and its pipes, they shall be replaced.
Finally, it shall be considered that whether ECU data is correct or is damaged. If the problems
still cannot be found and solved when working voltage of each sensor is normal, mechanical
faults shall be further considered.
Oxygen Sensor Assembly
LSF can only be used for closed-loop control (A =1). Main characteristics of LSF sensor
are as follows:
- Small in size, light in weight
- Adoption of one-piece technology enables fast heating and short time to enter into
closed-loop control
- Low heating power
Product Structure
Notes to Installation
Do not use cleaning fluid, oily liquid or volatile solid on the plug of the oxygen sensor.
Thread of the oxygen sensor is M18X1.5.
Hexagon wrench for the oxygen sensor is 22mm in size.
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Tightening torque for the oxygen sensor is 50 N·m±10N·m.

Fault description and judgment method
Fault description: unstable idling, poor acceleration, exhaust gas exceeding the standard,
high fuel consumption.
General Fault Causes:
1. Moisture entering the inside of the sensor, sudden change of temperature, probe
fracture;
2. “Poisoning ” of the oxygen sensor (Pb, S, Br & Si)
Notes to maintenance: It is prohibited to use cleaning fluid, oily liquid or volatile solid
on oxygen sensor during maintenance.
Simple Measuring Method:
1. Remove the plug; turn the digital multimeter to ohms range, with the two probes
respectively contacting the sensor pins 1# (white) and 2# (white). The resistance of the sensor
is 7~14Ω under normal temperature.
2. Connect the plug; turn the digital multimeter to DC voltage position when the oxygen
sensor reaches its working temperature (350°C) under idling, with the two probes respectively
contacting the sensor pins 3# (grey) and 4# (black). Then the voltage shall fluctuate quickly
between 0.1V and 0.9V.
Knock Sensor
The operating principle of the knock sensor is to enclose a piezoelectric ceramic and
generate and output an output voltage with relatively large amplitude to the electronic
controller by utilizing specific piezoelectric effect of the piezoelectric ceramic in case of
engine knocking.
Product Structure
Characteristic Line
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Installation torque is 20N·m±5N·m;
Make sure that the boss surface for installation is clean and free of oil dirt, and make sure
that its metal surface closely contact with the cylinder block during installation;
Any type of washer shall not be used between the sensor and the cylinder block during
installation;
Pay attention to prevent resonance so as to avoid breakage during signal cable wiring for
the sensor.
General Fault Causes
Open circuit or short circuit of harness, or poor contact of harness connector;
Contact between various fluid (such as engine oil, coolant, brake fluid, water, etc.) and
the sensor for a long time, causing corrosion to the sensor;
Looseness of the knock sensor bolts, causing poor contact between the knock sensor and
the cylinder block boss surface.
Notes to Maintenance
It is prohibited to connect high voltage to pins 1#-2#; otherwise, piezoelectric elements
may be damaged;
1- knocking signal A; 2 - knocking signal B; 3 - shielded wire;
Troubleshooting Method
Step one: for harness and connectors
We shall inspect the knock sensor position signal wire and the sensor grounding for open
circuit or short circuit of harness first when the fault detected by the diagnostic scanner
(unsmooth acceleration, metal knock within the cylinder block, excessive high or low voltage
in signal circuit of the knock sensor, etc.) is related to the knock sensor. Uneven height of
bus-end harness terminals due to abnormal connection of the harness will also cause signal
circuit faults of the knock sensor. We shall first replace parts not inspect the harness at this
time.
Step two: for single part
1. (Remove the connector); turn the digital multimeter to ohms range, with the two
probes respectively contacting the sensor pins 1# & 2# and 1# & 3#. The resistance of the
sensor is 1MΩ under normal temperature.
2. Turn the digital multimeter to millivolt range and tap nearby the knock sensor with a
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small hammer; then, there shall be a voltage signal output at this time.
Note: Please inspect whether the 3# shielded wire is well grounded.
3. Communicate with a diagnostic scanner and electronic injection system ECU specified
by complete vehicle factory to read fault data in the ECU, so as to make judgment on failure
of the throttle position sensor.
Crankshaft Position Sensor Assembly
The crankshaft position sensor is an element in the engine management system. The
sensor is installed on the engine body to detect the crankshaft position and speed. The sensor
detects teeth and grooves of a ferromagnetic signal gear and outputs electrical signals
representing the signal gear speed and position.
Product Structure
Characteristic Line
The output performance of the sensor shall meet provisions in Table 1 and Figure 1.
Table 1 Output Waveform Parameter
Working voltage Output voltage (V) Voltage rise time (tr) Voltage fall time (tf)
(V) High level Low level μs μs
5±0.25 ≤4. 75 ≤0.5 ≤25 ≤1
Output voltage
Figure 1 Sensor Output Waveform Diagram

Installation torque is 10±2 N·m;
The sensor must be in original package material before being installed on a vehicle, and
inspect that the sensor is not damaged and polluted before installation.
Apply lubricating oil on the O-ring before installing the sensor, and then press in the
sensor manually. Fix the sensor with mounting bolts M6×12-8.8 finally.
Open circuit or short circuit of harness, or poor contact of harness connector;
Contact between various fluid (such as engine oil, coolant, brake fluid, water, etc.) and
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the sensor for a long time, causing corrosion to the sensor;

Looseness of bolts for fixing the crankshaft position sensor, causing change in distance
between the sensor end face and signal panel as well as inaccurate output signal.
1. It is prohibited to connect high voltage to pins 1#-3#; otherwise, piezoelectric
elements may be damaged.
2. Prevent sundries from falling into installation opening when the sensor is removed.
We shall inspect the crankshaft position sensor supply terminal and the sensor grounding
for open circuit or short circuit of harness first when the fault detected by the diagnostic
scanner (generally, vehicle cannot be started) is related to the crankshaft position sensor, with
supply voltage being 5V.
Inspect the sensor harness and the engine harness for poor contact of connectors for poor
contact of connectors will also cause signal distortion.
Step two: for the sensor
Turn on the ignition switch and use the multimeter to detect whether the sensor has 5V
power supply; ignite and start the engine, and inspect whether the sensor outputs signal and
whether the output signal meets requirements.
Camshaft Position Sensor Assembly
Overview
The camshaft position sensor is used to detect position signal of the camshaft and to
correctly judge work phase of each cylinder of the engine at such moment, so as to make the
system control fuel injection and ignition as per engine work sequence.
Product Structure
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Characteristic Line
The output performance of the sensor shall meet provisions in Table 1 and Figure 1.
Table 1 Output Waveform Parameter
Working Voltage rise time
Output voltage (V) Voltage fall time (tf) Output low level angle (°)
voltage (V) (tr)
High level Low level μs μs a 1, a 2 a 3, a 4
5±0. 25 ≤4. 75 ≤0.4 ≤150 ≤20 68±2. 5 18±2.5
Output voltage
Figure 1 Sensor Output Waveform Diagram

1. The installation torque is 10 N·m±2 N·m;
2. The sensor must be in original package material before being installed on a vehicle,
and inspect that the sensor is not damaged and polluted before installation.
3. Apply lubricating oil on the O-ring before installing the sensor, and then press in the
sensor manually. Fix the sensor with mounting bolts M6×12-8.8 finally.
A. Open circuit or short circuit of harness, or poor contact of harness connector;
B. Contact between various fluid (such as engine oil, coolant, brake fluid, water, etc.)
and the sensor for a long time, causing corrosion to the sensor;
C. Looseness of bolts for fixing the camshaft position sensor, causing change in distance
between the sensor end face and signal panel as well as inaccurate output signal.
1. It is prohibited to connect high voltage to pins 1#-3#; otherwise, piezoelectric elements
may be damaged.
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2. Prevent sundries from falling into installation opening when the sensor is removed.
We shall inspect the camshaft position sensor supply terminal and the sensor grounding
for open circuit or short circuit of harness first when the fault detected by the diagnostic
scanner (generally, torque decrease and emission increase) is related to the camshaft position
sensor, with supply voltage being 5V.
Inspect the sensor harness and the engine harness for poor contact of connectors for poor
contact of connectors will also cause signal distortion.
Step two: for the sensor
Turn on the ignition switch and use the multimeter to detect whether the sensor has 5V
power supply; ignite and start the engine, and inspect whether the sensor outputs signal and
whether the output signal meets requirements.
Coolant Temperature Sensor Assembly
The coolant temperature sensor encloses a NTC (negative temperature coefficient)
thermistor, coverts changes of ambient temperature into changes of the thermistor resistance
value by utilizing temperature sensibility of the thermistor and outputs voltage signals which
are converted through bleeder circuit to the electronic controller.
Product Structure
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1. Hex bolt; 2. Insulation tube; 3. Blade; 4. Thermistor; 5. Insulating bush; 6. Plug; 7. Seal
ring
Characteristic Line
1. The installation torque is (15±2) Nm;
2. Apply sealant TONSAN 1596 evenly on tightening thread of the sensor during
installation. Pay attention that the sealant shall not enter into the sensor connectors. Make sure
that sensor is screwed up without leakage of coolant.
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A. ECU cannot get accurate and continuous coolant temperature change signals or the
thermometer indicates that the coolant temperature does not meet actual temperature of anti-
freeze coolant in the tank due to disconnection, short circuit or incontinuous connection of
harness.
B. Man-made fault (such as thread failure, incorrect harness connection causing burn,
etc.).
It is prohibited to remove the sensor when the vehicle is in high temperature.
We shall inspect for open circuit or short circuit of harness connection between the
coolant temperature signal control line and earth wire first when the fault detected by the
diagnostic scanner (constant rotation of fan, rotation failure or relatively high idle speed, etc.)
is related to the coolant temperature sensor.
If the actual coolant temperature is not conform to that indicated on combination
instrument, we shall judge the signal line between the coolant temperature sensor and the
combination instrument for open circuit or short circuit first. We shall first replace parts not
inspect the harness at this time.
Step two: for single part
1. (Remove the connector); turn the digital multimeter to ohm range, with the two probes
respectively contacting the sensor pins 1# and 2#. The rated resistance is 2.5kΩ±5% at 20ºC,
and other values can be measured from the characteristic line above. Simulation method can
also be adopted for measurement: put the working portion of the sensor into water (make sure
that the dipping time is sufficient), and observe the change of the sensor resistance. The
resistance shall decrease to 300Ω-400Ω (specific value depends on the temperature of boiling
water) at this time.
2. Check that the temperature parameters in the diagnostic scanner for the engine are
close to coolant temperature at that time and have obvious changes. Make judgment as per the
data indicated.
Oil Pressure Alarm Assembly
Diagram and Pin
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The oil pressure alarm is a pressure switch, consisting of housing, spring, oil removal
diaphragm and upper & lower contacts. Alarm pressure range of the pressure alarm is
15Kpa~30Kpa. The alarm is installed on the oil line of the cylinder block.
Operating Principle
The oil pressure alarm is of upper contact type. Before establishment of oil pressure, the
upper contact and the lower contact will contact with each other under spring force; the switch
is closed; then the oil pressure alarm lamp will be on. After start of the engine and
establishment of oil pressure, the upper contact and the lower contact will separate by
overcoming the spring force under effect of oil pressure; the switch is opened; then the oil
pressure alarm lamp will be off. When the engine oil is insufficient and the oil pressure cannot
overcome the spring force, the switch will be closed, and the alarm lamp will be on to give an
alarm.
It must be installed on the oil line of the cylinder block.
It is not allowed using any impact tool (such as hammer) to knock the alarm into
mounting hole.
The installation torque is 21N·m±2N·m.
Fault Description and Judgment Method
● Fault description: function failure, etc.;
● Oil pressure alarm lamp ON by mistake: inflow of water into connectors, causing
short circuit between upper and lower contacts;
● Unable to give an alarm:
1. Impurities enter in pipe, blocking upper and lower contacts;
2. The oil pressure alarm is burnt up;
Notes to Maintenance:
1. Inspect state of sensors when the alarm failure is found and the alarm needs to be
replaced;
2. Prevent water and other fluid from entering into the bush and connectors during
maintenance.
Intake Air Temperature/Pressure Sensor
Diagram and Pin
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Pins: the intake air temperature/pressure sensor has four pins – pin 1# for grounding, pin
2# for output of temperature signal, pin 3# for power supply input and pin 4# for output of
pressure signal. It shall be instead on inlet manifold.
Operating Principle
Profile of DS-S Pressure Sensor
Profile of DS-S/TF Pressure/Temperature Sensor
The intake air temperature/pressure sensor integrates a pressure sensor element which
has piezoresistive effect and a match circuit which is for expansion and temperature
compensation on a silicon wafer. The active surface of the silicon wafer is exposed to
standard vacuum; the thin film on the silicon wafer separates the measurement medium and
the vacuum; the inlet manifold pressure affects on the back of the thin film through pressure
bushing.
The temperature sensing element is a NTC resistor.
Characteristic Parameters:
Value
Measurement Unit
Minimum Typical Maximum
Working voltage 5±0.25 V
Working temperature -40~125 ºC
Working pressure range 20~115 KPa
Installation torque 8±2 N·m
It must be installed on upward side of the inlet manifold to prevent ponding.
It is not allowed using any impact tool (such as hammer) to knock the
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measurement bushing of the sensor into mounting hole of the inlet manifold.
Fault Description and Judgment Method
● Fault description: function failure, etc.;
● The worst fault of pressure signal: pressure signal line is open, or short
to power supply;
● The slightest fault of pressure signal: pressure signal line is short to
power supply;
● The worst fault of temperature signal: temperature signal line is short to
ground;
● The slightest fault of temperature signal: temperature signal line is open, or short to
power supply;
● General fault cause: falling off of connectors or harness connection fault.
1. Inspect the state of the sensor when the sensor failure is found and the intake air
temperature/pressure sensor needs to be replaced;
2. Prevent water, oil and other fluid from entering into the bushing during maintenance;
Electronic Throttle Body Assembly
Overview
The electronic throttle body assembly is a major component of EGAS safety monitoring
system of a gasoline engine; it controls gross air inflow of the engine directly, so as to control
speed and output power of the engine. It mainly consists of actuator, throttle plate and
position sensor.
Product Structure
Characteristic Line
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1. Connector terminal shall not face upward.
2. The throttle body axis shall at most deflect ±20° against the horizontal plane.
3. The throttle body throat shall not be arranged horizontally but at least 5° inclined in
order to discharge possibly gathered water.
4. DC motor shall be arranged downward as much as possible for an electronic throttle
body of a contact-type position sensor.
5. Inflow position of fresh air supply through PCV pipe shall be lower than the throttle
body, and excessive moisture brought by the fresh air can be collected; the pipe shall at least
be about 63.5mm away from the valve plate.
6. The throttle body shall be installed on the inlet manifold on a relatively higher position
relative to the manifold. It is not allowed installing the throttle body on the lowest position of
the manifold.
7. The installation torque for the electronic throttle body assembly is 10 N·m±2 N·m.
a) Faults of the actuator, causing poor running of the electronic throttle body assembly,
thus leading malfunction of the engine;
b) Damages to relevant components of throttle plate, such as excessive wear of
transmission gear and bearing and severe pollution of the plate, causing malfunction of the
electronic throttle body;
c) Excessive wear, relatively large vibration magnitude, poor sealing and other
problems inside of the sensor, causing the sensor signal faults, leading to malfunction of the
electronic throttle body assembly;
d) Poor contact of harness connectors, causing excessive high contact resistance,
signal distortion, unstable idling, fault lamp ON and other faults, leading to malfunction of the
electronic throttle body assembly;
1. Turn off the ignition switch and disconnect the harness connectors before disassembly;
2. Inspect the manifold sealing gasket or seal ring carefully for completeness before
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assembly;
3. The installation torque for the electronic throttle body assembly is 10 N·m±2 N·m;
4. Make sure that the harness connectors and inlet manifold are installed well before start;
Step one: for the actuator
Slightly pull the throttle plate with hands to inspect the plate for stable opening and
automatic return;
Step two: for harness and connectors
Connect and disconnect the sensor connectors to inspect the connectors for poor contact
or open circuit due to vibration and other causes;
Step three: for electronic components
Turn the digital multimeter to ohm range, with the two probes respectively contacting
pins 1# and 4# and pins 2# and 3#; the resistance values shall be 1.55Ω ±0.25Ω and 1.25KΩ
+25% under normal temperature. Use R, L & C testers to measure inductance values of
pins1# and 4# with test frequency being lKHz; the measured values shall be within
1.1mH±0.15 mH;
Fuel Manifold Assembly
Overview
The fuel manifold assembly is a very important component of the fuel supply system for
the engine, and it mainly consists of fuel guide, fuel injector, fuel injector clamp, etc. EA12FF
fuel manifold assembly is not equipped with a pressure regulator; the resistance of its fuel
injector is 12Ω±5% (20°C).
Basic operating principle: turn on or off the fuel injector as per ECU signals for fuel
injection.
Product Structure
Product structure diagram of EA14FF fuel manifold assembly is as shown in Figure 1.
Figure1 Product Structure Diagram of EA14FF Fuel Manifold Assembly

1 - Fuel guide; 2 - Fuel injector clamp; 3 - Fuel injector; 4 - O-ring under fuel injector; 5 -
Mounting bracket plate; 6 - Fuel injector cup; 7 - Fuel inlet
Take off the fuel manifold assembly from plastic bag and inspect its part for
completeness, damages or pollution. Fuel manifolds that do not meet requirements or ever fall
down on the ground shall not be installed;
Apply clean lubricating oil on the lower O-ring of fuel injector before assembly; prevent
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the lubricating oil from polluting the orifice plate during such lubrication process; meanwhile,
make sure that the mounting holes of the fuel injector on the engine are clean;
Assemble the fuel manifold assembly onto the cylinder head carefully with even force
along the axial direction of the fuel injector; avoid excessive impact during the assembly
process;
Correct fuel pipes, connectors or clamps shall be used for installation of external piping;
Avoid deformation or damages to the harness bracket due to excessive impact on the fuel
manifold assembly during installation if tightening harness is necessary. Make sure that the
harness is under free status without squeezing or dragging after installation.
Make sure that the connection mode is correct during installation of the fuel injector
connectors;
Corresponding seal ring and fuel injector clamp shall be replaced when the fuel injector
is removed and then re-installed;
The lower seal ring of the fuel injector shall be replaced when the fuel manifold
assembly is disassembled from and then re-installed onto the engine.
Fault Description, Causes and Measures
Fault description: 1. Fuel pipe leakage; 2. Leakage from O-ring of fuel injector; 3.
Leakage of fuel injector; 4. Injection failure of fuel injector; 5. Poor injection of fuel injector;
General Fault Causes and Measures:
1. Fuel pipe leakage:
Possible causes: welding problems of or cracks on the fuel pipe
Measure: replace the fuel pipe and conduct tightness inspection
2. Leakage on O-ring of fuel injector
Possible cause: the O-ring of fuel injector is cut or polluted; Measure: keep parts clean or
replace the O-ring
3. Leakage of fuel injector
Possible causes: (1) There are metallic or non-metallic particles on sealing face of the fuel
injector, causing sealing failure and leakage (constant open) of the fuel injector; (2) There are
gasoline impurities or residues on the sealing face
Measures: (1) Replace the fuel injector; (2) Power on the fuel injector and wash it with
gasoline; it is recommended to clean the fuel line regularly with fuel detergent;
4. Injection failure of fuel injector
Possible causes: (1) Poor contact between the fuel injector and harness connectors; (2) It is
not used for a long time after being powered on, and the needle valve is sticked by thick
substance (olefin) in residual gasoline.
Measures: (1) Conduct visual inspection on electrical plugs or harness connectors of the fuel
injector for bending or retraction; (2) Power on the fuel injector and wash it with gasoline
5. Poor injection of fuel injector
Possible causes: (1) The injector hole is blocked by carbon deposit; (2) There is an oil film in
the injector hole of the injector hole board, which narrows or even blocks the injector hole,
causing unsmooth injection or even injection failure of the fuel injector
Measures: (1) Power on the fuel injector and wash it with gasoline until there is no carbon
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deposit in the injector hole; it is recommended to clean the fuel line regularly with fuel
detergent; (2) It is recommended to use clean fuel of code designation during test drive
Starter Assembly
Removal
1. Disconnect the negative harness of battery.
2. Jack up and support the vehicle.
3. Disconnect harness connectors of starter motor.
4. Remove fixed nuts for electromagnetic switch harness of the starter motor.
5. Remove upper and lower fixed bolts of the starter motor.
1. Separate the harness from its fixing clips.
2. Remove upper and lower fixed bolts of the starter motor.
6. Take off the starter motor and its baffle from the vehicle.
Installation
Install in reverse sequence of removal.
Operating Principle of Starter Assembly
Turn on the vehicle ignition switch with the vehicle key; the terminal S of the
electromagnetic switch of the starter motor will be on, and the electromagnetic switch will be
actuated to popup the isolator of the starter motor to engagement position of the engine
flywheel; at this time, the terminals M and B of the electromagnetic switch will be on; the
battery current flows into the engine; the starter runs to drive the flywheel to start the engine.
After restoration of the ignition switch, the terminal S of the starter will be off; the isolator
will return to original position; the terminals M and B of the electromagnetic switch will be
off; then the starter will stop working.
Basic Parameters of Starter Assembly
Indicator Conventional starter
Rated voltage 12V
Power 1.0KW
Power supply 12V, 400A
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Inspection and Maintenance

General Inspection
General equipment: multimeter
Warning: each test must be completed within 3~5s to avoid burnout of the coil.
Test on Electromagnetic Switch
Note: Disconnect the excitation coil and binding post ‘M’ before the test.
1. Remove the starter motor armature wire from the electromagnetic switch.
2. Connect the starter motor housing and electromagnetic switch housing to the
negative pole of the battery reliably with jumper wires.
3. Connect one end of another jumper wire to the positive pole of the battery, while
connect the other end to terminal 1# of starter engine harness connector E05.
4. Move out the starter motor pinion.
5. Remove the negative wire of ‘M’ binding post, and then the starter motor pinion
shall not return.
6. Connect the wire pinion well as per description above; then remove the negative
wire of ‘M’ binding post to inspect whether the pinion rotates outward; if not, the
electromagnetic shall be replaced.
Pinion Return Test

1. Connect the starter motor housing and electromagnetic switch housing to the
negative pole of the battery reliably with jumper wires.
2. Connect one end of another jumper wire to the positive pole of the battery, while
connect the other end to terminal 1# of starter engine harness connector E05.
3. Move out the starter motor pinion.
4. Disconnect the positive jumper wire of the battery, and then the pinion shall return
immediately.
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No-load Test
1. Make sure that the battery has been fully charged.
2. Connect the starter motor, battery and tester as shown in the picture.
3. Operate the starter motor to make sure whether it is rotating smoothly. Please
inspect the starter motor device in case of unsmooth rotation of the starter motor.
4. Measure voltage and current when the starter motor is running.
5. Please replace the starter motor if measured values are not within specific range.
Fault Description, Diagnosis and Test

General equipment: multimeter
Inspection and Confirmation
1. Confirm problems indicated by customers.
2. Conduct visual inspection on sign of any obvious mechanical or electrical damage.
Appearance Inspection List
Mechanical Electrical
Starter motor Fuse
Battery
Harness
Looseness or corrosion of a
connector
3. If the observed or raised problem is apparent and its cause has been found, it shall
be corrected before next step.
4. If the visual inspection passes, confirm the fault and refer to the fault description
table.
If a fault occurs but DTC is not stored in ECM and the cause cannot be made sure during
basic inspection, conduct fault diagnosis and elimination in the order listed in the table below.
Fault Description Possible Causes Measures
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• Battery
Starter operation • Loop
• Diagnosis process for starter operation failure
failure • Electrizer
• Ignition switch
• Ignition switch
Starter stop failure • Diagnosis process for starter stop failure.
• Electrizer
• Battery
Slow operation of
• Loop • Diagnosis process for slow operation of starter.
starter
• Electrizer
• Inspect the flywheel ring gear for missing teeth. Reference:
Engine operation flywheel ring gear
failure while starter
• Electrizer • Inspect the starter motor for correct fixing. Install a set of new
works normally starter motor if the problem continues. Reference: Removal and
Installation of Starter.
Inspect the flywheel ring gear.
Abnormal noise of • Electrizer Inspect whether the starter is aligned or its housing cracks.
starter motor • Flywheel ring gear Make sure that all fixed bolts are tightened. Install a set of new
fixed bolt for the starter if necessary.
Diagnosis Process for Starter Operation Failure
Test Condition Detail/Result/Measure
1. Inspect battery
A. Inspect the battery voltage.
Is the battery voltage normal?
Is the starter voltage higher than 10.5 V
→Yes, go to Step 2.
→No
Charge the battery.
Reference: Charging of Battery.
Replace a new battery.

Reference: Removal and Installation of
Battery.
2. Inspect power supply circuit of the electromagnetic switch
A. Turn the ignition switch to “ST” position.
B. Measure voltage of terminal 1# of harness
connector E05 for electromagnetic switch of
the starter motor to ground.
Is the voltage measured higher than 10 V?
→No, go to Step 4.
3. Inspect starter motor
A. Conduct no-load test.
Reference: No-load Test of Starter, General
Inspection.
Is the starter motor qualified through test?
→No, replace the starter motor.
Starter Motor.
4. Inspect ignition switch
A. Disconnect the ignition switch connector.
B. Turn the ignition switch to “ST” position.
C. Measure resistance between terminal 1#
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and terminal 5# of the ignition switch

connector P13.
Is the resistance lower than 1 Ω?
→Yes. If the vehicle is configured with
manual transmission, repair high resistance
faults in the following lines.
• From terminal 1# of harness connector C29
for the starter motor to terminal 1# of harness
connector C07 for the battery.
• Circuit from terminal 1# of harness wire
C08 for the battery to G304 grounding point.
If the vehicle configured with automatic
transmission, go to Step 5.
→No, replace the ignition switch.
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Diagnosis Process for Starter Motor Stop Failure

1. Inspect ignition switch
A. Disconnect the ignition switch connector.
B. Turn the ignition switch to “off” position.
C. Measure resistance between terminal 1#
and terminal 5# of the ignition switch
connector P13.
Is the resistance value lower than 1Ω
→No, replace the ignition switch.
2. Inspect power supply circuit of the electromagnetic switch for short to power supply
A. Turn the ignition switch to “OFF” position.
B. Use a multimeter to measure voltage of
terminal 1# of harness connector E05 for the
starter motor to ground.
Is the voltage within 11~14 V?
→Yes
Manual transmission: repair short circuit fault
between the circuit from terminal 1# of
harness connector P13 of the ignition switch
to terminal 1# of harness connector E05 of the
starter motor and the power supply.
Automatic transmission: go to Step 3.
→No, replace the starter motor.
Diagnosis Process for Slow Operation of Starter Motor
1. Inspect engine and belt drive system
A. Inspect the engine and belt drive system for
mechanical clamping (engine clamping,
generator clamping).
→Yes, repair clamping faults.
2. Inspect cable between battery and starter motor electromagnetic switch for high resistance
A. Turn the ignition switch to “OFF” position,
and measure resistance between terminal 1# of
harness connector E05 for starter motor and
positive binding post of battery.
Is the resistance lower than 0.3Ω?
→Yes, go to Step 3
→No
Clean and lock all positive wire connectors of
the battery. Replace a set of new battery to the
starter motor harness if the problem continues.
Battery
3. Inspect ground wire between battery and starter motor for high resistance
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A. Turn the ignition switch to “OFF” position,

and measure resistance between the starter
motor housing and the negative battery
terminal.
Is the resistance lower than 1Ω?
→No
Clean and lock all negative battery connectors
and the ground strap from the starter motor
fixed seat and vehicle body to the engine. Test
whether the system works normally. Install a
set of new negative battery wire if the problem
continues.
4. Inspect battery and charging system
A. Inspect the battery and charging system.
Reference: Charging System.
Is the fault cleared?
→Yes, replace or repair the battery, and repair
the charging system.
Integral AC Generator Assembly

Removal
1. Remove the engine trim plate.
2. Disconnect the negative harness of battery.
3. Jack up and support the vehicle.
4. Remove the harness connectors of the engine.
1. Disconnect the harness connectors of the generator regulator.
2. Remove the fixed nuts for the charging harness of the engine.
5. Disconnect the generator drive belt.
1. Loosen the fixed nuts for tensioning pulley of the generator drive belt.
2. Rotate the tensioning bolts of the tensioning pulley clockwise until the drive belt
can be removed from the tensioning pulley easily.
6. Remove the lower fixed bolts of the generator assembly.
7. Take out the generator assembly.
Installation:
Install in reverse sequence of removal.
Operating Principle of Integral AC Generator Assembly
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1. Use the vehicle key to turn on the ignition switch but not start the engine; the battery
voltage works on IG; after MIC detects that the voltage at IG point is the battery voltage,
connect audion VT1; then there is initial magnetic field current passing through the rotor coil,
and electricity generation is ready. At this time, the generator does not yet generate electricity;
point P of the regulator is at point location 0; MIC sends signal to connect VT2, so as to turn
on the charge lamp, i.e. the battery indicator lamp on the instrument panel is on. The
generator is normally powered on.
2. Use the vehicle key to turn the ignition switch to ON position; after starting the engine,
the generator voltage is lower than the regulating voltage, and the generator starts to generate
electricity; the point location of point P rises, and MIC turns discontinuous conduction of VT1
to continuous conduction, so as to increase the magnetic field current; the generator voltage
increases, and MIC cuts off VT2; then the charge lamp will be off. If the generator voltage
exceeds the specified regulating voltage when the vehicle runs normally and the generator
works normally, the regulator MIC will quickly send out control signal to cut off VT1, so as
to cut off the field circuit; then the field current will decrease quickly, and the generator
voltage will also decrease. When the voltage at point B decreases to the specified regulating
voltage, MIC will connect VT1, so as to connect the field circuit; the generator voltage will
increase, and then the VT1 will be cut off again. So repeatedly, the generator generates
electricity normally.
Basic Parameters of Integral AC Generator Assembly
Indicator Conventional Generator
Rated working speed 5000 rpm
Generation voltage 14V
specification
Rated generation current 70A
General tool: multimeter
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1. Confirm problems indicated by customers.

2. Conduct visual inspection on sign of any obvious mechanical or electrical
damage.
3. If the apparent cause of observed or raised problem has been found, it
shall be corrected (if possible) before next step.
4. If the problem cannot be found apparently, confirm the fault and refer to
the fault description table.
• Accessory drive • Fuse

belt • Harness
• Electrical connector
• Generator
• Battery
• Battery wire
• Charging system alarm lamp
If a fault occurs but DTC is not stored in ECM and the cause cannot be made sure during
basic inspection, conduct fault diagnosis and elimination in the order listed in the table below.
• Generator belt
• Diagnosis process for
Undercharge of battery • Generator regulator
undercharge of battery
• Generator
• Generator regulator • Diagnosis process for
Overcharge of battery • Generator overcharge of battery
• Looseness or wear of drive
belt • Diagnosis process for charge
Charge lamp always on
• Generator lamp always on
• Circuit fault
• Luminous diode of
instrument
• Instrument
• Diagnosis process for charge
Charge lamp off • Circuit fault
lamp off
• Poor contact between electric
brush and slip ring
• Voltage regulator
• Belt
• Diagnosis process for
Generator noise • Bearing
generator noise
• Stator and rotor
Diagnosis Process for Undercharge of Battery
1. Inspect charging voltage of generator
A. Start the engine to speed up the engine from
idling to 2000rpm.
B. Use a multimeter to measure voltage between
the positive wire of the battery and its negative
wire. Is the voltage value no less than 14.2 V
2. Inspect parasitic current of battery
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A. Conduct inspection process for parasitic

current of the battery. Reference: Parasitic
Current Test of Battery
Is the check result normal?
→No, charge the battery.
Reference: Charging of Battery or Replacement
of Battery.
3. Inspect generator
A. Conduct generator test process.
Is the test result qualified?
→Yes, charge the battery.
→No, inspect the generator.
Reference: Diagnosis Process for Charge Lamp
Always On.
Diagnosis Process for Overcharge of Battery
A. Start the engine to speed up the engine from
idling to 2000rpm.
B. Use a multimeter to measure voltage between
the positive wire of the battery and its negative
wire. Is the voltage value higher than 14.8V?
→No, the system is normal.
2. Inspect generator regulator
A. Replace the generator regulator. Is the
charging voltage of the generator normal?
→Yes, the system is normal.
→No
Overhaul the generator.
Reference: Disassembly and Assembly of
Generator
Diagnosis Process for Charge Lamp Always On
1. Inspect generator belt
A. Inspect the installation of the generator belt.
B. Inspect the tension of the generator belt.
Reference: Inspection on Tension of Generator
Drive Belt
Is the generator belt normal?
→No, adjust or replace the generator belt or
tensioning pulley.
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A. Start the engine to increase its speed to

2000rpm.
B. Use a multimeter to measure voltage of
terminal 1# of generator output harness connector
C30 to ground.
Is the output voltage within 14.2~14. 8V?
→Yes
Repair the circuit between the terminal 1# of the
generator harness connector E03 and the terminal
12# of the instrument connector P07.
3. Inspect power circuit of generator
regulator
A. Turn the ignition switch to “OFF” position.
B. Inspect the fuse IF29.
C. Disconnect the generator harness connector
E03.
D. Measure the voltage value between the
terminal 2# of the generator harness connector
E03 and the reliable grounding.
Standard voltage value: 11~14V.
E. Connect the generator harness connector E03.
Is the confirmed voltage value within the
standard value range?
→No, repair the power circuit of the generator
regulator.
A. Replace the generator regulator. Is the
charging voltage of the generator normal?
→No, replace the generator.
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Diagnosis Process for Charge Lamp Off

1. Inspect luminous diode of charge lamp
A. Turn the ignition switch to “ON” position.
B. Visually inspect whether the charge lamp is
off after being on for 2s?
2. Inspect resistance of circuit from instrument and voltage regulator

A. Turn the ignition switch to “LOCK”
position.
B. Disconnect the instrument harness
connector P07, and measure the resistance of
the terminal 12# to ground. Is the resistance
value less than 1Ω?
→Yes, conduct troubleshooting for or replace
the instrument.
3. Inspect circuit from instrument and voltage regulator
position.
B. Disconnect the instrument harness
connector P07, and measure the resistance
value between the terminal 12# and the
terminal 1# of the generator regulator harness
connector E03;
Is the resistance value less than 1Ω?
→No, repair the circuit from the regulator to
the instrument.
A. Replace the generator regulator.
Generator
Is the fault cleared?
→Yes, finished
→No
Replace the electric brush.
Generator
Diagnosis Process for Generator Noise
Diagnosis hint: the generator noise may be caused by electrical or mechanical noise. The
electrical noise (electromagnetic whine) generally varies along changes of electrical load on
the generator; it is a characteristic of all generators under normal operation, and attentions
shall be paid to separate the noise during maintenance and diagnosis; otherwise, unnecessary
customer complaint may be caused. As for diagnosis on a generator with mechanical noise,
firstly inspect components around the generator for looseness, mutual interruption and other
abnormal situations. Sometimes, noise that sounds slight in engine compartment will also be
transmitted to passenger compartment. Under such situation, replacement of the generator still
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cannot solve the problem, and thus erroneous judgment may be caused.
1. Inspect generator belt
A. Inspect the installation of the generator
belt.
B. Inspect the tension of the generator belt.
Reference: Inspection on Tension of
Generator Drive Belt
Is the generator belt normal?
→No
Adjust or replace the generator belt or
tensioning pulley.

A. Remove the generator belt.
B. Start the generator. Does the generator
noise still exist?
→Yes, inspect the compressor and booster
pump noise.
→No
Repair the generator.
Generator.
Disassembly and Assembly of Generator
Disassembly
1. Remove the fixed bolts and conducting strip of the rear-end cover.
2. Remove the insulating bush for the output terminal of the generator.
3. Take out the electric brush.

1. Take out the electric brush boot.
2. Remove the fixed bolts of the electric brush.
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4. Remove the fixed bolts of the regulator and take out the regulator.
5. Remove the fixed screws between the stator output terminal and the rectifier.
6. Take out the rubber pad.
7. Remove the generator pulley.
8. Separate the front and rear covers.

1. Remove the fixed nuts of the front and rear covers.
2. Separate the front and rear covers.
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9. Remove the stator; measure that the resistance values at the starter output terminal and
the generator housing shall be infinite; if the resistance values are abnormal, replace the stator
coil.
10. Measure that the resistance values at the rotor conducting ring and the rotor housing
shall be infinite; if the resistance values are abnormal, replace the rotor assembly.
Assembly
Assemble in reverse sequence of disassembly.
Ignition System
Overview
ECU of the electronic ignition system will input signals sent by various sensors to the
electronic ignition trigger (ignition module) in ECU; after being processed by the ignition
controller, the signals generated by the signal generator will control the high-power audion of
the igniter in ECU, so as to make primary current of the ignition coil on and off, which
enhances the ignition reliability and service life and improves dynamic property and economy
of engine operation; the secondary winding of the engine ignition coil is directly connected to
a spark plug for ignition.
The ignition system consists of the following components and parts:
• ECU
Detect the engine and vehicle status as per signals sent by various sensors; ECU
assembly has an ignition trigger in it; the trigger will confirm the most suitable ignition
timing and ignition time as per ignition signal transmitted in ECU; ECU output will
switch on or off current inflowing to the primary coil.
• Ignition coil assembly
The ignition coil consists of primary winding, secondary winding, iron core and housing.
When the primary winding is grounded, it is charged; once ECU cuts off the primary
winding circuit, the charging will be ended; meanwhile, high voltage will be induced in
the secondary winding to enable discharging of the spark plug.
• Spark plug
• PG sensor (phase sensor) and DG sensor (speed sensor) work together with pulsed plate
by utilizing an inductive speed sensor to provide the engine speed information and
crankshaft TDC (top dead center) information in the ignition system.
Schematic Diagram of Ignition Coil
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Diagnosis
Fault Diagnosis
Diagnosis of several typical faults
Description Causes Handling Methods
Shake the engine 1. Low battery Check battery faults
crankshaft, but the engine 2. Looseness or poor contact of Inspect whether the wires are
does not start or is difficult battery post wire securely fixed
Start failure
to start; or the engine shuts 3. Damage of ignition coil Replace
of engine
down suddenly during 4. Falling off of the ignition coil Inspect whether the wires are
operation and cannot be harness connector securely fixed
started again. 5. ECU fault Check ECU faults or replace
There are roar sound and 1. Looseness of the ignition coil
Replace or reassemble
Malfunction black smoke from the harness connector
of some exhaust pipe when the 2. Poor operation status of some Adjust, clean or replace
cylinders engine operates at each spark plug
speed.
1. Malfunction of some
cylinders Refer to fault diagnosis above
The engine is difficult to 2. Electric leakage of the Replace
Insufficient
start and is weak for ignition coil
power of
acceleration and climbing 3. Looseness of the ignition coil
engine Replace or reassemble
during running. harness connector
4. Severe carbon deposit in the Replace
spark plug
Fault Diagnosis Process Sheet
Step Operation Yes No
1 Inspect as per engine fault diagnosis process or Go to Step 2 Go to engine fault diagnosis
not process
2 Go to Step 3 Go to engine fault diagnosis
Is the fault indicator lamp on process
3 Inspection of DTC Go to Step 4 Go to engine fault diagnosis
Read DTCs with a diagnostic scanner; is there process
any “misfire” fault
4 Restart after clearing faults; is there still any Go to Step 5 Go to engine fault diagnosis
“misfire” fault process
5 Inspection of electrical connection Go to Step 6 Re-connect
1. Inspect the ignition coil harness connector
for reliable connection and inspect the
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harness “on-off” state
2. Inspect the coil for high voltage and the
sparkplug for reliable connection
6 Inspection of ignition coil Go to Step 7 Replace faulty ignition coils
Inspect the coils one by one; is the result
qualified
7 Inspection of spark plug The ignition Replace faulty spark plugs
Inspect the spark plugs one by one; is the result system is in
qualified good condition
On-board Inspection
Ignition Spark Test
1) Turn the transmission shift lever to “Neutral” and draw back the brake lever to prevent
wheels from rotating.
2) Disconnect the fuel injector connectors and the ignition coil connectors.
Warning: Combustible gas may come out from the spark plug hole during test process if
the fuel injector connectors are not disconnected, which may cause a fire on the vehicle.
3) Remove the spark plug and inspect its state and figure number.
4) If normal, connect the ignition coil connectors, connect the spark plug to the coil HV
connecting pipe, and conduct ground connection to the spark plug.
5) Start the engine, and inspect whether the spark of the spark plug is normal; inspect relevant
parts as per “Diagnosis” if the spark plug cannot generate spark normally (no spark or
abnormal spark).
6) Install the spark plug and the ignition coil after inspection.
7) Connect the fuel injector connectors.
Ignition Coil Assembly
• Fault description: start failure, etc.

• General fault causes: burnout due to excessive current, damage due to external force, etc.
• Notes to maintenance: it is prohibited to use “short-circuit ignition test method” to test
ignition function during maintenance process, so as to avoid damages to the ignition coil.
• Simple test method:
1) Disconnect the negative battery wire.
2) Remove bolts and pull out the ignition coil from the cylinder head.
3) Measure the resistance of the ignition coil with a digital multimeter under ohm
range (terminals C and B shown in the picture below).
Resistance of primary coil: 1Ω±0.1Ω (23°C±3°C)
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4) Install the ignition coil assembly onto the cylinder head and connect its harness connectors;
connect the negative battery wire.
Spark plug
Removal
1) Remove the spark plug after removing the ignition coil.
2) Inspect the spark plug.
• Electrode wear
• Carbon deposit
• Damage of isolator
3) Replace with a new spark plug of corresponding specification if any abnormal
situation is found.
Electrode gap of spark plug “a”: 0. 85mm~0. 95mm
4) Joint surface between the spark plug and the mounting hole shall be clean without
impurities; screw the spark plug into the cylinder head and tighten with specific torque.
Tightening torque for spark plug: 20N·m~24N·m
Special Tools
Diagnostic scanner for electronic fuel injection system

Function: reading/clearing of DTCs of the electronic fuel injection system, observation of data
flow, motion test of parts, etc.
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Digital multimeter
Function: inspection of voltage, current, resistance and other characteristic parameters in the
electronic fuel injection system.
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Chapter IV Mechanical Maintenance of Engine

Inspection of Cylinder Pressure
Inspect compression pressure of the engine
cylinder as per the method below.
1) Warm up the engine.
2) Shut down the engine after warm-up.
Note:
Turn the transmission shift lever to
“Neutral” position after warming up the
engine, and fix the parking brake and
withstand drive wheels.
3) Disconnect the harness connectors of the

fuel injector.
4) Take off the ignition coil assembly and
spark plug.
5) Install a special tool (compression pressure
gauge) into the spark plug hole.
6) Press down the clutch (reduce start load of
the engine), and press the accelerator pedal to
downward limit to completely open the
throttle.
7) Start the engine with a fully-charged
battery, and read the maximum pressure on
the compression pressure gauge.
Compression pressure
1300kPa
Limit (minimum)
(300r/min)
Maximum pressure
difference between 100kPa
the two cylinders
8) Compression pressure value for each

cylinder is as shown in the table.
Note:
9) Operate each cylinder as per Step 5) to
Start the engine with a fully-charged Step 7) to obtain 4 readings.
battery to speed up the engine at least to
10) Install the spark plug and ignition coil
300r/min to measure the compression
assembly and reconnect the fuel injector
pressure.
harness connectors after inspection.
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Inspection of Oil Pressure

Inspect the following items first before
inspecting the oil pressure:
1. Oil level in oil pan. Fill oil to the full oil
level mark on oil scale in case of low oil
level.
2. Oil quality. Replace oil if it turns colors
or goes bad.
3. Oil leak. Repair if oil leak is found.
Maintenance
1) Remove the oil pressure alarm assembly.
2) Install and tighten a special tool (oil
pressure gauge) into the mounting hole of the
oil pressure alarm assembly.
3) Fix the engine tachometer.
4) Start and warm up the engine to normal
working temperature.
5) Increase the engine speed to 3000 r/min
and measure the oil pressure after warming
up.
Standard indicators related to oil
pressure are shown below:
≤52kPa @ idling
200~480kPa @ 3000r/min
320~500kPa @ rated speed
6) Shut down the engine and take off the oil

pressure gauge after inspecting oil pressure.
7) Remove sealant on thread of the oil
pressure alarm assembly, and re-apply Loctite
516 sealant in length of 4mm~5mm evenly
on place 1~2 teeth away from the thread top;
then, re-screw the oil pressure alarm
assembly into the mounting hole and tighten
it as per specified torque.
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Note:
The sealant edge around the seal ring shall
be smooth and level without embossing.
Tightening torque: 21N·m + 2N·m

8) Start the engine, and inspect the oil
pressure alarm assembly for oil leakage.
9) Shut down the engine, and connect the
harness terminal and the oil pressure alarm
terminal.
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Inspection and Adjustment of Valve

Clearance
1) Remove the cylinder head cover assembly.
2) Rotate the crankshaft clockwise, and
measure the clearance between the cam base
circle and the tappet working face with a
feeler gauge.
3) Replace corresponding valve tappet if

the valve clearance exceeds standard to
make sure that the clearance is within
specified standard.
Note:
Plug the feeler gauge between the cam base
circle and the tappet during inspection of
the valve clearance.
Cold state (coolant The valve clearance shall be inspected once

Valve temperature 15~25°C) every 20,000km
clearance Air
0. 16~0. 24mm
standard inlet Specific option and assembly method of the
Exhaust 0. 26~0. 34mm valve tappet is as follows:
1) Grouped sheet of valve tappet is shown
below.
S/N D ±T No. S/N D ±T No. S/N D ±T No.

1 3.08 0.010 308 15 3.36 0. 010 336 29 3.64 0.010 364
2 3. 10 0.010 310 16 3.38 0. 010 338 30 3.66 0.010 366
3 3. 12 0.010 312 17 3.40 0. 010 340 31 3.68 0.010 368
4 3. 14 0.010 314 18 3.42 0. 010 342 32 3.70 0.010 370
5 3. 16 0.010 316 19 3.44 0. 010 344 33 3.72 0.010 372
6 3. 18 0.010 318 20 3.46 0. 010 346 34 3.74 0.010 374
7 3.20 0.010 320 21 3.48 0. 010 348 35 3.76 0.010 376
8 3.22 0.010 322 22 3.50 0. 010 350 36 3.78 0.010 378
9 3.24 0.010 324 23 3.52 0. 010 352 37 3.80 0.010 380
10 3.26 0.010 326 24 3.54 0. 010 354 38 3.82 0.010 382
11 3.28 0.010 328 25 3.56 0. 010 356 39 3.84 0.010 384
12 3.30 0.010 330 26 3.58 0. 010 358 40 3.86 0.010 386
13 3.32 0.010 332 27 3.60 0. 010 360 41 3.88 0.010 388
14 3.34 0.010 334 28 3.62 0. 010 362 42 3.90 0.010 390
Notes:
1. “D”: nominal size of tappet thickness
2. “±T”: tolerance of tappet thickness
3. “No.”: located on top surface of inner tappet wall, with value of DX100
Grouped Sheet of Valve Tappet
2) Select one group from the grouped
sheet as standard tappet (generally Group
7 - 3.20).
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3) Assemble the selected standard tappet

onto the cylinder head assembly (valve,
camshaft and other parts are already
installed in place), and measure clearance
between each tappet and camshaft base
circle with a feeler gauge and make
records, for example, clearance of the
first valve on inlet side cylinder 1# is 40.
4) Replace proper tappet as per the valve
clearance specified in standard valve
clearance sheet and the clearance
measured above, for example, Group 17 -
3.40 can be selected, and thus the valve
clearance is 20.
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-{}-
Cylinder Head Cover Assembly

Removal and Installation
1) Remove the engine oil level gauge
assembly and the filler cap assembly.
2) Remove the engine harness assembly and
ignition coil assembly.
3) Remove the breather pipe of PCV valve.
4) Remove the cylinder head cover assembly.
5) Remove the sealing gasket from the
cylinder head cover.
6) Installation of the cylinder head cover is in
reverse sequence of its removal.
Apply small amount of gasoline engine oil on
the spark plug seal ring during assembling of
the cylinder head cover assembly; do not
damage the spark plug seal ring.
As shown in the picture, apply sealant
(TONSAN 1596Fa) on the upper end of the
contact surface between the cylinder head
sub-assembly and the oil pump front housing
assembly during installation. Install the
cylinder head cover assembly within 5min
after applying the sealant.
Requirements on installation of PCV valve:

Notes:
Install the PCV valve seal ring into the
1. Inspect each part for any defect or
cylinder head cover assembly;
damage before installation; if any, replace
the part immediately. Press the PCV valve assembly into the
PCV valve seal ring, and make sure tight
2. Apply sealant on upper matching
press fitting without inclination and
surface between the cylinder head and the
dropping.
oil pump front housing during installation
of the cylinder head cover, and inspect
carefully whether the sealing gasket on the
cylinder head cover is installed smoothly. Note: oil seal, cylinder gasket, metallic and
Inspect to make sure that there is not any non-metallic sealing gasket and non-
foreign matter in the installation groove of metallic seal ring shall not be used
the cylinder head cover sealing gasket and repeatedly during maintenance.
its sealing surface is free of oil stain and
foreign matter before installation of the
sealing gasket
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Oil Pan Assembly, Oil Filter

Assembly and Oil Strainer Assembly
Removal and Cleaning
1) Remove the oil filter assembly, drain bolt
and gasket to drain engine oil.
2) Remove the oil pan bolt, oil pan assembly,
strainer bolt, oil strain assembly and oil
strainer seal ring in order.
3) Clean matching surface between the oil
pan assembly and the cylinder block, and
remove the oil, used sealant and dirt on the
matching surface and clean the inside of the
oil pan.
4) Clean the screen of the oil strainer
assembly.
Note: On the oil strainer assembly there is

installed with two O-rings of oil pump
outlet, which shall not be omitted.
Installation
1) Install the oil strainer assembly; tightening
torque of the bolt is 10N·m±1N·m. Note to
inspect whether the oil strainer assembly and
its seal ring are intact; immediately replace
them in case of any damage.
2) Apply sealant (TONSAN 1591) as shown
in the left lower picture during installation of
the oil pan.
3) Install the oil pan assembly before
hardening (within 5min) of the sealant, and
tighten bolts in diagonal mode as per torque
specified in appendix.
Tightening torque: 10N·m±lN·m.
4) Tighten the drain plug of the oil pan.
Tightening torque: 45N·m±2N·m
5) Re-fill oil for the engine after 20min upon
installation (the sealant surface will be
solidified in 20min, and oil filling before
solidification of the sealant surface may cause
oil seepage, leakage or other problems).
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Oil Filter Assembly

1) The oil filter assembly is a vulnerable part
and shall be replaced every 5,000km (first
service cycle: 2,500km). Special tools must
be used for replacement and disassembly;
otherwise, the oil filter will be damaged
easily.
Tightening torque: 14N·m + 2N·m
2) During installation of the oil filter, its
connecting pipe must be screwed to bottom.
The connecting pipe thread shall not be
damaged, so as to cause burr. Apply
appropriate amount of gasoline engine oil on
the sealing surface of the oil filter assembly.
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Front Gear Train

Disassembly
1) Loosen connecting bolts between the
generator and its adjusting support.
2) Loosen connecting bolts between the
compressor and the compressor bracket as
well as those between the generator and the
generator bracket. The bolts shall only be
loosened not removed.
3) Loosen the adjusting bolts on the generator
regulating support.
4) Remove the generator belt and compressor
belt.
Inspection
Inspect the compressor belt and the generator
belt for crack, missing tooth, breakage,
abnormal wear and other defects. Replace the
belts immediately in case of any defect.
Inspect the water pump pulley and the
crankshaft pulley for breakage, falling off and
other defects; if any, please remove and
replace the damaged pulley immediately.
Detection method of generator belt tension: Installation

a) Rotate the crankshaft clockwise for two 1) Install the water pump pulley, and tighten
circles without reversal; the four Q1860610 hexagon flange bolts
b) It is not allowed touching the generator diagonally as per torque specified in
belt after stop of the crankshaft and before Appendix C.
detection of the generator belt tension; 2) Install the crankshaft pulley, and tighten
the crankshaft pulley bolts as per torque
c) Detect the generator belt tension with a
specified in Appendix C; tightening torque:
sonic tensiometer (the sonic tensiometer shall
90N·m+90° (note: torque to 90N·m first and
be on the middle position of the belt tension-
then rotate for 90°).
side span, i.e. above the crankshaft pulley –
water pump pulley, perpendicular to the
Note:
generator belt, and about 10mm away from
the generator belt); Please replace new crankshaft pulley bolts
for installation of the crankshaft pulley.
d) Parameters measured by the tensiometer:
The crankshaft pulley bolts can only be
MASS=4.4g/m, WIDTH=17.8mm/R, used for 1 time.
SPAN=181. 5mm.
3) Install the generator belt and pre-tighten
e) The generator belt tension shall be
the adjusting bolts; adjust the generator belt
controlled within 750N±50N (before ignition
tension to specification.
of engine);
4) Tighten the adjusting block bolts
f) Repeat the belt installation steps if the
(Q1860840) for the generator adjusting
tension is detected unqualified until
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qualification. support assembly and the mounting bolts

Detection method of compressor belt tension: (GB/T 16674.2 M10X95) of the generator
assembly in order as per torque limits
a) Rotate the crankshaft clockwise for at least specified in Appendix C.
two circles without reversal;
5) Install the compressor belt and use
b) It is not allowed touching the compressor crowbar to support the cylinder block; tension
belt after stop of the crankshaft and before the compressor belt outward to qualification.
detection of the compressor belt tensioning
6) Tighten the three mounting bolts (two:
force;
1000094-H01 and one: Q1840825) of the
c) Detect the compressor belt tension with a compressor in order as per torque limits
sonic tensiometer (the sonic tensiometer shall specified in Appendix C.
be on the middle position of the belt tension-
side span, i.e. above the crankshaft pulley – Note: make sure to face the engine gear train
compressor pulley, perpendicular to the while assembly the engine belt and the
compressor belt, and about 10mm away from compressor belt and make sure that the letters
on the belts are positive, so as to prevent
the compressor belt);
reserve.
d) Parameters measured by the tensiometer:
MASS=4.4g/m, WIDTH=14.2mm/R,
SPAN=212mm.
e) The compressor belt tension shall be
controlled within 600N±50N (before ignition
of engine);
f) Repeat the belt installation steps if the
tension is detected unqualified until
qualification.
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Timing Mechanism
Note: the timing system adopted for the
JL473Q1 engine is free of maintenance for
life time; thus, it is recommended to avoid
unnecessary disassembly of the timing
system.
Timing Inspection
1) Remove the cylinder head cover
assembly as described above.
2) As shown in the picture, rotate the
crankshaft to make the camshaft assembly
at TDC (top dead center) for compression
of four cylinders.
3) Observe the position of the crankshaft
pulley mark point. As shown in the picture,
the timing system is aligned if the mark 0
point on the oil pan front housing assembly
is aligned.
Removal
1) Remove all parts connected with the oil
pan assembly, oil pump front housing and
cylinder head cover assembly.
2) Remove the oil pan assembly and the
3) Remove the water pump pulley.
4) Remove the crankshaft pulley and the oil
pump front housing assembly.
5) Remove the hydraulic tension assembly,
chain tensioning guide assembly, chain
guide rail assembly, timing chain assembly
and crankshaft timing chain in order.
Notes:
Inspection
1. The hydraulic tensioner shall be
Inspect the timing chain and guide rail for
fixed by a lockpin first for removal.
crack, and replace them if necessary.
2. Never rotate the camshaft and the
crankshaft after removal of the timing
system without instruction. Otherwise,
interference may exist between the piston
and the valve and damage relevant parts of
the both.
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Installation
1) Rotate the camshaft as per the timing mark
to make the inlet and exhaust valves of the
four cylinders all under closed state (slightly
rotate for a small angle but a big one to
achieve);
Rotate the crankshaft to make sure that the
four pistons are basically at same height, i.e.
the woodruff key of the crankshaft faces to
both side of the engine. As shown in the left
picture, rotate the camshaft to align the
timing mark.
As shown in the picture, rotate the crankshaft

to make its front end woodruff key align to
arrow mark on the crankshaft and to make the
fourth cylinder piston at TDC.
2) Installation of Timing System

Install the crankshaft timing chain, chain
guide rail assembly, timing chain assembly
and chain tensioning rail assembly in order;
inspect whether the timing mark is aligned to;
if not, please re-align it; install the hydraulic
tensioner assembly after alignment, and make
sure that the lockpin of the chain is already
pulled out from the tensioning and guide rail
grooves. Inspect whether the hydraulic
tensioner piston correctly contacts the chain
tensioning guide assembly at this time. Drop
(spray) gasoline engine oil at the camshaft
sprocket (two), chain tensioning rail
assembly, chain guide rail assembly,
crankshaft timing sprocket and chain
assembly engagement position after assembly
of the timing system.
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Notes:
It is not allowed using the inlet and exhaust
camshaft timing sprockets to drive rotation
of the crankshaft and not allowed reversal
of the timing system after completing
installation of the timing system.
Make marks as per the following method if
the timing mark on the timing chain
assembly is not clear:
1. Make a mark on any external chain
plate;
2. As shown in the picture, make timing
marks on the 9th and 43rd chain plates in
clockwise direction of the mark above, and
take the three marks as the timing marks.
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3) Install the oil pump front housing as per

description below.
4) Install the water pump pulley and
crankshaft pulley.
5) Apply torque specified in Appendix C
while installing the crankshaft pulley.
6) Install other removed parts and
components, and inspect that all removed
parts are already installed back to original
positions.
7) Adjust the tension of the compressor belt.
8) Adjust the tension of the generator belt.
9) Re-fill gasoline engine oil for the engine.
Water Pump Assembly

Removal
1) Refer to timing removal to water pump
pulley for removal steps.
2) Remove the generator adjusting support
and water pump assembly.
Inspection
Inspect the water pump for damages; rotate
the water pump to observe whether there is
clamping; if any, please replace the water
pump.
Installation
1) Install the water pump assembly and
compressor tensioning support baseplate.
Apply sealant for installation of the water
pump; make sure that the gluing surface is
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clean without oil dirt and scratch. The gluing

area is as shown in the picture. Install the
water pump assembly within 5min after
completing gluing.
Note:
Do not add coolant within 20min after
installing the water pump, so as to prevent
the sealant from entering into the water
pump turbine.
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Oil Pump Front Housing

Removal
1) Remove all parts connected with the oil
pan assembly, oil pump front housing and
2) Remove the oil pan assembly and the
3) Remove the water pump pulley.
4) Remove the crankshaft pulley and the oil
pump front housing assembly.
5) Take off the oil pump from the oil pump
front housing assembly.
The crankshaft front oil seal shall not be
reused once removed; please replace a new
crankshaft front oil seal during installation.
Measurement
1009027-H01 Upper locating pin of oil 1) Radial clearance
1
pan Inspect back lash between inner and outer
1703051-H01 Sealing gasket of oil filter rotors with a feeler gauge. Replace the oil
2
oil line
3 1000036-01 Locating pin of pressure
pump if the back lash exceeds limit.
plate Back lash between inner and outer rotor:
4 1000360-H03 Oil level gauge assembly 0.030mm~0.099mm;
6 1009010-H03 Oil pan assembly 2) Side clearance
7 1000018-H01 Connecting pipe of oil filter Measure side clearance with a ruler and
8 1012010-H01 Oil filter assembly
feeler gauge.
GB/T 70. 1
9 Hexagon socket cap screw
M6*25 Side clearance limit: 0.045mm~0.105mm
10 1009022-H01 Drain plug
11 1009023-H01 Drain plug gasket Notes:
12 1000038-01 Flywheel locating pin
13 1009025-H01 O-ring of oil pump outlet 1. Press in the oil seal forward for
14 Q1860830 Hexagon flange bolt installation to make the oil seal end face
15 1000600-H01 Front oil seal assembly of 1.5 mm lower than the end face of the oil
crankshaft pump housing.
1000096-H03 Mounting bolt of front
16 housing 2. Inspect the inner & outer rotors, rotor
17 1000097-H03 Mounting bolt of inlet cover plate and oil pump housing of the
manifold oil pump for wear or damage.
1011010-H03 Oil pump front housing
18
assembly 3. Replace the oil pump front housing
19 1006040-H04 OCV valve assembly assembly when the oil pump is damaged.
1006051-A01 Mounting bolt of oil
20
control valve
22 1024011-H03 1# engine lifting hook
23 1000381-H03 1# kg harness support
Note: if the OCV is removed, please
Sealing gasket of phaser oil
24 1009031-H04
line apply sealant (TONSAN 1596) on
25 Q1860616 Hexagon flange bolt mounting bolts for reinstallation.
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26 1010010-H03 Oil strainer assembly
Installation
1) Install the oil pump back onto the front housing, and pre-tighten bolts with 5N·m±lN·m
and tighten with 11N·m±l. 5N·m. The bolts must be tightened (or pre-tightened)
simultaneously with tightening machine or manually in diagonal mode as per the torques
above.
2) Install a special tool (oil seal duct) on the crankshaft and apply engine oil on the special
tool to prevent damages or scrolling up of the oil seal lip while install the oil pump on the
crankshaft.
3) Install the oil pump front housing assembly onto the cylinder block after 5min upon gluing
(gluing area is shown in the picture). Correctly use and tighten the bolts simultaneously with
a tightening machine or manually in diagonal mode as per specified torque (tightening torque:
23N·m±2N·m).
4) Install the oil strainer assembly as

described above.
5) Install the oil pan assembly and oil
strainer. Note to inspect whether the upper
locating pin and oil line seal ring of the oil
pan are intact and whether the seal ring is
elastic; if not, replace them. Please first
knock the locating pin into the oil pan
assembly for replacing upper locating pin of
the oil pan; inspect to make sure that the
mounting groove for the oil line sealing
gasket of the oil strainer is clean without
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foreign matters and its underside is smooth

and level; then, install the oil line seal ring
before installing the locating pin. Gluing
area of the oil pan assembly is shown in the
picture. Install the oil pan assembly within
5min after completion of gluing.
components, and inspect that all removed
parts are already installed back to original
positions.
9) Re-fill gasoline engine oil for the engine
after 20min upon completion of installation.
Camshaft
Removal
1) Remove the timing system as described
above.
2) Remove the camshaft cap and camshaft.
Remove the camshaft cap bolts in order of
E5# - 15# - E2# - 12# - E4# - 14# - I/El# -
E3# - 13# (opposite order for installation).
3) Remove the phaser assembly from the
inlet camshaft if necessary.
Wear of Camshaft Bearing Bush

Inspect the camshaft bearing bush for pitting,
scratch, wear or damage. Replace it
immediately if any defect is found.
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Wear of Camshaft
Measure the cam height with a micrometer.
Replace the camshaft if measured height is
less than limit value.
Radial Run-out of Camshaft
Place the camshaft between two V-shape
blocks and measure its radial run-out with a
dial indicator. Replace the camshaft if the
radial run-out goes beyond limit value.
1. Limit for radial run-out of 1# and 5#
journals: 0.03mm;
2. Limit for radial run-out of 2#, 3# and 4#
journals: 0.015mm;
3. Run-out limit of all cam base circles:
0.02mm.
Wear of Camshaft Journal

Inspect the camshaft journal and camshaft
cap for iron mold, scratch, wear or damage.
Replace the camshaft or cylinder head and
the camshaft cap if any defect is found. Do
not replace the cylinder head when the
camshaft cap is not replaced nor replace the
camshaft cap when the cylinder head is not
replaced. Measure clearance as follows with
a plastic feeler gauge:
1) Clear the camshaft cap and camshaft
journal;
2) Install the camshaft onto the cylinder
head;
3) Place a plastic feeler gauge along entire
width of the camshaft journal (parallel with
the camshaft);
4) Install the camshaft cap; please refer to
the installation procedure below;
5) Tighten the camshaft cap bolts; please
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refer to the installation procedure below.
Standard Limit value Note:

Clearance 0. 045~0. 0. 117mm
087mm Please do not rotate the camshaft after
installing the feeler gauge.
Item Standard
Cylinder head 6) Remove the camshaft cap and measure
camshaft hole 27.0000~27. 021mm clearance width at the widest point of the
diameter feeler gauge with a graduated scale. Measure
Outer diameter of the outer diameter of camshaft journal if the
22.934~22. 955mm measured camshaft journal clearance exceeds
camshaft journal
limit value. Replace the camshaft in case of
large difference from specification.
Notes: Installation
1. Make sure that each cylinder piston is 1) Apply engine oil on the cam and journal
basically at same height while assembling of inlet and exhaust camshafts, the camshaft
the camshaft. bearing seat of cylinder head and the valve
tappet; place the camshaft on the cylinder
2. Note to distinguish the inlet and exhaust
head; install the camshaft cap onto the
camshafts; the inlet camshaft is longer with
camshaft and cylinder head. Make sure that
one more signal panel.
the mounting surface of the camshaft cap is
3. Applied and filled oil shall be oil used free of scratch, rust and other defects and the
for the engine: SL 5W-30; camshaft bearing cap shall be assembled as
4. Please note to inspect whether the high per specified sequence and arrow direction.
pressure oil plug is installed in case of As shown in the picture below, the arrow
replacement of the cylinder head. shall point to the front end of the engine.
2) Please make sure that the locating pin is
installed in place when the phaser is installed
back to the inlet camshaft assembly; tighten
mounting bolts after align the phaser to the
locating pin. Tightening torque:
70N·m±5N·m.
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Note: 2) Install the camshaft cap bolts and tighten

them in order of 13# - E3# - I/E1# - I4# -
Rotate the camshaft for clamping after
E4# - I2# - E2# - I5# - E5# after pre-
tightening the camshaft cap bolts; if any,
tightening (pre-tightening torque must be
please inspect whether the installation
less than tightening torque); tighten them to
procedure is wrong, remove and inspect the
specified torque. Tightening torque:
matching surface and then re-install.
13N·m±lN·m.
3) Inspect the valve clearance as described

above; select and assemble the tappet again
if the clearance does not meet requirements.
Remove the camshaft and replace the tappet
as described above; re-install the camshaft;
inspect the valve clearance until the
clearance reach standard.
4) Align to the timing marks while installing
the timing system.
components as described above.
8) Re-fill gasoline engine oil for the engine.
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Valve and Cylinder Head

Removal
1) Remove the timing system and inlet and
exhaust camshaft bearing as described above.
2) Remove the exhaust manifold assembly.
3) Remove the cylinder head connecting
bolts.
4) Inspect around the cylinder head to
determine what part is necessary to be
removed or disassembled, and then remove or
disassemble such part.
5) Separate the cylinder block and cylinder
head.
Removal of Cylinder Head Assembly

1) As shown in the left picture, use a valve
lift to extrude valve spring.
2) Then, use a tweezers to take off cone
locking piece, as shown in the picture below.
3) Release the tool, and remove the valve

spring retainer and valve spring.
4) Remove the valve from the combustion
chamber side.
5) Use a special tool to remove the valve oil

seal from the valve duct side, and then
remove the valve spring base (as shown in the
picture).
Note:
The oil seal shall not be reused once being
removed. A new oil seal must be used for
assembly.
6) Use a valve duct ejector to push out the
valve duct from the combustion chamber
side to the valve spring side.
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Note:
The valve duct shall not be reused once
being removed. A new (large size) valve
duct shall be used for assembly.
7) Place the removed parts (except for the
valve oil seal and valve duct) in sequence,
so as to be able to assemble the parts back
to original positions.
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Inspection
Valve duct:
Measure diameter readings of the valve rod
and duct with a micrometer and caliper
gauge, so as to inspect clearance of the valve
rod and duct. Make sure to measure the
diameter readings for several times along the
entire length of the valve rod and duct.
Replace the valve and valve duct if the
clearance exceeds limit value.
Inspect the tail end offset of the valve rod

with a caliper gauge; if unavailable, use a dial
indicator instead. Remove the tail end of the
valve rod in directions 1 and 2 to inspect the
tail end offset. Replace the valve and valve
duct if the offset exceeds limit value.
Valve
1) Clear all carbon deposit on the valve.
2) Inspect working surface of each valve and
the valve rod for wear, burn or deformation;
replace valves if necessary.
Refer to the table below for relevant sizes of
valves
Item Standard
Diameter of Inlet 5. 465~5. 48mm
valve rod Exhaust 5. 44~5. 455mm
Inlet
Inner diameter 5. 5~5. 512mm
Exhaust
Clearance Inlet 0. 02~0. 047mm
between valve
Exhaust 0. 045~0. 072mm
rod and duct
3) Measure thickness of the valve head.
Replace the valve if measured thickness
exceeds limit.
Refer to the table below for thickness of
valve head.
Thickness of valve head
Standard
Inlet 3~3. 3mm
Exhaust 2. 3~2. 7mm
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4) Inspect the valve rod end face for

indenture and wear. Level the valve rod end
face if any indenture or wear is found;
however, pay attention to the leveling extent,
so as not to grind off its chamfer. Replace the
valve if its chamfer is ground off.
5) Contacting width of valve seat: In general,

make contacting marking graph on each
valve, for example, evenly apply a layer of
blotting membrane on the valve seat, and
rotate and inspect the valve seat and valve
head. Valve grinding tools must be used
(such tools are used for grinding of valves).
Standard
width of Minimum: 1.1mm;
Inlet
surface uneven extent: 0.4mm
marking
6) Repair of valve seat: Re-grind, cut and

polish if the mark generated by contact
between the valve seat and the valve is
uneven, or the marking width id not within
specified scope.
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(1) Exhaust valve seat: as shown in the

picture, use the valve seat reamer to repair
twice. Repair with two reamers: one be
positioned to 15°, and the other 45°. Required
valve seat width must be achieved in the
second time of repair.
Exhaust valve width: 1.0mm~1.4mm
(2) Inlet valve seat: the repair procedure is the

same as that for the exhaust valve seat; one
reamer be positioned to 30°, and the other
45°. Inlet valve width: 1.1mm~1.3mm
(3) Valve grinding: the valve seat shall be

ground in two steps; step one: apply coarse
grinding paste on end face for grinding; step
two: grind with fine grinding paste; in each
step, valve grinding tools shall be used to
grind as per common grinding method.
Cylinder Head
Note: 1) Clear carbon deposit in the combustion
chamber.
It is not allowed using any sharp tool to
scrap carbon deposit. Pay attention not to 2) Inspect the cylinder head inlet and outlet
damage or scratch metal surface while holes, combustion chamber and cylinder head
clearing carbon deposit. It is the same for surface for scratch.
valves and valve seats. 3) Flatness of cylinder head surface: inspect
the surface at 6 positions (as shown in the left
picture) with a knife straight edge and feeler
gauge. Level the cylinder head surface with
plate and about 400 abrasive paper
(waterproof emery paper) if deformation limit
is exceeded: place the abrasive paper on the
plate, and grind the cylinder head surface on
the paper to grind off high points. Replace the
cylinder head if the feeler gauge reading still
cannot reduce to the limit scope after the
grinding operation. Leakage of combustion
gas from the cylinder head mating face is
usually caused by crease and deformation of
the cylinder head surface, and such leakage
may reduce output power and engine
overheating due to high temperature of
coolant.
Deformation limit: 0.030mm
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Inspection method of surface flatness: 4) Inspect the matching surface between the
cylinder head and manifold with a knife
Press a ruler on the cylinder head mating
straight edge and feeler gauge for
surface as per the bold black line shown in
deformation to make sure whether the
the picture above, and then measure the
surface is necessary to be leveled or the
clearance between the ruler and mating
cylinder head is necessary to be replaced.
surface with a feeler gauge.
Deformation limit: 0.05mm
Note:
The used ruler shall be straight and level;
keep the ruler still during measurement to
make sure measurement accuracy.
Valve Spring
Inspect whether each spring is intact,
damaged or weakened in reference to the
data in the table below. Remember that a
weak valve spring will cause vibration and
generate gas leakage due to pressure
reduction of the valve seat, leading to
reduction of output power.
Item Standard
Free length of valve
40mm
spring
Pre-load of valve
29. 9mm for 109N~127N
spring
1) Use a ruler and plate to measure the
clearance between the valve spring end and
ruler.
2) Inspect perpendicularity of each spring as
per the clearance value. The valve spring
must be replaced if the clearance exceeds
the limit value given below.
Perpendicularity limit of valve spring:
1.0mm
Assembly
1) Use a φ 10. 5mm reamer to ream the duct
mounting hole to 10. 5 00..098
083 mm before
installing the valve duct into the cylinder
head.
The valve duct is then φ10. 5 00..098
083 mm in
size.
Notes:
1. The valve duct shall not be reused once
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being removed. Install a new valve duct

(large size).
2. It is the same for inlet and exhaust
valves.
2) Install the valve duct into the cylinder

head. Press the new valve duct into the hole
with tools under normal temperature until
the duct installer contacts the cylinder head.
Make sure that the valve duct extends 11.3
±0.2mm out from the cylinder head and the
inlet and exhaust valves shall keep the same.
3) Use a 5.0mm reamer to ream the valve

duct hole diameter. Clear the duct hole after
reaming.
4) Install the valve spring seat onto the
cylinder head.
Note: 5) Install a new valve oil seal; apply

gasoline engine oil on the valve duct head;
Do not use a hammer or other objects to
install the oil onto main shaft and press the
tap or knock the valve oil seal duct installer
valve oil seal duct installer handle manually
handle. The valve duct installer handle
to install the oil seal on the valve duct.
only needs to be pressed manually.
Tapping or knocking the valve duct
installer handle may cause damages to the
oil seal.
6) Install the valve and apply gasoline

engine oil on the valve oil seal, valve duct
hole and valve rod.
7) Install the valve spring seat and valve

spring, and make sure that the mark faces
upward while installing the valve spring (the
mark is on coarse pitch end of the valve
spring). Each valve spring has top end
(coarse pitch end) and bottom end (fine
pitch end) if the mark cannot be identified.
Make sure that the bottom end (fine pitch
end) of the spring faces the bottom end
(valve spring seat) during installation of the
spring.
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8) Install the cone locking piece and valve

spring seat. Put the cone locking piece into
the valve spring seat hole; as shown in the
picture, combine the two locking pieces into
a circle and put them in with their large ends
facing upward.
9) Use tools for valve pressing to press the
cone locking pieces in the valve spring seat
hole into the valve rod groove. Re-inspect
whether all cone locking pieces are pressed
and fitted correctly after completing press
fitting.
Cylinder Gasket Assembly

Remove the old cylinder gasket assembly;
clean the mating surface between the
cylinder block and cylinder head; install the
new cylinder gasket assembly as shown in
the picture (note to inspect whether each
water line, oil line and bolt hole for
matching of the cylinder gasket assembly
and cylinder block are aligned; observe
whether the cylinder head locating pin is
deformed or damaged, and if so, please
replace it immediately).
Notes:
The original connecting bolts of the
cylinder head shall not be reused and shall
be replaced during maintenance.
High-pressure oil hole of the cylinder
gasket assembly shall be aligned to the oil
hole on the crankcase; the marked surface
shall face upward; the gasket assembly
shall not be installed reversely.
The cylinder gasket assembly shall not be
reused once being removed and shall only
be pressed to installation once; a new
cylinder gasket assembly must be used for
reinstallation.
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The connecting bolts of the cylinder head

shall be tightened as per the following steps.
1) All connecting bolts (with pads) of the
cylinder head shall be pre-tightened in speed
no more than 20r/min and at torque of
25N·m±2 N·m as per sequence shown in the
left picture or simultaneously.
2) All connecting bolts (with pads) of the
cylinder head shall be screwed for 90º for
tightening at torque of 25N·m and in speed
no more than 20r/min as per sequence
shown in the left picture or simultaneously;
the angle is measured from 25N·m.
3) Install in reverse sequence of removal.
4) Adjust the inlet and exhaust valve
clearance as described above.
5) Inspect to confirm that all removed parts
are put back to original places. Re-install all
parts that have not been re-installed.
6) Re-fill coolant and exhaust air in the
cooling system.
7) Install the battery and re-connect the
battery wires.
8) Inspect each connection for fuel leakage,
coolant leakage and exhaust gas leakage.
9) Make sure that the ignition timing is
within specified scope.
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Piston, Piston Ring, Connecting Rod

and Cylinder
Removal
1) Drain the gasoline engine oil.
2) Remove the cylinder head assembly from
the cylinder block as described above.
3) Remove studs of the oil pan separator plate
and oil retainer plate.
4) Remove the carbon deposit on the upper
end of the cylinder before removing the
piston from the cylinder.
5) Remove the connecting rod bolts; remove
the connecting rod cap; push out the piston
and connecting rod from the cylinder.
6) Mark cylinder numbers on all pistons,
connecting rods and connecting rod caps with
a pencil or sharp paint (remove and mark
each part one by one to avoid marking error).
7) Use a piston ring expander to remove the
compression ring, scraping ring, scraper ring
and backing ring from the piston.
8) Remove the piston pin from the connecting

rod.
(1) Carefully loosen the piston pin snap ring
as shown in the picture.
(2) Press out the piston pin.
Cleaning
Clean out the carbon deposit on the piston
head and piston ring with proper tools.
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Cylinder
1) Observe the cylinder wall for obvious
scratch, unevenness or embossment. Replace
the crankcase if the cylinder wall is very
rough, deeply scratched or uneven.
2) As shown in the picture, measure cylinder
bore diameter at two direction of the cut
circle 10mm from the top surface of the
cylinder block with a inside micrometer;
replace the crankcase if average of the two
measured values is more than φ 73. 025mm.
Piston
1) Inspect the piston for wear, crack or other
damages, and replace any damaged or faulty
piston.
2) Piston diameter
As shown in the picture, the piston diameter
shall be measured at 15mm along vertical
direction from the piston skirt bottom mouth
up to the piston pin.
3) Piston clearance
The piston clearance is difference between
the cylinder diameter and the piston diameter.
The piston clearance shall be within the scope
specified below. Inspect the cylinder bore
diameter or piston diameter if out of
tolerance, and replace corresponding out-of-
tolerance parts. Piston clearance: 0. 01~0.
039mm
The piston diameter and piston pin hole

diameter are shown in the table below.
Piston
Standard φ72. 975~φ72. 99mm
diameter
Piston
pin hole Standard φ18. 002~φ18. 006mm
diameter
Side clearance of piston ring groove
The piston ring groove must be clean and dry
without carbon deposit before inspection.
Install the piston ring in the ring groove;
measure the clearance between the ring and
the ring groove with a thickness gauge; if the
clearance is out of tolerance, inspect the
piston ring groove width and piston ring
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height, and replace corresponding out-of-

tolerance parts. Side clearance of piston ring
groove:
First ring: 0.03mm~0.07mm
Second ring: 0.03mm~0.07mm
Piston Pin
Inspect the piston pin, connecting rod small
end hole and piston pin hole for wear or
damage, and replace them if they are severely
worn or damaged.
Piston pin clearance. Inspect the clearance
between the piston pin and connecting rod
small end at the small end; replace the
connecting rod or piston pin if the connecting
rod small end hole or piston pin is severely
worn or damaged or the clearance is out of
tolerance.
Item Standard
Clearance between 0. 003~0.

connecting rod small end 016mm
hole and piston pin
Clearance between piston 0.002~0.011

pin hole and piston pin mm
Diameter of connecting rod small end hole:

φ18. 003mn~φ18. 011mm
Note:
piston pin diameter: φ17. 995~φ18mm
Clean the cylinder top and clean out carbon
deposit before inserting the piston ring.
Piston Ring
Measure the opening clearance at the piston
ring end; insert the piston ring in the cylinder;
measure clearance with a thickness gauge.
Replace the piston ring if the clearance is out
of tolerance.
Item Standard Limit
Working First
0. 155~0. 275mm (0. 5mm)
clearance ring
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of piston
ring (after
being Second
inserted in ring 0. 28~0. 41mm (0. 5mm)
cylinder
bore)
Connecting Rod
Side clearance at big end: connect the
connecting rod and the crank pin and inspect
the side clearance at the connecting rod big
end under normal status. Replace the
Item Standard Limit connecting rod if the measured side clearance
is out of tolerance.
Side clearance 0. 10~0. 25mm 0. 35mm
at big end Straightening of connecting rod: put the
connecting rod on a straightener and inspect
the connecting rod for bend or twist; replace
the connecting rod if out of tolerance.
Bend limit: 0.05/80
Twist limit: 0.10/80
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Crank Pin and Connecting Rod

Bearing Bush
Inspect the crank pin for irregular wear or
damage. Measure out-of-roundness or cone
straightness of the crank pin with a
micrometer. Replace the crank or re-grind
the crank pin if the crank pin is damaged or
its out-of-roundness or cone straightness is
out of tolerance.
Model of
connecting rod Diameter of crank pin
bearing bush
Standard size cp 37. 982~cp 38. 000mm
Roundness and straightness limit of crank
pin: 0.005mm.
Connecting Rod Bearing Bush

Inspect the bearing bush for melting, pit,
erosion or surface peeling, and observe
contacting shape. The bearing bush must be
replaced in case of obvious situation above.
Clearance of Connecting Rod Bearing

Bush
1) Clean the bearing bush and crank pin
before inspecting clearance of the bearing
bush.
2) Install the bearing bush onto the
connecting rod and bush cover.
3) Place a plastic feeler gauge on entire
width of the crank pin in parallel to the
crank axis while connecting with the
bearing bush; keep away from the oil hole.
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4) Connecting rod bolt: inspect that the boss

on the connecting rod cap shall point to
engine front end while installing the
connecting rod big end cap.
Tightening torque: 15N·m+90º (refer to
Chapter IX for tightening of connecting rod
bolt).
Note:
The connecting rod bolt shall not be
reused and must be replaced with a new
one once being removed.
5) Remove the connecting rod cap; place a

scale plate on the surface of the plastic
feeler gauge and measure the width of the
plastic feeler gauge at the widest point of
the clearance. Use a new standard-size
bearing bush and re-measure the clearance
if the clearance is out of tolerance.
6) Replace the crankshaft if the clearance is
still out of tolerance after using a new pair
of standard bearing bush.
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Chapter V Air Inlet System

Air Cleaner Element
Removal
1) Use a 10mm socket wrench to
remove the tightening bolts on mounting
points of the air cleaner; use a cross
screwdriver to loosen tightening hoop
between the rubber inlet pipe and the air
cleaner lower housing; remove the rubber
inlet pipe, and disassemble left and right clips.
Pull out the lower housing from the ball bolt
mounting point.
2) Draw the upper housing pin out
from the lower housing pin hole; remove the
air cleaner lower housing; take out the air
cleaner element.
3) Inspect the air cleaner element for
dirt. Use compressed air to blow off the dirt
from outlet end of the cleaner element if
necessary. Replace the cleaner element if it is
too dirty or of severe deformation.
Installation
1) Place the element in the air cleaner
lower housing and place the air cleaner lower
housing on mounting position; plug the upper
housing pin into the lower housing pin hole.
Tighten left and right clips.
2) Install the lower housing to the ball
bolt mounting point; assemble the rubber inlet
pipe to the cleaner lower housing and tighten
the hoop.
3) Install and tighten the bolt to its
mounting point. Tightening torque: 10 Nm±
1Nm.
Notes:
1. Inspect from the left side of the air
cleaner whether the air cleaner upper and
lower housings are well matched and
whether the upper housing pin is correctly
plugged in the pin hole after tightening the
left and right clips during installation of the
air cleaner.
2. When compressed air is used to clean the
element, please blow the air from outlet end
(clean end) of the air cleaner element, and
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the airflow outlet of the compressor air spray

gun shall be 30cm away from the element.
Throttle Body and Inlet Manifold

Removal
1) Remove the harness, breather pipe, vacuum
booster hose, minor-cycle hose and shall
return-water hose connected with the inlet
manifold.
2) Remove the fuel manifold assembly with
fuel injector, throttle body assembly and inlet
manifold reinforcing plate.
3) Remove the inlet manifold and 10# harness
support.
Note: the inlet pressure and temperature
sensor installed on the inlet manifold may not
be removed if unnecessary. Please inspect the
sensor for damage if it is removed, and
replace it immediately in case of any damage.
Installation
1) Assemble the inlet manifold in place with
the inlet manifold studs; tighten bolts and nuts
simultaneously with a tightening machine or
manually in cross mode from center to both
sides. The tightening torque is 23Nm±2Nm.
Install the inlet manifold reinforcing plate and
tighten bolts.
2) Install the electronic throttle body
assembly; tighten the connecting bolts in
diagonal at torque of 10Nm±1Nm.
3) Inspect to make sure that all removed parts
are installed back to original positions; if not,
install required parts that are still not installed.
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Chapter VI Exhaust System

Exhaust Manifold with Three-way Catalyst
Assembly
The exhaust manifold of EA14FF engine is
installed on exhaust side of the engine
cylinder head, with inlet flange being
tightened and connected to the cylinder head
exhaust side with bolts (nuts) and outlet
flange being connected to the silencer inlet
flange with compressed spring bolts. Due to
relatively high working temperature, the
exhaust manifold and the three-way catalyst
are installed with thermal shrouds to reduce
heat damage to other parts in the engine
compartment. The main purpose of the
exhaust manifold is to collect exhaust gas
from each cylinder of the engine, avoid
mutual interference of exhaust gas from each
cylinder and discharge the exhaust gas from
the engine safely and completely to the
greatest extent. The main purpose of the
three-way catalyst is to reduce the
concentration of HC, CO and NOx in the
exhaust gas, so as to improve emission
indicator.
1000330-H04 Sealing gasket of exhaust
Removal
1 manifold 1) Lift the vehicle.
Exhaust manifold with
2 1008030-H04 three-way catalyst 2) Remove the front and rear oxygen
assembly sensor harness.
3 1000099-H01 Exhaust manifold stud
3) Remove the connecting bolts with
4 1000321-H01 Hexagon flange nut
5 Q1841025 Hexagon flange bolt the silencer inlet flange.
6 Q1860610 Hexagon flange bolt 4) Lower the engine.
7 1000420-H04 Three-way catalyst upper
housing assembly 5) Remove the front and rear oxygen
1000380-H04 Exhaust manifold upper sensor connectors.
8 housing assembly
6) Remove the thermal shroud and
GB/T 5789
9 Hexagon flange bolt bolts of the exhaust manifold with three-way
M10X1. 25X25
10 1024012-H03 2# engine lifting hook catalyst.
8) Remove the connecting bolts and
nuts for the inlet flange face of the exhaust
manifold with three-way catalyst, and then
remove the exhaust manifold with three-way
catalyst.
Note: Installation
Replace with a new graphite ring, 1) Tighten the mounting bolts (nuts) of
compressed spring and compressed spring the inlet flange face in sequence from center
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bolt for reinstallation. to two sides or simultaneously with a

tightening machine while assembling the
exhaust manifold with three-way catalyst
Warning: assembly.
When the exhaust manifold with three- 2) Tighten the front and rear oxygen
way catalyst is still hot, do not repair it, so as sensors as per specified torque after tightening
to prevent being scalded. Maintenance is only the mounting bolts (nuts) of the exhaust
allowed after the system cools down. manifold with three-way catalyst assembly as
per torque requirements.
As for other parts of the exhaust system,
please do not repair them when they are hot, 3) As for other parts, install in reverse
so as to prevent injuries. sequence of removal.
Poisoning of Three-way Catalyst

Warning: Sulphur in fuel may cause catalyst poisoning,
and lead content over 5mg/l in fuel will cause
Warning: catalyst carrier will be melted severe catalyst poisoning. Thus, leaded
when temperature is more than 900ºC. To gasoline is not allowed for vehicles equipped
prevent occurrence of such faults, describe with three-way catalysts. Zinc and phosphorus
the fault causes in detail and conduct repair. in engine oil will cause catalyst poisoning in
case of excessive oil consumption. H2S
exhausted from the three-way catalyst can be
noted the easiest. Such gas smells like rotten
Notes: eggs. The phenomenon above can be solved
1. Excessive high temperature of the by changing fuel of other brands. Make sure
catalyst carrier is mainly caused by the that the CO emission meets standards under
ignition system or fuel system. idling and the engine exhaust system works
normally, so as to reduce H2S emission.
2. The carrier may be melted instantly in
case of engine misfire in high speed.
3. Melting of catalyst will block exhaust,
causing excessive high backpressure of
exhaust and reducing power performance.
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Silencer Assembly with Accessories

The silencer for CX20-EA14FF is installed on
rear end of the exhaust manifold with three-
way catalyst assembly; its inlet flange is
connected to the outlet flange of the three-
way catalyst with compressed spring bolts; it
is connected to the vehicle body beam hook
with rubber lifting eyes. The main purpose of
the silencer is to lead smooth emission of
exhaust gas from each engine cylinder and to
reduce emission noise generated by exhaust
flow.
Removal
1) Lift the vehicle.
2) Remove the connecting bolts to the
outlet flange of the exhaust manifold with
three-way catalyst.
3) Remove the lifting eyes connected
to the vehicle body hook, and remove the
silencer assembly with accessories.
Note:
Replace with a new graphite ring,
compressed spring and compressed spring
bolt for reinstallation.
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Chapter VII Clutch

Clutch Specification
Type One-piece, dry-type, membrane spring
clutch
Operation mode Mechanical
Diameter (inner/outer) of clutch friction plate assembly 200/130 (mm)
Wear limit of clutch friction plate assembly 1. 7 (mm)
Clutch and Description
Clutch
The clutch consists of a clutch friction plate
assembly and a clutch pressure plate assembly
fixed with flywheel. The clutch friction plate
assembly transmits the engine power to the
transmission assembly through flywheel gear
ring assembly connection under effect of the
clutch pressure plate assembly under normal
working status. When the clutch pedal is
completely pressed down, the clutch pressure
plate assembly will separate from the clutch
friction plate assembly, and the clutch friction
plate assembly cannot transmit the engine
power to the transmission assembly at this
time. When the clutch pedal is completely
released, the clutch pressure plate assembly
will compress the clutch friction plate
assembly, and the clutch friction plate
assembly will transmit the engine power to
the transmission assembly.
Clutch Pressure Plate Assembly, Clutch

Friction Plate Assembly and Flywheel
Removal
Use a special tool (A) to clamp the flywheel,
remove the clutch cover assembling bolt,
clutch pressure plate assembly and clutch
friction plate assembly.
Special Tool
(A): 09924-17810
Inspection of Clutch Friction Plate

Assembly
Measure the sinking depth of rivet head,
which is the distance from the rivet head and
the clutch friction plate assembly surface. If
the depth at any hole exceeds the service
limit, replace the clutch friction plate
assembly.
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Rivet head depth

Standard: 1.15mm~l.65mm
Service limit: 0.5mm
Inspection of Clutch Pressure Plate

Assembly
1) Inspect for abnormal wear or
damage of diaphragm spring.
2) Inspect the clutch pressure plate
assembly for wear or local hot spot.
3) If abnormality is found, replace the
assembly. The diaphragm and pressure plate
cannot be detached.
Flywheel Inspection
Inspect the contact surface of the clutch
friction plate assembly for abnormal wear or
local hot spot, and replace the assembly if
necessary.
Installation
Notes:
Make sure that the flywheel surface and
the pressure plate surface are clean and
completely dry before assembling.
The flywheel bolt is provided with
sealant. Before assembly, confirm that the
sealant is continuous without breakage.
The flywheel bolts can only be used for
once. After removal, the mounting hole shall
be cleaned and the parts shall be replaced.
1) Install the flywheel on the

crankshaft and torque in diagonal to
specification.
Special Tool
(A): 09924-17810
Tightening torque:
(a): 74N·m±2N·m (7.4kg-m)
2) Use special tool to straightly align
clutch disc with the center of flywheel. Install
the clutch pressure plate assembly and bolts
and torque in diagonal to specification.
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Notes:
Use a special tool (C) to compress the
clutch disc while tightening the clutch cover
combination bolts, so as to make sure the
clutch friction plate assembly aligning with
the center.
Tighten the clutch cover combination
bolts in diagonal sequence evenly.
Special Tool
(A): 09924-17810
(C): 09923-36330
Tightening torque:
(a): 32N·m±2N·m(3. 2kg-m)
3) Apply small amount of lubricating
grease on the input shaft, and then connect the
transmission assembly with the engine.
“A”: lubricating grease 99000-25210
Note:
Rotate the crankshaft with a wrench
from front side until spline engagement at the
same time when the transmission input shaft
is inserted into the clutch friction plate
assembly.
Clutch Release Fork

Removal
1) Remove the release fork return spring and
release fork clip.
2) Remove the release fork and release
bearing together.
Inspection
Inspect that the rotation of clutch release
bearing is smooth. If abnormality is found,
replace it.
Caution:
Do not wash the release bearing to
avoid cleaning off the grease, which will
damage the bearing.
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Inspection of Clutch Release Fork

Inspect the clutch release fork and clips for
damages or deformation. If abnormality is
found, replace them.
Installation
Install in reverse sequence of removal, and
pay attention to the following requirements
during installation:
• As shown in the picture, apply lubricating
grease on the shaft sleeve between the release
bearing and the input shaft.
Lubricating Grease 99000-25210
As shown in the picture, install the release
bearing, release fork and clutch rocker arm
onto the release fork shaft.
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Chapter VIII Transmission Maintenance

Transmission Structure
MF512E01 transmission is a mechanical transmission for cars. The transmission is a
manual fully synchronous gear shift type mechanical transmission, with five forward gears
and one reverse gear. All forward gears are normally engaged, and the reverse gear is a
sliding idler gear. The gear shift is easy without impact noise. The maximum input torque is
125 Nm. The transmission efficiency, service life of synchronizer, fatigue life, noise,
cleanliness and other important indicators have all reached the leading level of domestic
similar products. The transmission housing of this series is left and rear separate box type,
which is of rigid structure, easy to process and convenient for disassembly and assembly.
With compact and reasonable structure, the inertial synchronizer is adopted, so gear shifting is
reliable, smooth and flexible.
This series of transmission is applicable to the front-engine front-drive vehicle model.
The transmission is highly adaptable, with relatively high cost performance and extensive
market prospect.
Functions and Work Principles
Functions
a. Change the transmission ratio, enlarge the driving wheel torque of engine and engine
speed variation scope, so as to adapt to the power demand and driving conditions under
various circumstances of the vehicle, and enable the engine to work under favorable work
conditions;
b. Realize reversing under the condition that the rotation direction of engine crankshaft
remains unchanged.
c. Stop the power transmission from engine, so as to meet the demand of temporary
vehicle stopping, sliding and other conditions, and to facilitate transmission gear shift or
power output.
Work Principles
The transmission can realize change of speed, torque and rotating speed through shifting
between different gear pairs. The specific transmission route is shown in Fig. 1.
Transmission Route (Fig. 1)
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Main Technical Parameters

Transmission Ratios
Transmission Maximum Input
Gear Gear
type Torque (N • m) Gear Gear I Gear II Gear V Reverse
III IV
First transmission
46/13 40/21 37/29 32/33 29/36 45/13
ratio
MF512E01 125
Final drive ratio 79/19
Total drive ratio 14. 713 7. 92 5. 305 4. 032 3. 349 14. 393
MF512E01 Transmission Structure
MF512E01 transmission consists of 6 assemblies according to the functions and
positions: left box, right box, input shaft assembly, intermediate shaft assembly, differential
assembly and gear shift and position shift assembly (see Fig. 2).
The inside of transmission is of double-shaft type. The input shaft and intermediate shaft
are parallel with each other. Power is inputted from input shaft and outputted through
intermediate shaft and from the transmission shaft at differential end. MF512E01 transmission
realizes position shift through shift shaft which is driven by gear shift and position shift
assembly, realizes gear shift through the shift lever rotating around the center, and realizes
flexible gear shift through inertial synchronizer.
Transmission Structure
1. Gear I of input shaft

2. Reverse idler gear shaft
3. Reverse idler gear
4. Reverse gear of input shaft
5. Gear II of input shaft
6. Gear V of input shaft
7. Five-gear synchronizer
8. Gear III of input shaft
9. High-speed synchronizer
10. Spindle transmission gear
11. Spindle
12. Extension box
Schematic Diagram of MR512E01 Transmission 13. Gear IV of intermediate shaft
Structure (Fig. 2) 14. Rear box
15. Gear III of intermediate shaft
16. Intermediate shaft
17. Gear V of intermediate shaft
18. Gear II of intermediate shaft
19. Low-speed synchronizer
20. Gear I of intermediate shaft
21. Front box
22. Input shaft
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Transmission Power Delivery Route

MF512E01 transmission realizes power transmission and conversion through gear pairs
and synchronizer.
Gear I: input shaft—Drive Gear 1 of input shaft—Transmission Gear 1 of intermediate
shaft—low-speed synchronizer—intermediate shaft—main reduction gear of
intermediate shaft—main reduction gear of differential—transmission shaft
Gear II: input shaft—Drive Gear 2 of input shaft—Transmission Gear 2 of intermediate
shaft—low-speed synchronizer—intermediate shaft—main reduction gear of
Gear III: input shaft—high-speed synchronizer—Drive Gear 3 of input shaft—
Transmission Gear 3 of intermediate shaft—intermediate shaft—main reduction gear of
Gear IV: input shaft—high-speed synchronizer—Drive Gear 4 of input shaft—
Gear V: input shaft—five-gear synchronizer—Drive Gear 5 of input shaft—
Reverse gear: input shaft—reverse drive gear of input shaft—reverse idler gear—reverse
transmission gear of intermediate shaft (gear sleeve of low-speed synchronizer)—
intermediate shaft—main reduction gear of intermediate shaft—main reduction gear of
differential—transmission shaft
Drawing List of Functional Assemblies and Parts of Transmission
Transmission Reverse Gear Shaft Assembly (Fig. 3)
Transmission Input Shaft Assembly (Fig. 4)
Transmission Intermediate Shaft Assembly (Fig. 5)
Transmission Differential Assembly (Fig. 6)
Transmission Gear Shift Mechanism Assembly (Fig. 7)
Transmission Gearbox Assembly (Fig. 8)
Transmission Clutch Fork Assembly (Fig. 9)
Left and Right Boxes and Peripheral Part of Transmission (Fig. 10 & 11)
Transmission reverse gear shaft assembly (Fig. 3)

1. Idler gear of reverse gear shaft, 2. Reverse gear shaft gasket, 3. Reverse gear shaft
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Transmission Input Shaft Assembly (Fig. 4)

1. Right bearing of input shaft, 2. input shaft, 3. Gear III needle bearing of input shaft, 4. Gear
III assembly of input shaft, 5. Gear III synchronizer ring gear, 6. synchronizer spring, 7. high-
speed synchronizer gear hub, 8. sliding block of high-speed synchronizer, 9. gear sleeve of
high-speed synchronizer, 10. Gear IV input shaft bush, 11. Gear IV needle bearing of input
shaft, 12. Gear IV synchronizer ring gear, 13. Gear IV assembly of input shaft, 14. Gear V
input shaft bush, 15. Gear V needle bearing of input shaft, 16. Gear V assembly of input shaft,
17. Gear V synchronizer ring gear, 18. Gear V synchronizer gear hub, 19. sliding block of
Gear V synchronizer, 20. gear sleeve of Gear V synchronizer, 21. left bearing of input shaft
Transmission Intermediate Shaft Assembly (Fig. 5)

1. Right bearing assembly of intermediate shaft, 2. intermediate shaft, 3. Gear I assembly of
intermediate shaft, 4. Gear I needle bearing of intermediate shaft, 5. ring gear assembly of
Gear I synchronizer, 6. low-speed synchronizer assembly, 7. ring gear assembly of Gear II
synchronizer, 8. Gear II intermediate shaft bush, 9. Gear II needle bearing of intermediate
shaft, 10. Gear II assembly of intermediate shaft, 11. Gear III of intermediate shaft, 12. Gears
III & IV spacer bush, 13. Gear IV of intermediate shaft, 14. Gear V of intermediate shaft, 15.
Gear V collar of intermediate shaft, 16. left bearing assembly of intermediate shaft
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Transmission Differential Assembly (Fig. 6)

1. Right bearing of differential, 2. signal panel, 3. axle shaft gasket of differential, 4. axle
shaft of differential, 5. differential housing, 6. retainer ring of planetary-gear pin, 7. planetary-
gear pin, 8. planetary gear gasket, 9. planetary gear, 10. main reduction gear, 11. differential
bolt, 12. left bearing of differential
Transmission Gear Shift Mechanism Assembly (Fig. 7)

1. Shift lever collar, 2. Gear V shift fork, 3. Gears I & II interlock pins, 4. Gears III & IV shift
fork, 5. elastic pin, 6, Gear V fork spring, 7. Gears I & II shift fork 8. Gears III & IV shift
lever, 9. Gear V and reverse gear shift levers, 10. Gears I & II shift lever, 11. Gear V and
reverse shift forks, 12. reverse gear shift suspension arm, 13. Gears III & IV interlock pins, 14.
Gears I & II shift forks
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Transmission Gearbox Assembly (Fig. 8)

1. Gear shift swivel arm assembly, 2. gear shift swivel arm pin, 3. position shift swivel arm
assembly, 4. position shift swivel arm pin shaft bush, 5. gearbox bolt, 6. oil seals of gear shift
and position shift shaft, 7. rotating shaft bush of position shift swivel arm, 8. position shift
swivel arm gasket, 9. position shift swivel arm collar, 10. No.2 harness support, 11. gearbox,
12. cam pin, 13. cam return spring, 14. Gear V/reverse gear interlock cam, 15. dense ball
bearing, 16. return spring collar, 17. high-speed return spring seat, 18. low-speed return spring,
19. high-speed return spring, 20. return spring gasket, 21. low-speed return spring seat, 22.
spring seat bolt, 23. gear shift and position shift shafts, 24.swing link pin of gear shift , 25.
interlock plate, 26. gear shift swing link, 27. gear shift lock bolt assembly, 28. “王” shaped
groove, 29. gear shift stop pin gasket, 30. gear shift stop pin, 31. “王” shaped groove pin
Transmission Clutch Fork Assembly (Fig. 9)
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Left and Right Boxes of Transmission (Fig. 10)
Right Box of Transmission and Peripheral Parts (Fig. 11)

Operation and Maintenance Method
Operation of Transmission
The appropriate speeds for forward gears of transmission are as follows:
Gear Gear I Gear II Gear III Gear IV Gear V
Mileage 0~15 20 ~30 35 ~45 50 ~60 65 ~75
Note: 1. The gear shifting operation of transmission shall be within the mileage scope.
2. For different vehicles, the mileages suitable for all gears of transmission are
different.
Gear Shift Principle
When the vehicle is driving forward, the gear shift principle of the transmission is as
follow: the acceleration gear shift shall be from Gear 1 to Gear 5; the deceleration gear shift
shall be from Gear 5 to Gear 1; under the forward state, it is prohibited to engage the reverse
gear. During gear shift of the vehicle, to avoid wrong operation, the lock device from Gear 5
to reverse gear is provided for the transmission.
In principle, it is required to engage the reverse gear after 3 seconds after depressing the
clutch when the vehicle is static; it is prohibited to engage the reverse gear under the forward
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state; meanwhile, it is prohibited to engage the forward gears under the reverse state.
Note: in case of an emergency during driving, you may not obey the gear shift principle of
transmission.
Transmission Maintenance
The oil consumption of transmission is 1. 7~1.9L.
For early maintenance, the mileage for the first transmission oil replacement is 7500 km;
afterwards, regular maintenance is carried out. The maintenance shall be conducted at the
special complete vehicle maintenance center.
Regular Maintenance Cycle List:
Mileage of First Mileage of Later
Transmission Oil Transmission Oil Oil Brand Oil Grade
Replacement Replacement
Replacing after every 30000 Shell Spirax
7500Km 75W/90 GL-4
Km
If due to other maintenance work instead of oil replacement, when lifting the vehicle,
check the transmission for oil leakage at the same time.
Maintenance and Troubleshooting of Complete Vehicle
During maintenance, the methods for checking transmission oil are as follows:
1 Make sure that the vehicle is on a level surface for the purpose of checking the oil
level;
2 Check the transmission for trace of oil leakage. If any, repair the leaking part. Refer
to Chapter III Disassembly and Assembly of Transmission for the repair method, and
repair the leaking part.
3 Remove the filler plug.
4 Check the oil level. Check the oil level roughly through the filler plug hole. If the
transmission oil level is flush to or slightly lower than the filler plug hole bottom, it
suggests that the oil level is normal. Otherwise, add the transmission oil to the specified
level.
During maintenance, the methods for replacing transmission oil are as follows:
1 Stop the engine prior to replacing the oil, and lift the vehicle horizontally.
2 When the vehicle is lifted, check the oil level and the leakage condition. If leakage
exists, repair the leaking part.
3 Remove the drain plug, drain the used oil, and fill the specified oil to the specified
level (fill to the oil level hole);
4 Apply sealant on the drain plug and tighten to the specified torque.
5 Remove the filler plug.
6 Add transmission oil as specified.
7 Apply sealant on the filler plug and tighten to the specified torque.
♦ During maintenance, if it is discovered that the input shaft oil seal leaks,
replace the oil seal.
♦ During maintenance, if it is discovered that the differential oil seal leaks,
replace the oil seal.
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Disassembly and Assembly of Transmission

Main Steps of Transmission Disassembly and Assembly
1. Oil discharge.
Remove the drain plug with a wrench, and discharge oil from the drain plug. It is
prohibited to drain oil from other locations.
2. Remove gear shift actuating mechanism and other parts.
Remove clutch swivel arm, lock bolt assembly, gear shift stop pin, gearbox closing bolts
and other parts, and take down the gearbox.
3 Remove the closing bolts and separate the boxes.

1) Remove closing bolts from the inside and outside of transmission.
2) Use a soft hammer to knock the edge of the left box and remove the left box.
Special tool: box separator (A)
4 Remove reverse gear shift mechanism and reverse gear.

1) Take down the guide oil pan of input shaft, input shaft gasket, adjusting gasket of
intermediate shaft left bearing. Precautions: the input shaft gasket and adjusting gasket of
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intermediate shaft are for adjustment of the axial dimension. If after the box is opened, the
shaft parts or boxes are not replaced, it is unnecessary to replace the adjusting gasket. If the
parts or boxes of input shaft and intermediate shaft are to be replaced, re-measure the gaskets,
and the rules for selecting gaskets are as follows:
a. The scope for selecting input shaft gasket is the actual interval value: 0~0.0 9 mm. For
example, the measured interval is 2.53m, the gasket thickness shall be 2.44 mm~2.53 mm.
b. The scope for selecting intermediate shaft gasket is the actual interval value: 0.10
mm~0.15 mm. For example, the measured interval is 1.73 mm, and the gasket thickness shall
be 1.83 mm~1.88 mm.
2) Remove the support bolt of reverse shift fork, and take down reverse shift fork
assembly.
Fig. 3-3-a Remove Reverse Gear Shift Mechanism and Reverse Gear
3) Remove reverse idler gear shaft and reverse idler gear assembly.
4) Remove gear mechanism and gear shift mechanism.
Fig. 3-3-b Remove Gear Mechanism and Gear Shift Mechanism

5 Remove other parts of right box
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Fig. 3-4-a Remove Other Parts

1) Remove other parts
2) Remove differential assembly from right box
3) Remove bolts
4) Use special tools to remove input shaft oil seal
Special Tools: (A): Rotating shaft;
(B): Oil seal puller
5) Use special tools to remove the outer race of intermediate shaft right bearing.
Special Tools: (A): Rotating shaft;
(B): Bearing puller
6) Remove right oil seal of differential from the right box.
Fig. 3-4-b Remove Oil Seal of Input Shaft

Inspection of Important Parts and Components
Checking Input Shaft Assembly
Check the input shaft gear for tooth breakage, pitting, severe wear or gluing of tooth
faces. If any of the above situations exists, replace the input shaft. Check the input shaft spline
for serious wear or damage; if any, replace the input shaft.
Use a hand to feel whether the bearing rotates flexibly without clamping; if the bearing
does rotates flexibly and clamps, replace the bearing. Checking Intermediate Shaft Assembly
Check the intermediate shaft gear for tooth breakage, pitting, severe wear or gluing of
tooth faces. If any of the above situations exists, replace the intermediate shaft.
does rotates flexibly and clamps, replace the bearing. Checking Differential Assembly
Check the differential gear for tooth breakage, pitting, severe wear or gluing of tooth
faces. If any of the above situations exists, replace the differential.
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does rotates flexibly and clamps, replace the bearing.
Checking Gear and Synchronizer Ring Gear
Attach the synchronizer ring gear on the cone surface of paired gear, and check the
clearance between gear engaging teeth and the ring gear end face. See the table below for
specific requirements. If the clearance has reached or exceeded the limit, replace the part.
Clearance between gear Theoretical Clearance (mm) Limit Clearance (mm)
engaging teeth and ring gear end
1. 0 ~1. 2 0. 5
face
Check whether the synchronizer assembly slides flexibly. Repair or replace the assembly if it
clamps.
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Transmission Maintenance
Oil Replacement
1) When replacing or inspecting the lubricant, be sure to shut down the engine and lift
the vehicle steadily.
2) After the vehicle is lifted, check the oil level and leakage condition. If leakage
exists, timely repair the leaking part.
3) Empty the lubricant and add the specified lubricant.
4) The torque specification of the drain plug and filler plug is as follows. Apply certain
amount of sealant on the threads of the drain plug before mounting.
Sealant: Loctite 5900
Tightening torque: 12-18N·m
Transmission oil: Shell Spirax S4 GS 75W-90
Filling capacity: 1.7-1.9L
Note: when the vehicle is jacked up for maintenance work other than lubricant replacement,
check whether lubricant leakage exists.
Replacement of Left and Right Oil Seals of Differential
1) Jack up the vehicle and empty the lubricant in the transmission.
2) Remove the drive shaft from differential.
3) Use the special tools and hammer to remove the oil seal and install a new one.
Special tools: (A) oil seal installer 1 (right); oil seal installer 2 (left)
Mounting specification “a” for the oil seal on the differential side: 1. 0-1. 5mm
4) Apply grease on the edge of oil seal, and check the contact part between the drive
shaft and oil seal to ensure smooth contact. “A”: Grease A manufactured by Suzuki
2-1 Replacement of Differential Oil Seal

5) Install the drive shaft into the differential.
Caution: When inserting the drive shaft plug pin, do not damage the oil seal edge.
Ensure that the drive shaft plug pin is fully inserted in, and the circlip is fixed as in
the original way.
6) Add transmission oil as specified, and ensure that the oil is sealed tight by the oil
seal.
Overhaul of Transmission Assembly
Input Shaft Assembly
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1) Check the assembly for any abnormality, check the wear of input shaft tooth, and
replace as necessary.
2) Check Gear III assembly, Gear IV assembly and Gear V assembly of input shaft for
any abnormality, and check whether they rotates flexibly without clamping; check the
clearance “a” between the ring gear and engaging ring gear; check the convex tooth, ring and
sleeve of each gear; replace as necessary. (Clearance “a”: theoretical value: 1.0 mm-1.2 mm)
3) Check the high-speed synchronizer and Gear Five synchronizer for any abnormality,
and replace them as necessary.
4) Check each bearing for any abnormality, and whether each bearing rotates flexibly
without clamping, and replace the bearing as necessary.
5) Check each collar for abnormality, and replace it as necessary.
Intermediate Shaft Assembly
1) Check the assembly for any abnormality, check the wear of intermediate shaft tooth,
and replace as necessary.
2) Check Gear I assembly and Gear II assembly of intermediate shaft for any
abnormality, and check whether they rotates flexibly without clamping; check the clearance
“a” between the ring gear and engaging ring gear; check the convex tooth, ring and sleeve of
each gear and replace as necessary. (Clearance “a”: theoretical value: 1.0 mm-1.2 mm)
3) Check the low-speed synchronizer for abnormality, and replace it as necessary.
Differential Assembly
1) Check the assembly for any abnormality, check the wear of differential planetary-
gear pin, and replace as necessary.
2) Check the differential gear for abnormality, and replace it as necessary.
3) Check the signal panel for abnormality, and replace it as necessary.
Gearbox Assembly, Shift Lever Assembly and Shift Mechanism
1) Check each part of the gearbox assembly for abnormality, and replace it as
necessary.
2) Check each shift lever assembly for abnormality, whether each locating pin works,
and replace them as necessary.
3) Check whether Gears I & II shift levers rotates flexibly, and replace them as
necessary.
4) Check whether reverse shift fork assembly rotates flexibly, and replace it as
necessary.
Left and Right Box Assembly
Check each box for any abnormality, whether the box wall has cracks and other defects,
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If the transmission has been stored for over half a year, rust-preventing measures shall be
taken for each peripheral metal part.
It is prohibited to pile up the transmissions.
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Chapter IX Final Assembly

The quality group letters are engraved on the
side of big end of conrod assembly. During
assembling, the conrod assemblies of the same
gasoline engine shall be in the same quality
group.
There is no quality group for the piston.
1) The installation of piston ring assembly
shall meet the following requirements:
(1) The gas ring and scraper ring shall be
installed into the corresponding ring groove of
the piston, and the marked surfaces shall be
directed to the top surface of piston.
(2) Butt joint, instead of lap joint, shall be
adopted for the opening of backing ring.
When installing combination oil ring, install
backing ring, and then install two scraper
rings. The mounting position of piston ring is
as shown in the left picture.
2) Assembling of piston assembly and conrod
assembly.
(1) The top concave pit of piston and oil hole
at big end of conrod shall be on the same side
as shown in the left picture.
(2) The retainer ring of piston pin shall be
installed in place. All retainer rings shall be in
the retainer ring groove. The opening of
retainer ring shall be directed to the opposite
side of the mounting hole of piston pin
retainer ring.
(3) Before assembly, apply gasoline engine oil
on the piston pin outer wall, conrod small end
hole and piston pin hole.
3) Before putting the piston conrod assembly
into the cylinder, apply the suitable amount of
gasoline engine oil on the cylinder bore and
piston skirt. The opening direction of each
ring shall be distributed evenly, as shown in
the left picture.
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Installation or Connection
1) Apply gasoline engine oil on the piston,
piston ring, cylinder wall, conrod bearing bush
and the conrod journal of crankshaft.
2) When assembling the piston and conrod
into the cylinder, the concave pit on the piston
top shall be at the intake side, and the
direction mark “-” on the top surface of piston
shall be directed at the front end of gasoline
engine.
3) Assemble the piston and conrod into the
cylinder. Use piston ring compressor to
compress the piston ring. Put the conrod on
the crankshaft. Use a hammer handle to knock
at the piston head, and install the piston in the
cylinder. Stay close to the cylinder block and
hold the piston ring compressor, until all
piston rings are into the cylinder.
4) Install conrod cap: when installing conrod
cap, ensure that the boss marks on the cap all
direct to the crankshaft pulley side.
Tightening torque for conrod bolt: pre-

tighten all conrod bolts with the rotating speed
of no more than 20r/min and the tightening
force of 15N.m±1N.m. Tighten with the
torque of 15N.m, and rotate for 90° with the
speed of 20r/min.
5) As aforesaid, assemble in the reverse
sequence of disassembly.
6) As aforesaid, adjust the clearance of
intake valve and exhaust valve.
7) Connect the harness of throttle body.
8) Check and ensure that all removed
components are installed back to the original
position. Re-install the components which
have not been installed.
9) Add oil into the engine again
according to the clauses of Gasoline Engine
Oil Replacement.
10) Add coolant again, and empty the air
from the system.
11) Connect the negative wire of battery.
12) Check all joints for leakage of
gasoline, coolant, oil and gas.
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13) Check whether the ignition timing is

within the technical reference scope.
Note:
Once the conrod bolt is removed, it
cannot be reused, and it shall be replace with
a new one.
The signal panel screw and flywheel
bolt are provided with sealant. Before
assembly, confirm that the sealant is
continuous without breakage.
The bolts, screws and plugs which are
provided with sealant can only be used for
once. After removal, the mounting hole shall
be cleaned and the parts shall be replaced.
No. Part No. Name

1 1004023-H01 Gas ring
2 1004024-H01 Scraping ring
3 1004022-H01 Backing ring
4 1004012-H01 Piston pin
Locating pin of
5 1000036-01
pressure plate
6 1005011-H01 Flywheel bolt
Flywheel ring gear
7 1005020-H03
assembly
8 1005031-H04 Crankshaft
9 1000263-H01 Conrod bearing bush
10 1004032-H02 Conrod cap
11 1004033-H01 Conrod bolt
12 1005034-H01 Signal panel dowel
13 1005033-H01 Signal panel screw
Crankshaft speed signal
14 1005032-H04
panel
15 GB/T1099-1979 Woodruff key
16 1004034-H01 Conrod locating pin
17 1004031-H02 Conrod body
Retainer ring of piston
18 1004013-H01
pin
19 1004011-H03 Piston
20 1004021—H01 Scraper ring
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Chapter V Heavy Repair

Engine Assembly
Removal
1) Reduce the pressure in the fuel line
according to the above fuel pressure relief
steps.
2) Disconnect the harness connector and
sensor connector from the engine.
No. Part No. Name
1 1000321-H01 Hexagon flange nut 3) Remove the battery and battery box.
2 1000326-H01 Hexagon flange bolt
Oil pump chain guard 4) Discharge the transmission oil.
3 1000291-H03
stud
Hexagon flange bearing 5) Discharge the coolant.
4 1000437-B01
surface toothed nut
5 1001022-H04 Right support
6) Remove the air intake pipe.
6 09103-10009 Hexagon flange bolt 7) Disconnect all connectors which are
7 09103-12008 Hexagon flange bolt
Right suspension cushion
connected with the engine fuel system.
8 1001070-H04
assy
8) Disconnect all connectors which are
Connection bolt between connected with the engine cooling system.
10 1000146-A01 rear support and rear
cushion 9) Disconnect all connectors which are
Rear suspension cushion connected with the engine control air line.
11 1001050-H04
assy
12 1000326-H01 Hexagon flange bolt 10) Disconnect all clamps which are related
13 1001033-H04 Rear support to the engine harnesses.
14 09103-10009 Hexagon flange bolt
Left suspension cushion 11) Lift the vehicle.
15 1001060-H04
assy
Hexagon flange bearing 12) Discharge the engine oil.
16 1000437-B01
surface toothed nut
13) Disconnect the exhaust manifold with
the three-way catalytic converter and
silencer connection.
14) Disconnect the clutch release arm and
the clutch cable of gearbox.
15) Disconnect the gear selection cable of
transmission.
16) Remove the left, right and rear cushion
bolts of the engine.
17) Remove the engine with transmission
from the engine room.
18) Separate the engine from the
transmission.
19) Remove the timing mechanism
according to the aforesaid method.
20) Remove the cylinder head and
intake/exhaust manifold according to the
aforesaid method.
21) Remove the oil pan according to the
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aforesaid method.
Installation
1) Connect the engine and transmission.
2) Tighten the engine support bolts.
3) The installation procedure is in the
reverse sequence of the removal procedure.
Tighten the bolts to the specified torque.
4) Connect gear shift mechanism cable to
the control rod of gear shift mechanism
No. Part No. Name according to Gear Shift Mechanism Control
1 1700010-H06 Transmission assembly Installation.
3 1000325-H01 Hexagon flange bolt 5) Connect the parking brake cable to
4 1000321-H01 Hexagon flange nut parking brake control rod. Adjust the
5 1000112-H03 Mounting bolt of starter parking brake according to Parking Brake
Inspection and Adjustment.
6) Adjust the free travel of clutch pedal.
7) Connect the corresponding harness
connector on the engine.
8) Check and confirm that all removed parts
have been installed back to the proper
location.
9) Add oil to the engine according to
provisions in Engine Oil Replacement.
10) Add coolant and discharge air.
11) Check each joint for leakage of fuel,
coolant and waste gas.
Main Bearing Bush, Crankshaft

and Cylinder Block
Removal:
1) Remove the engine from the vehicle body
according to the aforesaid method.
2) Remove the starting motor and
transmission from the engine, then remove
the clutch pressure plate assembly, clutch
friction plate assembly and flywheel.
3) Remove the harness, generator belt,
compressor belt, generator adjusting
support, compressor adjusting support,
compressor, compressor bracket, generator
and generator bracket.
4) Remove the intake mechanism, exhaust
mechanism, water pump pulley, water inlet
pipe, left and right suspensions, fuel level
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gauge and other peripheral parts.

5) Remove the cylinder head cover, oil pan
assembly, water inlet pipe, front casing
assembly of oil pump, water pump and
timing system.
6) Remove the cylinder head assembly and
cylinder head gasket.
7) Remove the rear end cap of crankshaft, as
shown in the left picture.
Note:
The sealant has been applied during
installation of the rear end cap of crankshaft.
Please apply sealant during re-installation. The
sealant application line is as shown in the
picture below.
Rear Oil Seal of Crankshaft

1) Before installing the rear oil seal of
crankshaft, check the rear oil seal assembly
mounting hole of crankshaft rear end cap for
no flash, burr, bruise or scratch, etc. Ensure
that the inner wall of mounting hold is clean,
and apply a film of gasoline engine oil on
the inner wall of mounting hole of
crankshaft rear oil seal assembly according
to provisions in Appendix D (note: avoid
applying too much oil, so as to avoid
leakage of oil seal).
2) Use oil seal press fitting machine or
special tooling to press the crankshaft rear
oil seal assembly into the rear end cap of
crankshaft.
3) The end face of crankshaft rear oil seal
shall be parallel with the mounting face of
crankshaft rear end cap. With the machined
surface of crankshaft rear end cap as the
reference, the height of top surface of the
pressed crankshaft rear oil seal is 9. 8mn±0.
2mm, and the oil seal spring shall not shift
position or fall off.
4) Avoid contacting foreign materials or
bumping/scratching the oil seal lip, and
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avoid touching the lip with your hand.
Note:
The pressing direction of crankshaft
rear oil seal into crankshaft rear end cap is
shown in the left picture. It is prohibited to
press in the opposite direction. Before
installation, clean the crankshaft rear end
cap.
8) Remove main bearing cap.

9) Loosen the main bearing cap bolts
(the loosening procedure is in the
reverse sequence with the tightening
procedure) and main bearing cap. The
installation sequence of the main
bearing cap bolts of crankshaft is as
shown in the picture.
Tightening Method:
(1) All bolts of the main bearing cap
shall be pre-tightened in speed no more than
20r/min and at torque of 35N·m±2N·m as
per sequence (1-10) shown in the left picture
or simultaneously.
(2) All bolts of the main bearing cap
shall be pre-tightened for 45° in speed no
more than 20r/min and at torque of 35N·m
as per sequence (1-10) shown in the left
picture or simultaneously (the angle 45°
shall be calculated from 35N·m).
10) Remove the crankshaft from the

cylinder block. Do not forget to remove the
thrust plate. Check the thrust plate for any
abnormal wear. If any, replace it
immediately.
Note:
Once the main bearing cap bolt is
removed, it cannot be reused, and it shall be
replace with a new one.
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Crankshaft
Radial Run-out of Crankshaft
Use micrometer to measure radial run-out at
the journal of central shaft. Rotate the
crankshaft slowly. If the radial run-out
exceeds the limit value, replace the
crankshaft.
Radial run-out limit: 0.02mm
Thrust Clearance of Crankshaft

Use the conventional method, namely
installing the thrust plate and journal bearing
cap to fix the crankshaft in the cylinder, so
as to measure the clearance.
Use
micrometer to
read the axial
(thrust)
displacement
of crankshaft.
If the Standard Limit
displacement
exceeds the
limit value,
replace the
thrust plate of
crankshaft.
Name
Thrust clearance 0. 11 ~0. 31
0. 36mm
of crankshaft mm
Ovality and Taper (Uneven Wear) of Journal
The uneven wear of crankshaft journal
suggests a difference in the diameter or a
difference along the length direction (or
both) of the cross section. You may use
micrometer to read and determine this
difference. If any journal is severely
damaged or the uneven wear exceeds the
following limit value, re-grind the
crankshaft or replace it. Ovality limit and
taper: 0.005mm
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Main Bearing
General Description
1) The standard main bearing bush and the
enlarged 0.25mm bearing bush are useful for
repair. They are respectively divided into 5
groups with different tolerance dimensions.
2) Engrave the arrow marks and numbers on
each main bearing cap as shown in the
picture. When each main bearing cap is
installed onto the cylinder block, direct the
arrow mark to the front end of engine (the
pulley side of crankshaft) and arrange the
bearing caps from the front end to rear end
(on the flywheel side) according to the
ascending order of “1”, “2”, “3”, “4”, “5”.
Tighten the bearing cap bolts to the specified
torque.
Check the pitting, scratches, wear or damage
on the bearing bush. If any defect is found,
replace the upper and lower main bearing
bushes at the same time, instead of replacing
a single bearing bush.
Note:
1. Please differentiate the upper
bearing bush from the lower bearing bush,
so as to avoid wrong installation, as shown
in the left picture.
2. During assembly of the bearing
bush, be sure to make it horizontal. The
upper edge of bearing bush shall be
basically in the same plane with the upper
edge of main bearing seat.
Note:
Do not rotate the crankshaft during
installation of the plastic feeler gauge.
Bearing Bush Clearance

Use plastic feeler gauge to check the
clearance according to the following
procedure.
1) Remove the bearing bush cap.
2) Clean the bearing bush and main journal.
3) Put a plastic feeler gauge with full width
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of the bearing on the main journal (parallel

to the crankshaft), and avoid the oil hole.
Bearing Standard Limit
bush 0. 026~0. 4) Install the main bearing cap according to
0. 020~0. 040mm
clearance 046mm the aforesaid schematic diagram, and tighten
the bolts evenly to the specified torque.
5) In order to ensure correct reading of the
clearance, tighten the main bearing cap to
the required torque.
Tightening torque: 35N·m+45°.
6) Remove the main bearing cap, and use a
ruler to measure the cap width at the widest
point of the plastic feeler gauge. If the
clearance exceeds the limit, replace the main
bearing bush. Always replace the upper and
lower bearing bushes as a whole. A new
standard bearing bush may generate correct
clearance. If the corrected clearance cannot
be generated, it is necessary to use a
enlarged 0. 25mm bearing bush to regrind
the crankshaft journal.
After choosing a new bearing bush, recheck

the clearance.
Selection of Main Bearing Bush

Standard bearing bush: if the bearing bush is
incorrect, or the bearing bush clearance
exceeds the technical requirement, choose
and install a new standard bearing bush
according to the following procedure.
1) The five words are printed on the bottom

of cylinder block: first, second, third, fourth
and fifth (from left to right) respectively
represents the crankshaft hole diameter of
the bearing caps “1”, “2”, “3”, “4”, “5”.
2) The crankshaft holes are divided into 3
groups: Group 1, Group 2 and Group 3,
respectively representing the diameter of the
following main bearing holes.
3) There are five standard bearing bushes,
which are different in thickness. In order to
differentiate them from each other, the
marks “2”, “3”, “4”, “5”, “6” are printed on
the steel back of the bush (on the thrust
side). The bearing thickness and fit relations
shall conform to the following table.
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Engine
Dimension Groups and Fit of Crankshaft Main Journal, Main Bearing Hole and Main Bearing
Bush
Diameter Groups of Crankshaft Main Journal
Unit: mm
1 2 3
Fit Clearance
Group Marks
0. 006 ~0. 026
1 2 3
Group
Grou Mar
Dimension
Spindle p k
Scope
hole
0 0 0
diameter 1 1
6 5 4
of
0 0 0
crankcas 2 2
5 4 3
e
0 0 0
3 3
4 3 2
5) Use plastic feeler gauge to check the
clearance of the newly selected standard
bearing bush. If the clearance still exceeds
the limit, use the next thicker bearing bush
and recheck the clearance.
6) During replacement of the crankshaft or
cylinder block, select the new standard
bearing bush to install according to the
numbers printed on the new crankshaft or
the letters printed on the fit surface of the
new cylinder block.
Installation and Inspection of

Conrod Bearing Bush
Check the group number of the sector plate
conrod journal, such as 2223.
Check the group number of conrod big end
hole diameter, such as 3333.
Select the conrod bearing bush according to
the following table, and the corresponding
group number of conrod bearing bush is
2221.
The conrod bearing bush clearance is as
shown in the table.
Use plastic feeler gauge to check the
clearance between conrod big end and
crankshaft handle plate side. The clearance
shall be 0. 10mm~0. 20mm.
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Engine
Diameter Groups of Crankshaft Conrod Journal

Dimension Groups and Fit of
Crankshaft Conrod Journal, Conrod 1 2 3
Big Hole and Conrod Bearing Bush Group Marks
Unit: mm
Fit Clearance 1 2 3
0. 020 ~0. 040
Group
Grou Mar
Dimension
p k
Conrod Scope
big end 0 0 0
1 1
hole 5 4 3
diamete 0 0 0
2 2
r 4 3 2
0 0 0
3 3
3 2 1
Flywheel Ring Gear Assembly
If the flywheel ring gear is damaged, broken
or worn, replace the flywheel. If the surface
which contacts the clutch disc is damaged or
over-worn, replace the flywheel. Use
micrometer to check the end face run-out of
flywheel.
If the end face run-out exceeds the limit,
replace the flywheel, and re-measure the
run-out.
End face run-out limit: 0.2mm
Measurement of Crankshaft Rear End

Circular Run-out
After the flywheel ring gear is replaced
according to the above steps, if the end face
run-out is unqualified, measure the rear end
circular run-out of crankshaft (the measuring
position is as shown in the left picture). If
the run-out exceeds the limit, replace the
crankshaft, and re-measure the run-out.
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Engine
If the run-out is still unqualified, please

replace the cylinder block.
Note:
When replacing the crankshaft or cylinder
block, all bearing bushes shall be replaced
at the same time.
Deformation of Sealing Surface of Cylinder

Block
Use a ruler and thickness gauge to check the
deformation of the sealing surface. If the
planeness exceeds the limit, conduct
planeness finishing.
The checking
method and
planeness
finishing method
are the same as
the checking
method and
Standard Limit
planeness
finishing method
of the aforesaid
cylinder sealing
surface
deformation
Name
Planeness 0. 05mm 0. 10mm
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Engine
Attached Tables
1. Tightening Method of Important Bolts
Table 1 Tightening Method of Important Bolts
Unit: N•m
S/N Code Name Qty. (pc./set) Tightening Method
Rotation angle method: (35±2) Nm+
1 1002041-H01 Main bearing cap bolt 10
(45±2) °, monitoring: 60Nm~90Nm
Cylinder head Rotation angle method: (25±2) Nm+
2 1000010-H01 10
connecting bolt (90±3) °, monitoring: 40Nm~90Nm
3 1004033-H01 Conrod bolt 8
(90±3) °, monitoring: 25Nm~55Nm
4 1000033-H01 Crankshaft pulley bolt 1
(90±5) °, monitoring: 170Nm ~350Nm
Remarks:
1. Refer to GB/T16823. 2-1997 General Rules of Tightening for Fasteners for definition of
rotation angle method and yield point method.
2. When removing the main bearing cap bolts, cylinder head bolts and conrod bolts, put them lightly, and
do not bump or scratch the threads; during storage and final assembly, be sure to keep the bolts clean, rust-
free, bruise-free and scratch-free, apply anti-rust oil on the surface of the bolts, and there shall be no foreign
materials on the bolts.
3. Operate according to the assembly process. The main bearing cap bolts, conrod bolts, cylinder head bolts
and crankshaft pulley bolts can only be used for once.
2. Tightening Torque Limits of Bolts and Nuts
Table 2 Tightening Torques of Bolts and Nuts
Unit: N·m
Qty. for
S/N Part No. Name Single Torque Value Remarks
Machine
1 1000321-H01 Hexagon flange nut 3 50±3
2 1000322-H01 Hexagon flange nut 6 23±2
3 GB/T 16674.2 M10X95 Hexagon flange bolt 1 50±3
4 1003117-H01 Camshaft cap bolt 21 13±1
5 1000213-B01 Timing chain guide bolt 1 23±2
Clutch cover
6 1000230-H01 6 32±2
assembling bolt
7 1000099-H01 Exhaust manifold stud 3 8±1
8 1005033-H01 Signal panel screw 2 11±1
9 1000098-H03 Intake manifold stud 2 5±1
10 1002028-H03 Process hole plug 2 26±2
11 1007016-H01 Local pressure oil plug 1 3±0. 5
12 1005011-H01 Flywheel bolt 6 74±4
Hexagon socket head
13 GB/T 70. 1 M6^25 1 10±1
cap screw
14 1009022-H01 Drain plug 1 45±2
15 1012010-H01 Oil filter assembly 1 14±2
16 3707010-H01 Spark plug assembly 4 22±2
Rear oxygen sensor
17 3742050-A01 2 50±3
assembly
Water temperature
18 3762020B3 1 15±2
sensor assembly
Oil pressure alarm
19 3810010-H01 1 21±2
assembly
20 1009013-H01 Oil baffle plate stud 4 10±1
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Engine
Mounting bolt of
21 1000094-H01 2 32±2
compressor bracket
Intake air
22 Q1860620 Hexagon flange bolt 1 8±2 temperature/pressure
sensor assembly
23 GB/T 5789 M8X35 Hexagon flange bolt 1 23±2 Knock sensor
Front housing
Mounting bolt of front
24 1000096-H03 5 23±2 assembly/cylinder
housing
block of oil pump
Phaser
VVT phaser mounting
25 Q1841040TF2 1 70±5 assembly/intake
bolt
camshaft
Mounting bolt of oil
1006051-A01 10±1 OCV/front housing
26 control valve 1
Intake manifold
assembly/intake
Mounting bolt of intake
27 1000097-H03 1 23±2 manifold connection
manifold
plate and cylinder
head
28 1000015-A01 Self-tapping screw 1 6.5±0.5
Front housing
Mounting bolt of intake
29 1000097-H03 1 23±2 assembly/cylinder
manifold
block of oil pump
3. The tightening torques of the other bolts shall conform to provisions in Table 3.
Table 3 Tightening Torque Limits
Unit: N·m
Thread Specification (Coarse Thread/Find Tightening Torque
Thread) Grade 8. 8 Grade 10. 9
M6 10±1 13±1
M8 23±2 32±2
M10 50±3 65±3
M12 80±5 110±5
4. Parts, components and positions for application and filling of gasoline engine oil.
Table 4 Parts, Components and Positions for Application and Filling of Gasoline Engine Oil
Parts and Components
for Application and Positions for Application and Filling of Gasoline Engine
S/N Remarks
Filling of Gasoline Oil
Engine Oil
1 Crankcase assembly Working surface of cylinder bore
Working surface of main journal, working surface of conrod
2 Crankshaft assembly
journal and inside of high pressure oil hole Lubricating
3 Conrod assembly Conrod small end hole System
4 Piston pin Working surface
5 Main bearing bush Working surface
6 Conrod bearing bush Working surface
Crankshaft thrust
7 Working surface
washer
Working surface of camshaft bearing seat hole, working
8 Cylinder head assembly
surface of tappet hole, valve guide head Lubricating
9 Valve cylindrical surface and end surface of valve stem System
10 Valve tappet Cylindrical surface of tappet
11 Camshaft assembly Working surface of camshaft journal
Chain tensioning and
12 Working surface
guide assembly
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Engine
Front housing assembly
13 Inner hole and inside of oil pump
of oil pump
Outer circle surface of seal ring of oil filter assembly (and the
14 Oil filter assembly
inside of oil filter)
15 Oil strainer assembly Outer circle surface of O-ring
Oil level gauge
16 Outer circle surface of rubber plug
assembly
Front oil seal assembly
17 Oil seal seat surface
of crankshaft Ventilation
Crankshaft rear end System
18 Inner wall of mounting hole of crankshaft rear oil seal
cover
19 PCV valve seal ring Inner and outer circle surfaces of PCV valve seal ring
Intake air
Outer circle surface of O-ring of intake air
20 pressure/temperature
pressure/temperature sensor
sensor
Electric
Crankshaft position
21 Outer circle surface of O-ring of crankshaft position sensor System
sensor
Camshaft position
22 Outer circle surface of O-ring of camshaft position sensor
sensor
23 Fuel manifold assembly Outer circle surface of O-ring of fuel manifold assembly
Cylinder head cover Seal ring surface on cylinder head cover assembly which
24
assembly contacts spark plug guide
Camshaft cover bolts,
Camshaft cover bolts, timing chain guide bolts, high pressure
timing chain guide Others
oil plug, clutch cover assembling bolts are all phosphorized.
25 bolts, high pressure oil
Before assembly, if there is on oil on the surface, apply
plug, clutch cover
gasoline engine oil.
assembling bolts
5. Tightening torques for transmission screws.
Table 5 Tightening Torque Reference for Transmission Screws
Unit: N·m
S/N Name Qty. Tightening Torque Remarks
1 Clutch release support 1 22 ~35
2 Clutch fork bracket bolt 1 8~12
3 Cable support bolt 2 18 ~28
4 Gears I & II shift lever bolts 2 18 ~28 Apply sealant
5 Reverse shift fork assembly bolt 2 18 ~28 Apply sealant
6 Front and rear box closing bolt 9 18 ~28
7 Rear gear screw 1 18 ~28 Apply sealant
8 Reversing lamp switch assembly 1 15 ~22
9 Extension box bolt 8 18 ~28
10 Gearbox closing bolt 4 18 ~28
11 Lock steel ball assembly 1 18 ~28 Apply sealant
12 Clutch cable guide block screw 1 18 ~28
13 Reverse gear lock bolt 1 18 ~28
14 Gear shift lock bolt 3 10 ~16 Apply sealant
15 Speedometer sensor bolt 1 8~12
16 Oil drain bolt 1 5~10
17 Oil inlet bolt 1 5~10
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Engine
Special Tools
Table 1 Special Tools for Engine Repair
1. 09915-64510-001
pressure gauge
2. 09915-64510-002
connector
3. 09915-64530 hose 09915-67310 09915-77310 09915-78211
4. 09915-67010 fixer Vacuum gauge Oil pressure gauge Oil pressure gauge fixer
1. 09916-14510 valve
opener 09916-34542
2. 09916-14910 valve Reamer handle 09916-34550 09916-38210
opener fixer Reamer (5mm) Reamer (9mm)
09916-56011
09916-44910 Valve guide installer 09916-58210 09916-77310
Valve guide puller fixer Valve guide installer handle Piston ring compressor
09917-98221
09917-68220
Valve stem seal installer
Fixing wrench for camshaft
timing cam
09916-84511 09917-18210
Forceps Valve clearance
adjustment wrench
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Engine
09918-08210 09924-17810 09926-18210

Vacuum gauge hose connector Flywheel tightener Oil seal guide pipe (vinylite)
Model (8200-01)
Torque angle indicator
Gedore Tool Trading (Shanghai)
Co., Ltd. (Zhang Jianmin
13638332006)
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Engine
Table 2 Special Tools for Transmission
Auxiliary tool for

Auxiliary tool for
oil seal of input
gearbox oil seal
shaft
Auxiliary tool for

Auxiliary tool for
press fitting of
press fitting of
spindle rear
front (rear) bearing
bearing (front
of intermediate
bearing of input
shaft
shaft)
Auxiliary tool for

press fitting of
low-speed
synchronizer
assembly
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Engine
After-sales Repair Materials

S/N
Auxiliary Materials Use
The joint between cylinder head assembly and front
housing assembly of oil pump
The binding face of front housing assembly of oil
pump
1 TONSAN 1596Fa
The binding face of water pump assembly
The joint between crankcase assembly, cylinder
head gasket assembly, cylinder head assembly and
front housing assembly of oil pump
The binding face of crankshaft rear end cap
The binding face of oil pan assembly (with
crankcase assembly)
2 TONSAN 1591 Mounting face of oil pump front housing assembly
and lower plane of crankcase
Mounting face of crankshaft rear end cap and lower
plane of crankcase
3 Loctite 516 Oil pressure alarm assembly
4 Suzuki 1215 Oil drain plug of transmission
The first oil filling amount is 3. 7L/set, the filling
amount for maintenance is 3. 7L/set (when the oil
filter is replaced) or 3.2L/set (when the oil filter is
5 Oil: SL 5W-30 not replaced)
Remarks: each time after the oil is added, operate
the engine and check the oil level (the best oil level
is above the middle line and below the upper line)
Transmission oil: API (GL-4) SAE 75W-90,
6 1. 7~1. 9L/set
Shell Spirax S4 GS
For scrubbing each fitting surface during
maintenanceThe silk is used for scrubbing oil, and
7 Silk and cotton woven single jersey
the single jersey is used for scrubbing water, sealant,
etc.
8 TONSAN 1596 Tightening flat of thread of water temperature sensor
9 Loctite 243 Tightening flat of thread of process hole plug
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Part 2
Chassis
Section Title Page
2.1 Suspension System
2.1.1 Suspension System Overview 2.1.1-1
2.1.2 Front Suspension 2.1.2-1
2.1.3 Rear Suspension 2.1.3-1
2.1.4 Wheel and Tire 2.1.4-1
2.2.1 Drive System Overview 2.2.1-1
2.2.2 Drive Shaft Specifications 2.2.2-1
2.2.3 Manual Gearshift Control Mechanism 2.2.3-1
2.2.4 Manual/Automatic Integrated Gearshift Control Mechanism 2.2.4-1
2.2.5 Fuel System Overview 2.2.5-1
2.2.6 Evaporative Emission Control System 2.2.6-1
2.2 Drive System
2.2.1 Drive System Overview 2.2.1-1
2.2.2 Drive Shaft Specifications 2.2.2-1
2.2.3 Manual Gearshift Control Mechanism 2.2.3-1
2.2.4 Manual/Automatic Integrated Gearshift Control Mechanism 2.2.4-1
2.2.5 Fuel System Overview 2.2.5-1
2.2.6 Evaporative Emission Control System 2.2.6-1
2.3 Brake System
2.3.1 Brake System Overview 2.3.1-1
2.3.2 Front Disc Brake 2.3.2-1
2.3.3 Rear Drum Brake 2.3.3-1
2.3.4 Parking Brake Control Mechanism 2.3.4-1
2.3.5 Hydraulic Brake Control 2.3.5-1
2.3.6 Power Brake System 2.3.6-1
2.3.7 Anti-lock Brake System (ABS) 2.3.7-1
2.4 Steering System
2.4.1 Steering System Overview 2.4.1-1
2.4.2 Steering Column Assembly 2.4.2-1
2.4.3 Steering Gear Assembly 2.4.3-1
2.4.4 Steering Wheel Body Assembly 2.4.4-1
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Suspension System
2.1 Suspension System
Contents Page
2.1.1 Suspension System Overview
Specifications 2.1.1-1
General Specifications 2.1.1-1
Instructions and Operation 2.1.1-1
System Overview 2.1.1-1
General Inspection 2.1.1-2
Wheel Bearing Inspection 2.1.1-2
Inspection of Tie Rod Ball Joint 2.1.1-3
Inspection of Front Swing Arm Ball Joint 2.1.1-3
Inspection of Suspension Device 2.1.1-3
Vehicle Inspection 2.1.1-4
Lifting Vehicle for Inspection 2.1.1-4
Workbench Test 2.1.1-4
Inspection of Rear Shock Absorber 2.1.1-5
Road Test 2.1.1-5
Front Wheel Toe-in Inspection and Adjustment Procedure 2.1.1-5
Fault Description, Diagnosis and Test 2.1.1-6
Inspection and Confirmation 2.1.1-6
Fault Description Table 2.1.1-7
Vehicle Deviation Diagnosis Procedure 2.1.1-11
Diagnosis Procedure of Abnormal Movement Track (Vehicle Cannot Keep Running
Straightly) 2.1.1-12
Vehicle Hunting Diagnosis Procedure 2.1.1-13
Diagnosis Procedure of Steering Wheel off Central Position 2.1.1-15
Diagnosis Procedure of Abnormal Movement Track 2.1.1-15
Excessive Noise Diagnosis Procedure 2.1.1-16
Vibration Diagnosis Procedure 2.1.1-17
Abnormal Tire Wear Diagnosis Procedure 2.1.1-19
2.1.2 Front Suspension
Torque Specifications 2.1.2-1
Component Location Drawing 2.1.2-1
Component Exploded View 2.1.2-2
Disassembly and Assembly 2.1.2-4
Front Strut Assembly 2.1.2-4
Removal and Installation 2.1.2-5
Front Swing Arm Assembly 2.1.2-5
Front Strut Assembly 2.1.2-5
Engine Bracket Assembly 2.1.2-6
Front Stabilizer Rod 2.1.2-7
2.1.3 Rear Suspension
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Suspension System
Component Location Drawing 2.1.3-1
Rear Axle Assembly 2.1.3-2
Rear Shock Absorber Assembly 2.1.3-3
2.1.4 Wheel and Tire
Component Description 2.1.4-1
Tire Wear Diagnosis 2.1.4-2
Wheel Runout Inspection 2.1.4-2
Preliminary Inspection before Tire Alignment 2.1.4-2
Tire Wear Inspection 2.1.4-3
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2.1.1-1 Suspension System Overview 2.1.1-1
2.1.1 Suspension System caster angle can affect the direction control
Overview when steering but not affect the tire wear.
Excessively soft spring or vehicle overload
Specifications may impact on the kingpin caster angle.
General Specifications When the kingpin caster angle of a wheel is
positive, it pulls the vehicle partially
Name Specifications towards the vehicle center. Even the
Front wheel minimum positive kingpin caster angle may
toe-in 0.04°±0.16°
Front wheel
cause vehicle lateral movement or tilting.
Front wheel camber angle -0.15°±0.5° The measuring unit of the kingpin caster
alignment Kingpin 13.87°±0.5° angle is degree and it is unadjustable.
parameters inclination 2. Camber Angle
angle
Kingpin caster 3.4°±0.5° Camber angle is the angle that the tire
angle top deviates from the vertical plane when
Rear wheel toe- 0.2°±0.16° observing from the front end of vehicle.
Rear wheel
in When the tire inclines outward, the camber
alignment
Rear wheel
parameters angle is positive. When the tire inclines
camber angle -1.58°±0.5°
inward, the camber angle is negative. The
Instructions and Operation camber angle is the degree deviating from
the vertical plane. It will affect the direction
System Overview
control and tire wear. If the positive camber
The primary goal of the vehicle angle is excessive large, the outer side tire
engineering is to guarantee safe and reliable shoulder will be worn. If the negative
steering and suspension systems. Each camber angle is excessive large, the inner
component must have adequate strength to side tire shoulder will be worn. The camber
bear and absorb the extreme impact. The angle is unadjustable.
steering system and the front & rear
3. Toe-in
suspension systems must maintain certain
geometrical relationship with the body. Toe-in refers to tire inclining inward
from the geometric center line or thrust line,
The steering and suspension systems
while toe-out refers to tire inclining outward
require the front wheels to return
from the geometric center line or thrust line.
automatically so as to minimize the front
The function of toe-in is to ensure that
wheel rolling resistance and the road friction
wheels rotate parallelly. Toe-in can offset
and to enable the user control the vehicle
the slight deviation of the wheel support
direction easily and comfortably.
system when the vehicle moves forward.
Overall wheel alignment inspection The specified toe-in angle is the setting
shall include measuring rear wheel toe-in value to make the toe-in reach 0 degree
and rear wheel camber angle. Four-wheel when the vehicle moves forward.
alignment can ensure that all four wheels
Incorrect toe-in or toe-out may cause
rotate in the same direction accurately. After
tire wear and reduce fuel efficiency. As each
geometric alignment, the vehicle can get
component of steering and suspension
optimal fuel efficiency, tire service life and
systems will wear with the increase of the
steering performance.
vehicle driving mileage, toe-in shall be
1. Kingpin Caster Angle increased to compensate for such component
Kingpin caster angle is the forward or wear. Be sure to calibrate the toe-in angle at
backward inclination amount that the last.
steering axis apex deviates from the vertical 4. Steering axis inclination
plane when observing from the vehicle side.
Steering axis inclination angle refers to
Backward inclination is positive while
amount that the knuckle top deviates from
forward inclination is negative. Kingpin
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the vertical plane. Observing from the front

end of vehicle, the steering axis inclination
angle is the included angle between the
vertical plane and a straight line going Dial indicator retaining
seat
through the strut center and the lower ball
joint. Steering axis inclination angle helps
the vehicle maintain running in straight line
and assists wheels in returning to straight
front position. The steering axis inclination
Dial indicator
angle of front drive vehicles shall be
negative.
5. Wrap Angle 1. Lift the front of vehicle.
Observing from the front end of vehicle, Reference: Lifting (1.1.3 Traction and
the wrap angle is the included angle between Lifting).
the camber angle and a straight line going
2. Shake the wheel to check the front
through the strut center and the lower ball
wheel bearing for looseness.
joint. Wrap angle is calculated in degree.
Many alignment racks do not measure the
wrap angle directly. The wrap angle is the
steering axis inclination angle less negative
camber angle or plus positive camber angle.
6. Scrub Radius
Scrub radius is the distance between the
vertical plane and a straight line going
through the strut center and the lower ball 3. Rotate the wheel quickly, and make
joint. It is the design feature of vehicle, sure that the wheel rotates smoothly
which is unadjustable. and quietly.
7. Misalignment Distance 4. Remove the front brake caliper and the
Misalignment distance is the distance retaining plate.
that one front hub and bearing assembly Reference: Brake Caliper (2.3.1 Brake
falls behind the other front hub and bearing System, “Removal and Installation”).
assembly. It is mainly caused by road
obstacle or vehicle collision. 5. Install a proper dial indicator retainer or
similar equipment on the wheel hub,
8. Steering Angle then push and pull the wheel hub.
Steering angle is the angle that each Measure the axial clearance between
front wheel relates to the vertical direction the wheel hub and the front wheel
during vehicle steering. bearing assembly. There shall be no
axial clearance. If any, replace the front
General Inspection wheel bearing.
Wheel Bearing Inspection
Note: Do not mix the swing arm ball
joint looseness with the bearing
looseness.
Tool
6. Install the front brake caliper and the
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retaining plate. damaged.

Inspection of Tie Rod Ball Joint 3. If free movement occurs, replace the
ball joint.
Note: Before checking or aligning the
front suspension, check the wear of tie Reference: Front Swing Arm (2.1.2
rod ball joint. Front Suspension, “Removal and
Installation”).
1. Check the pressure of four tires.
4. After the ball joint is replaced, conduct
2. Lift the vehicle. front wheel alignment. Refer to general
Reference: (1.1.3 Traction and Lifting). process for relevant information.
Check the front suspension ball Inspection of Suspension Device
joint and support for looseness, wear or
Note: All vehicles are equipped with
damage. For relevant information, refer
low-pressure gas and liquid suspension
to Front Swing Arm Ball Joint. Torque
device. Such device cannot be adjusted
all loose nuts to specification. Replace
or refilled.
parts as necessary.
1. Leak oil. It is normal to allow a layer of
Reference: Tie Rod Ball Joint (2.4.3
oil film (seeps) attaches on the front/
Steering Mechanism, “Removal
rear shock absorber. Oil seepage refers
and Installation”).
to a thick layer of oil film accumulates
3. Check the connection of steering on the outside of shock absorber
mechanism and tie rod for looseness, housing, and it is easy to be observed
and torque to specification. If the tie due to a large amount of dust
rod ball joint wears or breaks, replace accumulated. Oil seepage occurring to
the ball joint. the shock absorber is its normal
Reference: Tie Rod Ball Joint (2.4.3 function, so it is unnecessary to replace
Steering Mechanism, “Removal the shock absorber due to oil seepage.
and Installation”). Oil leakage refers to that the whole
shock absorber is covered by the leaked
4. Remove the front wheels. Check the oil and the oil drops from the
tire runout and uneven wear, and suspension to the floor.
conduct tire dynamic balancing.
If such situation occurs:
5. Check the operating condition of the
suspension device and its accessories. • Make sure that the oil film
Refer to Inspection of Suspension observed comes only from the
Assembly for relevant information. shock absorber.
Jamming of suspension assembly will • Replace if the shock absorber
cause that the vehicle cannot reach the wears or damages.
normal position so that the front wheel
2. Vehicle body sinks. It frequently
alignment will be affected.
happens to solve the vehicle body
Inspection of Front Swing Arm Ball Joint sinking through replacing the front/rear
1. Lift the vehicle. shock absorber. As our shock absorbers
are hydraulic damping devices which
Reference: Lifting (1.1.3 Traction and cannot be used for bearing loads unlike
Lifting). suspension springs, replacing the
2. Grasp the front swing arm outer end suspension device cannot solve the
firmly, try to move it up and down, and vehicle sinking problem.
observe whether there is movement.
Note: When one suspension device
“Click" always comes along with free
damages, it is unnecessary to replace in
movement which means it has been
pair. In the past, we recommend to
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replace the shock absorber in pair if of the shock absorber. If the total length of
one of them damages. But now, we shock absorber does not reach the standard,
apply new technology and enhance the it indicates that some certain parts do not
management during production, so the meet the requirement and the shock absorber
sealing technology increases and the shall be replaced. If the suspension device is
operating reliability of shock absorber in vertical position, compress the suspension
advances significantly. assembly and allow it to stretch for 3 times
so as to eliminate the gas entered into the
Vehicle Inspection
pressure chamber during handling.
1. Check the tire pressure of all tires.
Warning: When removing the dust
2. Check tires for the tie rod ball joint cover/limit stop, prevent the shock
positioning, the tire dynamic balance absorber push rod being pushed
and crack or abnormal bulging. downward excessively during
3. Check selectable suspension devices compressing for fear of causing
such as suspension for heavy traction damage of internals.
trailer. Such suspension is more secure The shock absorber shall be placed on a
than the standard suspension during vise vertically. Compress the shock absorber
driving process. with large travel as soon as possible. Each
4. Check the vehicle for overload. Check compression movement must be smooth and
the trunk for heavy materials. consistent. It is normal that the stretching
resistance is bigger than the compressing
5. After the above steps are completed, resistance.
conduct road test to confirm the fault
reported by the customer. The following situations are abnormal:
Lifting Vehicle for Inspection 1. During the installation and returning

after the shock absorber is installed in
1. Noise: place, drag and jump occur.
The looseness of suspension or 2. Jamming.
suspension assembly may cause noise.
Check and tighten the suspension 3. Noise. Besides the slight swish, tick
assembly and its accessories. Replace if occurs when returning quickly.
the lower support bushing damages. 4. Leakage.
Check the front/rear suspension
assembly for external damage. 5. When the shock absorber push rod is
stretched completely, the shock
2. Bottom/ rebound: absorber piston rod swings relative to
Check the travel of the rubber the shock absorber housing.
shock absorber bushing. Replace with a If the shock absorber is still unstable
new one if there is damage or missing. after the air purification, replace it with a
Check the shock absorber bushing for new one.
overload. Replace if overload exists.
Reference: Disassembling and
3. If a shock absorber is worn, replace the Assembling of Front Strut
damaged one only. Assembly (2.1.2 Front
Workbench Test Suspension, “Removal and
Installation”), Rear Shock
The interior of shock absorber is filled Absorber Assembly/Rear
with compressed gas, so it shall be stretched Spiral Spring/Upper and
completely when it is not restricted. If the Lower Seats of Rear Spiral
shock absorber is not stretched completely, Spring (2.1.3 Rear
it indicates that it is broken. Replace with a Suspension, “Removal and
new shock absorber. Check the total length Installation”).
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Inspection of Rear Shock Absorber It means that the vibration occurs at

different speeds and in different gears.
Conduct the following inspections on the
Sometimes, it can be defected through
rear shock absorber periodically:
increasing or decreasing the engine speed in
1. Check the rear shock absorber for oil neutral position or through transmission stall
leakage. (It is allowed t to have a layer test. If the situation is relevant to the speed
of oil film, so make sure that the engine, it may be irrelevant to tires.
leakage is not from other places.)
If the road test indicates tire whimper
2. Check the operating state of the rear without shaking or vibration, the noise is
shock absorber. caused by the contact between the tire and
3. Check the operating state of the upper/ the pavement.
lower bushing. Huge noise normally indicates flat tire
Road Test or soft material contacting with the
pavement. Tire whimper may be taken as
The tire vibration diagnostic program axle noise by mistake. Tire whimper will be
starts from the road test. Road test and given out constantly within a certain vehicle
talking with the customer can provide a lot speed range.
of information required for finding out the
vibration sources. Road test shall be Front Wheel Toe-in Inspection and
conducted on even pavement without ups Adjustment Procedure
and downs. If vibration occurs, pay attention Common Tools
to and record the following items:
Wheel alignment ruler
Vehicle speed when the vibration
Inspection
occurs; vibration type occurred in each
speed range; and being mechanical or Conduct toe-in adjustment on an even
audible. surface with a wheel alignment ruler as per
the instruction.
1. When the following conditions change,
they have impact on the vibration: • Check the suspension and steering
components for wear.
Engine torque; vehicle speed; and
engine speed. • Check and adjust the tire pressure
2. Vibration Type as necessary.
• Make sure that the vehicle is in
Sensibility: being sensitive to the
curb mass. The spare tire, jack and
torque, vehicle speed or engine speed.
onboard tools are equipped in
The following explanations help to place. Take out other tools or
distinguish the vibration sources: loads.
1. Sensitive to Torque • Press the vehicle up and down to
It means that the situation will be make the vehicle suspension
improved or worsened due to accelerating, system in normal position.
decelerating, coasting, fixing speed or Adjustment
applying engine torque.
1. Turn the steering wheel in the central
2. Sensitive to Vehicle Speed position and lock it.
It means that the vibration always
occurs under the same vehicle speed and is
free from the impact of engine torque,
engine speed or drive axle gear selection.
3. Sensitive to Engine Speed
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Visual Check List

Tire pressure
Wheel and tire
Wheel steering knuckle
Tie rod ball joint
Front swing arm and swing arm ball joint pin
Front busing and rear bushing of front swing arm
Front strut and spring
2. Loosen the lock nut of tie rod ball joint. Front stabilizer bar and connecting rod
Rear spring
Rear shock absorber
Rear axle and rear axle busing
3. If the problem observed or reported is
obvious, eliminate the fault before
implementing the next step.
4. If the visual check is passed, confirm
the fault and refer to the Fault
Description Table.
3. Rotate the tie rod ball joint locking nut

clockwise or counterclockwise to adjust
the toe-in.
4. Tighten the lock nut of tie rod ball joint.
Tightening torque: 55±5N.m
5. Check the toe-in.
Fault Description, Diagnosis and
Test
1. Confirm the problem reported by the
customer.
2. Check visually whether there is
obvious mechanical damage.
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Fault Description Table

If a fault occurs but DTC is not stored in the control module and the cause cannot be
made sure during the basic examination, conduct fault diagnosis and elimination in the order
listed in the table below.
Wheel and tire
Wheel alignment
Misalignment distance
Driving height
Reference: Vehicle Deviation
Vehicle deviation Wheel bearing
Diagnosis Procedure
Ball joint
Braking drag
Steering rod
Rear suspension
Wheel and tire
Wheel alignment
Wheel bearing
Abnormal movement track Reference: Diagnosis Procedure of
Ball joint
(vehicle cannot keep running Abnormal Movement Track (Vehicle
Control arm bushing
straightly) Cannot Keep Running Straightly)
Steering rod clearance
Steering mechanism clearance
Rear suspension
Imbalance or excessive wear of
tire
Wear of front wheel drive shaft
Wear of wheel bearing
Wear of steering system
Looseness or wear of suspension
assembly
Reference: Vehicle Hunting
Vehicle hunting Wear of front swing arm ball joint
Diagnosis Procedure
Wear or looseness of front
suspension front swing arm
bushing
Wear of stabilizer bar bushing
Wear or looseness of rear
suspension rear busing
Abnormal wheel alignment
Vehicle shaking during driving Check tires
Imbalance or excessive wear of Reference: Tire Wear Inspection
tire (2.1.4 Wheel and Tire, “General
Inspection”)
Check the front wheel drive shaft
Reference: Drive Shaft Inspection
Wear of front wheel drive shaft
(2.2.1 Drive System Overview,
“General Inspection”).
Replace the wheel bearing
Reference: Removal and Installation
of Front Wheel Bearing (2.1.2
Front Suspension, “Removal
and Installation”), Removal of
Rear Wheel Bearing (2.1.3 Rear
Suspension, “Removal and
Installation”).
Vehicle shaking during driving Replace the steering system wear-out
Wear of steering system
components
Check the suspension assembly
Looseness or wear of suspension
Reference: Torque Specifications
assembly
(2.1.2 Front Suspension,
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“Specifications”), Torque
Specifications (2.1.3 Rear
Suspension, “Specifications”)
Torque to specification
Reference: Torque Specifications
Looseness of suspension assembly (2.1.2 Front Suspension,
support “Specifications”), Torque
Specifications (2.1.3 Rear
Suspension, “Specifications”)
Replace the front swing arm ball joint
Reference: Front Swing Arm and
Wear of front swing arm ball joint Swing Arm Ball Joint Pin (2.1.2
Replace the front suspension front
swing arm bushing
Wear or looseness of front
suspension front swing arm
Swing Arm Ball Joint Pin (2.1.2
bushing
Replace the stabilizer bar bushing or
connecting rod
Wear of stabilizer bar bushing Reference: Front Stabilizer Bar (2.1.2
Replace the rear suspension bushing
as necessary
Reference: Rear Axle (2.1.3 Rear
Wear or looseness of rear Suspension, “Removal and
suspension rear busing Installation”), Rear Axle
Bushing (2.1.3 Rear
Installation”).
Conduct wheel alignment
Reference: Wheel Alignment (2.1.1
Abnormal wheel alignment
Suspension System Overview,
Steering wheel off the central Wheel alignment Reference: Diagnosis Procedure of
position Steering system components Steering Wheel off Central
Position
Excessive Noise Looseness or wear of suspension Reference: Excessive Noise
assembly support Diagnosis Procedure
Front swing arm bushing
Shock absorbing spring
Tire
Front swing arm ball joint
Abnormal wheel wear Tire rotation
Tire pressure
Wheel deformation
Imbalance of tire Reference: Abnormal Tire Wear
Wheel alignment Diagnosis Procedure
Suspension components
Driving at high speed
Rear axle
Abnormal wheel wear Overload Reference: Abnormal Tire Wear
Poor operation habits Diagnosis Procedure
Excessive positive kingpin caster Conduct wheel alignment
Difficulty in steering
angle Reference: Wheel Alignment (2.1.1
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Incorrect driving height If the load reaches the standard,
replace the standard spring
components
Wear of steering mechanism or Replace the steering system wear-out
steering tie rod components
Wear of front suspension front Replace the front swing arm ball joint
swing arm ball joint Reference: Front Swing Arm and
Wear or imbalance of tire Check tires
Reference: Tire Wear Inspection
(2.1.4 Wheel and Tire, “General
Inspection”).
Inadequate power steering force Check EPS
Reference: read EPS data with a
diagnostic apparatus, and
conduct EPS fault diagnosis.
Unstable orientation Imbalance, damage or excessive Check tires
runout of tire Reference: Tire Wear Inspection
(2.1.4 Wheel and Tire, “General
Inspection”).
Toe-in value beyond the specified Conduct wheel alignment
range Reference: Wheel Alignment (2.1.1
Wear of steering system Replace the steering system wear-out
components
Damage of front suspension front Replace the front suspension front
swing arm ball joint swing arm ball joint
Softened front or rear shock Check the shock absorbing spring,
absorbing spring and replace as necessary
Assembling of Front Strut
Assembly (2.1.2 Front
Absorber Assembly/Rear Spiral
Spring/Upper and Lower Seats
of Rear Spiral Spring (2.1.3
Rear Suspension, “Removal and
Installation”).
Wear of front or rear suspension Replace the suspension assembly
assembly wear-out components
Wear or looseness of rear Replace the rear suspension wear-out
suspension, busing or bolt components
Wear of stabilizer bar bushing or Replace the stabilizer bar bushing or
connecting rod connecting rod
Reference: Front Stabilizer Bar (2.1.2
Steering wheel not return Abnormal wheel alignment Conduct wheel alignment.
normally Reference: Wheel Alignment (2.1.1
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Wear of steering system Check the steering system
Reference: (2.4.1 Steering System
Overview, “General
Inspection”).
Wear of front suspension front Replace the front suspension front
swing arm ball joint swing arm ball joint
Wear of front stabilizer bar Replace the stabilizer bar connecting
connecting rod or bearing (if rod or bushing
equipped) Reference: Front Stabilizer Bar (2.1.2
Wear or looseness of front Repair or replace the front suspension
Body shaking suspension front swing arm front swing arm bushing
bushing Reference: Front Swing Arm and
Looseness or wear of suspension Check the suspension assembly and
assembly replace wear-out components
Softened or damaged front or rear Check the shock absorbing spring,
shock absorbing spring and replace as necessary
Body tilting Installation”), Rear Shock
Installation”).
Improper tire pressure Adjust the tire pressure
Softened front or rear shock Check the shock absorbing spring,
absorbing spring and replace as necessary
Poor driving comfort
Installation”).
Wear of front or rear suspension Replace the suspension assembly
assembly wear-out components
Tire Reference: Driving Vibration
Front wheel bearing Diagnosis Procedure
Driving vibration Rear wheel bearing
Front hub
Rear hub
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Vehicle Deviation Diagnosis Procedure

1. Check left-right deviation
Warning: to avoid injury due to operating out of control, the road test shall be conducted by two
persons to maintain safe driving condition. Be sure to keep proper control of the steering wheel.
Failing to follow such instructions may cause injuries.
A. Drive the vehicle at a speed of 80km/h on
a flat and straight road.
B. Make sure that there is no crosswind or
strong wind during driving.
C. When the vehicle runs straightly after
adjustment, both hands leave the steering wheel. If
the track of vehicle deviates 3.7m (i.e. distance of a
lane) in 7s, it indicates vehicle deviation.
Whether it is vehicle deviation or not?
Yes. Go to Step 2.
No. Adjust the steering wheel to
make it straight.
2. Check tires
A. Check all wheels for uniform tire model.
B. Check whether the wear situations of all
tires are similar.
C. Check tires for bulging or crack.
D. Check the tire pressure.
Are tires normal?
No. Adjust or replace the tire.
3. Check the impact of tire on fault
A. Exchange the left and right tires of front
suspension.
B. Install four tires in good state as
necessary.
Is it vehicle deviation?
No. Replace tires.
4. Check left/right wheel base
A. Check left/right wheel base.
Are the left and right wheel bases uniform?
No. Correct left/right wheel base.
5. Check the steering connecting rod
A. Lift the vehicle.
Reference: Lifting (1.1.3 Traction and Lifting).
B. Check the steering connecting rod for
excessive wear.
Is the steering connecting bar worn
excessively?
Yes. Replace or repair damaged
components.
No. Go to Step 6.
6. Check driving height
A. Check the driving height.
Is the driving height normal?
No. Eliminate the fault of
inconsistent driving height.
7. Check wheel alignment
A. Check wheel alignment.
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Whether the steering wheel is in central

position and the wheel alignment data is in
specified range?
No. Conduct wheel alignment as
necessary.
8. Check braking drag
B. Check wheels for braking drag.
Is there braking drag?
Yes. Eliminate the braking drag.
Reference: Braking Drag (2.3.1 Brake System
Overview, “Fault Description, Diagnosis
and Test”).
9. Check rear suspension
A. Check the rear suspension alignment
parameters.
Is the rear suspension alignment normal?
Yes. Check the suspension parts
for wear. Replace or repair damaged parts
as necessary.
Reference: Disassembling and Assembling of
Front Strut Assembly (2.1.2 Front
Suspension, “Removal and Installation”),
Rear Shock Absorber Assembly/Rear
Spiral Spring/Upper and Lower Seats of
Rear Spiral Spring (2.1.3 Rear
Suspension, “Removal and Installation”).
No. Adjust or repair abnormal rear
suspension alignment.
Diagnosis Procedure of Abnormal Movement Track (Vehicle Cannot Keep Running
Straightly)
Warning: To avoid injury due to operating out of control, the road test shall be conducted by two
1. Check tires
B. Check whether the wear situations of all tires
are similar.
Are tires normal?

suspension.
B. Install four tires in good state as necessary.
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3. Check front swing arm bushing

A. Check the front swing arm bushing for crack,
looseness or shaking.
Is the front swing arm normal?
No. Replace the front swing arm
bushing.
Reference: Front Swing Arm and Swing Arm
Ball Joint Pin (2.1.2 Front Suspension,
“Removal and Installation”).
4. Check steering connecting rod
B. Check the steering connecting rod for
excessive wear.
Is the steering connecting bar worn
excessively?
Yes. Replace or repair damaged
components.
specified range?
necessary.
6. Check steering mechanism clearance
B. Check the steering mechanism clearance.
Reference: Inspection of Steering Linkage
(2.4.1 Steering System Overview,
Is the steering mechanism clearance normal?
No. Repair or replace faulty
components.
parameters.
for wear. Replace or repair damaged
parts as necessary.
No. Adjust or repair abnormal
rear suspension alignment.
Vehicle Hunting Diagnosis Procedure
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Warning: To avoid injury due to operating out of control, the road test shall be conducted by two
1. Check tires
B. Check whether the wear situations of all tires
are similar.
Are tires normal?
suspension.
B. Install four tires in good state as necessary.
3. Check front swing arm bushing
A. Check the front swing arm bushing for crack,
looseness or shaking.
Is the front swing arm normal?
No. Replace the front swing arm
bushing.
4. Check wheel bearing
B. Check the wheel bearing.
Reference: Wheel Bearing Alignment (2.1.1
Suspension System Overview, “General
Inspection”).
Is the wheel bearing normal?
No. Replace the wheel bearing.
5. Check stabilizer rod
A. Check the stabilizer bar bushing for crack,
looseness or missing.
B. Check the stabilizer bar for damage.
Is the stabilizer bar normal?
No. Repair or replace the
stabilizer bar and the bushing.

specified range?
necessary.
7. Check steering mechanism clearance
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B. Check the steering mechanism clearance.
Reference: Inspection of Steering Linkage
(2.4.1 Steering System Overview,
Is the steering mechanism clearance normal?
No. Repair or replace faulty
components.
parameters.
for wear. Replace or repair damaged parts
as necessary.
No. Adjust or repair abnormal rear
suspension alignment.
Diagnosis Procedure of Steering Wheel off Central Position
1. Check steering components
B. Check the steering components for excessive
wear.
Are the steering components worn excessively?
Yes. Replace or repair worn
components.
specified range?
Yes.
Reference: Diagnosis Procedure of Abnormal
Movement Track (2.1.1 Suspension
System Overview, “Fault Description,
Diagnosis and Test”).
necessary.
Diagnosis Procedure of Abnormal Movement Track
1. Check front wheel kingpin caster angle
A. Check the front wheel kingpin caster angle.
Is the front wheel kingpin caster angle in the
specified range?
No. Check the suspension
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components for wear. Replace or repair

worn components as necessary.
A. Check the left and right wheel bases of the
vehicle.
B. Compare the measured values.
Are the data the same?
Yes. Conduct wheel alignment.
No. Check the suspension
components for wear. Replace or repair
worn components as necessary.
Excessive Noise Diagnosis Procedure
1. Inspect suspension
B. Check the mounting bolts of suspension
components.
Are bolts loosened or damaged?
Yes. Tighten or replace bolts.
2. Check shock absorbing spring
A. Check the shock absorbing spring for damage.
Is the shock absorbing spring damaged?
Yes. Replace the shock absorbing
spring.
3. Check front suspension front swing arm
A. Check the front suspension front swing arm
bushing for excessive wear or damage.
Is the front suspension front swing arm bushing
damaged?
Yes. Replace the front suspension
front swing arm bushing.
4. Check ball joint
B. Grasp the outer end of the front suspension
front swing arm firmly, try to move it up and
down, and check whether free movement
exists. Note that free movement is not allowed.
Does free movement exist?
Yes. Replace the front swing arm.
Reference: Removal and Installation of Ball
Joint (2.1.2 Front Suspension, “Removal

5. Check tires
A. Check tires for uneven wear.
Are tires worn unevenly?
Yes. Replace tires. Conduct wheel
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alignment.
6. Check front wheel bearing
A. Check the front wheel bearing.
B. Seize the bottom and top of the wheel, and
shake with great effort. Check the bearing for
excessive looseness.
C. Rotate the front wheel and check the operating
state.
Does the bearing loosen or have noise?
Yes. If necessary, replace the front
wheel bearing.
No. Make sure the fault stated by
the customer.
Vibration Diagnosis Procedure
1. Check tires
B. Check tires for damage or excessive wear.
Does tires damage or wear?
Yes. Replace tires.
2. Check front wheel bearing
A. Check the front wheel bearing.
C. Rotate the front wheel and check the operating
state.
3. Measure axial clearance of front wheel bearing
A. Remove the wheels, brake caliper and brake
disc.
B. Install the dial indicator with mounting
support, and keep it stand against the front hub
closely.
C. Push and pull the hub in axial direction, and
check the axial clearance between the hub and
the front wheel bearing.
Is the axial clearance of front wheel bearing is
in the specified range?
Yes. Check the ball joint. Go to
Step 4.
No. Replace the hub and the
bearing assembly.

4. Check rear wheel bearing
A. Check the rear wheel bearing.
C. Rotate the rear wheel and check the operating
state.
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5. Measure axial clearance of rear wheel bearing
A. Remove rear wheels.
B. Install the dial indicator with mounting
support, and keep it stand against the rear brake
drum closely.
C. Push and pull the hub in axial direction, and
check the axial clearance of the rear wheel
bearing.
Is the axial clearance of rear wheel is in the
specified range?
No. If necessary, replace the rear
wheel bearing.
Reference: Rear Wheel Bearing (2.1.3 Rear
6. Check wheel/tire runout value beside vehicle
A. Measure the radial runout values of the wheel
and tires with a radial runout meter. The lateral
and radial runout of the assembly shall be
smaller than 1.14mm.
Are measurements in the specified range?
7. Check wheel/tire runout value under vehicle
A. Measure the wheel with radial or lateral runout
over 1.14mm. Before removing the wheel,
mark the positions of tire bolt and the
corresponding bolt hole so that the wheel can
be installed back to the original position.
Remove the wheel, install it on the tire
balancer, and measure the runout value. The
radial and lateral runout values of the wheel
and tire assembly must be smaller than
1.14mm.
Are measurements in the specified range?
8. Match mounting position
A. Mark the maximum runout positions of the tire
and the wheel. Release the air in the tire and
rotate it for 180 degrees. Inflate the tire and
measure the runout value.
Do the wheel and tire runout positions
coincide?
Yes. Conduct tire dynamic
balancing.
No. If the distance of two highest
points measured is beyond 101.6mm,
replace the tire. If it is within 101.6mm,
go to Step 9.

9. Measure wheel runout
A. Remove the tire cover, and install the wheel on
the tire balancer. Measure the runout values at
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the inner and outer edges of the wheel. Both

the lateral and radial runout values shall be
smaller than 1.14mm.
Is the runout normal?
No.
Replace the wheel. Check the new wheel
runout. If it is in the specified range, find out
and mark the runout lowest point. Install the
tire, and match the highest point of tire runout
with the lowest point of wheel runout for
balancing.
10. Radial runout of rear hub and tire bolt
A. Measure the hub flange face runout (over
0.254mm) and the wheel bolt circular runout
(over 0.08mm). Are measurements in the
normal range?
No. Replace the rear hub.
11. Front hub and tire bolt circular runout
A. Remove the front wheel.
B. Remove the brake disc.
C. Measure the tire bolt circular radial runout
(over 0.06mm). Are measurements in the
normal range?
Yes. Check the brake disc runout.
Reference: Brake Disc Runout Inspection
(2.3.1 Brake System Overview, “General
Inspection”).
No. Replace the hub.
12. Wheel balance
A. Conduct tire balancing. Carry out road test.
Does vehicle vibration exist?
Yes. Repair it.
Reference: (1.1.5 Noise, Vibration and
Unsmoothness). No. Make
sure that the repair is completed.
Abnormal Tire Wear Diagnosis Procedure

1. Check tire wear situation
B. Check the tire wear situation.
Are front wheels worn excessively?
Yes. Exchange tires, or replace
tires as necessary.

2. Check tires
A. Check the tire pressure and model.
Is the tire pressure normal and the tire model
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uniform?
No. Replace wheels of different
models and adjust the tire pressure.
Reference: General Specifications (2.1.4
Wheel and Tire, “Specifications”).
3. Check wheels
A. Check wheels for torsion and deformation.
B. Check the wheel runout value.
Reference: Wheel Runout Inspection (2.1.4
Wheel and Tire, “General Inspection”).
Are wheels normal?
No. Adjust or replace wheels.
4. Check tire balance
B. Remove the tire.
C. Check the tire balance on a balancer.
Is the tire balance normal?
No. Balance the tire, or replace the
tire as necessary.
Do wheel alignment parameters conform to
specifications?
No. Adjust wheel alignment
parameters.
6. Check front/rear suspension components
A. Check whether fastening bolts of front
suspension components are tightened.
B. Check the front swing arm bushing and
stabilizer bar bushing for crack, looseness or
missing.
C. Check the front suspension ball joint for
looseness.
D. Check whether fastening bolts of front
suspension components are tightened.
E. Check the rear suspension bushing for crack,
looseness or missing. Are front and rear
suspension components normal?
No. Repair front/rear suspension
faults.
7. Check axle base
A. Check the left and right axle bases of the
vehicle.
Are the left and right axle bases uniform?
Yes. Check the vehicle load and
the driver’s habits, and correct the
overload or improper operation habits.
No. Correct left/right axle base.
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2.1.2-1 Front Suspension 2.1.2-1
2.1.2 Front Suspension

Specifications
Torque Specifications
Name Nm lb-ft lb-in
Bolts/nuts for connecting engine bracket and body 150±5 -
Nuts for connecting front strut and body 60±5 -
Bolts/nuts for connecting front strut and steering knuckle 100±10 -
Bolts (front) for connecting front swing arm and engine 130±10 -
bracket
Bolts (rear) for connecting front swing arm and engine 130±10 -
bracket
Bolts for connecting front swing arm ball joint pin and 70±10 -
steering knuckle
Nuts for connecting front stabilizer bar and connecting 70±10 -
rod
Connecting nuts between connecting rod and front strut
assembly
Bolts for connecting front stabilizer bar and engine 30±5 -
bracket
Instructions and Operation

System Overview
Being McPherson independent type, the front suspension consists of two front strut
assemblies (including shock absorbing spring), engine bracket, front swing arm, stabilizer bar,
connecting rod and other accessories.
The front swing arm is welded with pressed steel plates. Each one is passed through the
bushing vertically with two bolts in length and breadth and connects with the engine bracket.
The front swing arm is connected to the steering knuckle through the ball joint.
The steering knuckle and the suspension assembly are connected to the stabilizer bar ball
joint.
The suspension device is supported on the mounting position by the rubber sleeve
installed on the strut top seat. The spiral spring is installed between two spring seats of the
suspension device. The piston rod is equipped with dust cover to prevent dirt or water from
entering. To protect suspension device under complete compression state, anti-collision
rubber gasket is installed.
The engine bracket is welded with several pressed steel plates and a hydroformed ring
beam. Its front and rear ends are connected to the vehicle body by bolts and nuts of different
specifications.
Component Location Drawing
S/N Component Name Qty. S/N Component Name Qty.
1 Front strut assembly (right) 1 5 Connecting rod assembly 2
2 Engine bracket assembly 1 6 Front swing arm assembly (left) 1
3 Front stabilizer bar 1 7 Front swing arm assembly (right) 1
4 Front strut assembly (left) 1 8
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Component Exploded View

Primary Exploded View—Front Suspension System
S/N Component Name Qty.

1 (see Secondary
1 Front strut system
Exploded View)
1 (see Secondary
2 Front swing arm system
Exploded View)
1 (see Secondary
3 Engine bracket system
Exploded View)
4 Hexagon flange bolt M12X1.25X75 4
5 Hexagon flange nut 4
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Secondary Exploded View—Front Swing Arm System

1 Front swing arm assembly (left) 1
3 Swing arm busing position limiter 4
4 Front swing arm assembly (right) 1
Secondary Exploded View—Front Strut System

1 Front strut assembly (left) 1
2 Hexagon flange lock nut (with non-metallic insert) 4
3 Hexagon flange nut 4
4 Front connecting rod assembly 2
5 Front stabilizer bar assembly 1
6 Front stabilizer bar bushing 2
7 Hexagon flange bolt 4
8 Front stabilizer bar bracket 2
9 Hexagon flange bolt 4
10 Front strut assembly (right) 1
11 Inner connecting bushing set 2
12 Nut 2
Secondary Exploded View—Engine Bracket System
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1 Engine bracket assembly 1
2 Assembling unit of hexagon flange bolt and flat washer 4

Test
Reference: Fault Description Table (2.1.1
Suspension System Overview, “Fault
Description, Diagnosis and Test”).
Disassembly and Assembly
Front Strut Assembly
Disassembly
1. Compress the spiral spring
partially.
Note: As the spiral spring is in extreme
stress, take care all the time for fear of
Component Name Qty.
injury. 1 Front shock absorber assembly 1
2 Front buffer block 1
3 Spiral spring 1
4 Dust cover 1
5 Upper spring seat assembly 1
Front strut upper mounting seat
6 1
assembly
7 Nut 1
• Step 1: remove the thrust nut.
• Step 2: remove the upper
mounting seat assembly.
2. Disassemble the front shock absorber
• Step 4: remove the upper spring
and the spiral spring.
seat assembly.
• Step 5: remove the dust cover.
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• Step 6: remove the spiral spring. Rear 130N.m

• Step 7: remove the buffer block.
Installation
Install in opposite sequence of removal.
Front Strut Assembly
Removal
Assembly
1. Remove the wheel.
The assembly procedure is in reverse
sequence of the disassembly procedure. Reference: Wheel and Tire (2.1.4
Wheel and Tire, “Removal and
Note: Place the spiral end on the spring Installation”).
seat correctly.
2. Lift the vehicle.
Reference: (1.1.3 Traction and Lifting).
Front Swing Arm Assembly
3. Remove the front wheel speed sensor
Removal from the front strut.
Reference: Wheel and Tire (2.1.4
Installation”).
3. Remove the swing arm ball joint.
Note: Use cotton cloth to protect the
ball joint during removal for fear of
damage. Torque: 70N.m 4. Remove the connecting rod ball joint
from the front strut.
Note: Use cotton cloth to protect the
ball joint for fear of damage. Torque:
70N.m
4. Remove the front swing arm fastening

bolt.
Torque: front 130N.m
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5. Remove bolts and nuts for connecting 2. Lift the vehicle.

front strut and steering knuckle. Torque: Reference: (1.1.3 Traction and Lifting).
100N.m
3. Separate the front stabilizer bar from
the connecting rod.
Torque: 70N.m
6. Separate the steering knuckle from the

front strut assembly.
7. Loosen 1 fastening nut on the upper of
the front strut assembly, and remove
the front strut assembly.
5. Remove bolts connecting the steering
Torque: 60N.m
tie rod and the knuckle.
Torque: 55N.m
6. Remove bolts connecting the swing

arm ball pin and the steering knuckle.
Torque: 70Nm
Installation
Engine Bracket Assembly
Removal
Special Tools
Engine bracket 7. Remove bolts connecting the engine

supporting tool bracket and the rear suspension
assembly.
Torque: 110N.m
Installation”).
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9. Remove bolts connecting the engine

bracket and the body. (There are 4 in Installation
total on the left and right) Install in opposite sequence of removal.
Torque: 150N.m
10. Use the special tool to support the

engine bracket assembly. Special tool:
engine bracket supporting tool
12. Remove the engine bracket assembly.

Installation
Front Stabilizer Rod
Removal
Installation”).
2. Remove the engine bracket assembly.
Reference: Engine Bracket Assembly
(2.4.4 Steering Column, “Removal
3. Remove 4 fastening bolts on the left
and right for the front stabilizer bar.
Torque: 30N.m
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2.1.3-1 Rear Suspension 2.1.3-1
2.1.3 Rear Suspension

Specifications
Name Nm lb-ft lb-in
Bolts and nuts connecting rear shock 40±5
absorber and body
Bolts and nuts connecting rear shock 78±8
absorber and rear axle
Bolts and nuts connecting rear axle 150±5
assembly and body

System Overview
Being twist-beam semi-independent type, the rear suspension consists of rear axle
assembly, spiral spring and shock absorber assembly. The wheels are connected to the rear
suspension through the brake. The wheels are fixed on the rigid twist beam, so it is
unnecessary to adjust the rear wheel alignment.

1 Rear axle assembly 1 4 Rear spiral spring 2
2 Rear brake assembly (right) 1 5 Rear brake assembly (left) 1
Rear shock absorber
3 2
assembly
Rear Suspension Exploded View
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1 Rear axle assembly 1
2 Hexagon flange bolt-M14X1.5X125 2
3 Upper seat, rear spiral spring 2
4 Rear spiral spring 2
5 Lower seat, rear spiral spring 2
6 Rear shock absorber assembly 2
7 Hexagon flange bolt-M10X1.25X55 2

Reference: Fault Description Table (2.1.1 Suspension System Overview, “Fault Description,
Diagnosis and Test”).
Rear Axle Assembly
Removal
Installation”).
3. Remove bolts connecting the rear
shock absorber assembly and the rear
axle.
Torque: 78N.m
4. Remove the left and right brake hoses.

• Step 1: remove the brake hose
connector.
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• Step 2: pull out the elastic clip

fastening the connector.
Note: after removing the brake hose,
block the brake hose to prevent dirt
from entering.
Note: Drain the brake fluid into a
proper container.
Torque: 78N.m
Torque: 40N.m
8. Lift the left and right brake assembly
with lift mechanism.
9. Lower the rear axle assembly.
Installation
Note: When the whole mass of vehicle
is borne by wheels, the rear suspension
parts can be tightened finally.
5. Remove bolts connecting the rear brake 1. Install in opposite sequence of removal.
assembly and the rear axle.
2. Exhaust air in the brake system.
Torque: 70N.m
Reference: Exhaustion of Brake System
(2.3.1 Brake System Overview,
3. Adjust the parking brake cable.
Reference: Adjustment of Parking
Brake Cable (2.3.4 Parking Brake
and Control, “General
Inspection”).
Note: Nuts are required to be at least 23mm
6. Remove connecting bolts of rear wheel into bolts.
speed sensor. Rear Shock Absorber Assembly
Torque: 10N.m Removal
Installation”).
3. Remove lower mounting bolts of the
rear shock absorber assembly.
7. Remove bolts connecting the left/right
rear axle trailing arm and the body. Torque: 78N.m
Torque: 150N.m
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4. Remove upper mounting bolts and nuts

of the rear shock absorber assembly.
Torque: 40N.m
Installation
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2.1.4-1 Wheel and Tire 2.1.4-1
2.1.4 Wheel and Tire

Specifications
General Specifications
Name Specifications
Tire Specifications 175/60R15
Front tire No load
pressure Full load
Rear tire No load
pressure Full load Component Exploded View
Torque Specifications Wheel and Tire Exploded View

Name Nm lb-ft lb-in
Wheel nut 85±5

Component Description
Tire Identification
The tire model, size, load index and
applicable speed rating have been made into
code composed of letters and numbers,
which is stamped on the tire side wall. Refer
to Tire Identification Table for code
interpretation. For convenience of
explanation, the tire specification of
1 Tire (175/60R15) 1
P175/60R1581H is taken as example in the 2 Aluminum alloy wheel (15x5J) 1
table. For all-weather tire, M+S, M&S or M- 3 Wheel nut 4
S (indicating mud and snow traction) is also 4 Wheel trim cover 1
stamped on the side wall. Overload or 5 Tire valve 1
underload mark (“XL” or “LL”) can also be
listed on the tire side wall. When there is no General Inspection
“XL” or “LL” mark, it can be inferred to be Warning: Besides emergency
standard load tire. (temporary backup), it is forbidden to
Tire Identification Table (P175/60R1581H) install different types of tires (such as
radial tire, diagonal tire and bias-ply
P-passenger vehicle
Tire type (not
T-spare tire
tire) on the same vehicle.
appear on all
P C-commercial Warning: It is forbidden to start the
kinds of tires)
vehicle
vehicle when replacing tires. When
LT-light truck
175 End face width Unit: mm
tires touch the ground, the vehicle may
Height-width End face height/end move.
60
percentage face width
Warning: Tire sealant on the market is
R Structure type R-radial tire
inflammable. Remind customers often
D-diagonal tire
15 Tire diameter Unit: inch that it is forbidden to use such materials.
81 Load index Consult the tire Warning: When repairing the wheel
H Speed rating manufacturer for
and tire assembly, wear safety goggles
detailed information
or mask.
Height-width percentage=end face
height/end face width Warning: After replacing the wheel or
loosening the wheel bolt, re-tighten the
2—end face height; 1—end face width wheel bolt after driving the vehicle for
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800km. mounting surface shall be correct. When

measuring, the tires can be on or off.
Warning: If the wheel bolt is not
Measure the radial and end face runout (③
tightened within the specified mileage,
in the figure) shall be measured in the inner
the wheel separating from the body
side and outer side of the wheel flange. Fix
may happen in the process of driving.
the dial indicator beside the wheel and the
Warning: Axle, wheel and tire all have tire assembly. If the measured values exceed
maximum load. Overload is forbidden. the following specifications and the wheel
balancing cannot eliminate the vibration,
Warning: It is forbidden to use steel replace the wheel.
wire to grind or use detergent to wash
the aluminum alloy wheels. Measure the free radial runout (① in
the figure) of the thread center. A piece of
Warning: Before removing the tire adhesive tape can be attached on the thread
valve, it is forbidden to reduce tire to form a smooth surface. Measure the free
pressure by pressing the valve piston. end face runout (② in the figure) on the tire
Failing to follow the above instructions may outer side nearest to the thread.
cause injury.
To exert the maximum efficacy of tires,
check whether the tire pressure and tire are
abnormal. If any abnormality exists, it
indicates that the tire needs dynamic
balancing, tire rotation or front wheel
alignment. Check tires for cut, scratch, wear,
bulging and foreign materials in the thread Wheel Radial End face Free radial
periodically. If the tire temperature rises fast type runout runout runout
or the road is rough with debris scattered, Aluminum 0.5mm 0.5mm 1.5mm
check tires more frequently. Steel 0.9mm 0.9mm 1.5mm
As more direct inspection of tire Preliminary Inspection before Tire
condition, the tire wear indication line is Alignment
marked on the bottom of the thread. When Inspection Operation
the tire wear indication line is exposed, it is Check whether the tire Check tires and wheels,
indicates that the tire shall be replaced. model and wheel model and replace wheels or
Tire Wear Diagnosis are uniform tires as necessary
Check whether the tire
Inflate tires to correct
When the tire wear indication line is pressure is appropriate
pressure and replace
exposed or the tire shoulder is severely worn, and whether the thread
tires as necessary
replace the tire. Tire shoulder wear is wear is normal
usually caused by excessively large radial Torque the axle nut to
Check the wheel correct specification.
tire camber angle or toe-in. Sometimes, bearing for looseness Replace the strut wheel
incorrect rear wheel toe-in setting or strut bearing as necessary
damage may cause severe “sinking” or Check the ball joint and
“sector” wear of non-drive tires. Extremely Tighten the ball joint
steering tie rod for
and steering tie rod
incorrect rear wheel toe-in may cause other looseness
abnormal wears. Check the wheel and Measure and correct the
tire runout tire runout
Wheel Runout Inspection Correct the unladen
Check the vehicle
Use a dial indicator to measure the height and adjust the
unladen height
toe-in
wheel runout. It can be measured beside the
Check the rear axle Correct the rear axle
vehicle or under the vehicle, but the base base
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Check the rack and Tighten the rack and for looseness connecting bolt.
pinion mounting for pinion assembly Replace the control arm
looseness mounting busing as necessary
Check whether the strut Replace the strut
operation is correct assembly
Check the control arm Tighten the control arm
Tire Wear Inspection
Fault Description Causes
Fast wear of tire Inadequate tire pressure (not conduct tire rotation)
Fast wear of center Excessive tire pressure (not conduct tire rotation)
Thread wear
Inadequate tire pressure

Excessive vehicle speed
Measure: When the tire in cold state, adjust the pressure as per the specifications and conduct tire rotation.
Fault Description Causes

Uneven wear Incorrect camber angle
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Measure: adjust the camber angle to specification

Feather-edge wear Incorrect toe-in
Measure: adjust the toe-in to specification

Small-thread-pattern wear Defective tire (may be but not limited to wheel
imbalance)
Measure: adjust the tire dynamic balance or replace the tire

Large-edge-pattern wear
Abnormal suspension
Measure: conduct tire rotation; adjust or repair the suspension

Special Equipment
Four-wheel aligner Tire balancer Tire changer
Road Test
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1. The tire vibration diagnostic program starts from the road test. Road test and talking with
the customer can provide a lot of information required for finding out the vibration
sources. Road test shall be conducted on even pavement without ups and downs. If
vibration occurs, pay attention to and record the following items:
Vehicle speed when the vibration occurs; vibration type occurred in each speed range;
and being mechanical or audible.
2. When the following conditions change, they have impact on the vibration:
Engine torque; vehicle speed; and engine speed.
3. Vibration Type
Sensibility: being sensitive to the torque, vehicle speed or engine speed.
The following explanations help to distinguish the vibration sources:
1. Sensitive to torque: it means that the situation will be improved or worsened due to
accelerating, decelerating, coasting, fixing speed or applying engine torque.
2. Sensitive to vehicle speed: it means that the vibration always occurs under the same
vehicle speed and is free from the impact of engine torque, engine speed or drive axle
gear selection.
3. Sensitive to engine speed: it means that the vibration occurs at different speeds and in
different gears. Sometimes, it can be defected through increasing or decreasing the
engine speed in neutral position or through transmission stall test. If the situation is
relevant to the speed engine, it may be irrelevant to tires.
If the road test indicates tire whimper without shaking or vibration, the noise is caused
by the contact between the tire and the pavement.
Huge noise normally indicates flat tire or soft material contacting with the pavement.
Tire whimper may be taken as axle noise by mistake. Tire whimper will be given out
constantly within a certain vehicle speed range.
Tire rotation
Tire pressure
Wheel deformation
Tire imbalance
Reference: Diagnosis Procedure of Abnormal Tire
Wheel alignment
Tire wear diagnosis Wear (2.1.1 Suspension System Overview, “Fault
Suspension components
Driving at high speed
Rear axle
Overload
Poor operation habits
Excessive tire pressure Adjust the tire pressure.
Imbalance of wheel or
Adjust the balance of wheels or tire assembly.
tire
Vehicle vibration caused Replace with new tires to eliminate the vibration as
Nonuniform tire wear
by wheel and tire necessary.
Check the brake disc for dirt or debris (if there is no
Imbalance of brake disc damage or debris on the brake disc, it may
accumulate a thick layer of dirt).
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Water entered in tire Drain the water.

Replace with new wheel (trying to repair the wheel
Wheel torsion may cause wheel breakage and reduce the wheel
strength).
Turn wheels and check the connection between the
tire and the wheel. If any part is found to shake
Incorrect tire bead
during turning, such part may not be well assembled.
assembling
Remove the tire, and clean the connection of the
wheel and the tire.
Use a dial indicator to measure the radial runout of
the wheel or the tire. If such runout value is not
Excessive wheel or tire within the specified range, further inspect the radial
radial runout runout of the wheel bolt; if the radial runout of the
wheel bolt exceeds the specified range, replace the
wheel or the tire.
Looseness or damage of
wheel bolt, or expanded Tighten or replace components as necessary.
wheel bolt hole
Foreign material in
between wheel mounting
Clean the mounting faces.
face and hub mounting
face
Replace the front wheel bearing.
Damage of front wheel
Reference: Front Wheel Hub (2.1.4 Wheel and Tire,
bearing
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Removal
1. Loosen the wheel nut.
Loosen the wheel fastening nut
counterclockwise.
Torque: 95N.m

3. Remove the wheel fastening nut, and
remove the wheel and the tire.
Note: Do not heat to loosen the stuck
wheel bolt. Heating may damage the
wheel and the hub.
Note: Remove the rust or dirt on the
mounting face of the wheel, hub or
brake disc. Such stuff may cause the
wheel bolt looseness and the wheel
dropping off during vehicle running.
Failing to follow the above instructions
may cause injuries.
Installation
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Drive System
2.2 Drive System

Contents Page
2.2.1 Drive System Overview1
Drive Shaft Inspection 2.2.1-1
Inspection of Drive Shaft Oil Seal 2.2.1-1
Diagnosis Procedure of Drive Shaft Abnormal Sound 2.2.1-3
Diagnosis Procedure of Dull Metallic Sound Occurred When Accelerating after Coasting
in Neutral 2.2.1-3
Diagnosis Procedure of Shaking or Vibration When Accelerating 2.2.1-4
Drive Shaft Falling off 2.2.1-4
Drive Shaft Hunting 2.2.1-5
Vehicle Low-speed Shimmy 2.2.1-5
2.2.2 Drive Shaft Specifications1
Material Specifications 2.2.2-1
Capacity 2.2.2-1
Notes on Drive Shaft Maintenance 2.2.2-1
Disassembly and Assembly 2.2.2-3
Internal Constant Velocity Universal Joint and Dust Cover 2.2.2-3
External Constant Velocity Universal Joint and Dust Cover 2.2.2-4
Left Drive Shaft 2.2.2-5
Right Drive Shaft 2.2.2-6
2.2.3 Manual Gearshift Control Mechanism1
Diagnosis Procedure of Difficulty in Gear Shift Mechanism Operating 2.2.3-2
Gear Shift Mechanism 2.2.3-3
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Drive System
Shift Cable 2.2.3-4

2.2.4 Manual/Automatic Integrated Gearshift Control Mechanism1
Diagnosis Procedure of Unavailable Gear Shift 2.2.4-2
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2.2.1-1 Drive System 2.2.1-1
2.2.1 Drive System Overview burr.

3. Check the oil seal mounting face on the
Instructions and Operation transmission side for abnormality such
System Overview as rust, scratch or burr.
The drive system adopts the front- Fault Description, Diagnosis and
engine front-drive mode, and the differential Test
is located inside the transmission assembly.
The drive shaft delivers the power from the Inspection and Confirmation
transaxle to the front wheel assembly. Each 1. Confirm the problem reported by the
drive shaft assembly contains internal and customer.
external constant velocity universal joints
connected to the drive shaft. The internal 2. Check visually whether there is
universal joint is flexible completely, which obvious mechanical damage.
can stretch inside and outside. The external 3. If the problem observed or reported is
universal joint is also flexible but cannot obvious, eliminate the fault before
stretch inside and outside. The inner ends of implementing the next step.
both drive shafts have an external spline
4. If the visual check is passed, confirm
which interlocks with transaxle gear through
the snap ring.
Description Table.
General Inspection
Drive Shaft Inspection
1. Check and make sure that the play of
the outside ball joint is not excessive.
2. Check and make sure that the inside
ball joint slide smoothly along the
thrust direction.
3. Check and make sure that the radial
play of the inside ball joint is not
excessive.
4. Check the sheath for damage.
5. Check the circlip on the side of
connection to the transmission.
Inspection of Drive Shaft Oil Seal

1. Check the oil seal lip and the seal
spring for intactness.
2. Check whether the mating surface of
the drive shaft and the oil seal is
smooth and whether there is
abnormality such as rust, scratch or
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2.2.1-2 Drive System 2.2.1-2

1. Adequate or polluted
lubrication of drive shaft
Reference: Diagnosis Procedure of
Abnormal sound of drive shaft universal joint
Drive Shaft Abnormal Sound
2. Contact between drive shaft
and other components
Dull metallic sound occurred 1. Breakage or damage of Reference: Diagnosis Procedure of
when accelerating after coasting universal joint sheath Dull Metallic Sound Occurred
in neutral 2. Wear or damage of constant When Accelerating after Coasting
velocity universal joint in Neutral
1. Imbalance of wheel A. Adjust the wheel balance
2. Excessive front wheel radial
Vibration when driving at high
runout B. Refer to Removal and
speed
3. Incorrect drive shaft Installation of Drive Shaft
installation
1. Excessive tripod universal
joint angle due to improper
Shaking or vibration when Shaking or Vibration When
assembling height
accelerating Accelerating
2. Excessive wear or damage of
drive shaft
1. Drive shaft falling off or not
A. Replace or re-install the snap
installed correctly in
ring
differential
2. Incorrect assembling of engine B. Check the engine mounting
and transmission support for damage or wear
Falling off of tripod universal 3. Torsion or bending of
C. Measure the chassis
joint or ball cage joint subframe or chassis
D. Check the bushing for wear
and components for torsion
4. Wear or damage of front
(stabilizer bar, suspension
suspension components
arm, etc.), and replace as
necessary
1. Adequate or polluted
A. Check and clean; replace the
lubrication of drive shaft
grease as necessary
universal joint
Cracking, knocking or grating
2. Contact between drive shaft B. Check and replace as
sound accompanying with
and other components necessary
driving
3. Wear or damage of wheel
bearing, brake components, C. Check and replace as
suspension components or necessary
steering components
1. Deformation of circlip on the
connection between drive shaft
and transmission
Falling off of drive shaft 2. Deformation of drive shaft
Drive Shaft Falling off
3. Deformation of front strut
4. Damage of drive shaft
fastening nut
1. Incorrect tire dynamic balance
2. Incorrect tire alignment
Reference: Vehicle Low-speed
Vehicle low-speed shimmy 3. Damage of hub bearing
Shimmy
4. Damage of drive shaft
5. Damage of strut
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2.2.1-3 Drive System 2.2.1-3
6. Wear or damage of stabilizer

bar and bushing
Diagnosis Procedure of Drive Shaft Abnormal Sound
B. Check whether the drive shaft is wound by
other materials.
C. Check whether the drive shaft contacts with
1. Check whether the drive shaft contacts with other parts.
other materials Is it normal?
Yes
Go to Step 2.
No
Handle the faulty part.
A. Check the drive shaft dust cover for damage.
B. Check whether the drive shaft dust cover is
correctly installed.
C. Check the drive shaft universal joint lubricant
for leakage.
2. Check drive shaft dust cover
Yes
Go to Step 3.
No
A. Remove the drive shaft.
B. Check the drive shaft.
Reference: Drive Shaft Inspection (2.2.1 Drive
System Overview, “General Inspection”).
3. Check drive shaft
Yes
No
Replace the drive shaft assembly.
Diagnosis Procedure of Dull Metallic Sound Occurred When Accelerating after
Coasting in Neutral
Note: Dull metallic sound occurred during coasting accelerating or static starting
may be caused by wear or damage of the wheel drive shaft internal universal joint. The
wheel drive shaft internal universal joint damage usually results from inadequate grease
or foreign material or dirt in the universal joint. Such situation is usually caused by
breakage or damage of the internal universal joint sealing sleeve.
C. Check the drive shaft universal joint lubricant
for leakage.
1. Check drive shaft dust cover
Yes
Go to Step 2.
No
2. Check drive shaft Reference: Drive Shaft Inspection (2.2.1 Drive
C. Any jamming or blocked movement of
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2.2.1-4 Drive System 2.2.1-4
universal joint indicates that there may be

damage which can result in fault.
Yes
No
Diagnosis Procedure of Shaking or Vibration When Accelerating
A. Check the front strut assembly for deformation.
1. Check front strut assembly height Yes. Go to Step 2.
No. Handle the faulty part, and
replace the front strut as necessary.
A. Check the swing arm ball joint for abnormality
such as clearance or damage.
2. Check swing arm ball joint
No. Replace the lower swing arm
ball joint.
A. Check each mounting bolt of the swing arm for
abnormality such as looseness.
B. Check each bushing of the swing arm for
abnormality such as damage.
3. Check swing arm and each mounting bolt Is the check result normal?
No. Handle the faulty part, and
replace the swing arm assembly as
necessary.
4. Check drive shaft dust cover C. Check the drive shaft universal joint lubricant
for leakage. Is the check result normal?
No. Handle the faulty part.
Yes.
No. Replace the drive shaft
assembly.
Drive Shaft Falling off
1. Check drive shaft Is the check result normal?
Yes.
Go to Step 2.
No. Handle the faulty part.
B. Check the circlip on drive shaft and
transmission side.
2. Check circlip on drive shaft and transmission
side
Yes.
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2.2.1-5 Drive System 2.2.1-5
Go to Step 3.
No. Replace the drive shaft
assembly.
A. Check the front strut assembly for deformation.
3. Check front strut Yes.
No. Replace the front strut
assembly.
A. Check the drive shaft lock nut for damage.
4. Check drive shaft lock nut
Yes.
No. Replace the lock nut.
Drive Shaft Hunting
Yes
Go to Step 2.
No
B. Check the circlip on drive shaft and
transmission side.
2. Check circlip on drive shaft and transmission System Overview, “General Inspection”).
side Is the check result normal?
Yes
Go to Step 3.
No
Vehicle Low-speed Shimmy
A. Check whether the tire runout is normal.
Reference: Wheel Runout Inspection (2.1.4
Wheel and Tire, “General Inspection”).
1. Check wheels Is the check result normal?
Yes
Go to Step 2.
No Handle the faulty part.
A. Check whether the wheel alignment is normal.
2. Check wheel alignment Yes
Go to Step 3.
C. Check the drive shaft for bending or
3. Check drive shaft deformation.
Yes
Go to Step 2.
A. Check the suspension system.
4. Check suspension system
Reference: (2.1.1 Suspension System
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2.2.1-6 Drive System 2.2.1-6
Overview, “General Inspection”).

Yes
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2.2.2-1 Drive Shaft 2.2.2-1
2.2.2 Drive Shaft Specifications

Specifications
Material Specifications
Name Model
High-performance grease (color: black), constant velocity universal CVJM-2008G.A
joint CAPLEXGTE
Other alternative grease GL-3
Capacity
Name Weight
High-performance grease, external constant velocity universal joint
90±10g
(MT/IMT)
High-performance grease, internal constant velocity universal joint
100±10g
(MT/IMT)
Name Nm lb-ft lb-in
Tie rod ball joint lock nut 45 - -
Cotter bolts/nuts between front swing arm
70 - -
ball joint and steering knuckle
Drive shaft lock nut 200 - -
Wheel nut 85 - -
Bolts/nuts connecting front strut and
100 - -
steering knuckle

System Overview
Both ends of the drive shaft have constant velocity universal joint.
1. The internal constant velocity universal joint (consisting of constant velocity ball
ring, tripod universal joint, roller, steel ball and universal joint housing) is installed on the
drive axle.
2. The external constant velocity universal joint (consisting of steel ball, ball cage and
universal joint housing) is installed on the wheel side.
3. The internal constant velocity universal joint is fixed on the differential with a
differential spring ring.
4. The external constant velocity universal joint is fixed on the hub bearing.
The drive shaft delivers the torque from the engine to the wheels. To adapt to the up-and-
down movement of the wheel and the engine, the drive shaft has to operate with different
lengths and angles. The constant velocity universal joint allows the length change of the drive
shaft in the process of the axial motion.
Notes on Drive Shaft Maintenance
1. When removing the drive shaft, do not push or pull the constant velocity universal
joint.
2. The working angle of the constant velocity universal joint cannot be over 22.5
degrees.
3. Check the polished surface and the spline for damage.
4. The dust cover is forbidden to contact with the sharp edge, hot engine or exhaust
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2.2.2-2 Drive Shaft 2.2.2-2
system.
5. Do not let the drive shaft fall off because the dust cover can be damaged internally
but it cannot be seen from the appearance.
6. When installing other parts and components, do not use the drive shaft as prying
tool. Do not hang the drive shaft arbitrarily.
7. Tap the universal joint cage from outside may damage the universal joint.

1 Drive shaft assembly (left) 1
2 Drive shaft assembly (right) 1
3 Rear axle lock nut 2
1-1 Fixed ball cage universal joint 2
1-2 Fixed end large clamp 2
1-3 Fixed end dust cover 2
1-4 Fixed end small clamp 2
1-5 Movable end small clamp 2
1-6 Movable end dust cover 2
1-7 Movable end large clamp 2
1-8 Three-column groove housing 1
1-9 Tripod universal joint 2
1-10 Snap ring 2
2-1 Three-column groove housing 1
2-2 Transmission round wire snap ring 2
2-3 Damping block clamp 1
Inject 90±10g of grease into
the fixed end ball cage
2-4 Fixed end grease universal joint, with 40±5g
in the outer race and 50±5g
in the dust cover.
Inject 100±10g of grease
2-5 Movable end grease into the movable end tripod
universal joint
Fixed end dust cover service kit 2
Movable end dust cover service kit 2
Movable joint service kit (left) 1
Movable joint service kit (right) 1
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2.2.2-3 Drive Shaft 2.2.2-3

Test
Reference: (2.2.1 Drive System Overview,
“Fault Description, Diagnosis and Test”).
Disassembly and Assembly
Internal Constant Velocity Universal
Joint and Dust Cover 3. Use a proper tool to remove the tripod
Disassembly universal joint circlip.
Special Tools
Drive shaft dust

cover clamp
removal pliers
4. Remove the internal constant velocity

universal joint dust cover.
Assembly
Drive shaft dust
cover clamp Note: Replace all circlips and clamps.
installation pliers
1. Install the dust cover/tripod universal
joint.
• Install the dust cover.
Material • Install the tripod universal joint.
Name Model
• Install the tripod universal joint
High-performance CVJM-2008 (fixed end) (GL-
grease 3) circlip.
G.ACAPLEXGTE (movable
end) (GL-3)
1. Remove the drive shaft.
Reference: Left Drive Shaft (2.2.2
Drive Shaft, “Removal and
Installation”).
2. Remove the ball joint assembly.
2. Fill the grease in the ball joint assembly.
• Use the special tool to remove the
dust cover clamp. 3. Install the ball joint assembly.
Special tool: drive shaft dust cover
clamp removal pliers
• Disassemble the ball joint
assembly.
• Remove the grease in the
universal joint.
4. Install the dust cover.

5. Use the special tool to install the dust
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2.2.2-4 Drive Shaft 2.2.2-4
cover clamp. Drive Shaft, “Removal and

Installation”).
Special tool: drive shaft dust cover
clamp installation pliers 2. Remove the dust cover clamp.
Note: After the large and small clamps • Use the special tool to remove the
are locked, the clamp mouth size C dust cover clamp.
shall be not more than 1.5mm. Special tool: drive shaft dust cover
clamp removal pliers
Note: Torque for 0.8mm thick clamp is
12N.m while that for 1.1mm thick • Remove the dust cover.
clamp is 20N.m. • Remove the grease.
6. Install the drive shaft.

3. Remove the ball cage and ball cage
Reference: Left Drive Shaft (2.2.2 holder from the housing.
• Pry the snap ring with sharp-nose
Installation”).
pliers.
External Constant Velocity Universal
• Tap with copper bar lightly to
Joint and Dust Cover
remove the constant velocity
Disassembly universal joint.
Special Tools • Remove the drive shaft ① from
the universal joint.
Drive shaft dust • Remove the circlip ② from the
cover clamp universal joint.
removal pliers
• Remove the dust cover ③.
Drive shaft dust

cover clamp
installation pliers
Material 4. Remove the ball cage holder.

Name Model
• Turn the ball cage holder.
High-performance CVJM-2008 (fixed end) (GL-
grease 3) • Take out the ball cage holder.
G.ACAPLEXGTE (movable
end) (GL-3)
1. Remove the drive shaft.

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2.2.2-5 Drive Shaft 2.2.2-5
• Insert the drive shaft into the drive

shaft universal joint until it
engages with the circlip.
5. Take out steel balls from the ball cage.
4. Fill high-performance grease into the

external drive shaft universal joint.
5. Install the dust cover.
6. Use the special tool to install the dust
cover clamp.
6. Check each moving surface for wear. Special tool: drive shaft dust cover
Assembly clamp installation pliers
Note: Replace all circlips and clamps. Note: After the large and small clamps
are locked, the clamp mouth size C
1. Install steel balls on the ball cage shall be not more than 1.5mm.
holder.
Note: Torque for 0.8mm thick clamp is
12N.m while that for 1.1mm thick
clamp is 20N.m.
2. Install the ball cage holder.

• Install the ball cage holder onto
the housing.
7. Install the drive shaft.
• Turn the ball cage holder.
Installation”).
Left Drive Shaft
Removal
Special Tools
3. Install the drive shaft into the universal
joint.
• Install the dust cover and inner Drive shaft removal
clamp. tool
• Insert a new circlip into the drive
shaft universal joint groove.
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2.2.2-6 Drive Shaft 2.2.2-6
1. Disconnect the battery negative harness. under the transmission.

Reference: Inspection of Storage 8. Use the special tool to remove the left
Battery (3.1.1 Charging System, drive shaft.
“General Inspection”). Special tool: drive shaft removal tool
Installation
Reference: Wheel and Tire (2.1.4 1. Install the drive shaft on the drive
Wheel and Tire, “Removal and axle.
Installation”).
3. Lift the vehicle. Note: Protect the drive shaft for fear of
damaging the constant velocity
Reference: (1.1.3 Traction and Lifting). universal joint. The working angle of
4. Remove the hub nut. the internal constant velocity universal
joint cannot be over 22.5 degrees. The
• Pull straight and pull out the lock working angle of the external constant
pin. velocity universal joint cannot be over
• Remove the hub nut. 45 degrees.
Note: When inserting the drive shaft,
use the oil seal installer (supplied along
with the oil seal) to protect the drive
axle oil seal.
Note: When installing the new snap
ring, make sure that the snap ring has
been installed into the groove.
5. Remove the front swing arm ball joint
from the steering knuckle.
• Remove the swing arm ball joint
retaining nut.
2. Install the drive shaft on the hub

bearing.
3. Install the swing arm ball joint.
6. Use a proper tool to remove the drive

shaft from the hub.
4. Install the hub nut.

5. Install wheels.
6. Connect the battery negative harness.
7. To avoid the transmission oil leaking Right Drive Shaft
on the floor, place a proper container
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2.2.2-7 Drive Shaft 2.2.2-7
1. Reference: Left Drive Shaft (2.2.2

Installation”).
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2.2.3-1 Manual Gearshift Control Mechanism 2.2.3-1
2.2.3 Manual Gearshift Control Mechanism

Specifications
Name Nm lb-ft lb-in
Gearshift control assembly retaining nut 23 - -
Shift cable retaining nut 9 - -

System Overview
Manual transmission gearshift mechanism is composed of gear shift seat assembly and
shift cable. The gear shift seat is connected to the transmission through the shift cable; thus,
the external gear shift mechanism is separated from the body to reduce the vibration.
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1 Gearshift control assembly 1
2 Hexagon flange bearing surface toothed nut M8 4
3 Flat washer 4
4 Hexagon flange bearing surface toothed nut M6 2
5 Shift cable assembly 1
6 E-clip 2
7 Elastic clip 3

1. Make sure the fault stated by the customer, and reset the fault as necessary.
2. If the fault stated by the customer cannot be found, conduct road test or visual inspection
with the help of the table below.
3. If the fault can be identified obviously, eliminate the fault; if not, conduct accurate
inspection as per the following fault description.
Mechanical Components
1. Obviously damaged or worn 2. Loosened or missing nut or bolt
components
1. Deformation of external gear A. Adjust the external gear shift
shift mechanism connection mechanism.
Difficulty in gear shift mechanism
2. Damage of shift lever B. Diagnosis Procedure of
operating
Difficulty in Gear Shift
3. Damage of shift cable
Mechanism Operating
Diagnosis Procedure of Difficulty in Gear Shift Mechanism Operating
Test Conditions Detail/Result/Measure
A. Separate the gear selection lever and the transmission.
Is the external shift mechanism operating difficult?
Yes. Remove the shift lever and find the
faulty component.
1. Check shift lever
Reference: Gear Shift Mechanism (3.4.4 External
Control of Manual Transmission, “Removal and
Installation”).
A. Remove the shift cable from the transmission.
Is the shift cable damaged?
Yes. Find out the fault and replace the
cable.
2. Check shift cable
Reference: Gear Shift Mechanism (3.4.4 External
Control of Manual Transmission, “Removal and
Installation”).
No. The transmission has fault.
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Removal and Installation vertically and separate the shift

cable.
Gear Shift Mechanism
• Pull up the shift cable sleeve cap
Removal vertically and separate the gear
1. Disconnect the battery negative harness. selection cable.
Reference: Inspection of Storage
Battery (3.1.10 Charging System,
“General Inspection”)
2. Remove the central control panel
assembly.
Reference: Instrument Panel (5.1.6
Instrument Panel and Console,
“Removal and Installation”). Installation
3. Remove the gear selection cable circlip. Install in opposite sequence of removal.
4. Separate the gear selection cable from

the shift lever.
5. Remove 4 places of retaining bolts for

the shift mechanism.
Torque: 23N.m
6. Remove the shift mechanism.

• Pull up the shift cable sleeve cap
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Shift Cable
Removal
1. Disconnect the battery negative harness.
2. Remove the central control panel
assembly.
6. Separate the shift cable from the
Reference: Instrument Panel (5.1.6 transmission.
Instrument Panel and Console,
“Removal and Installation”). • Disconnect the elastic clip from
the transmission rocker arm shaft.
3. Remove the gear selection cable circlip.
• Disconnect the cable retaining E-
clip on the transmission support.
4. Separate the gear selection cable from

the shift lever.
7. Remove nuts connecting the shift cable
and the dash panel.
Torque: 9N.m
5. Separate the shift cable from the shift

mechanism.
• Pull up the shift cable retaining Installation
clip vertically and separate the Install in opposite sequence of removal.
shift cable.
• Pull up the gear selection cable
retaining clip vertically and
separate the gear selection cable.
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2.2.4-1 Automatic Gearshift Control Mechanism System 2.2.4-1
2.2.4 Manual/Automatic Integrated Gearshift Control Mechanism

Specifications
Name Nm lb-ft lb-in
Retaining screw for electronic shifter
6 - -
(knob)

System Overview
IMT transmission gearshift control mechanism is IMT electronic shifter (knob), which
applies photoelectric sensing element. By turning to different positions, different make/break
signals corresponding to the photoelectric sensing element at different positions are given out;
after processed by single-chip microcomputer, such signals are transformed into
corresponding voltage pulse signals and input to TCU so as to realize gear shift.
S/N Name Qty.

1 Electronic shifter (knob) 1
Assembling unit of cross recessed pan head self tapping screw and flat
2 4
washer

1. Make sure the fault stated by the customer, and reset the fault as necessary.
2. If the fault stated by the customer cannot be found, conduct road test or visual inspection
with the help of the table below.
3. If the fault can be identified obviously, eliminate it.
4. If the fault cannot be identified obviously, conduct accurate inspection as per the
following fault description.
Mechanical Components
1. Obviously damaged or worn 2. Loosened or missing screw, or damaged or dropped harness
components

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1. Damage of electronic shifter A. Replace the electronic shifter
Abnormal R/N/D/M gear signal
(knob) (knob)
output
2. Fault of signal output harness B. Replace the signal harness
1. Damage of steering wheel +/-
A. Replace +/- paddle
paddle
Abnormal +/- gear signal output
2. Damage of rotary connector B. Replace the rotary connector
3. Fault of signal output harness C. Replace the signal harness
1. Damage of electronic shifter A. Replace the electronic shifter
(knob) (knob)
R/N/D/M gear indicator lamp not
2. Power not input normally B. Replace the signal harness
ON
3. Abnormal vehicle voltage
C. Replace the battery
(excessively low or high)
Jamming of knob and difficulty in A. Replace the electronic shifter
1. Damage of knob rail
rotating (knob)
Diagnosis Procedure of Unavailable Gear Shift
For detailed information, refer to Automatic Transmission Maintenance Manual.
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Gear Shift Mechanism
Removal
1. Disconnect the battery negative harness.
2. Remove the trim strip on the shift panel.
3. Remove the retaining screw for

electronic shifter (knob).
4. Disconnect the harness from the knob

shifter.
Installation
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Fuel System
2.2.5 Fuel System

Contents Page
2.2.5 Fuel System Overview1
Specifications ...............................................................................................................2.2.5-1
General Specifications ..................................................................................................2.2.5-1
Instructions and Operation ............................................................................................2.2.5-1
System Overview ..........................................................................................................2.2.5-1
Fuel System Pressure Relief ..........................................................................................2.2.5-1
Fuel Tank Pressure Relief .............................................................................................2.2.5-1
Fuel Filling ...................................................................................................................2.2.5-1
Fuel Discharging of Fuel System ..................................................................................2.2.5-2
Component Description ................................................................................................2.2.5-2
Component Location.....................................................................................................2.2.5-4
General Inspection ........................................................................................................2.2.5-4
Inspection of Fuel Pump and Support Assembly ...........................................................2.2.5-4
Inspection of Fuel Filter ................................................................................................2.2.5-5
Inspection of Filler Cap and Refueling Pipe ..................................................................2.2.5-5
Fuel Tank Inspection ....................................................................................................2.2.5-5
Fuel Supply Line and Connecting Pieces ......................................................................2.2.5-5
Fault Description, Diagnosis and Test ...........................................................................2.2.5-5
Tool ..............................................................................................................................2.2.5-5
Inspection and Confirmation .........................................................................................2.2.5-5
Fault Description Table.................................................................................................2.2.5-5
Fault Determination ......................................................................................................2.2.5-5
Diagnosis Procedure of Not Pumping Fuel ....................................................................2.2.5-5
Diagnosis Procedure of Difficulty in Starting ................................................................2.2.5-6
Diagnosis Procedure of Weak for Acceleration .............................................................2.2.5-6
Diagnosis Procedure of Inaccuracy in Oil Level Indication ...........................................2.2.5-6
Removal and Installation ..............................................................................................2.2.5-6
Removal and Installation of Nylon Pipe Quick-change Connector ................................2.2.5-6
Fuel Tank Filler Cap Assembly .....................................................................................2.2.5-7
Refueling Pipe Assembly ..............................................................................................2.2.5-7
Fuel Tank Assembly .....................................................................................................2.2.5-8
Fuel Pump and Support Assembly ................................................................................2.2.5-9
Fuel Filter Assembly ................................................................................................... 2.2.5-10
Fuel Supply Line and Connecting Pieces .................................................................... 2.2.5-11
2.2.6 Evaporative Emission Control System1
System Overview ..........................................................................................................2.2.6-1
Component Description ................................................................................................2.2.6-1
Safety Valve Assembly .................................................................................................2.2.6-1
Carbon Canister Assembly with Accessories.................................................................2.2.6-1
Carbon Canister Control Valve Assembly .....................................................................2.2.6-1
Fuel Vapor Line and Connecting Pieces ........................................................................2.2.6-1
Component Location.....................................................................................................2.2.6-2
Inspection of Carbon Canister Control Valve Assembly................................................2.2.6-2
Carbon Canister Inspection ...........................................................................................2.2.6-2
Inspection and Confirmation .........................................................................................2.2.6-2
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Fuel System
Fault Description Table.................................................................................................2.2.6-3

Fault Determination ......................................................................................................2.2.6-3
Diagnosis Procedure of Heavy Gasoline Smell .............................................................2.2.6-3
Safety Valve Assembly .................................................................................................2.2.6-3
Carbon Canister Assembly ............................................................................................2.2.6-4
Fuel Vapor Line and Connecting Pieces ........................................................................2.2.6-5
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2.2.5-1 Fuel System 2.2.5-1
2.2.5 Fuel System Overview fuel spilling and precautions of fuel

handling, or injuries may be caused.
Specifications
Warning: When operating components
concerning fuel, it is prohibited to
Name Specifications contact open fire of any form or start
Rated volume of fuel the engine. Highly flammable mixed
tank 38L
gas generated during operation may be
Fuel 93# gasoline
Rated fuel pressure 4bar
lighted. Misoperation may cause injury.
Fuel tank mounting Fuel Tank Pressure Relief
bolts/nuts 23±5N.m
1. Open the fuel tank door. The opening
Instructions and Operation handle of the fuel tank door is at the
System Overview left side of the driver seat. Pull the
handle upward to open the fuel tank
The fuel system contains fuel tank filler door.
cap assembly, refueling pipe assembly, fuel
tank assembly, fuel pump and support 2. Slowly loosen the fuel tank filler cap.
assembly, fuel filter assembly, fuel supply
line and connecting pieces. It is for storing,
transmitting and cleaning the fuel.
The fuel supply line contains the fuel
pipe assembly of fuel tank, fuel returning
assembly of fuel tank, nylon fuel supply
pipe assembly, nylon fuel supply connecting
pipe assembly, fuel supply hose, fuel tank
refueling hose and fuel tank ventilation hose. 3. Stop when “hiss” sound is heard.
It is for connecting the fuel pump, fuel filter Fuel Filling
and engine fuel rail so as to realize fuel
transmission. Warning: Fuel handling is involved in
this procedure. Pay close attention to
fuel spilling and precautions of fuel
Connecting pieces contain pipe clamp handling, or injuries may be caused.
and retaining support, which are for fixing
the fuel supply line on the body.
Fuel line and fuel vapor line are contact open fire of any form or start
arranged side by side and sharing connecting the engine. Highly flammable mixed
pieces. gas generated during operation may be
Fuel System Pressure Relief lighted. Misoperation may cause injury.
1. Place the transmission in neutral 1. Release pressure in the fuel tank.

position and apply the parking brake. 2. Remove the fuel tank filler cap.
2. Open the engine cover cap and
disconnect the fuel pump relay.
3. Place the ignition switch at “START”
until the engine turns off.
4. Connect the fuel pump relay and close
the engine cover cap.
Warning: Fuel handling is involved in 3. Put the fuel gun into the filler, start to
this procedure. Pay close attention to fill fuel, and stop it when the
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2.2.5-2 Fuel System 2.2.5-2
accumulated fuel quantity reaches the pump operate, and drain the fuel in the
rated volume. fuel tank.
Fuel Discharging of Fuel System Component Description
Warning: Fuel handling is involved in Fuel Tank Filler Cap Assembly
this procedure. Pay close attention to Cooperate with the refueling pipe to
fuel spilling and precautions of fuel guarantee the system airtightness. The lifting
handling, or injuries may be caused. rope is installed on the fuel tank door to
Warning: When operating components prevent the cap from missing when filling
concerning fuel, it is prohibited to fuel; and a one-way valve is equipped to
contact open fire of any form or start maintain the system pressure.
the engine. Highly flammable mixed
2. Discharge the fuel in the pipe: place a
container under the fuel pipe connector
on the floor, and then disconnect the
connectors of the nylon fuel supply Refueling Pipe Assembly
pipe and the fuel returning pipe
connecting pipe. It is installed on the left side of the
body through bolts. Connect the rubber hose
and the fuel tank to realize fuel filling.
3. Drain the fuel in the fuel tank. Refer to

Fuel Tank Draining Procedure, “Fuel
Tank Draining”.
Warning: Fuel handling is involved in
this procedure. Pay close attention to Fuel Tank Assembly
fuel spilling and precautions of fuel The fuel tank is equipped with rollover
handling, or injuries may be caused. valve, refueling one-way valve and thermal
shroud. It is installed on the rear of the body
Warning: When operating components through bolts.
contact open fire of any form or start
1. Remove the battery negative wire
(grounding wire).
2. Lift the vehicle. Fuel Pump and Support Assembly
3. Drain the fuel in the fuel pipe. The fuel is pumped out of the fuel tank,
4. Connect the fuel pump relay with an and transmitted to the fuel rail through the
iron wire or copper wire, make the fuel fuel filter and the line. The fuel pump is
installed in the fuel tank, fixed by fuel
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2.2.5-3 Fuel System 2.2.5-3
delivery pump flange and sealed by oil

resistant rubber sealing ring.
Fuel Supply Line and Connecting Pieces

They are fixed on the body for fuel
Fuel Filter Assembly supply.
Using for removing the moisture and
foreign materials in the gasoline, it is
installed on the cross member near the fuel
tank, which is on the lower part of the body,
with bolts.
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2.2.5-4 Fuel System 2.2.5-4
Component Location
S/N Name Qty.

1 Fuel pump and support assembly 1
2 Fuel filter assembly 1
3 Fuel tank filler cap assembly 1
4 Refueling pipe assembly 1
5 Fuel tank assembly 1
67 Fuel supply and vapor line 8
General Inspection
Inspection of Fuel Pump and Support
Assembly
1. Check the mounting bolts of the fuel
pump and support assembly for
looseness, re-install if any.
2. Check the fuel pump flange for damage;
if any, replace the fuel pump and
support assembly.
3. Unplug the harness, and check the
electrode plug PIN on the fuel pump
flange for bending or corrosion; if any,
replace the fuel pump and support
assembly.
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2.2.5-5 Fuel System 2.2.5-5
Inspection of Fuel Filter handling, or injuries may be caused.

1. Check the mounting bolts of the fuel Warning: When operating components
filter for looseness, re-install if any. concerning fuel, it is prohibited to
2. Check the fuel filter housing for contact open fire of any form or start
damage or fuel seepage; if any, replace the engine. Highly flammable mixed
the fuel filter. gas generated during operation may be
3. Check the fuel filter line connection for
fuel seepage; if any, use maintenance 1. Confirm problems stated by customers.
cloth to clean the fuel filter and the line 2. Visually check whether there are signs
connector and then re-assembly in of any obvious mechanical or electrical
place; if there is still fuel seepage, damages.
replace the fuel filter and the
Mechanical part Electrical part
connecting line. Damage of fuel supply
Damage of fuel pump
Inspection of Filler Cap and Refueling pipe
Pipe Damage of quick- Damage of electrical
change connector connector
1. Remove the filler cap, and check the Damage of fuel pump
Damage of fuel filter
filler accessories for obvious greasy relay
dirt and the cap sealing gasket for Damage of refueling Damage of electrical
damage; if any, replace the refueling pipe line
pipe and the cap. Damage of filler cap /
Damage of fuel tank /
2. Check the filler cap housing and the
lifting rope for damage; if any, replace 3. If the obvious cause of observed or
the cap. raised problem has been found, it shall
be corrected before the next step.
Fuel Tank Inspection
4. If visual inspection passes, confirm the
1. Check the fuel tank mounting bolts and fault as per the Fault Description Table.
nuts for looseness; if not in
conformance with standard, torque to Fault Description Table
specification. Fault Description Measures
Diagnosis Procedure of
2. Check the fuel tank for seepage; if any, Not pumping fuel
Not Pumping Fuel
replace the fuel tank assembly. Diagnosis Procedure of
Difficulty in starting
Fuel Supply Line and Connecting Pieces Difficulty in Starting
Weak for Diagnosis Procedure of
1. Check whether the fuel supply line and acceleration Weak for Acceleration
connecting pieces are assembled Inaccuracy in oil
Diagnosis Procedure of
correctly; re-assemble if not. Inaccuracy in Oil Level
level indication
Indication
2. Check the fuel supply line and
connecting pieces for damage; if any, Fault Determination
replace the damaged component. Diagnosis Procedure of Not Pumping Fuel
Fault Description, Diagnosis and Test 1. Eliminate the fuel pump relay fault,
Tool fuel pump fuse burning-out and poor
harness contact and other faults in the
Multimeter, fuel pressure gauge and three- harness system.
way connector
2. Eliminate the signal fault of pick-up
Inspection and Confirmation and disconnection of ECU-controlled
Warning: Fuel handling is involved in fuel pump relay.
this procedure. Pay close attention to 3. Make sure the usage date of fine filter
BENNI 2013.11
2.2.5-6 Fuel System 2.2.5-6
in the fuel line and eliminate the vehicle systems.

possibility of fine filter clogging. 3. If the fuel pressure under idle speed is
4. Disconnect the electrical connector of not between 3.5bar and 4.2bar or the
the fuel pump, and place the digital fuel pressure at high engine speed is
multimeter in ohm position. Connect smaller than 3.2bar, replace the fuel
the two probes to the two pins of the pump assembly and conduct the above
fuel pump respectively to measure the fuel pressure monitoring test again. If
internal resistance. If the internal the fuel pressure change is similar to
resistance is zero or infinity (i.e. non the original fuel pump state, it is not the
short circuit or open circuit state), fuel pump fault and it requires checking
replace the fuel pump and the support other possible causes in the fuel line
assembly. system.
Diagnosis Procedure of Difficulty in Diagnosis Procedure of Inaccuracy in Oil
Starting Level Indication
1. Connect a three-way connector in the 1. Observe whether the float lever is
fuel line with one end to the vehicle obviously bent or deformed, whether
fuel line and the other end to the fuel the float can turn freely, and whether
pressure gauge, and start the engine. the gasoline can float normally.
2. After the reading of fuel pressure gauge 2. Observe whether there is foreign
remains stable, shut down the vehicle, material/ colloid accumulation on the
and observe the fuel pressure change resistor disc of the fluid level sensor. (If
within 20 minutes. If the fuel pressure the condition allows, check the
is over 2.5bar after 20 minutes, it resistance signal referring to Step 3
indicates that the fuel pump is normal below.) Re-install the vehicle and
and other system problems are required observe whether the fault is eliminated.
to be checked; otherwise, replace the If not, replace the fuel pump and
fuel pump and support assembly. support assembly.
3. If the fuel pressure drops obviously in 3. Use the multimeter (ohm range) to
short period, replace the fuel pump connect the fluid level sensor signal
support assembly. wire, and slowly swing the float lever
from the lowest point to the highest
Diagnosis Procedure of Weak for
point. Observe whether the resistance
Acceleration
changes in descending order slowly and
1. Connect a three-way connector in the evenly in the process and whether open
fuel line with one end to the vehicle circuit occurs. If there is open circuit or
fuel line and the other end to the fuel abnormal fluctuation of resistance,
pressure gauge, and start the engine. replace the fuel pump assembly.
Monitor whether the fuel pressure is
between 3.5bar and 4.2bar under idle Removal and Installation
speed (the observation time is Removal and Installation of Nylon Pipe
suggested to be above 5 minutes). Quick-change Connector
2. Apply the acceleration petal, control Warning: Fuel handling is involved in
the engine speed between 4000 rpm this procedure. Pay close attention to
and 5000 rpm, and observe the fuel fuel spilling and precautions of fuel
pressure fluctuation. If the fuel pressure handling, or injuries may be caused.
is stable under idle speed and the fuel
pressure drops not more than 0.32bar at Warning: When operating components
high engine speed, it indicates that the concerning fuel, it is prohibited to
fuel pump works normally and there is contact open fire of any form or start
no fault. Check other possible reason of the engine. Highly flammable mixed
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2.2.5-7 Fuel System 2.2.5-7

Removal
1. Hold the female connector locating clip
to loosen it and then pull out the
connected pipe along the opposite
direction.
3. Remove the filler cap lifting rope from

the fuel tank door swivel arm.
Installation
1. Connect the quick-change connector,
and insert the connection into the
female connector along the coaxial
direction of the quick-change connector
until “click” is heard.
Installation
1. Install the filler cap lifting rope on the
fuel tank door swivel arm.
Fuel Tank Filler Cap Assembly

handling, or injuries may be caused. 2. Tighten the fuel tank filler cap.
Removal
1. Release the system pressure. Refer to 3. Close the fuel tank door.
the operation procedure of Fuel System
Pressure Relief. Refueling Pipe Assembly
2. Remove the fuel tank filler cap. Warning: Fuel handling is involved in
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2.2.5-8 Fuel System 2.2.5-8
handling, or injuries may be caused. lighted. Misoperation may cause injury.

Warning: When operating components Removal
concerning fuel, it is prohibited to 1. Drain the fuel. For details, refer to Fuel
contact open fire of any form or start Discharging of Fuel System.
gas generated during operation may be 2. Remove the fuel tank refueling hose
lighted. Misoperation may cause injury. and ventilation hose.
Removal
1. Remove the fuel tank refueling hose
and ventilation hose.
3. Remove the fuel line connector at the

floor.
2. Remove the filler cap. For details, refer

to the removal procedure of Fuel Tank
Filler Cap Assembly.
3. Remove the bolt at the filler.
4. Remove the connector between fuel

tank fuel pipe & fuel returning pipe and
the fuel filter.
Installation
Install in the reverse sequence of
removal.
Fuel Tank Assembly

fuel spilling and precautions of fuel 5. Use a flat jack to support the fuel tank.
handling, or injuries may be caused. Warning: Use proper material under the
Warning: When operating components fuel tank bottom for supporting in case
concerning fuel, it is prohibited to of damage.
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2.2.5-9 Fuel System 2.2.5-9
removal.
Fuel Pump and Support Assembly

Removal
6. Remove the fuel tank mounting bolt. fuel spilling and precautions of fuel
Warning: Before removing or repairing
7. Lower the fuel tank to a certain height the fuel pump and support assembly,
slowly. disconnect the battery negative cable.
Warning: When removing the fuel tank, Warning: When checking or repairing
make sure not to apply excessive the fuel pump and support assembly,
tensioning force on the fuel line and the smoking or near combustion source is
harness. prohibited.
8. Remove the fuel pump harness plug. Warning: When checking or repairing
the fuel pump and support assembly,
smoking or near combustion source is
prohibited.
Warning: Only when the fuel pressure
in the fuel line system is released, can
the fuel pump and support assembly is
removed.
1. Release the fuel system pressure. Refer
9. Remove the fuel pipe and the fuel
to the operation procedure of Fuel
refueling pipe connector.
System Pressure Relief.
2. Open the rear seat above the fuel tank,
and remove the fuel pump access panel
on the rear floor.
10. Remove the fuel tank.

3. Disconnect the fuel pump harness plug
Installation
under safe condition.
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2.2.5-10 Fuel System 2.2.5-10
Warning: Used or damaged O rings

cannot be reused.
Warning: Do not damage the fluid level
sensor assembly during installation.
Warning: Make sure that the fuel pipe
and fuel returning pipe will not leak
after installation is completed.
4. Remove the fuel pipe and the fuel 1. Use a new fuel pump O ring to replace
refueling pipe connector. the removed one from the fuel pump.
2. Install the rest in the reverse sequence
of removal.
Fuel Filter Assembly
5. Remove the eight hexagon screws in concerning fuel, it is prohibited to
symmetric and diagonal order, and contact open fire of any form or start
remove the fuel delivery pump flange. the engine. Highly flammable mixed
Torque: 9N.m lighted. Misoperation may cause injury.
Removal
1. Release the fuel system pressure.
3. Remove connectors of the fuel pipe and
fuel returning pipe connected to the
fuel filter. For connector removal, refer
to the removal procedure of nylon
6. Remove the fuel pump and support quick-change connection.
assembly.
Warning: Do not damage the fluid level
sensor assembly when removing the
fuel pump, or oil level indication fault
will be caused.
4. Remove the fuel filter mounting bolt.
Installation
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2.2.5-11 Fuel System 2.2.5-11
Installation
removal.
Fuel Supply Line and Connecting Pieces
fuel spilling and precautions of fuel 7. Remove the nylon fuel supply pipe.
8. Lower the vehicle.
concerning fuel, it is prohibited to 9. Remove the fastening clamp at
contact open fire of any form or start connection of the fuel supply hose and
the engine. Highly flammable mixed the fuel rail in the engine compartment,
gas generated during operation may be and pull out the fuel supply hose.
Removal
1. Release the fuel system pressure.
2. Discharge the fuel of the fuel system
3. Remove the fuel tank assembly.
4. Remove connectors of the fuel tank
fuel pipe and fuel returning pipe 10. Separate the nylon fuel supply & metal
connected to the fuel pump. For fuel supply pipe from the pipe clamp.
connector removal, refer to the removal
procedure of nylon quick-change
connection.
11. Remove the nylon fuel supply

connecting pipe.
12. Remove the fuel tank refueling hose
and ventilation hose.
5. Remove the fuel tank fuel pipe and fuel

returning pipe.
6. Remove connectors of the fuel pipe and
fuel returning pipe. For connector
removal, refer to the removal procedure
of nylon quick-change connection.
Installation
removal.
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2.2.6-1 Evaporative Emission Control System 2.2.6-1
2.2.6 Evaporative Emission Carbon Canister Assembly with

Control System Accessories
Instructions and Operation Carbon canister is an emission control

device containing active carbon granule, for
System Overview adsorbing and storing the fuel vapor from
The evaporative emission control the fuel tank. The fuel vapor is always
system contains the safety valve assembly stored in the carbon canister, the engine
(in the fuel tank assembly), the carbon control module will energize the carbon
canister assembly with accessories, the canister control valve when meeting certain
carbon canister control valve assembly and conditions, and the fuel vapor will be
the fuel vapor line and connecting pieces. It adsorbed into the engine cylinder and be
collects and stores the fuel vapor from the combusted. It is installed on the fuel tank.
fuel tank in the carbon canister, and delivers
the fuel vapor to the cylinder for combustion
when the engine reaches certain working
condition.
The fuel vapor line contains the carbon
canister adsorption tube, the desorption tube,
the metal fuel vapor pipe, the fuel vapor Carbon Canister Control Valve Assembly
hose and the carbon canister control valve The carbon canister control valve can
hose. It is used for connecting the fuel tank opened/closed to control the
assembly, the carbon canister assembly and adsorption/desorption process of the carbon
the carbon canister control valve assembly canister.
to realize fuel vapor delivery.
Connecting pieces contain pipe clamp
and retaining support, which are for fixing
the fuel vapor line on the body.
Fuel vapor line and fuel supply line are
arranged side by side and sharing connecting
pieces.
Fuel Vapor Line and Connecting Pieces
Safety Valve Assembly
It is fixed on the body to realize the
It is installed on the fuel tank and fuel vapor delivery.
supplies goods together with the fuel tank
assembly for balancing the pressure in the
fuel tank.
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Component Location

1 Carbon canister assembly 1
2 Fuel tank assembly 1
3 Fuel vapor line 1
4 Carbon canister control valve assembly 4
General Inspection valve, and apply 12V battery voltage

to the two connection terminals of the
Warning: Fuel handling is involved in valve. Absorb air into the carbon
this procedure. Pay close attention to canister control valve and the carbon
fuel spilling and precautions of fuel canister control valve shall ventilate.
Carbon Canister Inspection
Warning: When operating
components concerning fuel, it is 1. Check whether the carbon canister air
prohibited to contact open fire of any port is blocked; replace if any.
form or start the engine. Highly 2. Appearance inspection of carbon
flammable mixed gas generated canister: there shall be no breakage or
during operation may be lighted. deformation; replace if any.
Misoperation may cause injury.
3. Remove the carbon canister and shake
Inspection of Carbon Canister Control it with hands; replace if there is
Valve Assembly abnormal sound.
1. Appearance inspection of carbon 4. Check the connecting hose on the
canister control valve: there shall be carbon canister; replace if there is
no breakage, deformation or corrosion blockage or damage.
on connection terminal; replace if any.
5. Use proper gas source and blow the
2. Check the resistance of the carbon gas in from one of the carbon canister
canister control valve, which shall pipe orifice. There shall be gas
conform to the requirement of flowing out of the other two pipe
26Ω±4Ω; replace if not. orifices; replace if not.
3. Remove the carbon canister control Fault Description, Diagnosis and Test
valve and absorb air into the valve.
The carbon canister valve shall not Inspection and Confirmation
ventilate. Warning: Fuel handling is involved in
4. Remove the carbon canister control this procedure. Pay close attention to
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fuel spilling and precautions of fuel during operation may be lighted.

handling, or injuries may be caused. Misoperation may cause injury.
Warning: When operating 1. Check whether the O ring attaches
components concerning fuel, it is closely to the refueling pipe assembly
prohibited to contact open fire of any after the filler cap is normally
form or start the engine. Highly assembled; if not, re-assemble or
flammable mixed gas generated replace the refueling pipe.
during operation may be lighted. 2. Check the fuel filter housing for
Misoperation may cause injury. damage; if any, replace the fuel filter.
1. Confirm problems stated by 3. Check the fuel filter connecting line
customers. for leakage; if any, replace the fuel
2. Visually check whether there are filter and the connecting line.
signs of any obvious mechanical or 4. Check the fuel line and the vapor line
electrical damages. for damage; if any, replace the
Mechanical part Electrical part damaged component.
Damage of carbon
Damage of vapor line
canister control valve
5. Check the carbon canister control
Damage of quick- Damage of electrical valve for normal working; if it does
change connector connector/circuit not work, check and repair the
harness grounding terminals and
3. If the obvious cause of observed or connectors or replace the carbon
raised problem has been found, it canister control valve.
shall be corrected before the next step.
6. Check the vapor line for blockage; if
4. If the visual check is passed, confirm any, repair or replace the blocked
the fault and refer to the Fault component.
Description Table for help.
7. Check the carbon canister air port for
Fault Description Table blockage; if any, replace the carbon
Fault canister.
Possible Causes Measures
Description
Refueling pipe assembly
8. Check the carbon canister for damage;
Fuel filter assembly if any, replace the carbon canister.
Heavy Leakage of fuel vapor Diagnosis Removal and Installation
gasoline line Procedure
smell in of Heavy Safety Valve Assembly
Carbon canister control
vehicle Gasoline
valve assembly Warning: Fuel handling is involved in
Smell
Carbon canister assembly this procedure. Pay close attention to
Fault Determination handling, or injuries may be caused.
Diagnosis Procedure of Heavy Gasoline
Smell
components concerning fuel, it is
Warning: Fuel handling is involved in prohibited to contact open fire of any
this procedure. Pay close attention to form or start the engine. Highly
fuel spilling and precautions of fuel flammable mixed gas generated
handling, or injuries may be caused. during operation may be lighted.
Misoperation may cause injury.
components concerning fuel, it is Removal
prohibited to contact open fire of any 1. Remove the fuel tank. For details,
form or start the engine. Highly refer to the fuel tank assembly
flammable mixed gas generated removal procedure.
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2. Disconnect the hose connecting to the

safety valve.
3. Remove the safety valve assembly.

3. Disconnect the connection between
the carbon canister adsorption hose
and the carbon canister.
Installation
Install in the reverse sequence of removal. 4. Disconnect the connection between
the carbon canister desorption hose
Carbon Canister Assembly
and the carbon canister.
prohibited to contact open fire of any
form or start the engine. Highly
flammable mixed gas generated
during operation may be lighted. 5. Pull out the carbon canister from the
Misoperation may cause injury. fuel tank, separate it from the
mounting support completely, and
Removal remove the carbon canister.
1. Remove the fuel tank. For details,
refer to the fuel tank assembly
removal procedure.
2. Remove the fuel tank fuel returning
pipe from the clamp on the carbon
canister.
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3. Separate and remove wire clamps on

the carbon canister adsorption hose &
nylon vapor pipe and the fuel tank.
Installation
1. Connect and tighten the carbon 4. Disconnect the desorption hose from
canister adsorption hose to the the carbon canister control valve.
corresponding interface on the carbon
canister.
2. Install the rest in the reverse sequence
of removal.
Fuel Vapor Line and Connecting Pieces
Warning: Fuel handling is involved in 5. Separate the metal vapor connecting
this procedure. Pay close attention to pipe from the pipe clamp.
prohibited to contact open fire of any
form or start the engine. Highly
flammable mixed gas generated
during operation may be lighted.
Misoperation may cause injury. 6. Disconnect the connecting hose of the
carbon canister control valve.
Removal
1. Remove the carbon canister. For
details, refer to the carbon canister
assembly removal procedure.
2. Disconnect the carbon canister
adsorption hose from the safety valve
on the fuel tank.
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Brake System
2.3 Brake System

Contents Page
2.3.1 Brake System Overview1
Specification .................................................................................................................2.3.1-1
Material Specification ...........................................................................................2.3.1-1
General Specification ............................................................................................2.3.1-1
System Overview ..................................................................................................2.3.1-1
Component Location Drawing ..............................................................................2.3.1-2
Road Test ..............................................................................................................2.3.1-3
Inspection of Fluid Leakage of Hydraulic Brake System .......................................2.3.1-3
Inspection of Brake Pedal Travel Allowance .........................................................2.3.1-4
Vacuum Booster Inspection...................................................................................2.3.1-4
Brake Master Cylinder Inspection .........................................................................2.3.1-5
Brake System Exhaustion ......................................................................................2.3.1-5
ABS/ESC Hydraulic Unit Exhaustion ...................................................................2.3.1-6
Runout and Thickness Inspection of Brake Disc ....................................................2.3.1-7
Inspection and Confirmation .................................................................................2.3.1-8
Fault Description Table .........................................................................................2.3.1-8
2.3.2 Front Disc Brake1
Specifications ...............................................................................................................2.3.2-1
Specification of Front Disc Brake..........................................................................2.3.2-1
Torque Specification .............................................................................................2.3.2-1
System Overview ..................................................................................................2.3.2-1
Component Description.........................................................................................2.3.2-1
Component Exploded View...................................................................................2.3.2-2
Disassembly and Assembly...........................................................................................2.3.2-3
Brake Pad..............................................................................................................2.3.2-3
Brake Caliper ........................................................................................................2.3.2-3
Brake Disc ............................................................................................................2.3.2-4
2.3.3 Rear Drum Brake1
Specifications ...............................................................................................................2.3.3-1
General Specification ............................................................................................2.3.3-1
System Overview ..................................................................................................2.3.3-1
Component Exploded View...................................................................................2.3.3-2
Removal .......................................................................................................................2.3.3-2
Removal of Brake Drum .......................................................................................2.3.3-3
Brake Shoe............................................................................................................2.3.3-3
Brake Bottom Plate ...............................................................................................2.3.3-6
2.3.4 Parking Brake Control Mechanism1
Specification .................................................................................................................2.3.4-1
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Brake System

System Overview ..................................................................................................2.3.4-1
Adjustment of Parking Brake Cable ......................................................................2.3.4-1
Fault Description Table .........................................................................................2.3.4-2
Diagnostic Process for Parking Brake Indicator Lamp which is Normally On........2.3.4-3
Parking Brake Lever .............................................................................................2.3.4-5
Parking Brake Cable .............................................................................................2.3.4-6
Parking Brake Indicator Lamp Switch ...................................................................2.3.4-7
2.3.5 Hydraulic Brake Control
Specifications ...............................................................................................................2.3.5-1
Torque Specifications............................................................................................2.3.5-1
System Overview ..................................................................................................2.3.5-1
Brake Master Cylinder and Brake Fluid Reservoir.................................................2.3.5-2
Three-pedal Assembly...........................................................................................2.3.5-3
2.3.6 Power Brake System1
Specifications ...............................................................................................................2.3.6-1
System Overview ..................................................................................................2.3.6-1
Vacuum Booster Assembly ...................................................................................2.3.6-1
2.3.7 Anti-lock Brake System (ABS)1
Specifications ...............................................................................................................2.3.7-1
System Overview ..................................................................................................2.3.7-1
1. Diagnostic Process for Random Failure .............................................................2.3.7-4
2. Diagnostic Process for ABS Warning Lamp which is Normally On ...................2.3.7-5
3. Fault Removal without Fault Code: ...................................................................2.3.7-5
Diagnosis and Test ........................................................................................................2.3.7-6
Pin Definition: ......................................................................................................2.3.7-6
Fault Code List......................................................................................................2.3.7-7
Data Flow List .................................................................................................... 2.3.7-12
Dignostic Process for Commmunication Failure between Fault Diagnostic
Instrument and Vehicle ....................................................................................... 2.3.7-12
Diagnosis Process for Wheel Speed Sensor ......................................................... 2.3.7-13
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Brake System
Removal and Installation ............................................................................................ 2.3.7-14

Hydraulic Control Unit (HCU) ............................................................................ 2.3.7-14
Front Wheel Speed Sensor .................................................................................. 2.3.7-15
Rear Wheel Speed Sensor Assembly ................................................................... 2.3.7-16
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2.3.1-1 Brake System Overview 2.3.1-1
drum reaches the scrapping standard, brake

drum shall be replaced. When polishing the
2.3.1 Brake System Overview
brake drum of thickness that does not reach
the scrapping standard, pay attention not to
Specification over-polishing, resulting in thickness
exceeding the standard.
Material Specification
Item Specification
System Overview
Brake fluid HZY4
Foundation brake system is a two-circuit
General Specification hydraulic braking system laid in diagonal
manner (front left, rear right; front right, rear
Front disc brake Specification (mm) left), and it has front disc type and rear drum
type. The front wheel disc brake caliper is a
Brake disc diameter 244 floating type brake caliper installed on the
Normal thickness of
steering knuckle. The rear wheel drum brake
20 is designed as common primary and trailing
new brake disc
Thickness of brake disc shoe. The front and rear brake can
18 automatically adjust brake clearance.
that shall be scrapped
Maximum runout of Series-longitudinal layout is adopted for the
new brake disc (under 0.050 brake master cylinder, which directly
assembly status) connects with booster. The booster can
Diameter of brake 51.1 increase braking force, so as to reduce the
caliper piston
Minimum thickness of
force applied by driver on the brake pedal.
brake pad 2 Series-longitudinal design can ensure that in
case of a brake circuit failure, another circuit
Warning: when the diameter of brake can still work.
disc reaches the scrapping standard, brake On the basis of foundation braking,
disc shall be replaced. When polishing the electronic hydraulic control unit and wheel
brake disc of thickness that does not reach speed sensor are added on anti-lock control
the scrapping standard, pay attention not to system, and each wheel is provided with
over-polishing, resulting in thickness hydraulic system with independent circuit;
exceeding the standard. electronic control unit adjusts the brake
pressure during braking through hydraulic
Rear drum brake Specification (mm) control unit based on the wheel speed signal
Brake drum diameter
200
collected by the speed sensor installed on
wheel, so as to prevent wheels from locking;
Thickness of brake drum when ABS does not work, electronic brake
202
that shall be scrapped
force distribution system can still adjust the
Thickness of friction lining
of new primary brake shoe 4.5 braking force of rear wheel, and ensure that
the rear wheel will not lock prior to front
Thickness of friction lining
of new trailing brake shoe 4.5 wheel, so as to guarantee vehicle safety.
Parking brake system is a mechanical
Diameter of brake caliper 19.05 system that operates rear wheel drum brake
piston through parking brake control mechanism
Minimum thickness of (commonly known as hand brake). The
brake pad 1.5
parking brake handle locates between the
two front seats. The system is enabled when
Warning: when the diameter of brake pulling up the parking brake handle.
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Rear wheel speed sensor assembly
1 Front brake assembly (left) 1 9 (right) 1
Front wheel speed sensor
2 assembly (left) 1 10 Parking brake cable (left) 1
Brake master cylinder and Rear wheel speed sensor assembly
3 vacuum booster assembly 1 11 (left) 1
Front wheel speed sensor
4 assembly (right) 1 12 Rear brake assembly (left) 1
5 Front brake assembly (right) 1 13 Accelerator pedal assembly 1

Parking control mechanism
6 assembly 1 14 Brake pedal assembly 1
7 Parking brake cable (right) 1 15 Clutch pedal assembly 1
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ABS actuating mechanism

8 Rear brake assembly (right) 1 16 assembly 1
component will be deemed as the suspicious

General Inspection causes, while others will be excluded. More
importantly, the unsafe hidden trouble can
Road Test be checked or eliminated before road test
based on customer’s description. Also the
cause can be narrowed down to specific
Warning: the technician who performs components, speed or condition, so as to
road test shall be trained and shall have good help with the determination of road test
driving skill. method.
Road test is for comparing the actual brake Road test shall start from general brake
performance of vehicle with the standard performance inspection. Based on
performance expected by driver. The ability customer’s description, press pedal with
of technician about making correct different force to check vehicle braking at
comparison and determine if brake different speed. When determine whether
performance is good or bad depends on his the problem occurs on front or rear brake
experience. The technician shall have system, first use pedal and then the parking
complete knowledge about brake system brake for braking. If description (dragging,
working principle and receive systematic vibration, rhythmic runout) only occur when
training, in order to make correct using parking brake, it suggests that the rear
comparison and find problems. brake system has problem.
Before road test, make sure that the vehicle During road test, brake locking shall be
meets the following conditions: avoided. This situation does not suggest that
Tires are not over worn. The thread patterns braking is effective. Hard braking and
of left and right tires are basically the same. keeping wheel rotating is more effective
than brake locking in stopping the vehicle in
Tire pressure is within the specification. a shorter distance.
Wheel alignment is correct. If fault is apparent during the test, confirm
Brake fluid level is normal. that the fault is consistent with the
The indicating lamp of brake system is description. If fault is not apparent, the
normal without fault code. information from description shall be used
Road test shall be conducted on dry, clean to make the situation re-emerge.
and relatively flat road. Experienced If fault exists, use fault check list to narrow
technician will choose a route that is suitable down the cause to specific subsystem and
to conduct road test for brake diagnosis. The corresponding condition description.
road along the route shall be flat instead of Based on the described description, a list of
gravel or rough road. Because the adhesive possible causes can be used to further
forces of tire on gravel road and rough road narrow down the cause to specific part or
are different. Arch road is not suitable either, condition.
as the weight of vehicle body is mainly
distributed to the two lower wheels. Once Inspection of Fluid Leakage of Hydraulic
the route is determined and used frequently, Brake System
the road factor shall not be taken into
consideration.
Before road test, know customer’s Note: under normal circumstances,
description of the fault first. Based on the brake fluid level will drop accordingly with
description, the technician can find possible the wear of brake pad increasing. If the wear
causes for the fault description. Some of brake pad exceeds specification, it will
result in a low brake fluid level. If the wear
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of brake pad is within the specification and does not increase.

brake fluid level is low, it suggests that the 5. Hold the brake pedal to increase
system leaks. the engine speed to 2000 rpm.
Note: if driving in the rain or snow, the Note: the increase of vacuum degree of
leak trace may be rinsed off, as the brake engine intake manifold will lead to a
fluid is water-soluble. continuous downward movement of brake
Check by using the following methods: pedal (additional movement).
1. Confirm that the brake fluid level 6. Release the accelerator pedal, and
is low or drops quickly. observe the downward movement of brake
2. Check appearance for the trace of pedal during the process that engine speed
brake fluid leak. drops to idle speed.
3. Remove front wheel. Requirement: the brake pedal shall not reach
Reference: Wheel and Tire (2.1.4 Wheel and the bottom with additional travel exerted on
Tire, “Removal and Installation”). brake master cylinder, otherwise:
Check the leak of front brake wheel cylinder Reference: Fault Description Table (2.3.1
and wear of bake pad. Brake System Overview, “Fault Description,
4. Remove rear wheel. Diagnosis and Test”)
Reference: Wheel and Tire (2.1.4 Wheel and
Tire, “Removal and Installation”). Vacuum Booster Inspection
Check the leak of rear brake wheel cylinder
and wear of bake pad. 1. Check whether brake fluid level is
5. Remove brake master cylinder. normal.
Reference: Brake Master Cylinder (2.3.5 2. Place the transmission in neutral
Hydraulic Brake Control, “Removal and position and pull up the parking brake to idle
Installation”). the engine.
Check the leak of piston oil seal of brake 3. Turn off the engine, press and
master cylinder. release the brake pedal for several times to
6. Maintain the above possible fault release vacuum, and then press and hold the
points, and exhaust the air in brake system. brake pedal.
Reference: Exhaustion of Brake System 4. Start the engine. If the vacuum
(2.3.1 Brake System Overview, “General system works normally, the brake pedal will
Inspection”). move downward. If not, it suggests that the
vacuum booster system does not work.
Inspection of Brake Pedal 5. Remove the vacuum hose at
vacuum booster side. When the engine idles
Travel Allowance at neutral position, intake manifold vacuum
has an effect on the vacuum booster end of
When the brake pedal travel feels too long
hose. Feel with hand or measure with
during braking or reaches the bottom, its
vacuum gauge. If there is no vacuum degree
travel allowance shall be checked.
or the degree is small, check whether the
1. Place the transmission in neutral
vacuum hose is blocked, sealed, or leaks.
position, and pull up hand brake to idle the
Make sure that all the unused outlets of
engine.
vacuum hose are blocked, joint is intact, and
2. Press the brake pedal slightly for 3
vacuum hose is normal, so that the vacuum
or 4 times.
degree of intake manifold functions.
3. Then maintain 15s for the booster
Reconnect the vacuum hose to vacuum
to fill the vacuum.
booster, and repeat Step 3. If the brake pedal
Note: when resistance increases, you still doesn’t move downward, replace the
may feel that the pedal is pressed to bottom. vacuum booster.
4. Press brake pedal until its 6. Run the engine at 1000 rpm for
downward movement stops or resistance 10s. 10 min after the engine is turned off,
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press the brake pedal with about 889 N (20 system.

lb) force. The brake pedal shall feel the
same as it is during engine running (booster
works normally). Compensating port is
If the brake pedal feels hard, check and blocked;
make sure that the check valve of vacuum Spring of master
hose is normal and retest. If the fault still Brake pedal returns cylinder breaks
slowly. (fatigue)
exists, replace the vacuum booster.
Slightly press the brake
pedal, and rear brake
Brake Master Cylinder Inspection locks Proportioning valve
Brake pedal travel is too Internal leak
long
Note: before the diagnosis, make sure
Bypass Test
that the brake fluid level indicator lamp and
Observe the level of brake master cylinder
warning indicator lamp works normally, and
reservoir. If brake fluid level maintains
the brake system has no fault code.
unchanged after pressing the brake pedal for
Normal Condition
several times, when braking as per the
Under normal circumstances, if the brake
following steps, measure the torque for
pedal feels changed or travel changes, it
wheel to run backward.
suggests that the brake system may have
1. Place the transmission in neutral
problem. The following conditions are
position, and lift the vehicle.
normal, which means that the brake master
Reference: Lifting (1.1.3 Traction and
cylinder does not need maintenance:
Lifting).
1. The design of new brake system is
2. Press the brake pedal with a force
different from that of old one, the force
of 445 N, and then hold for about 15s.
necessary for pressing the brake pedal is
During the time that brake still works, apply
smaller.
10.1 N.m torque to wheels. If any wheel
2. When the brake works normally,
rotates, replace the brake master cylinder.
brake fluid shall rise; when release the brake
pedal, brake fluid shall drop. The volume of
Brake System Exhaustion
brake fluid shall not change.
3. Brake fluid level will drop with
wearing of brake shoe.
Abnormal Condition Warning: brake fluid contains
If the brake pedal feels changed or travel polyglycol ether and polyethylene glycol.
changes, it suggests that the brake system Avoid contact with eyes and skin.
may have problem. The following
Warning: if brake fluid comes into
conditions are abnormal, which means that
contact with eyes, please flush eyes with
the brake master cylinder shall be
cold tap water for 15 minutes. If eyes still
maintained:
feel pain, please seek medical treatment
Description Brake Assembly immediately.
Press the brake pedal, External leak (crack,
and it moves downward joint, sealing element Warning: in case of skin contact, please
quickly. failure)
wash skin thoroughly.
External leak;
Press the brake pedal, Internal leak (aging of Warning: in case of careless swallow of
and it moves downward master cylinder sealing
brake fluid, please drink water and vomit,
slowly. element)
Oil supply hole or oil and then seek medical treatment
tank vent hole is immediately.
Press the brake pedal, it blocked;
is low or feels soft. There is air in hydraulic Warning: wear safety glasses.
BENNI 2013.11
300 mm higher than the exhaust hole, so as

Note: if brake fluid splashes out on the to maintain fluid pressure and prevent air
painted surface, please flush the surface with from entering the system through the thread
clear water immediately. of exhaust hole.
Note: make sure to park the vehicle on 11. The assistant slowly presses the
flat road. brake pedal to bottom and holds it.
12. Open the exhaust valve to exhaust
Note: exhaust as per the following the air in wheel hydraulic oil line.
sequence: rear right, front left, rear left and 13. Tighten the exhaust valve, and
front right. then the assistant slowly releases the brake
pedal.
Note: when the ignition switch is in 14. Add brake fluid into the reservoir.
“LOCK” position and brake is in cold state, 15. Keep pressing the brake pedal, and
press the brake pedal for 3~5 times or until repeat Step 11~13 until the brake fluid
brake pedal force significantly increases, so without air flows into the exhaust bottle.
as to restore to normal pressure in vacuum 16. After exhausting the air in brake
booster. line, install the exhaust hole cover.
Otherwise, it may cause blocking of exhaust
Note: when exhausting, keep adding
hole.
new and clean brake fluid in the reservoir to
17. For other brake line, repeat the
maintain brake fluid level in the middle and
process.
upper of scale mark.
Note: if it known or suspected that there ABS/ESC Hydraulic Unit Exhaustion
is air in master cylinder hole, first exhaust
the air in master cylinder and then the air in “Automatic exhaustion program of anti-lock
brake wheel cylinder. brake system” functions by using fault
1. Put a cleaning cloth under the diagnostic instrument to operate system
master cylinder to prevent brake fluid from solenoid valve in a cyclic manner and run
dropping on other components. the cylinder, so as to exhaust air in auxiliary
2. The assistant slowly presses the oil line. Generally, those oil lines are closed,
brake pedal to bottom and holds it. and they only open during system
3. Remove a main brake line from initialization when starting the vehicle and
the master cylinder, and exhaust the air in during operation of anti-lock brake system.
the master cylinder. The automatic exhaustion program gives
4. Secure the brake line, and then the order to open those auxiliary oil lines, so as
assistant slowly releases the brake pedal. to make the air in the lines flow to brake
5. Repeat Step 2~4, until the air in a wheel cylinder.
brake master cylinder is completely Warning: before execute “automatic
exhausted. exhaustion program of anti-lock brake
6. Exhaust the air in another brake system”, exhaust the air in conventional
master cylinder from another main line joint brake system.
by using the same method. Reference: Exhaustion of Brake System
7. Lift the vehicle. (2.3.1 Brake System Overview, “General
Reference: Lifting (1.1.3 Traction and Inspection”).
Lifting).
8. Connect the open end of Note: in case of any of the following
transparent exhaust pipe to the exhaust hole circumstances, automatic exhaustion
of rear right wheel cylinder. program is recommended:
9. Dip another end of the exhaust 1. Pedal height is not correct or it
pipe in brake fluid in transparent exhaust does not feel good after exhaustion of
bottle. conventional brake system.
10. Place the exhaust bottle at least 2. It is suspected that there is air
BENNI 2013.11
resistance in auxiliary oil line of hydraulic safety.

regulator assembly. General Equipment
Dial indicator retaining seat
Note: make sure to park the vehicle on
Dial indicator
flat road.
Micrometer
Note: when the ignition switch is in 1. Lift the vehicle.
“LOCK” position and brake is in cold state, Reference: Lifting (1.1.3 Traction and
press the brake pedal for 3~5 times or until Lifting).
brake pedal force significantly increases, so 2. Remove the front wheels.
as to restore to normal pressure in vacuum Reference: Wheel and Tire (2.1.4 Wheel and
booster. Tire, “Removal and Installation”).
Note: when exhausting, keep adding 3. Remove the brake shoe.
new and clean brake fluid in the reservoir to Reference: Brake Shoe (2.3.2 Front Disc
maintain brake fluid level in the middle and Brake, “Removal and Installation”).
upper of scale mark. 4. Install tire nuts in reverse
1. When the engine is off, turn the sequence, and fix brake disc in position.
ignition switch to “ON” position. 5. Install dial indicator and retaining
2. Install fault diagnostic instrument. seat on suspension support.
3. Establish communication between
fault diagnostic instrument and anti-lock
brake system. Select “automatic exhaustion
program of anti-lock brake system”.
Reference: Lifting (1.1.3 Traction and
Lifting).
5. Operate as per the instruction of
fault diagnostic instrument until the brake
pedal height is correct. 6. Install dial indicator at the position
6. If the exhaustion program stops that is 10mm from the outer edge of brake,
abnormally, it suggests that fault exists. so as to make it contact with and
Read diagnostic trouble code. If there is perpendicular to the friction surface of brake
fault code, conduct maintenance. disc.
Reference: Fault Code List (2.3.7 Anti-lock 7. Rotate the brake disc until the dial
Control System, “DTC Diagnosis and Test”). indicator shows minimum reading, and then
7. If the brake pedal reaches correct reset the dial indicator.
height, press it to check if the pedal is firm. 8. Slowly rotate the brake disc until
If the brake pedal feels soft, repeat the the dial indicator shows maximum reading.
exhaustion program. Mark and record the runout of end face.
8. Lay down the vehicle. Standard value of new brake disc: 0.050 mm
9. Remove fault diagnostic If the runout of brake disc end face is out of
instrument. specification, check the runout of wheel hub.
10. For road test vehicle, check If it is normal, replace brake disc.
whether the pedal can maintain at correct 9. Inspect runout of wheel hub.
height and firm. Slowly rotate wheel hub to check runout. If
the runout is out of specification (less than
Runout and Thickness Inspection of 0.030mm), make sure the bearing clearance
Brake Disc is normal and replace wheel hub.
Warning: wear safety glasses to ensure
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the customer.
2. Visually inspect apparent
mechanical and hydraulic fault.
Visual Inspection List
Mechanical
Tire pressure, wheel and tire, brake fluid level,
brake line leak
3. Before next step inspection, first
solve the identified problem.
4. If the obvious cause of observed
or raised problem has been found, it shall be
Fault Description, Diagnosis and corrected before next step.
Test 5. If visual inspection passes,
confirm the fault and refer to the fault
Inspection and Confirmation description table.
General Equipment
Digital multimeter
Note: before diagnosis, confirm that the
Diagnostic instrument
warning indicator lamp of brake system is
normal.
1. Confirm the problem reported by
Notes:
1. Replace component carefully, because it may affect the performance of brake
system and cause danger to driving. Please use the standard parts of Changan Automobile Co.,
Ltd.
2. When maintaining the brake system, it is important to keep the component and site
clean.
3. If brake fluid leak is found, component shall be disassembled. If there is abnormal
condition, component shall be replaced with new one.
4. When removing brake component, wrap the connection part of brake line to prevent
dust, soil, etc. from entering the line.
5. When removing or installing brake line, do not damage or deform the brake line.
6. When installing brake line or brake hose, make sure it is not twisted or bent.
7. Brake hose shall be kept away from absorber oil, grease, etc.
8. After brake pipe and hose are installed, make sure that they do not interfere with
other components.
9. Prevent brake fluid from splashing on painted surface, like car body. If so, clean it
immediately.
If a fault occurs, brake system indicator lamp works normally, diagnostic trouble code (DTC)
is not stored in the control module, and the fault cause cannot be confirmed during basic
inspection, conduct fault diagnosis and removal in the order listed in the table below.
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Description Possible Causes Measures
Replace brake pad.

A. Wear, damage of brake pad or Reference: Brake Pad (2.3.3 Rear
with oil stain Drum Brake, “Removal and
Installation”) or Brake Pad (2.3.2
Front Disc Brake, “Removal and
Installation”).
1. Vibrate when braking Polish and grind the front brake
B. Abnormal wear, twist or
disc.
deformation of front brake disc
Polish and grind the rear brake
C. Abnormal wear, out-of-round, or
drum. .
deformation of rear brake drum
D. Looseness of brake caliper Tighten the mounting bolt of brake
mounting bolt caliper.
E. Looseness or missing of hub bolt Tighten or replace hub bolt.

2. Uneven/deviated braking A. Inconformity of tire thread Replace tire and adjust tire
pattern and pressure pressure.
B. Twist or deformation of brake
pipe, hose Replace brake pipe and hose.
C. Crack, twist of brake pad or with
oil stain Clean or replace brake pad.
D. Lining damage Reference: Brake Shoe (2.3.3 Rear
Drum Brake, “Removal and
Installation”) or Brake Pad (2.3.2
Installation”).
Polish and grind the front brake
E. Abnormal wear, twist or
disc.
deformation of front brake disc
F. Abnormal wear or deformation Polish and grind the rear brake
of rear brake drum drum. .
G. Clamping stagnation of brake Maintain or replace brake wheel
wheel cylinder or brake caliper cylinder or brake caliper.
Reference: Brake Wheel Cylinder
(2.3.3 Rear Disc Brake, “Removal
and Installation”) or Brake Caliper
(2.3.2 Front Disc Brake, “Removal
H. Incorrect wheel alignment Conduct wheel alignment.

3. Brake pedal moves downward A. The hydraulic system leaks.
rapidly Repair the leak position, add brake
fluid and exhaust air.
Reference: Exhaustion of Brake
System (2.3.1 Brake System
Add brake fluid and exhaust air in
B. There is air in the system. the system.

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C. Wear of seal ring of brake

master cylinder piston or cylinder Replace brake master cylinder.
crack Reference: Brake Master Cylinder
and Brake Fluid Reservoir (2.3.5
Hydraulic Brake Control,
D. Over wear of brake pad Replace brake pad.

4. Brake pedal is low or feels soft Reference: Brake Shoe (2.3.3 Rear
Installation”) and Brake Pad (2.3.2
Installation”).
A. The vent hole on oil tank cover Clean the vent hole.
is blocked or dirt.
B. There is air in the system.
Add brake fluid and exhaust air in
the system.
5. When slightly press the brake
pedal, the brake locks. A. Improper tire pressure Adjust the tire pressure.
B. Tire wear Replace tire.

C. Incorrect installation of bake
pad Reinstall the brake pad.
Reference: Brake Shoe (2.3.3 Rear
Installation”).
6. Press the brake pedal and hold, A. System leaks or has air.
and it moves down slowly. Repair the leak position, add brake
fluid and exhaust air.
B. Fault of brake master cylinder

Check the brake master cylinder. If
any fault is found, replace it.
Reference: Brake Master Cylinder
and Brake Fluid Reservoir (2.3.5
Hydraulic Brake Control,
7. Brake pedal travel is too long. A. Over wear of brake pad
Replace brake pad.
Installation”).
Check the returnability of caliper,
B. Brake clearance self-adjusting
and replace caliper assembly as
function is abnormal.
necessary.
A. Parking brake works (it is not
8. Braking drag fully released). Release the parking brake.
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B. Brake caliper or brake wheel Maintain or replace brake wheel

cylinder is stuck. cylinder or brake caliper.
Reference: Brake Wheel Cylinder
(2.3.3 Rear Drum Brake, “Removal
and Installation”) or Brake Caliper
(2.3.2 Front Disc Brake, “Removal
C. Clamping stagnation of brake
pad Maintain or replace brake pad.
Installation”).
D. Clamping stagnation of parking
brake cable
Replace the parking brake cable.
Reference: Parking Brake Cable
(2.3.4 Parking Brake and Control,
E. Clamping stagnation of vacuum
booster Adjust the length of vacuum
F. Insufficient free travel of brake booster push rod or replace
pedal vacuum booster.
Reference: (2.3.6 Assist Brake,
9. Poor brake assist effect A. The air intake system leaks. Check vacuum degree of air intake
system, and maintain it as
necessary.
Reference: (3.1.5 Air Intake
System, “General Inspection”).
B. The vacuum booster hose leaks.

Reference: Vacuum Booster
C. Failure of one-way valve of Inspection (2.3.1 Brake System
vacuum booster hose Overview, “General Inspection”).
Replace brake pad.

A. Over wear, crack, twist, dirt,
smooth of brake pad
Installation”).
B. Looseness or abnormal Replace leaf spring.
deformation of leaf spring
10. Brake system has noise. C. Looseness of fixing bolt of
brake caliper support Tighten or replace
D. Looseness of fixing bolt of
brake caliper Tighten or replace
E. Severe wear of shaft pin of
brake caliper Replace caliper.
Replace the front brake disc.
F. Abnormal wear, crack, or twist Reference: Brake Disc (2.3.2 Front
of front brake disc Disc Brake, “Removal and
Installation”).
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Replace the rear brake disc.

G. Abnormal wear, out-of-round, Reference: Brake Disc (2.3.3 Rear
crack or twist of rear brake disc Drum Brake, “Removal and
Installation”).
H. Fatigue of return spring of brake
pedal Replace the return spring.
I. Bend or deformation of brake
pedal push rod Replace
Check the vacuum booster and

replace it as necessary.
J. Vacuum booster Reference: Vacuum Booster
Inspection (2.3.1 Brake System
Check the brake master cylinder

K. Brake master cylinder Reference: Vacuum Booster
Inspection (2.3.1 Brake System
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2.3.2-1 Front Disc Brake 2.3.2-1
2.3.2 Front Disc Brake
Specifications
Item Specification
Brake fluid HZY4
Specification of Front Disc Brake
Front disc brake Specifications (mm)

Brake disc diameter 244
Normal thickness of new brake disc

20
Thickness of brake disc that shall be scrapped
18
Maximum runout of new brake disc (under assembly 0.050
status)
Diameter of brake caliper piston 51.1
Minimum thickness of brake pad

2
Warning: when the brake disc reaches the scrapping standard, it shall be replaced.
Carefully polish the brake disc that does not reach the scrapping standard.
Torque Specification
Name Nm Ib-ft lb-in

Fixing bolt of guide pin of brake caliper 34±3 - -
Fixing bolt of brake caliper 80±6 - -
Joint bolt of brake hoe of brake caliper 23±3 - -

friction slows down the speed of tire and
Instructions and Operation wheel assembly, so as to realize vehicle
braking. When the brake pad is worn, piston
System Overview further moves to fill the gap. When stop
pressing the brake pedal and the hydraulic
The brake caliper of front disc brake is pressure on piston is released, the rubber
single-piston type, and it is installed on seal ring of piston resumes its original shape,
knuckle with two mounting bolts. When so as to maintain a constant clearance
pressing the brake pedal, the brake caliper between brake disc and brake pad.
moves outward under hydraulic pressure.
The brake force makes the brake pad adhere Component Description
to brake disc. The force generated by
Disc Brake Pad
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The mechanical output force from hydraulic It is used to fix the disc brake pad and brake
brake caliper is exerted on the friction face caliper, so as to match with the hydraulic
of brake disc. brake caliper. The brake pad slides under the
Leaf Spring of Disc Brake Pad mechanical output force.
It locates between the disc brake pad and Shaft Pin of Disc Brake Caliper
brake pad mounting support. It can maintain It is used to install and fix hydraulic brake
a smooth movement of brake pad and caliper, so as to match with the brake caliper
eliminate noise. support. The brake caliper slides relatively
Brake Disc to brake pad under mechanical output force.
The speed of tire and wheel assembly is Operation of Front Disc Brake System
reduced by using the mechanical output The mechanical output force from hydraulic
force exerted on the friction face of brake brake caliper is exerted on the internal brake
disc from disc brake pad, so as to realize pad. When the piston pushes the internal
vehicle braking. brake pad outward, the brake caliper
Brake Caliper housing pulls the external brake pad inward
It receives and converts the hydraulic at the same time, so as to distribute output
pressure from brake master cylinder into force uniformly. The brake pad exerts output
mechanical output force, and exerts the force on the friction face at both sides of
force on the internal brake pad; when the brake disc, so as to reduce the speed of tire
master cylinder returns to original position, and wheel assembly. Normal functioning of
the brake caliper piston automatically brake pad leaf spring and brake caliper shaft
returns to original position. pin is important for uniform distribution of
Brake Button Support brake force.
Front Disc Brake
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Front knuckle assembly

1 1
2 Brake disc assembly 1

3 Brake caliper assembly 1
4 Mounting bolt of brake caliper 2
Note: when the brake wheel cylinder

Disassembly and Assembly piston is pressed into the piston cylinder,
brake fluid will spill from the brake master
Brake Pad
cylinder.
Removal
Material
Name Model
Brake fluid HZY4

1. Remove the tire.
Reference: Wheel and Tire (2.1.4 Wheel and
Tire, “Removal and Installation”).
2. Take down the brake caliper.
1). Remove the fixing bolt of lower shaft pin 2. Install the brake pad.
of brake caliper.
Note: the pads shall be replaced in
Note: the bolt is a single-use part, pairs (i.e. replace internal pad together with
which shall not be reused. external pad).
2). Rotate the brake caliper upward. 3. The torque for installing new
fixing bolt of brake caliper shaft pin is
34N.m.
Note: the bolt is a single-use part,
which shall not be reused.
4. Press the brake pedal hard more
than twice.
5. Check brake fluid level and add as
necessary.
Note: strictly perform the following
3. Remove the brake pad. steps when installing pad. Measure the
thickness of brake disc to make sure that it
meets the standard; make sure that the left
spring has sufficient spring force without
plastic deformation, crack or wear, and all
rust and dirt on it has been removed; if
necessary, replace the leaf spring.
Brake Caliper
Installation Removal
1. Use proper tool to compress brake 1. Remove the brake pad.
wheel cylinder piston. Reference: Brake Pad (2.3.2 Front Disc
BENNI 2013.11
Brake, “Removal and Installation”). 1. Remove the brake caliper.

2. Remove the brake hose from Reference: Brake Caliper (2.3.2 Front Disc
brake caliper. Brake, “Removal and Installation”).
1). Use proper clip to clamp the brake
Note: removing of brake pad and brake
hose.
hose can be omitted.
2). Remove the brake hose.
3. Hang the brake caliper.
Torque: 25N.m.
Note: hang the brake caliper to prevent
Note: seal the brake hose to prevent oil
it from stretching the brake hose.
loss and dirt from entering the hose.
4. Remove the brake disc.

3. Remove the brake caliper.
Torque: 80N.m.
Installation
1. Install in the reverse sequence of
Installation removal.
1. Install in the reverse sequence of Screw torque: 8N.m
removal. Torque of lock nut: 200N.m
2. Exhaust air in the brake system. 2. Exhaust air in the brake system.
Reference: Exhaustion of Brake System Reference: Exhaustion of Brake System
(2.3.1 Brake System Overview, “General (2.3.1 Brake System Overview, “General
Inspection”). Inspection”).
Brake Disc
Removal
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2.3.3-1 Rear Drum Brake 2.3.3-1
2.3.3 Rear Drum Brake
Specifications
Item Specification
Brake fluid HZY4
General Specification
Rear drum brake Specifications (mm)
Brake drum diameter

200
Diameter of brake drum that shall be scrapped
202
Thickness of friction lining of new primary brake
4.5
shoe
Thickness of friction lining of new trailing brake 4.5
shoe
Diameter of brake wheel cylinder piston 19.05
Minimum thickness of brake pad

1.5
Warning: when the diameter of brake drum reaches the scrapping standard, it shall be
replaced. When polishing the brake drum of thickness that does not reach the scrapping
standard, pay attention not to over-polishing, resulting in thickness exceeding the standard.
Name Nm Ib-ft lb-in

Joint bolt between rear brake and brake
16±3 - -
pipe
Brake bottom plate and rear shaft mounting
bolt 70±5
Wheel nut 85±5 - -
cylinder is a single-cylinder type, which is
Instructions and Operation installed at the top of bottom plate. The
clearance of service brake is adjusted
System Overview automatically.
The rear drum brake is a leading-trailing Component Description

type, which is under single-cylinder
hydraulic control. The two brake shoes are Brake Drum
pressed on the brake wheel cylinder piston The speed of tire and wheel assembly is
and fixing support pin by the upper and reduced by using the mechanical output
lower return springs. The brake wheel force exerted on the friction face of brake
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drum from drum brake shoe, so as to realize master cylinder returns to original position,
vehicle braking. the brake wheel cylinder piston
Brake Wheel Cylinder automatically returns to original position.
It receives and converts the hydraulic Brake Shoe
pressure from brake master cylinder into It exerts mechanical output force from brake
mechanical output force, and exerts the wheel cylinder piston or hand brake cable on
force on the internal brake pad; when the the friction face of brake drum.
Rear Drum Brake
1 Bottom plate assembly (left/right) 1
2 Rear wheel cylinder assembly 1
3 Brake shoe assembly (left/right) 1
4 Rear hub bearing assembly 1
5 Brake drum 1
Removal
1. Remove the parking brake lever
trim.
2. Put down the parking brake lever
and loosen the adjusting nut.
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2). Remove the brake drum.

Make sure that the wheel bearing is not
separated from bearing block.
Caution: the tightened fixing nut of

3. Loosen wheel nut. wheel hub shall not be loosened. If torque
4. Lift the vehicle. adjustment is required, loosen the nut two
5. Remove the wheel. turns, and then tighten it.
Note: hub shall be rotated when tightening
Caution: if the seal cover (dust cover) the hub retaining nut.
of grease cap is damaged, replace it when Installation
installing. 1. Install in the reverse sequence of removal.
6. Remove the seal cover (dust cover)
of grease cap.
7. Loosen the fixing nut of brake

drum.
2. Adjust the parking brake cable. Refer to

2.3.4-02 for relevant information.
Brake Shoe
8. Note: when removing the brake
drum, make sure that the wheel bearing is
Name Model
not separated from bearing block.
Grease SAM1C-9107-A
Removal of Brake Drum Removal
1. Remove the brake drum, axle and hub
1). Remove the nut.
assembly. Refer to the brake drum part in
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this section for relevant information.

2. Remove the fixing pressure spring of
brake shoe.
8. Remove the leading shoe from support

pin.
1). Push back the leading shoe on support
pin.
2). Take down the leading brake shoe.
3. Fix the brake wheel cylinder with rubber

strap.
Caution: do not damage the brake wheel
cylinder boot when taking out the bake shoe.
4. Remove the brake shoe from brake wheel
cylinder piston.
5. Remove the brake shoe from connection
support.
9. Remove the trailing brake shoe from

support pin.
1). Take down the spring.
Installation
1. Clean, check and apply grease to the
contact area of brake bottom plate.
6. Take down the parking brake cable.

1) Push back the trailing shoe lever.
2). Remove the cable from trailing shoe.
2. Install the support pin in the trailing shoe.

1. Install the spring.
7. Remove the return spring of brake shoe.

1). Remove the lower spring.
2). Remove the upper spring.
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6. Remove the rubber strap.

7. Caution: do not damage the brake
3. Install the leading shoe on the support pin.
wheel cylinder boot.
1). Install the brake hose.
Install the brake shoe on brake wheel
2). Install the leading shoe on the support
cylinder.
pin.
8. Install the brake shoe on the special

support pin at the bottom.
4. Install the return spring of brake shoe.

1). Install the upper spring.
2). Install the lower spring.
9. Install the pressure spring of brake shoe.
5. Install the parking brake cable.

1. Connect the parking brake cable.
2. Push forward the trailing shoe lever.
10. Install the brake drum, axle and hub

assembly.
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Installation
1. Install the brake wheel cylinder.
1). Install the bolt of brake wheel cylinder.
2). Install brake hose joint.

Brake Wheel Cylinder (12 305 0)
Common Tool
Brake hose clip
Removal
1. Remove the brake shoe. Refer to the
brake shoe part in this section for relevant
information.
2. Use proper clip to clamp the brake hose.
2. Remove the brake hose clip.
Inspection”).
Brake Bottom Plate
Removal
1. Remove the brake shoe. Refer to
3. Remove the brake wheel cylinder. the brake shoe part in this section for
1). Remove the brake line joint. relevant information.
2). Remove the bolt. 2. Remove the brake wheel cylinder.
3). Remove the brake wheel cylinder. Refer to the brake cylinder part in this
section for relevant information.
3. Take down the parking brake
cable.
1). Press the retaining clip.
2). Remove the cable.
4. Remove the brake bottom plate.

Remove the bolts.
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Installation
1. Install in the reverse sequence of removal.
Note: The mechanical performance of
the 4 nuts used for bottom plate installation
is Level 10, and their tightening torque is
70±3Nm.
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2.3.4-1 Parking Brake Control Mechanism 2.3.4-1
2.3.4 Parking Brake Control Mechanism
Specification
Name Nm Ib-ft lb-in

Mounting bolt of parking brake control
- -
mechanism 20±3
Mounting bolt of parking brake cable 20±3 - -

System Overview
Parking braking is realized through the rear brake. The parking brake system consists of
parking brake, hand brake lever, and parking cable.
The parking brake system is a mechanical system which operates the rear drum bake through
hand brake. It is enabled when pulling up the hand brake handle, which controls the rear
wheel drum brake shoe (leading shoe an trailing shoe) to spread out through cable, so as to
realize braking. When the hand brake handle is pulled up and the ignition switch is on, the
parking brake indicator lamp on the combination instrument will light. The parking brake is
released through pulling up the handle, pressing the button on it, and then putting it down, and
the parking brake indicator lamp on the combination instrument will go out.
General Inspection
Adjustment of Parking Brake Cable
Note: before adjusting, check whether

the wear of rear drum brake shoe exceeds
limit.
1. Remove the parking brake control
cover of console box.
2. Put down the parking brake handle.
3. Move the hand brake handle
repeatedly for 3-5 times, and then put it
down.
4. Loosen the adjusting nut until it

reaches the end of screw.
5. Press the brake pedal hard for 3-5
times.
• Pull up the parking brake handle
until there is 3-5 ratchet sound.
• Stop adjusting nut, and it locks
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automatically.
Tire pressure
7. Test the parking brake to see if it
Wheel and tire
works normally. Brake fluid level
8. Install the parking brake cover Brake line leak
plate. 3. Before next step inspection, first
solve the identified problem.
Fault Description, Diagnosis and 4. If the obvious cause of observed
Test or raised problem has been found, it shall be
corrected before next step.
Inspection and Confirmation 5. If visual inspection passes,
confirm the fault and refer to the fault
1. Confirm the problem reported by description table.
the customer. General Equipment
2. Visually inspect apparent Digital multimeter
mechanical and hydraulic fault. Visual
Inspection List
Mechanical

A. The travel of parking brake Brake Cable (2.3.4 Parking Brake
handle is too long. and Control, “General
Inspection”).
Repair or replace the parking brake
cable.
B. Left or right parking brake cable Reference: Replacement of Parking
is stuck or breaks. Brake Cable (2.3.4 Parking Brake
and Control, “Removal and
Installation”).
Parking brake does not work (fails),
or parking braking force is weak. C. Looseness, break or deformation Replace the cable counterbalance.
of cable counterbalance. Reference: Parking Brake Lever
(2.3.4 Parking Brake and Control,
Replace the brake shoe.
D. The wear of rear brake shoe Reference: Brake Shoe (2.3.3 Rear
reaches the limit. Drum Brake, “Removal and
Installation”).
F. Deformation or break of internal
Replace the support pin and
support pin of rear drum brake and
parking brake lever.
parking brake lever
A. The travel of parking brake Brake Cable (2.3.4 Parking Brake
lever is too short. and Control, “General
Inspection”).
Parking brake can not be released Repair or replace the parking brake
(drags). cable.
B. Left or right parking brake cable Reference: Replacement of Parking
is stuck. Brake Cable (2.3.4 Parking Brake
and Control, “Removal and
Installation”).
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Repair or replace the brake shoe.

C. Clamping stagnation, crack, or Reference: Brake Shoe (2.3.3 Rear
twist of rear brake shoe Drum Brake, “Removal and
Installation”).
D. Fatigue or brake of rear brake
return spring Replace the return spring.

A. Instrument fuse
B. Instrument harness connector Diagnostic process for the parking

C. Instrument power circuit indicator lamp which does not light
When the ignition switch is in when the ignition switch is in “ON”
“ON” position and vehicle is in D. Instrument grounding circuit position and vehicle is in parking
parking state, the parking indicator E. Harness between parking brake state.
lamp does not light. lamp switch and combination Reference: Fault Description Table
instrument (4.3.2 Instrument, “Fault
F. Parking brake switch
G. Combination instrument
A. Parking brake switch
B. Harness (harness connector)
between parking brake switch and
Reference: diagnostic process for
Parking brake indicator lamp is instrument
parking brake indicator lamp which
normally on. C. Harness (combination
is normally on
instrument assembly—power,
earthing)
D. Combination instrument
Diagnostic Process for Parking Brake Indicator Lamp which is Normally On

1. Check the parking brake switch
A. Disconnect the harness connector S12 of
brake switch.
B. Check whether the parking brake switch
is reliably grounded.
C. Check whether the switch is closed when
pulling up the parking brake lever. Are the above
conditions satisfied?
→Yes
To Step 2.
→No
Repair, adjust or replace the parking brake switch.
2. Check the circuit between harness S21 and X21.
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A. Disconnect the harness connector X21.

B. Measure the resistance between SO12
terminal 1 and car body grounding with multimeter.
Standard value: 10 MΩ or more
C. Measure the resistance between X21
terminal 1 and SO12 terminal 1 with multimeter.
Standard resistance: less than 5 Ω
Does the resistance meet standard?
→Yes
To Step 3.
→No
Repair or replace.

3. Check the circuit between harness X21 and P07.

position.
B. Disconnect the negative harness of
battery.
C. Disconnect the instrument harness
connector P07.
D. Measure the resistance between P07
terminal 29 and X21 terminal 1 with multimeter.
Standard value: less than 5 Ω

E. Measure the resistance between P07
terminal 29 and car body grounding with multimeter.
Does the resistance meet standard?
→Yes
To Step 4.
→No
Repair or replace.
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4. Check combination instrument assembly—power,

grounding
A. Turn the ignition switch to “ON” position.

Check the power supply circuit of terminal 4 and 5 of
combination instrument harness connector P07 with
multimeter.
Standard value: 11 ~ 14 V
B. Turn the ignition switch to “LOCK”
position. Check the grounding circuit of terminal 1
and 17 of combination instrument harness connector
P07 with multimeter.
Standard value: less than 5 Q
Is the check normal?
→Yes
Replace the combination instrument.
Reference: Combination instrument (4.3.2 Instrument,
“Removal and Installation”). →No
Overhaul the combination instrument circuit.

Parking Brake Lever
Removal
1. Remove the control box.
Instrument Panel and Console, “Removal
2. Put down the parking brake lever.
3. Loosen the adjusting nut.
5. Remove the parking brake lever.

• Disconnect the switch connector
of parking brake indicator lamp.
• Remove the parking brake lever.
4. Remove the mounting bolt of

parking brake lever. Torque: 23N.m
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Installation
removal.
Reference: Adjustment of Parking Brake
Cable (2.3.4 Parking Brake and Control,
“General Inspection”). 5. Remove the connecting bolts
between parking brake cable and car body
Parking Brake Cable rear floor (8 places at left and right in total).
Torque: 23N.m.
Removal
1. Remove the console box.
Instrument Panel and Console, “Removal
2. Put down the parking brake lever.
3. Loosen the adjusting nut.
6. Remove the connecting bolt

between parking brake cable and rear axle.
Torque: 23N.m
4. Remove the left and right parking

brake cable from the parking brake cable
counterbalance.
• Pull the No.2 parking brake cable
(left) out from the bottom of counterbalance
7. Remove the left and right parking
slot.
• Pull the No.2 parking brake cable brake cable from car body.
8. Remove the brake drum and hub
(right) out from the bottom of
counterbalance slot. assembly.
Reference: Brake Drum (2.3.3 Rear Drum
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Brake, Removal and Installation).

9. Take down the parking brake
cable.
• Push back the trailing shoe lever.
• Remove the cable from trailing
shoe.
Installation
Install in the reverse sequence of removal.
Parking Brake Indicator Lamp Switch
Removal
1. Remove the parking brake lever.
Reference: Parking Brake Lever (2.3.4
Parking Brake and Control, “Removal and
Installation”).
2. Remove the switch.
Installation
removal.
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2.3.5-1 Hydraulic Brake Control 2.3.5-1
2.3.5 Hydraulic Brake Control
Specifications
Item Specification
Brake fluid HZY4
Name Nm Ib-ft lb-in

Connecting lock bolt between brake master
17±3 - -
cylinder and oil pipe
Fixing nut of brake master cylinder 20±3 - -

Fixing nut of connecting shaft of brake
pedal 20±3 - -

System Overview
The mechanical force from brake pedal is converted into oil pressure by master cylinder,
which is then transmitted to brake wheel cylinder through brake pipe and hose after the
pressure is adjusted by hydraulic electronic control unit. The brake wheel cylinder converts
the oil pressure into mechanical force, which makes the brake shoe press on brake disc, so as
to realize vehicle braking.
Brake Pedal
Receive brake system input force from the driver, and enlarge and transmit it.
Brake Pedal Push Rod
It transmits the enlarged brake pedal input force to the vacuum booster.
Brake Master Cylinder Reservoir
It contains brake fluid for hydraulic brake system.
Brake Master Cylinder
It converts the mechanical input force into hydraulic output pressure. The output pressure is
distributed from the master cylinder to two hydraulic oil lines, so as to supply oil for diagonal
wheel brake oil lines.
Brake Pipe and Hose

They transport brake fluid to the components of hydraulic brake system.
Brake Wheel Cylinder
It converts the hydraulic input pressure into mechanical output force.
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Warning Lamp for Low Brake Fluid Level

When the combination instrument detects low brake fluid level (signal circuit potential is low),
it will light the indicator lamp for low brake fluid level.
3. Remove the brake line from brake
Removal and Installation master cylinder.
Brake Master Cylinder and Brake Fluid

Reservoir
Removal
Material
Name Model
Brake fluid HZY4 (or DOT4)
Note: if brake fluid splashes out on the 4. Remove the vacuum hose from
painted surface, please flush the surface with brake master cylinder.
clear water immediately.
Note: the brake fluid reservoir cover
shall not be stained.
1. Take down the brake fluid
reservoir cover.
• Remove the switch plug of
indicator lamp for low brake fluid level.
• Take down the brake fluid
reservoir cover.
5. Remove the brake master cylinder

and brake fluid reservoir assembly.
• Remove the fixing nut.
• Take out the brake master cylinder.
2. Drain brake fluid in the reservoir.

• Use a proper clean plastic pipe,
with an end connected to the system air
bleed valve and another end inserted into a
proper container.
• Unscrew the air bleed valve.
• Press the brake pedal repeatedly
until all brake fluid is drained out from
reservoir.
• Screw the air bleed valve.
Note: in order to drain all brake fluid in
reservoir, the step shall be taken for both
sides.
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Installation
1. Install in the reverse sequence of Installation
removal. Install in the reverse sequence of removal.
2. Exhaust air in the brake system. Pedal Control Mechanism Assembly (MT)
Reference: Exhaustion of Brake System Removal
(2.3.1 Brake System Overview, “General 1. Remove the steering column assembly.
Inspection”). Reference: Steering Column Assembly
Note: before installation, make sure that (2.3.5 Steering Column Assembly,
the brake booster push rod is in correct “Removal and Installation”).
position. 2. Pull out the connectors of clutch switch
and brake switch.
Note: before installation, make sure that
the vacuum sealing element of brake master
cylinder is in correct position.
Three-pedal Assembly
Electronic accelerator pedal assembly

Removal
1. Pull out the harness connector of
electronic accelerator pedal.
3. Remove the vacuum booster assembly.

Reference: Vacuum Booster Assembly
(2.3.6 Vacuum Booster Assembly,
4. Remove the clutch cable assembly.
2. Remove the 3 mounting bolts of

accelerator pedal.
Torque of electronic accelerator pedal (3
places): (9+3) N.m
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5. Remove the mounting nut of pedal control

mechanism assembly.
3. Remove the vacuum booster assembly.
Pedal torque (8 places, containing 4 places
Reference: Vacuum Booster Assembly
for vacuum booster): (23 ±3) N.m
(2.3.6 Vacuum Booster Assembly,
4. Remove the mounting nut of pedal control
mechanism assembly.
Pedal torque (7 places, containing 4 places
for vacuum booster): (23 ±3) N.m
6. Remove the pedal control mechanism

assembly.
Installation
After the steering column is installed, pay
attention to center the steering wheel.
Pedal Control Mechanism Assembly (IMT)
Removal 5. Remove the pedal control mechanism
1. Remove the connecting bolt (1 place) assembly.
between the steering column and steering Installation
gear. Install in the reverse sequence of removal.
Reference: Steering Column Assembly After the steering column is installed, pay
(2.3.5 Steering Column Assembly, attention to center the steering wheel.
2. Pull out the brake switch connector, and
rotate the switch clockwise by 45° to
remove the brake lamp switch.
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2.3.6-1 Power Brake System 2.3.6-1
2.3.6 Power Brake System
Specifications
Name Nm Ib-ft lb-in

Fixing bolt of vacuum booster 20±3 - -
Fixing nut of brake master cylinder 20±3 - -

System Overview
The brake system input force is enlarged through brake pedal, transmitted to the vacuum
booster by brake pedal push rod, and then exerted on hydraulic brake master cylinder after
boosted by the booster. The vacuum booster functions by making use of vacuum source,
which reduces the force exerted by the driver on brake pedal during braking.
Torque: 20N.m
Note: if brake fluid splashes out on the
Removal and Installation painted surface of car body, please flush the
surface with clear water immediately.
Vacuum Booster Assembly
Removal
1. Remove the brake master cylinder.
Reference: Brake Master Cylinder and
Brake Fluid Reservoir (2.3.5 Hydraulic
Brake Control, “Removal and Installation”).
2. Remove the connecting pin
between the vacuum booster and brake pedal.
1) Take down the elastic clip on the
connecting pin between brake master 4. Take out the vacuum booster
cylinder push rod and brake pedal arm. assembly.
2). Take down the connecting pin.
3. Remove the 4 mounting bolts of Installation

vacuum booster. 1. Install in the reverse sequence of
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2.3.6-2 Power Brake System 2.3.6-2
removal. the vacuum booster push rod is in correct

2. Exhaust air in the brake system. position.
the vacuum sealing element of brake master
Inspection”).
cylinder is in correct position.
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2.3.7-1 Anti-lock Brake System (ABS) 2.3.7-1
2.3.7 Anti-lock Brake System (ABS)
Specifications
Item Specification
Brake fluid HZY4
Name Nm Ib-ft lb-in

Fixing bolt of electronic hydraulic control unit 23 + 3 - -
Connecting lock bolt between brake line and

16 + 2 - -
electronic hydraulic control unit
Fixing bolt of wheel speed sensor 8+2 - -

System Overview
The anti-lock brake system is an electronic brake control system, which can prevent wheel
locking, shorten braking distance, and improve stability during braking. On the basis of
foundation braking, electronic hydraulic control unit and wheel speed sensor are added on
anti-lock control system, and each wheel is provided with hydraulic system with independent
circuit; electronic control unit adjusts the brake pressure during braking through hydraulic
control unit based on the wheel speed signal collected by the speed sensor, so as to prevent
wheels from locking. When ABS does not work, electronic brake force distribution system
(EBD) can still adjust the braking force of rear wheel, and ensure that the rear wheel will not
lock prior to front wheel, so as to guarantee vehicle safety. In case of ABS or EBD failure,
electronic hydraulic control unit will give an order to instrument to light the corresponding
indicator lamp.
1. Hydraulic Electronic Control Unit

Note: rubber cushion is installed between the mounting bolt and support of hydraulic
electronic control unit. It is used to avoid the hydraulic electronic control unit being affected
by vehicle vibration. Hydraulic electronic control unit shall not be disassembled; instead, it
shall be replaced as assembly.
The main components of ABS hydraulic electronic control unit mainly include ABS control
module, valve body and ABS cylinder.
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ABS cylinder
1 1
2 Valve body 1
3 ABS control module 1
ABS Electronic Control Unit (ECU)

Electronic control unit continuously detects the wheel state through wheel speed sensor and
controls the slip rate to a certain range through solenoid valve, so as to maintain vehicle
stability. ABS control module continuously compares its stored slip limit value with the speed
reduction value detected by wheel speed sensor, so as to detect the locking trend of each
wheel. If ABS control module detects that a wheel has locking trend, the corresponding
hydraulic valve in the valve body will be opened or closed. The four wheels are controlled
independently. When ABS does not work, electronic brake force distribution system (EBD)
can still adjust the braking force of rear wheel, and ensure that the rear wheel will not lock
prior to front wheel, so as to guarantee vehicle safety.
During system self-detecting and ABS functioning, electronic control unit starts the ABS
cylinder through controlling ABS cylinder relay.
When the ignition switch is turned on, ABS control module will give and order to the
instrument to light the ABS indicator lamp on instrument panel, which will go out after ABS
self-detection is completed. In case of system failure, the module will give an order to the
instrument to light the indicator lamp for warning.
ABS control module continuously monitors the system. Once a fault occurs, it will store
automatically. ABS control module can be accessed through DLC interface by using
diagnostic instrument.
Valve Body
Four oil filling valves (NO solenoid valve), control four wheels respectively.
Four oil draining valves (NC solenoid valve), control four wheels respectively.
Two low pressure accumulators and hydraulic line.
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ABS cylinder can also be actuated through the diagnostic instrument during self-detecting and
ABS functioning.
An ABS hydraulic control circulation includes 3 stages:
Stage I—Pressurization
Schematic Diagram of Anti-lock Brake System (ABS) Hydraulic Line
Close oil filling valve, and close oil draining wheel speed signal. The sensor acquires
valve. The driver presses the brake pedal, pulse signal from gear ring. The signal is
and system pressure will rise gradually. converted into digital signal by the
Stage II—Pressure Maintaining integrated circuit in sensor, and then sent to
Open oil filling valve, and close oil draining ABS control module. The front wheel gear
valve. The pressure of wheel brake (wheel ring is fixed on and integrated with the drive
cylinder or brake caliper) maintains shaft. The rear wheel gear ring is fixed on
unchanged. The pressure of wheel cylinder the rear wheel hub spindle.
or brake caliper shall be maintained 3. Brake Lamp Switch
unchanged when keep pressing the brake When pressing the brake pedal, the brake
pedal. lamp will light. ABS collects brake signal
Stage III—Pressure Relief through hardwire.
Close oil filling valve, and open oil draining 4. ABS Indicator Lamp
valve. The pressure of wheel brake (wheel ABS indicator lamp locates on the
cylinder or brake caliper) drops, and the combination instrument, which informs the
drained brake fluid flows back to the brake driver of ABS failure through lighting.
master cylinder under the effect of ABS When ABS works normally, turn the
cylinder. ignition switch from “LOCK” to “ON”
2. Wheel Speed Sensor (see the following position, ABS will perform self-detection
figure) and light will be on for 3s, and after which,
Wheel speed sensor is a two-wire the light will go out and maintain off state.
electromagnetic speed sensor. During wheel In case of the following circumstances, the
rotating, ABS control module calculates combination instrument will light the ABS
wheel speed and vehicle speed based on the indicator lamp:
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ABS control module detects ABS failure. It locates on the combination instrument,
The combination instrument receives a which informs the driver of EBD failure
request to light the indicator lamp from ABS through lighting. When ABS indicator lamp
control module. is on and EBD indicator lamp is off, the
• ABS performs self-detection at the system still has EBD function. When ABS
beginning of each ignition cycle. The and EBD indicator lamps are on, ABS and
indicator lamp will be on for about 3s. EBD will not function.
• The combination instrument detects that
the communication with ABS control General Inspection
module is lost.
1. Confirm the problem reported by

the customer.
2. Visually inspect apparent
mechanical or electrical fault.
Fuse
Wheel speed sensor Connector
Wheel speed sensor gear ring Harness
5. EBD Indicator Lamp

3. Before next step inspection, first solve the identified problem.
4. If the obvious cause of observed or raised problem has been found, it shall be
corrected before next step.
5. If visual inspection passes, confirm the fault and refer to the fault description table.
General Equipment
Digital multimeter Diagnostic instrument

1. Diagnostic Process for Random Failure
Note: 1. Clean up DTC.

2. Conduct simulation test.
3. Check and shake harness, connector and terminal.
In electronic system, momentary poor contact may occur at electrical circuit and signal
inputting or outputting places, which will result in random failure. Sometimes the cause of
failure will disappear on its own; therefore it’s not easy to find out the problem. In case of
random failure, first read historical fault code with diagnostic instrument and check as per the
code. Then simulate the failure as per the following methods to check if the failure reappears.
Failure definition: the failure does not appear, but the historical diagnostic trouble code record
indicates that it has occurred; or the customer has reported the failure, but because it is not
related to the diagnostic trouble code, it is not possible for the failure to reappear.
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S/N Possible Causes Simulated Failure Remarks

• Slightly shake the ECU If the harness is twisted off or breaks as
connector of ABS up, down, left it is strained too tight, replace it with
and right. new one. When vehicle is running, the
• Slightly shake the ABS harness wheel speed sensor will have momentary
If vibration is the up, down, left and right. open/short circuit due to fluctuation of
1
main cause • Slightly shake the sensor up, suspension system. Therefore, when
down, left and right. checking the sensor harness, vehicle
• Slightly shake other moving parts running test shall be performed.
(like wheel bearing).
• Heat the part considered as

If temperature is the having fault with blower.
2
main cause • Check for cold welding by using
cold spray.
• Turn on all switches of electrical
If high electrical appliances, including head lamp,
3
load is the main wiper, etc., so as to make vehicle
cause power work under high load.
If the failure does not reappear, it shall be diagnosed and maintained until next time it appears.
Generally, random failure will gradually reappear, and it won’t disappear on its own.
2. Diagnostic Process for ABS Warning Lamp which is Normally On
1). The vehicle is taken to repair shop.

2). Analyze the problem reported by the customer.
3). Read fault code
Fault code exists→go to step 4
No fault code→go to step 6
4). Record fault code and then clean it up.
5). Fault confirmation and reappearance: accelerate the vehicle above 25km/h to simulate the
state when fault occurs, and re-read the fault code.
Fault code exists→current fault code. Go to step 7.
No fault code→historical fault code. Go to step 8.
6). If there is no fault code, remove the fault and go to step 9.
7). Remove the fault as per the fault code list, and then go to step 9.
8). Remove the fault as per the fault description table, and then go to step 9.
9). Confirm that the fault has been removed and conduct maintenance completion test.
10). Prevent the fault from occurring again.
11). Finish.
3. Fault Removal without Fault Code:
If the brake system has fault, but ABS didn't restore the fault code, such fault is called fault
without fault code. It is generally caused by foundation brake system failure. For example:
1) Brake fluid leaks (which may cause soft braking, long brake pedal travel, or even braking
failure).
2) Use brake fluid of poor quality (which may erode brake line and internal element of ABS
hydraulic adjustment module, or even braking failure).
3) There is air in the brake line (which may cause soft braking or even braking failure).
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4) Brake line is blocked (which may cause hard braking or even braking failure).
5) Brake disc is over worn (which may cause soft braking and long brake pedal travel).
6) Booster fails (which may cause hard or soft barking, long brake pedal travel, or even
braking failure).
7) Brake line is connected incorrectly (which may cause ABS performance reduction, long
braking distance, etc.). Please refer the following for correct installation method:
Identification near oil hole on the ABS hydraulic adjustment module: MCI refers to No.1
master cylinder oil pipe; MC2 refers to No.2 master cylinder oil pipe; FL refers to oil pipe of
front left wheel cylinder; FR refers to oil pipe of front right wheel cylinder; RL refers to oil
pipe of rear left wheel cylinder; RR refers to oil pipe of rear right wheel cylinder.
Note: no power or abnormal power supply interruption will result in that the ABS warning
lamp lights for a long time but without fault code.
Diagnosis and Test

Pin Definition:
Pin Function Pin Function

1 Power end (positive pole) of motor 20 To be defined
2 Wheel speed output (front right) 21 To be defined
3 To be defined 22 To be defined
Signal end of wheel speed sensor (front
4 right) 23 To be defined
6 To be defined 25 Power end of valve relay
7 To be defined 26 CAN1P (high)
Signal end of wheel speed sensor (front
8 left) 27 To be defined
Power end of ECU (ignition power
9 To be defined 28 circuit)
Signal end of wheel speed sensor (rear
10 To be defined 29 right)
11 To be defined 30 Brake lamp switch
Power end of wheel speed sensor (rear
12 To be defined 31 left)
13 Grounding end of motor 32 To be defined
14 CAN1M (low) 33 Vehicle speed output
Power end of wheel speed sensor (front
Power end of wheel speed sensor (rear
Signal end of wheel speed sensor (rear
18 left) 37 To be defined
Power end of wheel speed sensor (front
19 left) 38 ECU grounding end
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Fault Code List
DTC Description
C120004 High power supply voltage of ECU
C120104 Low power supply voltage of ECU
C110004 ECU fault (hardware and microcontroller error)
C111008 ECU fault (software error)
C106B06 Unreasonable ABS control (like long control time)
C103108 Signal fault of front left wheel speed sensor: out of range, loss, noise, and intermittent
interruption
C103200 Circuit fault of front left wheel speed sensor: signal circuit is short to ground or open;
power circuit is open
C10A000 Circuit fault of front left wheel speed sensor: power circuit is short to ground
C10A100 Circuit fault of front left wheel speed sensor: signal circuit is short to power
C10A900 Fault of front left wheel speed sensor: general fault
C103408 Signal fault of front right wheel speed sensor: out of range, loss, noise, and intermittent
interruption
C103500 Circuit fault of front right wheel speed sensor: signal circuit is short to ground or open;
C10A200 Circuit fault of front right wheel speed sensor: power circuit is short to ground
C10A300 Circuit fault of front right wheel speed sensor: signal circuit is short to power
C10AA00 Fault of front right wheel speed sensor: general fault
C103708 Signal fault of rear left wheel speed sensor: out of range, loss, noise, and intermittent
interruption
C103800 Circuit fault of rear left wheel speed sensor: signal circuit is short to ground or open;
C10A400 Circuit fault of rear left wheel speed sensor: power circuit is short to ground
C10A500 Circuit fault of rear left wheel speed sensor: signal circuit is short to power
C10AB00 Fault of rear left wheel speed sensor: general fault
C103A08 Signal fault of rear right wheel speed sensor: out of range, loss, noise, and intermittent
interruption
C103B00 Circuit fault of rear right wheel speed sensor: signal circuit is short to ground or open;
C10A600 Circuit fault of rear right wheel speed sensor: power circuit is short to ground
C10A700 Circuit fault of rear right wheel speed sensor: signal circuit is short to power
C10AC00 Fault of rear right wheel speed sensor: general fault
C119904 Fault of wheel speed sensor group (wheel speed sensors are interchanged and many of
them fails )
U210500 Overvoltage of CAN bus
U210700 Undervoltage of CAN bus
C110104 CAN hardware fault
U210104 CAN bus off
U216104 CAN bus passive fault
C101004 Fault of front left liquid filling valve
C101104 Fault of front left liquid draining valve
C101404 Fault of front right liquid filling valve
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C101504 Fault of front right liquid draining valve

C101804 Fault of rear left liquid filling valve
C101904 Fault of rear left liquid draining valve
C101C04 Fault of rear right liquid filling valve
C101D04 Fault of rear right liquid draining valve
C119504 Valve relay fault
C102004 Return pump motor fault
C107208 General valve fault (overheat protection, invalid signal, hardware damage)
Fault Diagnosis:
1. High and Low Power Supply Voltage
Fault code: C120004; C120104
Possible Causes
(1) Fuse fault
(2) High or low battery voltage
(3) Connector, harness or ground wire fault
(4) Power shortage may occur under high power load.
Diagnostic Procedures
Is the initial inspection performed? Go to step Perform initial

1 2. inspection (see Page
3)
Measure battery voltage. Is there any fault and is the fault removed? Go to step Go to step 3.
2 Refer to the circuit diagram of specific item for pin definition. 4.
3 Make cross validation for ABS (refer to “Removal and Installation” -
section for specific steps). If ECU damage is validated, replace Go to step
ABS. Is the fault removed? 4.
4 Re-diagnose to confirm whether the fault appears again. - Diagnosis finishes
2.
Fault code: C101004; C101104; C101404; C101504; C101804; C101904; C101C04;
C101D04; C119504; C107208
Possible Causes
(1) Solenoid valve is short to power or ground, or circuit is open (poor grounding).
(2) Fuse fault
(3) System overheat protection (solenoid valve works for a long time, which generally occurs
when vacuumizing and filling, and end off line testing).
(4) ABS damage.
1 Keep the engine off for 5 minutes to see if the fault is removed. Is it? - Go to step 2.
2 Is the initial inspection performed? Go to step 3. Perform

initial
inspection
3 Measure the voltage of power supply pin of solenoid valve. Check fuse, Go to step 5. Go to step 4.
external relay, connector, harness and ground wire. Is there any fault and
is the fault removed? Refer to the circuit diagram of specific item for pin
definition.
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4 Make cross validation for ABS (refer to “Removal and Installation” Go to step 5.
section for specific steps). If ABS damage is validated, replace ABS. Is
the fault removed?
5 Accelerate the vehicle to 25km/h and then stop. Re-diagnose to confirm if - Diagnosis
the fault appears again. Does it? finishes
3. Pump Motor Fault
Fault code: C102004
Possible Causes
(1) Poor grounding of pump motor
(2) System overheat protection
(3) Abnormal power supply of pump motor (fuse, battery terminal)
(4) Fault of pump motor relay
(5) Pump motor fault
1 Keep the engine off for 5 minutes to see if the fault is removed. Is it? — Go to step 2.
2 Is the initial inspection performed? Go to step 3. Perform initial

inspection
3 Measure the voltage of power supply pin of pump motor, and check Go to step 5. Go to step 4.
connector, harness, and ground wire. Is there any fault and is the fault
removed? Refer to the circuit diagram of specific item for pin definition.
4 Make cross validation for ABS (refer to “Removal and Installation” Go to step 5. —
the fault removed?
5 Accelerate the vehicle to 25km/h and then stop. Re-diagnose to confirm — Diagnosis
if the fault appears again. Does it? finishes
4. Circuit Fault of Wheel Speed Sensor:
Fault code: C103200; C10A000; C10A100; C10A900; C103500; C10A200; C10A300;
C10AA00; C103800; C10A400; C10A500; C10AB00; C103B00; C10A600; C10A700;
C10AC00; C119904
Possible Causes
(1) Wheel speed sensor circuit is open, connection loosens or breaks.
(2) The signal circuit and power circuit of wheel speed sensor are connected inversely.
(3) Signal circuit is short to ground.
(4) Sensor head or pin damages.

inspection
2 Check if the connection of wheel speed sensor is intact, and check the Go to step 4. Go to step 3.
wheel speed sensor for open circuit or short circuit. Is there any fault
and is the fault removed? Refer to the circuit diagram of specific item
for pin definition.
3 Make cross validation for ABS (refer to “Removal and Installation” Go to step 4. —
the fault removed?
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4 Accelerate the vehicle to 25km/h and then stop. Re-diagnose to confirm — Diagnosis
5. Signal Fault of Wheel Speed Sensor:
Fault code: C103108; C10A900; C103408; C10AA00; C103708; C10AB00; C103A08;
C10AC00; C119904
Possible Causes
(1) Wheel speed sensor circuit is open, connection loosens or breaks.
(2) The signal circuit of wheel speed sensor is short to power.
(3) The power circuit of wheel speed sensor is short to ground.
(4) Gear ring is not installed, dirty with foreign matter, off center, tooth missing, or
demagnetizing.
(5) Air gap between the sensor and gear ring is large.
(6) Wheel speed sensor is interfered by external magnetic field (wheel or axle does not
demagnetize).
(7) Wheel speed sensor body fails.
(8) Number of teeth on gear ring is wrong.
(9) Tire size does not meet specification.
(10) ECU damages.

initial
inspection
2 Check if the connection of wheel speed sensor is intact, and check the Go to step 7. Go to step 3.
wheel speed sensor for open circuit or short circuit. Is there any fault
and is the fault removed? Refer to the circuit diagram of specific item
for pin definition.
3 Check the air gap between wheel speed sensor and gear ring; check if Go to step 7. Go to step 4.
the gear ring is dirty, or has foreign matter, missing teeth; check if the
number of teeth on gear ring is correct. Is there any fault and is the
fault removed?
4 Lift the vehicle and rotate wheel. Check if the signal output of wheel Go to step 5. Go to step 6.
speed sensor meets specification based on the data flow of diagnostic
instrument. Is there any fault?
5 Disconnect wheel speed sensor connector, connect 12V power between Go to step 2. Replace
two pins of wheel speed sensor, and connect ampere meter in series. wheel speed
Connect the positive pole of power to power supply pin, and connect sensor, and
the negative pole of power to signal pin. Slowly rotate wheel to see if go to step 7.
the reading of ampere meter fluctuates between 7mA and 14mA. Does
it?
-
6 Make cross validation for ABS (refer to “Removal and Installation” Go to step 7.
section for specific steps). If ECU damage is validated, replace ABS. Is
the fault removed?
7 Accelerate the vehicle to 25km/h and then stop. Re-diagnose to confirm Diagnosis
Notes:
1) After the signal fault of wheel speed sensor is removed, the vehicle shall be started and
accelerated to 25km/h, so that ABS warning lamp will go out.
2). Do not measure the power supply voltage between wheel speed sensor and ECU. If wheel
speed sensor circuit is open, ECU will automatically cut off power supply, which will restore
after next ignition self-inspection.
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6. ECU Fault:
Fault code: C110004; C111008
Possible Causes
(1) ECU fault

inspection
2 Make cross validation for ABS (refer to “Removal and Installation” Go to step 3. -
section for specific steps). If ECU damage is validated, replace
ABS. Is the fault removed?
3 Re-diagnose to confirm whether the fault appears again. Does it? - Diagnosis
finishes
7. Unreasonable ABS Control:
Fault code: C106B06
Possible Causes
(1) Continuously brake on ice surface.
(2) Wheel speed difference is large.

initial
inspection
2 Check wheel speed sensor and gear ring. Is the fault removed? Go to step 4. Go to step
3.
3 Make cross validation for ABS (refer to “Removal and Installation” Go to step 4. -
section for specific steps). If ECU damage is validated, replace ABS. Is the
fault removed?
finishes
8. CAN Bus Fault:
Fault code: U210500; U210700; C110104; U210104; U216104;
Possible Causes
(1) CAN control fault
(2) CAN configuration information does not match.
(3) CAN is off.

inspection
2 Diagnose CAN bus hardware and software. Refer to vehicle service Go to step 4. Go to step 3.
manual for details. Is there any fault and is the fault removed?
3 If ECU damage is validated, replace ABS. Is the fault removed? Go to step 4. -
finishes
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Data Flow List
The working condition of switch, sensor, and actuator can be checked through reading the
“Data Flow List” on the fault diagnosis instrument without disassembling any component.
Before diagnosing the fault of engine electronic control system, the first step is to observe and
analyze the data, which can reduce the time for removing fault.
Note: the data under normal condition are listed in the following table for reference only.
Do not judge whether a part fails based on these reference values. Generally, the vehicle
under diagnosis can be compared with a normal vehicle under the same status, so as to
confirm whether the data of vehicle under diagnosis are normal.
1. Keep the engine at normal operating temperature.
2. Turn the ignition switch to “LOCK” position.
3. Connect to the fault diagnostic instrument.
4. Turn the ignition switch to “ON” position.
5. Select “Changan Automobile”/”A301”/ABS system/read data flow.
6. Refer to the following table (diagnostic instrument has list; it is for illustration here), and
check the data.
Display item of Component Control range Diagnosis description
diagnostic
instrument
Front left wheel Signal comes from front left Front left wheel speed
Observe wheel speed change
speed wheel speed sensor changes with vehicle speed
Front right wheel Signal comes from front Front right wheel speed
speed right wheel speed sensor changes with vehicle speed
Rear left wheel Signal comes from rear left Rear left wheel speed
Rear right wheel Signal comes from rear right Rear right wheel speed
Light on and off can be
EBD warning lamp Signal comes from ABS Controlled by ABS
controlled by using
status module module
diagnostic instrument
Light on and off can be
ABS warning lamp Signal comes from ABS Controlled by ABS
controlled by using
status module module
diagnostic instrument
Action Test test path
The working condition of ABS actuator
under diagnosis can be tested by using fault Test conditions:
diagnostic instrument to conduct action test 1. Do not test in undervoltage state.
without disassembling any component. 2. Vehicle speed shall not exceed 3km/h.
Before diagnosing the fault of ABS control Test procedures:
system, the first step is to perform action test, Test item by item on the diagnostic
which can reduce the time for removing instrument screen in “Changan
fault. Automobile”/”A301”/ABS system path.
1. Keep the engine at normal operating
temperature. Diagnostic Process for Communication
2. Turn the ignition switch to “LOCK” Failure between Fault Diagnostic
position. Instrument and Vehicle
3. Connect to the fault diagnostic instrument.
4. Turn the ignition switch to “ON” position.
5. Select “Changan Note: short circuit in module may also
Automobile”/”A301”/ABS system/action cause this failure.
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Reference: Diagnostic Process for Network, “Fault Description, Diagnosis and

Communication Failure between Diagnostic Test”)
Instrument and ECM (M7) (4.3.15 Vehicle
Diagnosis Process for Wheel Speed Sensor
1. Check the installation of wheel speed sensor.
A. Check the installation of wheel speed

sensor.
Is it loose?
→Yes
Go to Step 2.
→No
Tighten it.
2. Measure the resistance of wheel speed sensor.
A. Remove the harness of wheel speed

sensor, and measure the resistance of sensor.
Standard value: 1.0~1.3 kΩ
Is the resistance normal?
→Yes
Go to Step 3.
→No
Replace the speed sensor.
3. Check the wheel speed sensor.
A. Remove the wheel speed sensor.

B. Check the sensor head for scratch,
foreign matter, and dirt.
C. Check if the gap of wheel speed sensor
is normal.
Standard value: 0.3~0.8 mm
Is the check normal?
→Yes
Clean or replace sensor.
→No
Go to Step 4.
4. Check the harness between wheel speed sensor and ABS control module.
A. Disconnect the harness connector of
ABS control module.
B. Measure the resistance between
connector terminals with multimeter. Standard
value: less than 5 Ω
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C. Measure the resistance between the two

terminals of connector and car body grounding.
→Yes
Go to Step 5.
→No
Repair or replace harness.
5. Check the gear ring of wheel speed sensor.

A. Check the gear ring of wheel speed
sensor for deformation or missing teeth.
→Yes
Replace the gear ring of wheel speed sensor.
→No
Go to Step 6.
6. Check the wheel bearing clearance.
A. Check whether the wheel bearing
clearance is normal.
→Yes
Go to Step 7.
→No
Repair or replace the wheel bearing.
7. Replace ABS control module.
A. Replace ABS control module.
lamp for low brake fluid level.
Removal and Installation 2) Take down the brake fluid reservoir cover.
Hydraulic Control Unit (HCU)
Removal
Material
Model
Name
Brake fluid HZY4
Note: if brake fluid splashes out on the

painted surface, please flush the surface with
clear water immediately. 3. Drain brake fluid in the reservoir.
1). Use a proper clean plastic pipe,
Note: the brake fluid reservoir cover with an end connected to the system air
shall not be stained. bleed valve and another end inserted into a
1. Disconnect the battery negative proper container.
harness. 2). Unscrew the air bleed valve.
Reference: Inspection of Storage Battery 3). Press the brake pedal repeatedly
(3.1.10 Charging System, “General until all brake fluid is drained out from
Inspection”). reservoir.
2. Take down the brake fluid 4). Screw the air bleed valve.
reservoir cover.
1). Remove the switch plug of indicator Note: in order to drain all brake fluid
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in reservoir, the step shall be taken for both

sides.
Installation
removal.
4. Disconnect the harness connector Reference: Exhaustion of Brake System
of ABS control module. (2.3.1 Brake System Overview, “General
5. Remove 6 brake lines from the Inspection”).
hydraulic control module.
Torque: 16N.m Note: before installation, make sure
that the brake booster push rod is in correct
Note: block the hydraulic control unit position.
(HCU) to prevent brake fluid from flowing
out or dirt from entering the unit. Note: before installation, make sure
that the vacuum sealing element of brake
Note: cover the brake line to prevent master cylinder is in correct position.
brake fluid from flowing out or dirt from
entering the pipe. Front Wheel Speed Sensor
Note: note the location of brake lines Removal
for the convenience of installation. 1. Disconnect the battery negative
harness.
Reference: Inspection of Storage Battery
(3.1.10 Charging System, “General
Inspection”).
2. Disconnect the connector between
wheel speed sensor and harness plug.
6. Remove the 2 connecting bolts

between hydraulic control module assembly
and mounting support.
Torque: 8N.m 3. Remove the rubber cover of car
body connecting clip that is clamped on
front strut.
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wheel speed sensor and harness plug.
2. Remove the clip that clamping the

rear wheel speed sensor harness on car body
brake hose support, and rubber boot, as well
as the double-pipe clip that clamping the
rear wheel speed sensor harness on brake
line.
between front wheel speed sensor and
knuckle. Torque: 16N.m

between rear wheel speed sensor and brake.
Torque: 16N.m
5. Remove the front wheel speed
sensor assembly.
5. Remove the front wheel speed

sensor assembly.
Installation
Rear Wheel Speed Sensor Assembly
Removal
1. Disconnect the battery negative
harness.
Reference: Inspection of Storage Battery
(3.1.10 Charging System, “General
Inspection”)
1. Disconnect the connector between
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Installation hydraulic control

Install in the reverse sequence of removal. unit
Specifications Connecting lock
Material Specification bolt between
Item Specification brake line and
16±2 - -
electronic
Brake fluid HZY4 hydraulic control
unit
Torque Specifications Fixing bolt of - -
wheel speed 8±2
Name Nm Ib-ft lb-in
sensor
- -
Fixing bolt of 23±3
electronic
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Steering System
2.4 Steering System
Contents Page
2.4.1 Steering System Overview1
Specification ................................................................................................................ 2.4.1-1
General Specification ................................................................................................... 2.4.1-1
Instructions and Operation ........................................................................................... 2.4.1-1
System Overview ......................................................................................................... 2.4.1-1
Operating Principle ...................................................................................................... 2.4.1-1
Fastener Torque ........................................................................................................... 2.4.1-1
System Schematic Diagram and Component Details .................................................... 2.4.1-2
Inspection and Confirmation ........................................................................................ 2.4.1-2
Table for Common Fault Desceiption of Steering System ............................................ 2.4.1-2
Steering System Function Inspection ........................................................................... 2.4.1-4
Returnability Inspection ............................................................................................... 2.4.1-4
Steering Column Regular Handle ................................................................................. 2.4.1-4
2.4.2 Steering Column Assembly
Steering Column Assembly Diagram ........................................................................... 2.4.2-1
Notes for Steering Column Assembly Maintenance ..................................................... 2.4.2-1
Schematic Diagram of Controller Assembly Harness Interface .................................... 2.4.2-3
Terminal Definition Table............................................................................................ 2.4.2-4
EPS Fault Diagnosis .................................................................................................... 2.4.2-4
Fault Code Table ......................................................................................................... 2.4.2-5
2.4.3 Steering Gear Assembly1
Torque Specifications .................................................................................................. 2.4.3-1
Steering Gear Component List ..................................................................................... 2.4.3-1
Installation and Maintenance of Steering Gear ............................................................. 2.4.3-2
Removal and Maintenance of Tie Rod Ball .................................................................. 2.4.3-2
Removal and Maintenance of Tie Rod Dust Cover ....................................................... 2.4.3-3
Common Fault of Steering Gear................................................................................... 2.4.3-3
2.4.4 Steering Wheel Body Assembly1
Torque Specification .................................................................................................... 2.4.4-1
Steering Wheel Diagram and Function ......................................................................... 2.4.4-1
Removal and Installation of Steering Wheel................................................................. 2.4.4-1
Removal and Installation of Paddle Shift ..................................................................... 2.4.4-2
Common Fault of Steering Wheel and Paddle Shift ...................................................... 2.4.4-2
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2.4.1-1 Steering System Overview 2.4.1-1
generates power assist through the power

steering system of reducing mechanism, so
2.4.1 Steering System Overview
as to reduce the turning force of steering
wheel.
Specification The turning of steering wheel is transmitted
to the steering gear through steering column.
General Specification The steering gear transforms such turning
into rectilinear motion through its internal
Specification gear and rack.
Minimum 10.5m
turning
Fastener Torque
diameter
Electric power Rated current: 45A; working Name N.m Thread
steering voltage: 12V(DC) Specification
Fixing nut of steering 33±4 M12-1.25
wheel
Number of 2.74 turns Fixing nut of upper 24±3 M8-1.25
steering wheel steering shaft
turns Fixing bolt of lower
28±2 M8-1.25
steering axle
Instructions and Operation Mounting bolt of 100±5 M12-1.25
steering gear
Toe-in adjusting nut 45±5 M12-1.25
System Overview
Mounting nut of tie rod 45±5 M12-1.25
Electric power steering gear is a new and knuckle
generation of vehicle power steering system The rectilinear motion is transmitted to
with mechanical-electrical integration. It wheel knuckle through steering tie rod and
consists of controller assembly, torque tie rod external joint, so as to realize wheel
sensor, motor sensor, mechanical steering steering.
column, lower steering shaft, etc. The
steering of this model is electric power type,
which is called EPS for short. The system is
a power assist steering system, which
enables easy turning at low speed and stable
turning at high speed. In case of EPS failure,
the steering wheel still has steering function
with a greater steering force.
Note: in order to ensure the service life
of EPS motor, do not hold the steering
wheel at the extreme position for over 10s,
otherwise it may cause overheat or even
damage of motor. Overheat will result in
power reduction and heavy steering.
Operating Principle
When turning the steering wheel, EPS will
calculate to determine the power force and
direction of motor based on the turning
direction and speed. Then the motor
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System Schematic Diagram and Hexagon flange

4 09159-08005 bearing surface 4
Component Details toothed nut
Steering gear
5 3404100-AM01 1
assembly
Hexagon flange bolt
6 09103-12010 2
(reduced shank)
Slotted hexagon
7 09159-12007 2
flange nut
8 Q5003220 Cotter 2
Note: before removing steering gear,

steering column assembly, and steering
wheel (or any one of the three), the power of
complete vehicle shall be cut off.

Investigate and verify the problem reported
by the customer.
Visually inspect apparent damage as shown
in the following table: Visual Inspection List
-Tire pressure Control harness
-Wheel and tire Motor
S/N Part No. Name Qty. If the cause of problem is obvious, the
problem shall be solved before the next step
operation.
Hexagon flange If the cause of problem is not obvious, find
1 09159-12005 bearing surface 1 it out based on the fault description table.
toothed nut
3402110-AM02/A Steering wheel body

2 1 Table for Common Fault
M03/AM04/AM05 assembly
Description of Steering System
Steering column
3 3404000-AM01 1
assembly
Vehicle speed signal loss or interference Check the vehicle speed signal.
Engine speed signal loss or interference Check the engine signal.
Poor power contact Check power and harness

Hard or easy steering
Suspension ball joint seizure Perform suspension ball joint
assembly test.
Steering mechanism damage Replace the steering mechanism.
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Steering column damage Replace the column assembly.
Insensitive steering Tie rod ball damage Replace the tie rod as necessary.
Front suspension axle bushing damage Check or replace.
Steering mechanism boot damage Check the assembly and replace it

as necessary.
Looseness of fixing bolt of steering mechanism Check and replace new fixing
bolt as necessary.
Looseness of fixing bolt of steering column Check and replace new fixing
bolt as necessary.
Looseness of fixing bolt that connecting steering Check and replace fixing bolt as
column and steering mechanism pinion necessary.
Excessive clearance of steering mechanism Replace the steering gear

assembly.
Looseness of lock bolt of universal joint Check bolt torque and retighten
it.
Excessive steering Looseness of steering gear bolt Retighten it.
clearance
Wear or looseness of ball bolt on steering tie rod Retighten the bolt and replace it
end assembly as necessary.
EPS without power assist Troubleshoot by taking fault
diagnosis mode as reference.
Abnormal ABS vehicle speed signal Troubleshoot by taking fault
diagnosis mode as reference.
Excessive friction in tie rod ball joint Replace it.
Large shaking moment of swing arm ball Replace it.

Heavy or hard steering
Defective internal tie rod or ball joint Replace it.
Four-wheel alignment parameter out-of-tolerance Test and adjust four-wheel

alignment parameter.
Low tire pressure Inflate
Bent rack Replace the steering gear

assembly.
Looseness of mounting bolt of steering gear Tighten the mounting bolts.
Abnormal sound of Looseness of tie rod ball joint Replace it.

steering gear
Excessive gear rack clearance Replace it.
Abnormal sound of Motor fault Replace the steering column

motor assembly.
Eccentric wear of tire Check four-wheel alignment
Steering wheel parameter.
vibration and braking Abnormal tire pressure Check tire pressure.
deviation during
braking Incorrect dynamic balance of tire Check dynamic balance of tire.
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Brake disc runout out-of-tolerance Check the runout of brake disc.
Steering wheel Abnormal electronic injection data Check electronic injection data.
vibration during
engine idling Looseness of mounting bolt of steering column Check and tighten the mounting
bolt.
there will be some working noise, which
Steering System Function will not affect the driving safety or the
Inspection steering performance.
Park the vehicle on dry and smooth road, Steering Column Regular Handle
pull up the hand brake, and turn the steering
wheel to central position. Adjustable steering column is provided for
Check the steering wheel button and horn to this vehicle for the convenience of driving
make sure that they function properly. and to improve the comfort during driving:
Turn off the engine, hold the steering wheel 1. Pull the regulator handle of steering
with two hands and shake it up, down, left column downwards gently.
and right (do not rotate it), so as to check if 2. It is possible to adjust the steering
the steering wheel or steering column is wheel after releasing the regulator handle.
loose. If so, check the torque of fixing bolt When the steering wheel is adjusted to a
of steering wheel, mounting point and proper height, press the regular handle in to
central spindle of steering column. Do not lock the steering wheel at the position.
repair the steering column assembly, and 3. Before driving, please check the position
replace it as necessary. of regulator handle. The vehicle is allowed
Do not repair the steering gear assembly, to move only when the handle is fully
and replace it as necessary. pressed in.
Check the steering tie rod boot for damage,
corrosion or warp to make sure that dust
prevention of boot is reliable.
Returnability Inspection
Start the vehicle and accelerate in a straight
line to 35km/h.
Turn the steering wheel 90° to the left or
right, hold it for 1-2 seconds and then
release.
If the return angle of steering wheel is more
than 60°, it suggests that returnability is
normal.
Note: the steering wheel returnability
inspection shall be conducted on a smooth
road with wide vision, so as to ensure
inspection safety.
Note: When the electric power Warning: when the vehicle is running,
steering system (EPS) is working, the power it is absolutely prohibited to adjust steering
assist for rotating the steering wheel is wheel angle by operating the steering
derived from the EPS motor. During column regular handle.
operation of such motor or mechanical drive,
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2.4.2-1 Steering Column Assembly 2.4.2-1
2.4.2 Steering Column Assembly
Steering Column Assembly Diagram

The steering column assembly of this vehicle model adopts electric power steering (called
EPS for short), which mainly consists of upper and lower shaft of steering column, motor
assembly, controller assembly, etc.
Notes for Steering Column Assembly Maintenance

Before maintenance: the connector between steering column assembly control unit and
complete vehicle harness shall be removed for disconnection only when the engine and EPS
system power is off.
Removal and installation of steering column assembly:
1) Disconnect the negative cable of storage battery;
2) Remove the connector plug of harness;
3) Loosen the mounting bolt of steering column assembly;
4) Remove the steering column assembly;
Installation: install in the reverse sequence of removal.
Note: the components of steering column assembly (like sensor) shall not be removed,
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installed, replaced or maintained. If steering column assembly fault is confirmed, it shall be

replaced as an assembly. Replacing of steering column assembly components (like sensor)
may cause unpredictable system match compatibility problem, which may result in serious
system failure. After replacing the steering column assembly, use diagnostic instrument to
inspect and confirm the steering system fault and clean up the historical fault.
Removal and Installation of Controller Assembly
2) Remove the plug;
3) Loosen the screw of EPS controller;
4) Remove the EPS controller;
Removal and Installation of Motor Assembly
2) Remove the plug;
3) Loosen the connecting screw between motor and shell to remove the motor.
Installation:
1) Check the motor and quincunx bush of worm shell to ensure that it is assembled together
with worm clamping jaw;
2) Make sure that the motor shaft and worm are coaxial. Before tightening the motor screw,
first screw it manually;
3) Turn the steering wheel with right hand and hold the motor with left hand to feel whether
the motor swings;
4) If it does not swing, tighten the screw; if it swings, adjust the motor position manually until
it stops swinging, and tighten the screw; the torque for tightening motor screw is 24±3N.m.
Removal and Installation of Lower Steering shaft:
2) Remove the connector plug of harness;
3) Loosen the mounting bolt of lower steering shaft;
4) Remove the lower steering shaft;
Notes:
If lower steering shaft fault is confirmed, it can be replaced separately.
Tightening sequence of steering column mounting bolts
1) Fix the bolts in the sequence of ①, ③, ②, ④;
2) Fix the bolts in the sequence of ⑤, ⑥;
3) Tighten the bolts in the sequence of ①, ③, ②, ④;
4) Tighten the bolts in the sequence of ⑤, ⑥. The ⑥ bolt shall be tightened at last after the
wheels are completely laid on the ground, so as to relieve assembly stress.
Notes:
1) The ⑦ bolt is above ⑥ bolt, do not remove the wrong one. The ⑥ bolt can release
assembly stress. Incorrect assembly sequence or removal will cause big driving torque
variation, abnormal sound of steering, etc.
2) When maintaining, removing and installing, pay attention to insert the bolt of lower
steering shaft into the unthreaded hole of joint yoke and then tighten it.
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Schematic Diagram of Controller Assembly Harness Interface
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Terminal Definition Table

Terminal Connecting Signal Signal Status
No. Component Input/Output
A1 Power + Input Positive pole of continuous power supply (battery) with
voltage of 12VDC
A2 Power - Input Negative pole of continuous power supply (battery) with
voltage of 12VDC
B1 Motor power + Input EPS motor power +
B2 Motor power - Input EPS motor power -
C2 Sensor auxiliary Input Sensor auxiliary circuit signal

circuit T2
C5 Sensor main circuit Input Sensor main circuit signal
T1
C6 Sensor grounding Input /
C7 NULL Input Reserved pin
C8 Sensor power Input Sensor power
D5 CANH Input/output To CAN (high) of complete vehicle
D6 CANL Input/output To CAN (low) of complete vehicle
D8 Ignition (IG) Input To ignition signal of complete vehicle
Remarks: A1, A2, D5, D6, D8 are the signals of complete vehicle power and harness, and the rest are
signals of EPS system.
EPS Fault Diagnosis and Fault Code List
EPS Fault Diagnosis

EPS fault indicator lamp: turn the ignition switch from “OFF” to “ON” position, and conduct
self-inspection for 3s. If fault is detected, EPS will send fault information signal 1 to the bus,
instrument will receive the fault information and light the fault indicator lamp; if no fault is
detected, EPS will send fault information signal 0, and the fault indicator lamp will go out. If
the condition is not in conformity with the above, it suggests that the system has detected fault.
Inspect the fault by using Changan Automobile diagnostic instrument.
Display and Cleanup of Diagnostic Trouble Code (DTC):
1) With the power off, connect the fault diagnostic instrument to diagnostic interface, and
then turn on the ignition switch to start the engine.
2) Select the corresponding EPS diagnostic function of Changan Automobile vehicle model
for the diagnostic instrument.
3) Start the fault code reading service of diagnosis to read the fault code.
4) Start the fault code cleanup service of diagnosis as required, and remove the fault.
Fault diagnosis process of EPS system:
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Fault Code Table

Possible Fault Causes and Removing
S/N DTC DTC Meaning Fault Type
Measures
Main circuit is short to ground wire,
Circuit voltage out of and main circuit is short to 5V power.
1 C1611
Voltage fault of torque range Measure: replace the upper shaft of
sensor main circuit steering column.
Main circuit and short circuit are
Voltage difference between short to ground or open. Measure:
2 C1613 High circuit voltage
main circuit and auxiliary replace the upper shaft of steering
circuit of torque sensor column.
5V sensor is short to ground.
Circuit voltage out of
3 C1614 Torque sensor power fault Measure: replace the upper shaft of
range
steering column.
Auxiliary circuit is short to ground
Circuit voltage out of wire, and auxiliary circuit is short to
4 C1615
Voltage fault of torque range 5V power. Measure: replace the
sensor auxiliary circuit upper shaft of steering column.
12V sensor is short to ground.
Circuit voltage out of
5 C1616 Power fault of non-contact Measure: replace the upper shaft of
range
torque sensor steering column.
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Vehicle speed sensor fault or poor

Loss of vehicle speed harness connection
6 C1621 Signal loss
signal Measure: check the signal harness of
complete vehicle.
harness connection
7 C1622 Loss of engine speed signal Signal loss
Measure: check the signal harness of
complete vehicle.
Mismatch between vehicle Signal comparison harness connection
8 C1623
speed signal and engine fault Measure: check the signal harness of
speed signal complete vehicle.
Sudden change of vehicle Signal comparison harness connection
9 C1624
speed signal fault Measure: check the signal harness of
complete vehicle.
Open circuit or motor fault
10 C1641 Excessively high or low Open circuit Measure: replace the motor assembly
motor voltage or controller.
Actual current of motor is Short circuit or motor fault
General electric
11 C1642 far more than the calculated Measure: replace the motor assembly
appliance fault
target current or controller.
Short circuit or motor fault
Excessively high motor General electric
12 C1643 Measure: replace the motor assembly
current appliance fault
or controller.
Open circuit or motor fault
General electric
13 C1644 Motor self-inspection fault Measure: replace the motor assembly
appliance fault
or controller.
Actual current of motor is Motor load is too small.
General electric
14 C1645 far less than the calculated Measure: replace the motor assembly
appliance fault
target current or controller.
ECU relay module fault
15 C1652 EPS controller relay fault Relay burn-out Measure: replace the upper shaft of
steering column.
Power input fault or power circuit
General electric fault
16 C1653 Low voltage power
appliance fault Measure: check the power supply of
complete vehicle.
Power input fault or power circuit
General electric fault
17 C1654 Low voltage power
appliance fault Measure: check the power supply of
complete vehicle.
Controller internal inspection fault
General electric
18 C1655 Controller internal fault Measure: replace the steering column
appliance fault
controller assembly.
CAN module fault and bus fault
19 U2273 EPS communication off Network fault Measures: check the signal harness of
complete vehicle.
Communication with EMS fails.
Loss of communication
20 U2215 Network fault Measures: check the signal harness of
with EMS
complete vehicle.
Communication with ESP fails.
Loss of communication
21 U2255 Network fault Measures: check the signal harness of
with ESP
complete vehicle.
After the above troubleshooting and repair have been finished, clean up the historical fault
code by using fault diagnostic instrument. Restart test run and read whether there is fault code.
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2.4.3-1 Steering Gear Assembly 2.4.3-1
2.4.3 Steering Gear Assembly
Description Nm
Toe-in adjusting nut 45±5
Mounting nut of tie rod 45±5
Mounting bolt of steering gear 100±5
Mounting bolt between steering gear 28±2

and steering column
Wheel nut 85±10
Diagram of Steering Gear Assembly Component
The steering gear pinion shaft is connected

Steering Gear Component List to the lower shaft of steering column by
inserting the bolt through the front wall hole
No. Name of complete vehicle. The steering gear is
1 Steering gear assembly installed on the engine bracket with bolt.
The steering tie rod and knuckle are fixed
2 Steel clamp of tie rod dust boot with mounting nut and cotter is used on
3 Tie rod dust boot them for anti-loose. Threaded connection
4 Tie rod dust boot clamp between internal and external ball of tie rod
is locked with toe-in adjusting nut.
5 Internal ball assembly of tie rod The joint between steering tie rod and
6 Toe-in adjusting nut steering mechanism is protected with rubber
7 External ball assembly of tie rod
dust cover to prevent dust from entering the
internal ball of tie rod.
8 Cotter The external ball assembly of tie rod is
9 Mounting nut of tie rod protected with rubber cover for dust
protection and to prevent leak of ball joint
10 Mounting bolt of steering gear
grease.
Toe-in adjustment:
Unscrew the adjusting nut;
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With the external ball stayed fixed, rotate

the internal ball joint assembly until toe-in is
in the design range; tighten the toe-in
adjusting nut and apply torque as per
requirement.
Installation and Maintenance of Installation:

Steering Gear Install in the reverse sequence of removal.
Removal: Removal and Maintenance of Tie

Set right the wheel. Rod Ball
Remove the connecting bolt between
steering gear and lower shaft of steering Special Tools
column.
Ball joint separator
Removal
1) Loosen the front wheel nut.
2) Lift and support the vehicle.
3) Remove the front wheel
4) Loosen the tie rod ball nut.
a. Loosen the toe-in adjusting nut.
b. Remove the cotter.
Note: when removing the connecting c. Unscrew the tire rod mounting nut.
bolt between lower steering shaft and power
steering gear, fix the steering wheel with
rope/belt to prevent it from rotating.
Lift the vehicle and support it.
Remove the wheel.
Remove the cotter and lock nuts of ball pin
(at both sides).
5) Warning: when separating the tie

rod external ball from knuckle, pay attention
to protect the ball joint protective cover.
Separate the tie rod ball from knuckle by
using ball joint separator. Pay attention to
protect ball protective cover during the
operation process.
Note: do not damage the ball pin dust
boot of tie rod external ball. If so, please
replace the tie rod end connector.
Remove the engine bracket assembly.
Remove the connecting bolt between
steering gear and engine bracket assembly,
and remove the steering gear assembly.
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6) Remove the tie rod ball and lock nut.

Removal and Maintenance of Tie
Rod Dust Cover
1) Remove the tie rod ball. Refer to the
relevant removal sequence in this chapter.
2) Remove the fixing clamp of steering
mechanism protective cover.
Note: confirm that the thread turns for

tightening the tie rod ball shall be the same
as that recorded when unscrewing for
removal. If the number of turns is unknown,
the visible thread lengths of both sides shall
be the same when installing the tie rod.
3) Warning: before removing the

steering mechanism dust cover, make sure
that the tie rod is clean.
Removal of Steering Mechanism Dust
Cover
Take down the dust cover of tie rod.

Pay attention to the nut torque during
assembly.
Installation
Common Fault of Steering Gear Steering System for details.
See the Table for Fault Description of
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2.4.4-1 Steering Wheel Body Assembly 2.4.4-1
2.4.4 Steering Wheel Body

Assembly
Description Nm
Lock nut of steering 33±4Nm

wheel
Steering Wheel Diagram and

Function 2) Remove the horn harness connector
connected with air bag, entertainment
button connector connected with rotary
connector, and paddle harness connector
(entertainment button connector is plugged
in the rotary connector hole in the 12
o’clock direction, and steering wheel
paddle connector is plugged in the rotary
connector hole in the 6 o’clock direction).
The steering wheel is connected with the

steering column, and torque is transmitted
through spline; install and fix the driver air
bag with the steering wheel as support,
which can absorb shock in a vehicle
collision to mitigate the injury on driver;
the steering wheel is connected with
complete vehicle harness and it controls
the horn and entertainment function. 3) Loosen the mounting nut of steering
The paddle shift on steering wheel is used wheel (do not completely remove it
for shifting up and down the manual temporarily). Hold the 3 o’clock and 9
transmission. o’clock places of steering wheel with two
hands. Loosen the steering wheel along the
axial direction of steering column (with the
Removal and Installation of left foot stepped on foot rest). Remove the
Steering Wheel nut and then remove the steering wheel.
1) Remove the module of driver’s air bag.

See Air Bag System.
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2.4.4-2 Steering Wheel Body Assembly 2.4.4-2
Installation of Paddle Shift

Installation of Steering Wheel Install in the reverse sequence of removal.
Common Fault of Steering Wheel
Removal and Installation of and Paddle Shift
Paddle Shift
1) Looseness of paddle
a. Check whether the fixing bolt of paddle
is tightened;
b. Check whether paddle shift limiting
angle breaks. If so, replace the paddle
assembly.
2) Paddle function failure
a. Check whether the signal of electronic
shifter is normal.
b. Check whether the signal of rotary
connector is normal.
The paddle shift is connected to the c. If the above signals are normal, replace
steering wheel with four bolts. the paddle assembly.
1) Remove the two bolts which connect the
left and right paddle shifts to steering
wheel separately.
2) Remove the connector between the left
and right paddle shifts and harness.
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Part 4
Electrical
Section Title Page
4.1 Air Conditioning Control System
4.1.1 Air Conditioning System Principles 4.1.1-1
4.1.2 Air Conditioning System Composition 4.1.2-1
4.1.3 Diagnosis and Maintenance 4.1.3-1
4.3 Vehicle Body Electrical Appliances
4.3.1 Combination Instrument 4.3.1-1
4.3.2 Horn 4.3.2-1
4.3.3 Power Socket and Cigarette Lighter 4.3.3-1
4.3.4 Information and Entertainment System 4.3.4-1
4.3.5 Lighting System 4.3.5-1
4.3.6 Wiper and Washer 4.3.6-1
4.3.7 Complete Vehicle Lock Assembly 4.3.7-1
4.3.8 Complete Vehicle Electric Switch 4.3.8-1
4.3.9 Reversing Radar System 4.3.9-1
4.3.10 Vehicle Body Control System 4.3.10-1
4.3.11 DLC 4.3.11-1
4.3.12 Power System 4.3.12-1
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Contents Page
4.1.1 Air Conditioning System Principles
Operating Principle of Ventilation System 4.1.1-1
Operating Principle of Refrigeration System 4.1.1-1
Electric Schematic Diagram of Manual Air Conditioning System 4.1.1-2
4.1.2 Air Conditioning System Composition
Add and Recycle of Refrigerant for A/C System 4.1.2-1
Compressor and Clutch of Air Conditioner 4.1.2-2
HVAC Assembly 4.1.2-3
Structural Composition 4.1.2-3
Installation Method 4.1.2-3
Operating Principle 4.1.2-3
Condenser and Drier Receiver Assembly 4.1.2-3
Basic Performance and Test Condition 4.1.2-4
Manual A/C Controller Assembly 4.1.2-4
Appearance and Installation 4.1.2-4
General Performance Parameters 4.1.2-4
Function Description 4.1.2-4
System Electric Wiring Diagram 4.1.2-5
Terminal Definition 4.1.2-6
Structural Composition 4.1.2-8
Installation Requirement 4.1.2-8
4.1.3 Diagnosis and Maintenance
Maintenance Tool 4.1.3-1
Visual Inspection List 4.1.3-1
Fault Description 4.1.3-1
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4.1.1-1 Air Conditioning System Principles 4.1.1-1
4.1.1 Air Conditioning System High pressure, liquid state

A and high temperature
Principles condition
Operating Principle of Ventilation Low pressure, liquid state
B and low temperature
System condition
Starting from suction canal of air Low pressure, gaseous state
C and low temperature
conditioner, fresh air goes through screen
condition
filter, HVAC system assembly and air duct, High pressure, gaseous state
and then enters the vehicle by air outlets. D and high temperature
condition
Operating Principle of
Refrigeration System Compressor sucks up and compresses
the gaseous refrigerant through the
compressor inlet. The refrigerant is heated to
70°C ~ 110°C thereby.
Then, the compressed air is pumped
into the condenser which consists of cooling
fins. The air flows through the cooling fins
so that the compressed air can be
sufficiently cooled by external wind and
indrawn air of condenser fan.
The cooled refrigerant is stored in
drying bottle.
Then, pressure and temperature drop
S/N Name rapidly after concentrated liquid refrigerant
1 Condenser goes through expansion valve and part of
2 Compressor refrigerant evaporates at the same time.
3 Drying bottle
Heater – Hot air/Air Expansion valve is just at the front
4
conditioner portion of evaporator in refrigeration
5 Evaporator pipeline. Refrigerant totally evaporates in
6 Expansion valve the evaporator. As the evaporator is cold, the
7 Cooling fan air passes through will be cooled down too.
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4.1.1-2 Air Conditioning System Principles 4.1.1-2
Electric Schematic Diagram of Manual Air Conditioning System
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4.1.2-1 Air Conditioning System Composition 4.1.2-1
4.1.2 Air Conditioning System filling machine.

Composition C. Start the machine to
carry out filling (if there is no
leakage, the evacuation and filling
shall be done in one time).
• Filling during after-sale
service
A. Remove filler cap of air
conditioner and install air
conditioner pressure gauge.
B. Push the lock sleeve of
quick coupler backwards. The one
of larger pipe diameter shall be
connected to high pressure end
S/N Name
and the one with smaller pipe
1 HVAC assembly
Manual A/C controller diameter shall be connected to
2 lower pressure end.
assembly
3 Compressor assembly • Fill the air conditioning
4 No.1 drain pipe assembly system with refrigerant
Condenser assembly with
5
accessories
(liquid refrigerant) through
No. 1 suction hose high pressure end.
6
assembly A. Open the high pressure valve
Evaporator connecting of pressure gauge.
7
pipe assembly
B. Switch the air
Add and Recycle of Refrigerant for conditioner maintenance
A/C System equipment to "FILL" mode and fill
1. Designation of refrigerant for A/C the air conditioning system with a
system: R134a certain volume of refrigerant (R-
134).
Note: It is strictly forbidden to add
other refrigerant than R134a, which Warning: It is forbidden to exhaust
may damage the air conditioning refrigerant to open air. The air
system!!! conditioning system shall be evacuated
through low pressure end.
2. Vacuum requirement for
refrigerant filling: the pressure Note: The evacuation shall last for
inside the system shall not be about 30 minutes to ensure the normal
more than 1kPa. operation of air conditioning system.
3. Refrigerant filling: 400g ± 10g.
Note: If there is water in the air
4. Filling method of air conditioning conditioning system, replace the drying
system refrigerant. bottle and keep evacuating for 2 to 3
• Filling on production line hours.
A. Connect the filler on Note: Evacuation of air conditioning is
filling machine to the filler of air required before filling the system with
conditioner. refrigerant.
B. Set the filling volume as
per operation requirement of Note: It is possible to fill the air
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conditioning system through the high
pressure end with liquid refrigerant or
through the low pressure end with
gaseous refrigerant based on different
types of maintenance tool and
equipment (with heatable filling
cylinder or not).
• Filling volume determination
A. Determine the volume
according to reading on filling
gauge. It shall be 100g ± 10g.
B. Determine the volume 1. Compressor model and
based on quantity of each package manufacturer
(if it is 100g per package, it Vehicle Model A301
requires four packages). Model 066
C. If there is no proper tool Manufacturer Nanjing AoteCar
for quantification, determine the 2. Compressor type and
filling volume by the simple displacement
method described below.
Vehicle Model A301
It is proper to fill the system with Type Vortex type
refrigerant until the pressure in air Displacement 66ml/r
conditioning system pipeline is 3. Basic parameters of clutch
about 0.7MPa in room
temperature. Vehicle Model A301
Type 4-slot multi-sprag type
5. Refrigerant Recycling Power consumption <48W (20℃)
• Maintenance personnel must Belt type 6PK
use special equipment to 4. Installation of compressor
collect the air conditioning (referring to the installation during
refrigerant for recycling maintenance).
during removal of air
conditioning pipeline. • The compressor is fixed on the
bracket on the engine by 3 bolts;
• If there is no special
recycling equipment, • Ensure the end face of belt pulley
maintenance personnel must parallel to the end faces of the
drain the refrigerant through crankshaft pulley and power
the low pressure test port generator pulley;
before removing the pipeline. • Tightening torque requirement of
compressor retaining bolt: 25Nm.
Note: It is strictly forbidden to point the
drain port at human's eyes when 5. Installation of compressor pulley
evacuating the refrigerant, otherwise • Choose proper belt based on slot
the eyes may be hurt!!! type and length of belt pulley;
Compressor and Clutch of Air • Ensure the belt end face is in one
Conditioner plane after belt is installed.
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HVAC Assembly • Check condensate water of air

conditioner.
Structural Composition
5. Left temperature door actuator
• Adjust outlet air temperature of air
conditioning system.
6. Evaporator core
• Evaporator absorbs great amount
of heat in the air to lower the air temperature.
7. Mode damper mechanism
• Adjust blowing mode of air
conditioning system.
• All dampers are driven by relevant
servo motors which are in the
charge of air conditioner controller.
• The air volume proportional
relation of air outlet and the mode
S/N Name damper cam mechanism are
1 Mode damper mechanism demarcated and checked in strict
Cold/hot damper
2 manner. Maintenance personnel
mechanism
3 Heater core mustn't adjust them at will during
4 Drain tube maintenance.
5 Evaporator core
Condenser and Drier Receiver
6 Blower
Inner/outer circulation Assembly
7
damper actuator 1. Condenser core
Installation Method • Overall dimension: 531mm ×
1. Secure the HVAC on welded stud of 389mm
dash panel with nut. • Flat tube specification: 2mm ×
2. Install HVAC on dash panel and insert 16mm, internally finned flat tube
the drain tube connector in the round • Flat tube type: super-cooled
hole of dash panel, with the tube multiple parallel flow
vertically downward.
• Molding process: overall brazing
Operating Principle
• Flow path of condensation section:
1. Choose air inlet mode
• Inner circulation
• Outer circulation
2. Blower motor
• Provide the air conditioning
system with power for air
circulation.
3. Temperature damper mechanism 2. Drier receiver
• Adjust temperature of air outlet. • Type: super-cooled type
4. Drain tube • Desiccant: XH-9 molecular sieve;
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desiccant filling quality: 35g, pre- system. Rotate the knob counterclockwise to
water-absorption capacity 1g; water widen the cold air passage and clockwise to
absorption capacity of desiccant is widen the hot air passage.
5g when the temperature is 60°C 2. A/C button
and the humidity is 90%.
Press the button to send air conditioner
Basic Performance and Test Condition start signal to EMS (i.e. engine management
Ambient temperature 35°C system, also known as electric injection
Pressure of condenser ECU). Then the A/C compressor will start
1.5MPa
intake (gauge pressure) and A/C indicator lamp will be on.
Degree of superheating 25°C
Degree of supercooling 5°C Note: The precondition is that the air
Wind velocity at windward
4.5 volume switch is already turned on.
side of condenser (m/s)
Air resistance of condenser
<140 3. Inner/outer circulation button
(Pa)
Heat dissipating capacity of Press the button to start inner
>15 circulation and corresponding indicator lamp
condenser (kW)
will be on. Press it again and air
Manual A/C Controller Assembly conditioning system will switch to outer
Appearance and Installation circulation mode. The indicator lamp will be
off.
A/C controller is firmly secured to
instrument panel by two self-tapping screws 4. Air volume regulation knob
at upside and two V-type clips and single- There are four gears of air volume knob.
side buckle at downside. The four gears are Gear 1 to Gear 4 along
the clockwise direction, in sequence of
which the air volume goes up gradually. It
meets the requirement of normal operation
of air conditioning system.
5. Mode changeover button
Press changeover button of various
modes to adjust the mode damper and
further to switch over among face mode,
foot mode, face and foot mode, foot and
defrosting mode and defrosting mode. The
indicator lamp of corresponding mode lights
up at the same time of switchover.
General Performance Parameters 4. Rear defrosting and rear-view
mirror heating switch
1. Working temperature: -40 ~ 85°C
Send the request of rear defrosting and
2. Working voltage: DC9V ~ 16V
rear-view mirror heating to BCM. The rear
Function Description defrosting and rear-view mirror heating
1. Temperature regulation knob function will be turned on after BCM
receives the signal. It also feedback effective
Rotate cold/hot air knob to control the signal to A/C controller at the same time and
positive and negative opening degree of corresponding indicator lamp will be on.
cold/hot damper and to satisfy the normal
operation requirement of air conditioning
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System Electric Wiring Diagram
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Terminal Definition feedback
signal
1. Definition of A/C controller A14 Reserve
terminal A15 Reserve
A16 Reserve
B1 Reserve
B2 Reserve
Rear
B3 defrosting Output 12/0
request signal
Background
B4 lamp power 800mA 12/0
supply ILL +
B5 Reserve
B6 IGN+ 12V
A/C request
B7 Output 12/0
signal
Blower
Terminal B8 starting signal Input
Voltage B9 Rear Input 12/0
Function Direction
Range
Pin Definition Lmax (A) defrosting
A1 Reserve feedback
A2 Reserve signal
A3 Reserve Background
A4 Reserve B10 lamp power 800mA 12/0
A5 Circulation 800mA Output 12/0 supply ILL -
damper B11 BAT + (spare) 800mA
driving signal B12 Ground 800mA
("+" indicates C1 Power ground
outer Air volume
C2 Output 12/0
circulation) load signal
A6 Circulation 800mA Output 12/0 C3 Gear 3 air 25A
damper volume
driving signal C4 Gear 4 air 25A
("+" indicates volume
inner C5 Gear 2 air 25A
circulation) volume
A7 Mode damper 800mA Output 12/0 C6 Gear 1 air 25A
driving signal volume
("+" indicates
face mode 2. Definition of HVAC (air
direction) conditioning cabinet ) connector terminal
A8 Mode damper 800mA Output 12/0
driving signal
("+" indicates
defrosting
mode
direction)
A9 5V power 5V
supply +
A10 5V power
supply -
A11 Evaporator Input 0.1~4.9V
temperature
signal
A12 Reserve
A13 Mode damper Input 0.1~4.9V
location
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Function of connector terminal Air Conditioner Pipeline Assembly
Pin S/N Pin Function Structural Composition
Mode damper location
○
4
feedback signal 1. No. 1 suction hose assembly
○
5 5V power supply + 2. No.1 drain pipe assembly
Circulation damper driving 3. Evaporator connecting pipe
○
6 signal ("+" indicates outer assembly
circulation)
Installation Requirement
○
7 Evaporator temperature signal
Mode damper driving signal 1. Fix the evaporator connecting pipe
○
10 ("+" indicates face mode to the HVAC assembly with cross recessed
direction) hexagon bolts (09128-06005) and tighten
Mode damper driving signal the bolts with torque of 10 ± 1Nm. The
○
11 ("+" indicates defrosting pressing plate of air conditioner pipeline
mode direction)
shall be parallel to the mounting surface of
○
13 5V power supply - expansion valve as much as possible during
Circulation damper driving connection;
○
14 signal ("+" indicates inner
circulation) Note: Check whether the two O-rings at
Speed regulation resistance
○
15
ground
the A/C connector are missing and
ensure the O-rings are not damaged.
○
16 Air volume position III Expansion valve shall contact to
○
17 mounting surface of HVAC assembly
Blower power supply +
and shall be applied with blue mark.
○
18 Air volume position I 2. Fix the evaporator connecting pipe
○
19 Air volume position II clip on vehicle body with one hexagon
flange nut (Q32006) and two cross recessed
3. HVAC (air conditioner cabinet) hexagon bolts (09128-06005). Locating rod
actuator wiring diagram of pipe clip shall be stuck at the limit hole of
HVAC has two servo motors (mode vehicle body. The pipe clip shall not suffer
motor and circulation motor), one blower from deformation or twisting.
and one speed regulation resistance. Wiring 3. Connect the No.1 suction hose
diagram and definition: assembly and No.1 drain pipe assembly to
the compressor with hexagon flange bolts
(Q1840625) and tighten the bolts with
torque of 10 ± 1Nm. Check whether there is
sealing ring at the connector of compressor
and the sealing ring shall be intact. Ensure
the axis direction of pipeline pressing plate
parallel to the mounting surface of
expansion valve as much as possible. End
face of pipeline pressing plate shall contact
with mounting surface of compressor after
connection. Tighten the fasteners and apply
blue mark.
4. Fix the evaporator connecting pipe
and No.1 drain pipe to the condenser
pressing plate with hexagon flange bolts
(Q1840625) and tighten the bolts with
torque of 10 ± 1Nm. The evaporator
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pressing plate shall be parallel to condenser
pressing plate as much as possible during
connection. Make sure the O-rings on air
conditioner pipeline are intact. End face of
pipeline pressing plate shall contact with
condenser pressing plate after connection.
Rubber hose of evaporator connecting pipe
assembly shall be free from noticeable
twisting. Apply blue mark after tightening.
5. Fix the No.1 suction hose
assembly to the evaporator connecting pipe
assembly with hexagon flange nut (Q32006).
Check the sealing rings for damage before
assembly and apply lubricant on the sealing
rings. Ensure the two connectors parallel to
each other and the central lines of the
connectors shall coincide with each other as No. Part
much as possible during assembly. The two Evaporator connecting pipe
pressing plates shall contact with each other. 1
assembly
The tightening torque shall be 9.5Nm ~ Cross recessed hexagon bolt
2
10.5Nm. 09128-06005
Cross recessed hexagon bolt
3
09128-06005
4 No. 1 suction hose assembly
5 Hexagon flange nut (Q32006)
6 Hexagon flange nut (Q32006)
7 Hexagon flange bolt Q1840625
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4.1.3-1 Diagnosis and Maintenance 4.1.3-1
4.1.3 Diagnosis and Maintenance

Maintenance Tool
1. Digital multimeter
2. Harness terminal probe (can make it by self)
1. Confirm the problem reported by the customer.
2. Visual inspect for noticeable mechanical fault or electric appliance failure.
Note: If the apparent cause of observed or raised problem has been found, it shall be
corrected before the next step. If the problem does not fade out, keep diagnosing based
on fault description diagnosis table.
Machinery Electrical
Refrigerant pipeline Insurance
Compressor Harness
Driving Belt Connector
Fault Description
Fuse, relay, circuit, blower, hot
Blower failure Location test A
air blower switch
Fuse, circuit, refrigeration
Air conditioner refrigeration pipeline, compressor temperature
system fault (hot air pressure switch, compressor Location test B
function operates right) relay, three-state pressure switch
and temperature sensor
Air conditioner drain pipe is not
connected to HVAC shell; air
Air conditioner water Check drain pipe and rubber gasket. If
conditioner drain pipe is badly
leakage at foot rest position there is damage, carry out maintenance.
connected to vehicle body; air
conditioner drain pipe is blocked.
Location Test A: Blower Failure
1. Confirm failure cause
A. Turn ignition switch to ON position;
B. Rotate the air volume switch from low speed
gear to the highest speed gear;
C. Check the air volume.
Does the blower fail to operate at the position?
→Yes
To 2
2. Check fuse SB6.
A. Turn ignition switch to OFF position;
B. Check fuse SB6.
→Yes
To 3
→No
Replace fuse SB6 (40A). Test and start the system to
check whether it operates right.
If the fuse breaks again, check and eliminate the short
circuit between circuit and ground point based on circuit
diagram.
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3. Check power supply on blower relay
A. Rotate the ignition switch to ON position;
B. Disconnect the relay to measure the voltage
of circuit pin HF04.
Whether the battery voltage is displayed?
→Yes
→To 4
→No
Test and start the system until it functions right.
4. Check ground condition on blower relay
B. Disconnect the relay to measure the voltage
to ground.
Does it indicate ground?
→Yes
→To 5
→No
5. Check the power supply of blower
B. Disconnect connector pin HF03 and G105
between blower and instrument;
C. Measure the voltage of instrument harness
pin HF03 connected to blower.
Whether the displayed voltage is batter voltage?
→Yes
→To 6
→No
6. Check the ground condition of blower
B. Disconnect connector pin A and C between
blower and instrument;
C. Measure the voltage to ground of instrument
harness pin C connected to blower.
Whether the voltage is displayed as ground?
→Yes
→Failure of blower. Replace the blower and carry out
new test.
→No
Location Test B: Air Conditioner Refrigeration System Fault
Detection Detailed step/result/test
1. Check fuse EF16
A. Turn ignition switch to OFF position;
B. Check fuse EF16
Whether the fuse is intact?
→Yes
To 2
→No
Replace fuse EF16. Start and test the system to
check whether it functions right; if the fuse breaks
again, please check and eliminate the short circuit
fault based on circuit diagram.
2. Check power supply of air conditioner panel
A. Rotate the ignition switch to ON
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position;
B. Disconnect the pin B6 and pin 12 of
instrument harness connector, which are
connected to air conditioner panel;
C. Measure whether the displayed voltage
on pin 6 of instrument harness connector, which is
connected to air conditioner panel, is the battery
voltage and whether the displayed voltages at pin
B6 and pin B12 are battery voltage?
→Yes
To 3
→No
3. Check starting end of three-pressure switch
A. Rotate ignition switch to ON position;
B. Disconnect the front compartment
harness connector connected to three-state
pressure switch;
C. Shortly connect the terminals of
harness 1 and 2 with lead and conduct ground
connection of lead.
Does the compressor operate?
→Yes
Check the pressure switch harness terminal 1 and
air conditioner panel compressor request signal
circuit based on circuit diagram. Test and start the
system until it functions right.
Pin Function
1 To AC request signal →No
To compressor thermal Check the pressure switch harness terminal 1,
2 protection 1 compressor terminal 1 and 2, and circuit between
3 Ground EOT based on circuit diagram. Test and start the
system to check whether it functions right.
4 Medium pressure signal (to A. Rotate ignition switch to ON position;
ECU)
Solenoid coil terminal

4. Check terminal end of three-pressure switch
position;
B. Press three-state pressure switch;
C. Disconnect the front compartment
harness connector connected to three-state
pressure switch;
D. Measure the voltage to ground of front
compartment harness connector AC17, which is
connected to three-state pressure switch.
Whether the displayed voltage is voltage to
ground?
→Yes
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To 5
→No
Replace three-pressure switch. Test and start the
system until it functions right.
5. Check the starting end of temperature pressure switch in compressor
position;
C. Disconnect the engine harness
connector connected with compressor;
D. Measure the voltage to ground of
engine harness connector AC17, which is
connected to compressor
ground?
→Yes
To 6
→No
Check circuit AC17 based on circuit diagram.
6. Check the terminal end of temperature pressure switch in compressor
position;
C. Disconnect the engine harness
connector connected with compressor;
D. Measure the voltage to ground of
engine harness connector EU10, which is
connected to compressor
ground?
→Yes
Fault of air conditioner components. Check the air
conditioner. Test again until it functions right.
→No
Replace temperature pressure switch in
compressor. Test and start the system until it
functions right.
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Vehicle Body Electrical Appliances
4.3 Vehicle Body Electrical Appliances

Applicable to A301
Contents Page
4.3.1 Combination Instrument
Internal Wiring Connection Diagram 4.3.1-1
Instrument Terminal Definition and Terminal View 4.3.1-1
Simple Maintenance 4.3.1-3
4.3.2 Horn
Installation and Removal 4.3.2-1
Basic Parameter of Electric Horn 4.3.2-1
Inspection and Maintenance 4.3.2-2
Common fault, cause and determination method of electric horn: 4.3.2-2
4.3.3 Power Socket and Cigarette Lighter
Circuit Schematic Diagram 4.3.3-1
System Inspection and Troubleshooting 4.3.3-1
4.3.4 Information and Entertainment System
DVD 4.3.4-1
Diagnosis and Maintenance 4.3.4-2
Radio 4.3.4-5
Antenna 4.3.4-9
Loudspeaker 4.3.4-10
4.3.5 Lighting System
Location of Lamps on Complete Vehicle 4.3.5-1
Installation of Lamps 4.3.5-1
Electrical Schematic Diagram 4.3.5-6
Fault Determination and Maintenance 4.3.5-6
Light Adjustment of Reciprocally Incorporated Headlamp 4.3.5-7
Preparation 4.3.5-7
Light Adjustment 4.3.5-7
4.3.6 Wiper and Washer
Installation of Front Wiper 4.3.6-1
Removal of Wiper 4.3.6-2
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Installation of Rear Wiper 4.3.6-2
Fault Determination and Maintenance of Front Wiper 4.3.6-3
Connector Definition and Basic Parameter 4.3.6-3
Fault Inspection and Confirmation 4.3.6-4
Wiper Fault Description 4.3.6-4
Diagnosis flow for the fault that wiper motor does not work 4.3.6-5
Diagnosis flow for the fault that wiper motor cannot reset 4.3.6-6
Diagnosis flow for the fault that the wiper is dirty and vibrating 4.3.6-6
Fault Determination and Maintenance of Rear Wiper 4.3.6-7
Connector Definition and Basic Parameter 4.3.6-7
Wiper Fault Description 4.3.6-7
Diagnosis flow for the fault that wiper motor fails to work 4.3.6-8
Diagnosis flow for the fault that wiper motor cannot reset 4.3.6-8
Diagnosis flow for the fault that the wiper is dirty and vibrating 4.3.6-8
4.3.7 Complete Vehicle Lock Assembly
Overview 4.3.7-1
Introductions and Operation of Steering Lock and Key 4.3.7-1
Circuit Schematic Diagram and Pin Definition 4.3.7-2
Inspection and Maintenance 4.3.7-2
4.3.8 Complete Vehicle Electric Switch
Power Window 4.3.8-1
System Inspection and Troubleshooting 4.3.8-5
Combination Switch 4.3.8-6
Pin Definition of Combination Switch Wiper Handle 4.3.8-10
Button Switch Box 4.3.8-10
4.3.9 Reversing Radar System
4.3.10 Vehicle Body Control System
Vehicle Body Controller 4.3.10-1
Function Instruction and Control System Composition 4.3.10-2
Connector Definition 4.3.10-6
Schematic Diagram of Peripheral Wiring 4.3.10-
12
4.3.11 DLC
Description of DLC 4.3.11-1
Description of CAN 4.3.11-1
Inspection for Completeness of CAN 4.3.11-1
4.3.12 Power System
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Wiring Diagram of Storage Battery 4.3.12-1
Inspection, Maintenance, Charging and Repair 4.3.12-3
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4.3.1-1 Combination Instrument 4.3.1-1
4.3.1 Combination Instrument

Appearance and Installation
Secure the combination instrument right ahead the driver on the instrument panel with two
screws.
Internal Wiring Connection Diagram

Circuit Schematic Diagram is seen below:
Instrument Terminal Definition and Terminal View

Connector model (electrical appliance end): 966658-1 (green);
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Harness end: cap: 1719057-1; bush: 1719059-1; terminal: 928999-1
View of connectors at the appliance end:
Definition of instrument connector interface:

Effective
S/N Interface Definition Signal Type Value Remarks
1 Storage battery supply Power supply
Ignition power supply
2 Power supply
KL15
Low
3 Low beam DI
effective
Instrument signal
4 ground Ground To vehicle body ground
5 Fuel sensor ground DO Resistance Fuel sensor can be regarded as a slide-
signal wire resistor. Connect both ends of this
resistor to the instrument on a complete
vehicle. It is required to carry out
internal grounding of the instrument.
Low
6 High beam DI
effective
High
7 Front fog lamp DI
effective
Resistance
8 Fuel signal AD
signal
9 NC
10 NC
Anti-theft indication Low
11 DI
(reserve) effective
Oil pressure warning Low
12 DI Lock switch
indication effective
Low
13 Low brake fluid level DI Lock switch
effective
14 NC
15 NC
Battery charging Low
16 DI
indication effective
17 NC
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High
18 Rear Fog Lamp DI Instrument of low configuration
effective
19 NC
Vehicle speed input Frequency
20 PWM Frequency range
(reserve) signal
Vehicle speed output Frequency
21 PWM Frequency range
(reserve) signal
22 CANH CAN
23 CANL CAN
Power supply of
24 Power supply
position lamp
Hand brake is not Low
25 released DI effective Lock switch
Low
26 TRIP reset button signal DI
effective
27 NC
28 NC
29 NC
High
30 Reversing Signal DI Lock type
effective
31 NC
32 NC
Remark: Controllers on upper CAN, which are related to the instrument are: EMS, TCU,
ABS, SRS, EPS, BCM and DVD.
Instrument Rear View
Maintenance Tool
1 Multimeter
2 Oscilloscope
3 Special tool for harness maintenance
4 Simple diagnostic apparatus
Simple Maintenance
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If there is noticeable damage of combination instrument, please replace the combination
instrument first.
Fault description:
Fault Description Measures
Dial lamp is not on when ignition switch is at ON
Location test A
position.
Turn on the position lamp when ignition switch is
at ON position, but the instrument back ground
Location test B
light, pointer backlight and LCD backlight do not
change.
The door open indicator lamp does not light up
when front left door is open (maintenance
measures are the same for other similar faults, for
example, corresponding indicator lamps fail to Location test C
light up when front right door, rear left door, rear
right door, trunk door or engine compartment
cover are open).
If oil pressure warning indicator lamp does not
light up when ignition switch is at ON position (in
normal condition, this lamp shall light up
immediately for 3 seconds and the go out); or the
indicator lamp functions right before starting the Location test D
engine and lights up after starting, please replace
the oil pressure warning switch or refer to
maintenance manual of oil pressure warning switch
for help.
If the charging indicator lamp does not light up
when ignition switch is at ON position; or the lamp
functions right before starting the engine and lights
Location test E
up after starting, please replace the power
generator or refer to maintenance manual of power
generator for help.
If the ABS signal indicator lamp does not light up
when ignition switch is at ON position (in normal
case, it will light up immediately for 3 seconds and
then go out); or ABS signal indicator lamp does
not go out when ignition switch is turned to ON
Location test F
position, please replace the ABS or refer to ABS
maintenance manual for help; if the indicator lamp
up after starting, please replace the ABS or refer to
ABS maintenance manual for help.
If the EBD indicator lamp does not light up when
ignition switch is at ON position (in normal case, it
will light up immediately for 3 seconds and then
go out); or EBD indicator lamp does not go out
when ignition switch is turned to ON position,
Location test G
please refer to maintenance manual of ABS system
and EBD system for help; if the indicator lamp
up after starting, please replace the ABS or refer to
maintenance manual of ABS system for help.
Brake fluid level warning indicator lamp does not
light up when ignition switch is at ON position (in
normal case, it will light up immediately for 3 Location test H
seconds and then go out); brake fluid level
indicator lamp does not go out when the ignition
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switch is turned to ON position.
Hand brake indictor lamp (it shares the same
warning lamp with low brake fluid level alarm)
Location test H
does not go out when ignition switch is turned to
ON position.
If the driver's safety belt indictor lamp does not
light up when ignition switch is at ON position; or
the indicator lamp does not go out after fastening
Location test I
the driver's safety belt, please replace the safety
belt switch or refer to safety belt maintenance
manual for help.
If the electric inject indicator lamp does not light
up when ignition switch is at ON position (in
normal case, it will light up immediately for 3
seconds and then go out); or the indicator lamp Location test J
up after starting, please refer to the maintenance
manual of engine and engine ECU for help.
If the SRS indicator lamp does not light up when
ignition switch is at ON position (in normal case, it
will light up immediately for 3 seconds and then
Location test K
go out); or the indicator lamp does not go out when
the ignition switch is turned to ON position, please
refer to SRS maintenance manual for help;
Abnormal indication of tachometer Location test L
Abnormal indication of speedometer Location test M
Abnormal indication of water-thermometer Location test N
Abnormal indication of fuel gauge Location test O
Left turn signal indicator lamp does not blink when
turn left (the maintenance measures are the same in
Location test P
case of similar fault of right turn signal indicator
lamp)
When the ignition switch is at ON position, the low
beam indicator lamp does not light up when the Location test Q
combination switch is turned to low beam gear
High beam indicator lamp does not light up when
combination switch light handle is turned to Location test R
overtaking light-shifting gear.
When ignition switch is at ON position, turn knob
switch of combination switch to low beam
position, and turn handle switch of combination Location test S
switch to high beam position, and the high beam
indicator lamp does not light up.
When ignition switch is at ON position, turn on the
lower bean lamp and rotate the combination switch
Location test T
to front fog lamp position, and the front fog lamp
indicator does not light up.
When ignition switch is at ON position, turn on the
low beam lamp and rear fog lamp switch, but the Location test U
rear fog lamp indicator does not light up.
When the ignition switch is at ON position and the
fuel gauge indicates Segment 1, the fuel warning Replace combination instrument
indicator lamp does not light up.
When the ignition switch is at ON position and the
water-thermometer indicates Segment 7 or above,
Replace combination instrument
the temperature warning indicator lamp does not
light up.
It is impossible to change over or reset the Replace combination instrument
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instrument by resetting bar.
Buzzer does not function right in specified power
Location test V
supply mode.
Position indication of LCD does not function right
Location test W
(only for vehicle with automatic transmission)
Location test A: Dial lamp is not on when ignition switch is at ON position.
1. Measure the voltage to ground at harness related to Pin 4 of combination instrument.
A. Remove combination instrument.
B. Measure the voltage to ground at harness
related to Pin 4 of combination instrument.
C. Whether it is grounded?
→Yes To Step 2
→No Check the harness and the connector.
2. Measure the voltage to ground at harness related to Pin 2 of instrument.
A. Turn the ignition switch to ON position.
B. Measure the voltage of harness end related to
Pin 2.
C. Is the measured voltage around 12V?
→Yes Check combination instrument
connector or replace combination instrument
→No Check the harness and the connecting
system.
Location test B: When ignition switch is at ON position, turn the combination switch to the
position lamp switch, and the dial lamp, pointer lamp and LCD backlight do not change.
C. Whether it is grounded?
→Yes To Step 2
→No Check the harness and the connector.
A. Turn the combination switch to position lamp
gear.
B. Is there position lamp signal?
→Yes Check the connecting harness between
instrument Pin 24 and the complete vehicle or
replace the combination instrument.
→No To Step 3
3. Check the position lamp.
Location test C: The door open indicator lamp does not light up when front left door is
open (maintenance measures are the same for other fault, for example, corresponding
indicator lamps fail to light up when front right door, rear left door, rear right door, front
compartment cover and trunk door are open).
B. Measure the voltage of harness end related to
Pin 1.
C. Is it equal to battery voltage?
→Yes To Step 2
→No Check the harness and connector from
battery positive harness to Pin 1 of combination
instrument.
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2. Read the CAN signal of the complete vehicle.
A. Read the CAN signal of the complete vehicle
with diagnostic apparatus.
B. Is there any signal of door open?
the instrument Pin 22 and Pin 23 and the complete
vehicle CAN or replace the combination instrument.
→No To Step 3
3. Check the network of complete vehicle and the vehicle body controller signal.
Replace vehicle body controller or refer to vehicle
body controller maintenance manual for help.
Location test D: If oil pressure warning indicator lamp does not light up when ignition
switch is at ON position; or the indicator lamp functions right before starting the engine and
lights up after starting, please replace the oil pressure warning switch or refer to maintenance
manual of oil pressure warning switch for help.
A. Turn the ignition switch to ON end.
→Yes To Step 2
→No Check the harness and connector
between the ignition switch Pin 6 and the
combination instrument Pin 2, or replace the ignition
switch.
2. Measure the voltage to ground at harness end related to instrument Pin 12 with multimeter.
A. Measure the voltage to ground at harness end
related to instrument Pin 12 with multimeter.
B. Whether it is grounded?
→Yes Replace combination instrument
→No To Step 3
3. Check the harness and connector between instrument Pin 12 and oil pressure warning switch.
A. Check the harness and connector between
instrument Pin 12 and oil pressure warning
switch.
B. Is it intact?
→Yes Replace oil pressure warning switch.
→No Replace the harness and connector
between instrument Pin 12 and oil pressure warning
switch.
Location test E: If the charging indicator lamp does not light up when ignition switch is at
ON position; or the lamp functions right before starting the engine and lights up after starting,
please replace the power generator or refer to maintenance manual of power generator for
help.
→Yes To Step 2
switch.
2. Measure the voltage to ground at harness end related to instrument Pin 16 with multimeter.
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related to instrument Pin 16 with multimeter.
→No To Step 3
3. Check the harness and connector between instrument Pin 16 and generator.
instrument Pin 16 and generator.
B. Is it intact?
→Yes Replace generator or refer to generator
maintenance manual for help.
between instrument Pin 16 and generator.
Location test F: if the ABS signal indicator lamp does not light up when ignition switch
is at ON position (in normal case, it will light up immediately for 3 seconds and then go out);
or the ABS signal indicator lamp does not go out several seconds later when ignition switch is
turned to ON position, please replace the ABS or refer to ABS maintenance manual for help;
if the indicator lamp functions right before starting the engine and lights up after starting,
please replace the ABS or refer to ABS maintenance manual for help.
→Yes To Step 2
switch.
B. Is there any ABS signal?
vehicle CAN network or replace the combination
instrument.
→No To Step 3
3. Check the network of complete vehicle and the ABS controller signal.
Replace ABS controller or refer to ABS maintenance
manual for help.
Location test G: if the EBD indicator lamp does not light up when ignition switch is at
ON position (in normal case, it will light up immediately for 3 seconds and then go out); or
the EBD indicator lamp does not go out when ignition switch is turned to ON position, please
refer to maintenance manual of ABS system and EBD system for help; if the indicator lamp
functions right before starting the engine and lights up after starting, please replace the ABS
or refer to maintenance manual of ABS system for help.
→Yes To Step 2
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switch.
B. Is there any ABS signal?
vehicle network or replace the combination
instrument.
→No To Step 3
Replace ABS controller or refer to ABS maintenance
manual for help.
Location test H: Brake fluid level warning indicator lamp does not go out when ignition
switch is at ON end.
1. Measure the harnesses related to instrument Pin 13 and Pin 25 with multimeter.
related to instrument Pin 13 and Pin 25 with
multimeter.
→No To Step 2 or Step 3.
2. Check the harness and connector between instrument Pin 13 and brake fluid level.
instrument Pin 13 and parking brake switch.
B. Is it intact?
→Yes Replace brake fluid level sensor or
refer to maintenance manual of brake fluid level
sensor for help.
between instrument Pin 13 and parking brake switch.
3. Check the harness and connector between instrument Pin 25 and hand brake.
instrument Pin 25 and hand brake switch.
B. Is it intact?
→Yes Replace hand brake sensor or refer to
maintenance manual of hand brake sensor for help.
between instrument Pin 25 and hand brake.
Location test I: If the driver's safety belt indictor lamp does not light up when ignition
switch is at ON position; or the indicator lamp does not go out after fastening the driver's
safety belt, please replace the safety belt switch or refer to safety belt maintenance manual for
help.
B. Is there any signal for unfastened safety belt?
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instrument.
→No To Step 3
3. Check the network of complete vehicle and the SRS controller signal.
Replace SRS controller or refer to SRS maintenance
manual for help.
Location test J: If the electric inject indicator lamp does not light up when ignition switch
is at ON position (in normal case, it will light up immediately for 3 seconds and then go out);
or the indicator lamp functions right before starting the engine and lights up after starting,
please refer to the maintenance manual of engine and engine ECU for help.
1. Measure the voltage to ground at harness
→Yes To Step 2
switch.
B. Is there electric injection lamp signal?
instrument.
→No To Step 3
3. Check the complete vehicle network and engine controller unit signal.
Replace engine controller unit or refer to
maintenance manual of engine controller unit for
help.
Location test K: if the SRS indicator lamp does not light up when ignition switch is at
ON position (in normal case, it will light up immediately for 3 seconds and then go out); or
the SRS indicator lamp does not go out when ignition switch is turned to ON position, please
refer to SRS maintenance manual for help; if the indicator lamp functions right before starting
the engine and lights up after starting, please refer to SRS maintenance manual system for
help.
B. Measure the voltage to ground at harness related
to Pin 2 of combination instrument.
→Yes To Step 2
between the ignition switch Pin 6 and the combination
instrument Pin 2, or replace the ignition switch.
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B. Is there any SRS signal?
instrument.
→No To Step 3
3. Check the network of complete vehicle and the SRS controller signal.
A. Replace SRS controller or refer to SRS
controller maintenance manual for help.
Location test L: Abnormal indication of tachometer
B. Is there any signal of revolving speed?
instrument.
→No To Step 2
A. Replace engine controller unit or refer to
the maintenance manual of engine controller unit for
help.
Location test M: Abnormal indication of speedometer.
B. Is there any signal of vehicle speed?
instrument.
→No To Step 2
A. Replace ABS controller or refer to ABS manual
for help.
Location test N: Abnormal indication of water-thermometer
B. Is there any signal of water temperature?
instrument.
→No To Step 2
A. Replace engine controller unit or refer to the
engine controller unit maintenance for help.
Location test O: Abnormal indication of fuel gauge.
1. Check the output resistance of fuel pump sensor.
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A. Take out fuel pump and support assembly.
Shake the floater of fuel pump sensor up and
down continuously.
B. Measure the resistance value of fuel pump
sensor with multimeter.
C. Whether the resistance variation comply with
Table 1?
→Yes To Step 2
→No Replace fuel pump.
2. Check the receiving resistance between Pin 5 and Pin 8 of corresponding harness end of combination
instrument.
A. Connect fuel pump and support assembly into
complete vehicle harness.
B. Remove the instrument and check the receiving
resistance between Pin 5 and Pin 8 of
corresponding harness end of combination
instrument.
C. Shake the floater of fuel pump sensor up and
down continuously.
D. Whether the resistance variation comply with
Table 1?
→Yes Replace instrument.
→No Check the harness connection between
combination instrument and fuel pump sensor.
Table 1
Capacity (L) Level (mm) Pump Resistance Value
0 0
1 10 275
2 17.5 275
3 24.5 270
4 31 264
5 37 258
6 44 252
7 50 246
8 56 240
9 62 233
10 68.5 225
11 74.5 217
12 79.5 209
13 84.5 200
14 88.5 193
15 93 186
16 97 179
17 102 172
18 106 165
19 110.6 158
20 114.5 153
21 119 146
22 123.5 139
23 128 132
24 132 125
25 137 118
26 141 112
27 146 107
28 150.5 100
29 155 93
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30 160 86
31 164 79
32 169 72
33 173 65
34 178 60
35 183 53
36 187.5 46
37 191.5 39
38 197 30
39 202 30
40 206 30
Location test P: Left turn signal indicator lamp does not blink when turn left (the
maintenance measures are the same in case of similar fault of right turn signal indicator lamp)
A. Read the CAN signal of the complete vehicle with diagnostic
apparatus.
B. Is there left turn signal?
→Yes Check the connecting harness between the instrument
Pin 22 and Pin 23 and the complete vehicle network or replace the
combination instrument.
→No To Step 2
A. Replace vehicle body controller or refer to vehicle body
Location test Q: When the ignition switch is at ON position, the low beam indicator lamp
does not light up when the combination switch is turned to low beam gear
1. Measure the harnesses related to instrument Pin 3 with multimeter.
A. Measure the voltage to ground at harness end related to
instrument Pin 3 with multimeter.
→No To Step 2
2. Check the harness and connector between instrument Pin 3 and low beam lamp switch.
A. Check the harness and connector between instrument Pin 3
and low beam lamp switch.
B. Is it intact?
→Yes Replace low beam lamp switch or fuse, or refer to
maintenance manual of low beam lamp for help.
→No Replace the harness and connector between
instrument Pin 3 and low beam lamp switch.
Location test R: High beam indicator lamp does not light up when combination switch
light handle is turned to overtaking light-shifting gear.
→No To Step 2
2. Check the harness and connector between instrument Pin 6 and high beam lamp switch.
and high beam lamp switch.
B. Is it intact?
→Yes Replace high beam lamp switch or fuse, or refer to
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instrument Pin 6 and high beam lamp switch.
Location test S: When ignition switch is at ON position, turn knob switch of combination
switch to low beam position, and turn handle switch of combination switch to high beam
position, and the high beam indicator lamp does not light up.
→No To Step 2
2. Check the harness and connector between instrument Pin 6 and high beam lamp switch.
A. Check the harness and connector between instrument Pin
6 and high beam lamp switch.
B. Is it intact?
→Yes Replace high beam lamp switch or fuse, or refer to
instrument Pin 6 and high beam lamp switch.
Location test T: When ignition switch is at ON position, turn on the lower bean lamp and
rotate the combination switch to front fog lamp switch, and the front fog lamp indicator does
not light up.
B. Is it approximately equal to battery voltage?
→No To Step 2
2. Check the harness and connector between instrument Pin 7 and front fog lamp switch.
A. Check the harness and connector between instrument Pin
7 and front fog lamp switch.
B. Is it intact?
→Yes Replace front fog lamp switch or fuse, or refer to
instrument Pin 7 and front fog lamp switch.
Location test U: When ignition switch is at ON position, turn on the low beam lamp and
rear fog lamp switch, but the rear fog lamp indicator does not light up.
B. Is it approximately equal to battery voltage?
→No To Step 2
2. Check the harness and connector between instrument Pin 18 and rear fog lamp switch.
and rear fog lamp switch.
B. Is it intact?
→Yes Replace rear fog lamp switch or fuse, or refer to
instrument Pin 18 and rear fog lamp switch.
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Location test V: Buzzer does not function right in specified power supply mode.
1. Read CAN signal of complete vehicle under the specified power supply mode.
A. Read the CAN signal of the complete vehicle with diagnostic
apparatus.
B. Is there buzzer signal?
→No To Step 2
A Replace vehicle body controller or refer to vehicle body
Location test W: Gear indication of LCD screen is not correct (only for vehicle with
automatic transmission).
A. Read CAN signal of the complete vehicle with diagnostic
apparatus.
B. Is there gear signal?
→No To Step 2
2. Check the network of complete vehicle and the transmission (TCU) signal.
A. Replace transmission (TCU) or refer to transmission (TCU)
maintenance manual for help.
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4.3.2-1 Horn 4.3.2-1
4.3.2 Horn Basic Parameter of Electric Horn

Installation and Removal a Operating current: ≤ 4A
Spiral type electric loudspeaker horn is b Sound level: 105 dB (A) ~ 118dB
installed on left support plate of front upper (A)
component as shown in the figure. c Frequency: 510±30Hz
d Rated voltage: DC.12V
Vocalism Principle of Electric Horn
An air chamber exists between
diaphragm and loudspeaker. Diaphragm
causes periodic variation of air volume in air
chamber during repeated vibration, so that
there will be a spherical plane wave. The
wave extends in the spiral loudspeaker
sound channel based on certain rules so as to
produce sound at the horn mouth in the form
of radiation.
Operating Principle of Electric Horn
Structure:
Power supply switches on the horn
circuit through contact point of horn relay
and creates magnetic field for coil
energization through contact point. Under
the effect of electromagnetic force in
S/N Name magnetic field, the armature is attracted and
Front upper component drives diaphragm and sounding board
1
support plate (left) moving downward. The armature also drives
Electric horn mounting the lower contact point arm to disconnect
2
bracket with upper contact point at the same time,
3 Hexagon flange bolt further to cut off the circuit. The
Spiral type electric
4 electromagnetic force disappears and the
loudspeaker horn assembly
armature is released after the coil is powered
Installation of Electric Horn off. The diaphragm and lower contact point
① Place and secure the support of will return to original position. The upper
electric horn between two limit and lower contact point close at the time and
flanging of mounting bracket with power supply creates magnetic field again
hexagon flange bolts. The required for coil energization through contact point.
torque is 22 ± 2 Nm. Repeat the cycle and the vibrating system
will make sound through repeated air
② Connect harness connectors after vibration.
electric horn is secured.
Removal of Electric Horn
Remove the electric horn in the other
way around of the installation.
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4.3.2-2 Horn 4.3.2-2

Common fault, cause and determination method of electric horn:
Fault Type Causes Repair Methods
The horn does not Check whether there is short circuit. If no, replace the
ring after pressing the Fuse burns out. fuse.
horn switch. Open circuit, fault of lead
Check and repair the circuit and the connector. Check
and connector, fault of horn
the horn button.
button
Extremely low voltage of Check the voltage of terminal connector and check the
complete vehicle (<12V) power supply.
Fault of horn. Replace the horn.
Abnormal sound of The horn interferes with
horn other components of vehicle
body. Remove the interfering component.
Loose installation Retighten it.
Fault of horn. Replace the horn.
The fuse burns out
after pressing the
horn button. Short circuit of horn. Replace the horn and the fuse.
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4.3.3 Power Socket and Cigarette Lighter 4.3.3
4.3.3 Installation and Removal of System Inspection and

Power Socket Troubleshooting
It is installed on the mounting hole of central Fault Solution
panel. Descript
ion
1. Failure of power socket
A. Check whether the battery voltage is
normal; if so, go to the next step; if not,
please check the battery;
B. Check whether the key is turned to ACC
or ON position; if so, go to the next step;
if not, turn the key to ACC or ON
position and recheck the operating
condition of power socket;
C. Check whether the fuse DF25 (15A) in
dashboard fuse box is break; if so,
replace the fuse; if not, go to the next
step;
Circuit Schematic Diagram D. Check the power supply end and ground
end of dashboard harness to be
connected to power socket. There shall
be at least 9V voltage output at the
power supply end and the ground end
shall be grounded properly; if the two
requirements are satisfied, please replace
the power socket; if not, check the
connecting circuit between power supply
end and battery and the connecting
circuit between ground end and ground.
S/N Name
1 Power supply
2 Ground
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4.3.4-1 Information and Entertainment System 4.3.4-1
4.3.4 Information and Entertainment System

DVD
Outside view of DVD assembly
Definition of power supply interface is seen below:
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Part A Part B
Pin Pin function Pin Pin function
SWC_IN1\wire control input
1 1 RR+\Rear right +
1
SWC_GND\wire control
2 2 RR-\Rear right -
ground end
3 3 FR+\Front right +
2
ACC_IN\power supply input
4 4 FR-\Front right -
end
5 ANT\antenna input end 5 FL+\Front left +
ILL\background light input
6 6 FL-\Front left -
end
7 BET\battery input end 7 RL+\Rear left +
8 GND\ground end 8 RL-\Rear left -
Part C
1 CAN-H\CAN-high 11
2 12
3 13 VIDIO+\reversing video signal
4 CAN_L\CAN_low 14
BACK_TRIG\reversing
5 15
activate
6 16 VIDIO-\reversing shield signal
7 17
8 18
9 19
10 20 POWER\camera power supply
Maintenance Tool
1 Multimeter
2 Oscilloscope
Fault Description
Fail to start Location test A
There is no sound or there is noise, or lack of
Location test B
sound track
Location failure of navigation Location test C
Fail to search radio band Location test D
Fail to read the USB Location test E
Diagnosis and Maintenance
Location test A: Fail to start.
1. Measure the Pin 7 or harness of power interface Part A.
A. Check whether there is voltage input about 12V.
→Yes
To step 2.
→No
To step 3.
Replace DVD host and test the new one.
→No
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A. Check the harness and confirm whether the ACC is at
ON position.
B. Refer to ignition switch maintenance manual for help or
go to step 3.
3. Check fuse of engine compartment (refer to fuse distribution diagram).
A. Whether the fuse is intact?
→Yes
Check the connectors or replace the terminal and test the device.
→No
Replace the fuse and test the device.
Location test B: There is no sound or there is noise, or lack of sound track.
1. Turn on the terminal to enter radio or USB mode.
A. Is there MUTE sign?
B.→Yes
Press the MUTE button to release the MUTE mode.
→No
Adjust the sound volume by VOL+ to confirm whether it is because
the extremely low sound setting.
→No
To step 2.
2. Check the pins of power supply interface Part B with oscilloscope.
A. Play a song to check whether there is alternative wave
output.
→Yes
To step 3.
→No
Replace DVD host and test the new one.
3. Check whether the horn is intact with multimeter.
A. Apply 1K Ohm position with multimeter.
B. Touch the positive and negative poles of horn with
multimeter probe.
C. Whether the horn rings or vibrates?
→Yes
Check horn harness and connector, and then test the device.
→No
Replace horn or horn harness, and then test the device.
Note: Check every horn as per Step 3.

Location test C: Location Failure of navigation.
1. Measure the GPS antenna interface with multimeter.
A. Check whether there is short circuit.
→Yes
Replace GPS antenna and test the device.
→No
To step 2.
2. Turn on the terminal and measure the GPS antenna interface with multimeter.
A. Check whether there is voltage output of 3.3V.
→Yes
Check GPS connector or go to Step 1.
→No
Replace the terminal and test the device.
Location test D: Fail to search radio band.
1. Check the radio antenna.
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A. Check whether the antenna is loose or damaged.
→Yes
Reinstall the antenna or replace the antenna.
→No
To step 2.
2. Measure the antenna amplifier with multimeter.
A. Check whether it is normal by measuring based on
radio wiring diagram.
→Yes
Check the harness or replace the terminal and test the device.
→No
Refer to maintenance manual of radio antenna for help or
replace the antenna.
Location test E: Fail to read USB.
1. Check the USB content.
A. Check whether there is mp3 file in
USB.
→Yes
To step 2.
→No
Replace USB or copy mp3 files to USB.
2. Check USB harness.
A. Check whether the USB harness is
loose or falling off.
→Yes
Replace USB harness and test the device.
→No
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Radio
Outside view of radio assembly
External Wiring Connection Diagram

Definition of power supply interface is seen below:
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Part A Part B
Pin Pin function Pin Pin function
1 1 RR+\Rear right +
1
SWC_GND\wire control
2 2 RR-\Rear right -
ground end
3 3 FR+\Front right +
2
ACC_IN\power supply input
4 4 FR-\Front right -
end
5 ANT\antenna input end 5 FL+\Front left +
ILL\background light input
6 6 FL-\Front left -
end
7 BET\battery input end 7 RL+\Rear left +
8 GND\ground end 8 RL-\Rear left -
Part C
1 11
2 12
3 13
4 14
5 15
6 16
7 17
8 18
9 19
10 20
Maintenance Tool
1 Multimeter
2 Oscilloscope
Fault Description
Fail to start Location test A
There is no sound or there is noise, or lack of
Location test B
sound track
Fail to search radio band Location test C
Fail to read the USB Location test D

Location test A: Fail to start.
→Yes
To step 2.
→No
To step 3.
A. Check whether there is voltage output about 12V.
Replace radio and test the device.
→No
A. Check the harness and confirm whether the ACC is
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at ON position.
B. Refer to ignition switch maintenance manual for help
or go to step 3.
3. Check fuse of engine compartment (refer to fuse distribution diagram).
A. Whether the fuse is intact?
→Yes
Check the connectors or replace and test the radio.
→No
Replace the fuse and test the device.
Location test B: There is no sound or there is noise, or lack of sound track.
1. Turn on the terminal to enter radio or USB mode.
A. Is there MUTE sign?
→Yes
Press the MUTE button to release the MUTE mode.
→No
Adjust the sound volume by VOL+ to confirm whether it is
because the extremely low sound setting.
→No
To step 2.
2. Check the pins of power supply interface Part B with oscilloscope.
A. Play a song to check whether there is alternative
wave output.
→Yes
To step 3.
→No
Replace the radio and test the device.
3. Check whether the horn is intact with multimeter (refer to the distribution diagram).
A. Apply 1K Ohm position with multimeter.
B. Touch the positive and negative poles of horn with
multimeter probe.
C. Whether the horn rings or vibrates?
→Yes
Check horn harness and connector, and then test the device.
→No
Replace horn or horn harness, and then test the device.
Note: Check every horn as per Step 3.

Location test C: Fail to search radio band.
1. Check the radio antenna.
A. Check whether the antenna is loose or damaged.
→Yes
Reinstall the antenna or replace the antenna.
→No
To step 2.
2. Measure the antenna amplifier with multimeter.
A. Check whether it is normal by measuring based on
radio wiring diagram.
→Yes
Check the harness or replace the terminal and test the device.
→No
Refer to maintenance manual of radio antenna for help or
replace the antenna.
Location test D: Fail to read USB.
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1. Check the USB content.
A. Check whether there is mp3 file
in USB.
→Yes
To step 2.
→No
Replace USB or copy mp3 files to USB.
2. Check USB harness.
A. Check whether the USB harness
is loose or falling off.
→Yes
Replace USB harness and test the device.
→No
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Antenna
Outside view of radio antenna and feeder is seen below:
Outside view of GPS antenna is seen below:
Maintenance Tool
1 Multimeter
2 Oscilloscope
Location test A: Fail to search radio band.
Test Condition
1. Check whether the pins are properly connected.
2. Check the power wire for connection and the amplifier for normal operation.
3. Check the feeder for sound conductivity.
Location test B: GPS antenna fails to receive the satellite signal.
Test Condition
1. Check whether the GPS antenna works.
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2. Replace the antenna.
Loudspeaker
Front and rear door loudspeakers:
Maintenance Tool
1 Multimeter
2 Cross screwdriver
1. Loudspeaker does not ring or rings intermittently.
Diagnose Maintenance
Whether the loudspeaker plug is loose? Reconnect the plug.
Whether the loudspeaker plug is of poor
connection? Check it with multimeter.
Whether there is short circuit at plug? Check it with multimeter.
Whether there is open circuit in the input circuit
of loudspeaker? Check it with multimeter.
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Loudspeaker voice coil is broken. Replace the loudspeaker.
Poor welding of loudspeaker plug. Check it with multimeter and carry out welding again.
These are all common fault and the loudspeaker can be replaced if the radio and tape player is confirmed as
normal.
2. There is noise of loudspeaker
Whether the loudspeaker plug is of poor Check it with multimeter.
connection?
Is there interference signal from mobile phone or Remove the interference source.
other sources?
Does the loudspeaker cause resonance of other Find the resonance and remove it.
components?
Whether the binding position of loudspeaker Replace the loudspeaker.
becomes open?
Diffuser is broken. Replace the loudspeaker.
3. Loudspeaker voice goes down.
Whether the sound track and equalizer are Carry out commissioning of radio and tape player.
balanced?
Whether the radio and tape player functions Carry out commissioning of radio and tape player.
right?
Whether the circuit between loudspeaker positive Test it with multimeter.
pole and metal plate is open?
Whether the magnetic part is loose, damaged or off-center. Replace the loudspeaker.
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4.3.5-1 Lighting System 4.3.5-1
4.3.5 Lighting System 3. Other lamps

Location of Lamps on Complete Vehicle
1. Front lamps
S/N Name Qty.

7 Side turn lamp assembly 2
8 Front roof lamp assembly 1
Installation of Lamps
S/N Component Name Qty. 1. Reciprocally incorporated

Reciprocally incorporated headlamp assembly
1 2
headlamp assembly
2 Front fog lamp assembly 2
2. Rear lamps

High-mounted brake lamp
3 1
assembly
Combination rear lamp
4 2
assembly
License plate lamp
5 2 S/N Name Qty.
assembly
6 Reflex reflector assembly 2 Reciprocally incorporated
1 2
headlamp assembly
2 Fender 2
Front bumper mounting
3 2
bracket assembly
Assembling unit of
4 hexagon bolt and flat 6
washer (09116-06009)
Assembling unit of
5 2
hexagon bolt and flat
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washer
(09116-06011)
6 Clip (09409-08401) 2
Manner of removal:
• Remove front bumper first;
• Then remove the lamps in the
other way around as per the installation
steps described below;
Manner of installation (the left lamp shown
in the figure is taken for example and the 2. Front fog lamp assembly
right lamp is symmetric with the left one):
• Insert the dowel of reciprocally
incorporated headlamp into the fender and
the front bumper mounting bracket;
• Install clip 6;
• Fasten the reciprocally
incorporated headlamp with bolt 4 and bolt
5. The tightening torque shall be 6 – 8 Nm.
• Connect the harness of
reciprocally incorporated headlamp; S/N Name Qty.
1 Front bumper body 1
Note: Do not pull the connector or 2 Front fog lamp assembly 2
harness of lamp, nor rotate the bulb seat and Cross recessed pan head self
rear cap, so as to avoid poor connection and 3 tapping screw 6
(09132-48002)
water leakage.
Manner of removal:
Details about bulb:
Bulb
• Remove the lamps in the other
S/N Name Model Qty. way around as per the installation steps
Low beam/high- described below;
1 beam lamps H4 2
2 Front turn lamp WY21W 2
in the figure is taken for example and the
Front position
3 lamp W5W 2 right lamp is symmetric with the left one):
Dimension and photoelectric property • Align the front fog lamp locating
of all bulbs shall comply with the hole to the dowel on front bumper body;
requirements of GB/T15766.1-2008. • Fasten front fog lamp with self-
Definition of connector interface at tapping screw 3;
component end: • Connect the harness of front fog
lamp;
Note: Do not pull the connector or

harness of lamp, nor rotate the rear cap, so
as to avoid poor connection and water
leakage.
Details about bulb:
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S/N Name
Bulb
Qty. • Remove the lamps in the other
Model way around as per the installation steps
1 Front fog lamp H3 2 described below;
Bulb Manner of installation (as shown in figure):
S/N Name Qty.
Model • Connect the harness of high-
High-mounted
1 W5W 4 mounted brake lamp;
brake lamp
• Connect rear nozzle water pipe
Dimension and photoelectric property
(only for configuration including rear wiper);
of all bulbs shall comply with the
requirements of GB/T15766.1-2008. • Install high-mounted brake lamp
into back door assembly and fasten it with
Definition of connector interface at
cap nut 3. The tightening torque of cap nut is
component end:
4 – 6 Nm.
Note: Do not pull the lamp

connector, harness or water pipe, so as to
avoid poor connection and water leakage.
Details about bulb:
component end:
4. Combination rear lamp assembly
S/N Name Qty.

1 1
assembly
2 Back door assembly 1
3 Cap nut (09145-06001) 2
Manner of removal:
S/N Name Qty.

1 Side body welding assembly 2
Combination rear lamp
2 2
assembly
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Assembling unit of cross Definition of connector interface at
recessed pan head self component end:
3 4
tapping screw and big
washer (09136-48001)
Clip
4 2
(09409-10104)
Clip
5 2
(09409-10105)
Nut seat
6 4
(09148-08002)
Clip
7 2
(09409-10102)
Manner of removal:
way around as per the installation steps
described below; 5. License plate lamp assembly
• Install clip 4, clip 5, nut seat 6 and
clip 7 in the corresponding holes of side
body welding assembly;
• Connect the harness of
combination rear lamp;
• Install combination rear lamp
along the direction of front end of vehicle.
Fasten the nut seat 6 with self-tapping screw
3 on combination rear lamp and side body S/N Name Qty.
welding assembly. The tightening torque is 1 Rear bumper body 1
3Nm; 2 License plate lamp assembly 2
Cross recessed pan head self
3 tapping screw (09132- 4
Note: Do not pull the connector or 48002)
harness of lamp, nor rotate the bulb seat, so 4 Stickers 2
as to avoid poor connection and water
Manner of removal:
leakage.
Details about bulb:
way around as per the installation steps
S/N Name Bulb Model Qty. described below;
1 Brake lamp P21W 2
Rear Manner of installation (As shown in figure,
2 position W5W 2 left and right lamps are of the same structure
lamp and the same direction. Observed from the
Rear turn tail end of vehicle, the harness of license
3 PY21W 2
lamp plate lamp assembly is on right side):
Rear fog 1 (left
4 PR21W • Fasten license plate lamp with
lamp only)
Reversing 1 (right self-tapping screw 3;
5 W16W
lamp only)
• Connect the harness of license
Dimension and photoelectric property plate lamp;
• Attach the license plate lamp
requirements of GB/T15766.1-2008.
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harness to the rear bumper body with sticker in the figure is taken for example and the
4; right lamp is symmetric with the left one):
Note: Do not pull the connector or • Install the reflex reflector on the
harness of lamp, nor rotate the bulb seat, so rear bumper body with the two plastic clips
as to avoid poor connection and water on the reflector.
leakage. 7. Side turn lamp assembly
Details about bulb:
Bulb
S/N Name Qty.
Model
License plate
1 W5W 2
lamp
Dimension and photoelectric property
requirements of GB/T15766.1-2008.
component end:
S/N Name Qty.

1 Fender 2
2 Side turn lamp assembly 2
Manner of removal:
• Push the side turn lamp along the
direction of front end of vehicle. Pry up the
side turn lamp with slotted screwdriver to
remove it (wrap the metal part of
6. Reflex reflector assembly screwdriver with cloth so as to avoid
damaging the lamp);
• Pull out the harness of side turn
lamp;
• Distinguish the left and right side
based on the sign on side turn lamp and
connect the harness of side turn lamp;
S/N Name Qty. • Insert one side of the fastening
1 Reflex reflector assembly 2 clip on side turn lamp into the fender along
2 Rear bumper body 1 the tail end direction and then push the side
turn lamp to insert the elastic clip in the
Manner of removal:
fender too (the clips are inserted in position
• Press the two plastic clips of reflex when there is a click).
reflector with pliers to remove the lamp
(wrap the metal part of the pliers with cloth Note: Do not rotate the bulb seat
so as to avoid damaging the clips); so as to avoid water leakage.
Manner of installation (the left lamp shown Details about bulb:
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Bulb • Pry up the front roof lamp with
S/N Name Model Qty. slotted screwdriver to remove it (wrap the
1 Side turn lamp WY5W 2 metal part of screwdriver with cloth so as to
Dimension and photoelectric property avoid damaging the lamp);
of all bulbs shall comply with the • Pull out the harness of front roof
requirements of GB/T15766.1-2008. lamp;
Definition of connector interface at Details about bulb:
component end:
Bulb
S/N Name Model Qty.
Front roof
1 lamp C10W 1
component end:
8. Front roof lamp assembly
Electrical Schematic Diagram

• Refer to *** Electric Diagram ***
Lighting System.
• Schematic Diagram of Fuse Box
and Relay
Refer to *** Electric Diagram ***
S/N Name Qty. Power Supply Distribution and Detailed
1 Front roof lamp assembly 1 Information of *** Fuse.
2 Roof lining assembly 1
Front roof lamp mounting Fault Determination and
3 bracket 1 Maintenance
Manner of installation (as shown in figure): Inspection and Confirmation
• Connect the harness of front roof • Confirm the faults reported by
lamp; customer.
• Insert the fastening clip of front • Visually inspect apparent mechanical
roof lamp into the front roof lamp mounting or electrical fault to exclude the bulb
bracket along the front end direction and damage.
then push the front roof lamp to insert the • If there is noticeable fault, please solve
metal elastic clip of front roof lamp into the problem before the next step.
mounting bracket (the clips are inserted in
position when there is a click). Manner of • If there is no noticeable fault, record
removal: the fault and report to the Changan
Company for confirmation.
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Warning: Make sure the lamp is off The light adjustment point is:
before replacing the bulb. Make sure Preparation
the new bulb is of the same model and
• Park the vehicle on flat ground.
power of the old one.
Ensure a 10m distance from datum center of
Instructions and Operation reciprocally incorporated headlamp to
• If there is fracture or water leakage of adjustment screen (or vertical wall);
lamp shell, lens, reflector and mounting • Check whether the reciprocally
support, please replace the lamp. incorporated headlamp functions right.
Replace the damaged component if
Note: Determination of fogging: There necessary.
shall not be water drops on lens 10
• Check the tire pressure to make
minutes after the lamp is on and there
sure the tires are in full bearing pressure
may be moisture where it is not
condition;
illuminated. If such condition is
satisfied, it indicates the normal • Check the load (fuel volume in
condition. fuel tank shall not be less than 90% of its
capacity);
• It is required light adjustment if the
reciprocally incorporated headlamp is • Adjust the horizontal adjustment
replaced. screw for several times to check whether the
horizontal adjustment functions right.
Light Adjustment of Reciprocally
• Place the adjustment switch to "0"
Incorporated Headlamp
position.
• Parameter
Light Adjustment
Adjustable Range
Ground clearance H of • Turn on the low beam lamp.
corner or midpoint of 560mm ≤ H ≤ 710mm • Horizontal adjustment
low beam cut-off line
Left avertence ≤ Adjust the horizontal adjustment point
Horizontal position of 170mm; 1 to make the corner or midpoint of low
corner or midpoint of Right avertence ≤ beam cut-off line averting leftward for not
low beam cut-off line 350mm more than 170mm and rightward for not
• Equipment more than 350mm on the adjustment screen
(or vertical wall).
General Equipment
Special electric tool for light adjustment. Adjust
Note: Diffused light of low beam
the torque of the tool to 0.4 ± 0.2Nm.
may be above the 15 degree line.
• Light adjustment mechanism
• Vertical adjustment
Adjust the vertical adjustment point 2 to
make the ground clearance of corner or
midpoint of low beam cut-off line within the
range of 560mm to 710mm, as shown in the
figure below.
Left lamp is shown in the figure above (the

right lamp is symmetric with the left one).
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Note: Another horizontal

adjustment may be required after vertical
adjustment.
S/N Name
1 Horizontal adjustment point
2 Vertical adjustment point
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4.3.6-1 Wiper and Washer 4.3.6-1
4.3.6 Wiper and Washer

Installation and Removal
Installation of Front Wiper
1. Wiper motor and drive arm assembly
(installed inside the fan heater pressure
chamber plate welding assembly).
Install M6 hexagon flange bolt in round

wiper mounting hole ③. It is the locating
point of secondary installation.
The name of each mounting point is seen

below:
S/N Name of Wiper Mounting Hole
① Round wiper mounting hole
② Round wiper mounting hole
③ Round wiper mounting hole
2. Ensure the opening hole of cowl
Install M6 hexagon flange bolt in round garnish assembly and the output shaft
wiper mounting hole ①. It is the locating of wiper motor and drive arm assembly
point of primary installation. are concentric after wiper motor and
drive arm assembly is installed.
Install M6 hexagon flange bolt in round

wiper mounting hole ②. 3. Sub-assembly of primary and
secondary wiper arm and wiper blade
shall be carried out in advanced.
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ignition switch to OFF position when
the wiper motor does not operate).
Fasten wiper arm with M10 nut (the
torque is 18 ~ 22Nm). Make sure the
initial position of primary and
secondary wiper blades is close to the
marked sign on front windshield.
Marked mounting point of wiper on
front windshield is seen in the figure
below (observed from the tail end of
vehicle):
At the time of installation, rotate the
clip counterclockwise for 90 degrees to S/N Name
make sufficient space. Then insert the wiper Marked point of mounting
① position of primary wiper blade
arm hanger counterclockwise from the left
Marked point of mounting
side of clip. Hold the wiper arm and tighten position of secondary wiper
the wiper blade along the opposite direction ② blade
of wiper arm.
The wiper system is seen as below when it is
fully installed:
It is properly installed when there is a

click at the joint of wiper arm and wiper
blade. Then rotate the wiper arm clockwise Removal of Wiper
(rotate the wiper blade counterclockwise) to Remove the wiper in the other way
finish the installation. around as per the installation steps. .
Installation of Rear Wiper
1. Thread the output shaft of rear
windshield wiper motor (installed on the
back door metal plate) through the opening
hole of back door metal plate. Install the
assembling unit of M6 hexagon bolt and flat
washer in the sequence of ① - ② - ③ and
with torque of 11 ± 2Nm. It is shown in the
figure below.
4. Install the sub-assembled wiper arm

and wiper blade on the output shaft of
wiper motor and drive arm assembly.
Make sure the wiper motor is at return
position (Method: Turn the ignition
switch to ON position → turn wiper
switch to OFF position → turn the
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Remove the hole cover ④ of wiper arm and

place wiper arm and wiper blade assembly
② on wiper motor output shaft ①. Rubber
strip of wiper blade shall cover the marked
point ⑤ on windshield.
Connect harness connector after wiper

motor is installed. Install the sealing rubber
mat and metal gasket of motor output shaft
on the shaft sleeve. Note: The bulge part ①
of metal gasket shall be inserted into the slot
② of shaft sleeve for locating at the time of Use M6 hexagon flange nut ③ for fastening
metal gasket installation. with torque of 11 ± 2Nm. Install hole cover
④ on the wiper arm ② . (Tighten the
fastener until there is a click.)
The view of rear wiper after installation is
seen as below:
Install nut ① on output shaft sleeve and

tighten it with torque of 9 ± 2Nm; install
shaft cap ② on output shaft and make sure
the marked point ③ on upper surface of
shaft cap faces upwards (the arrow points Fault Determination and
downward). Shaft cap shall attach to the Maintenance of Front Wiper
back door metal plate closely. The output
shaft cap may not rotate after assembly. Connector Definition and Basic
Parameter
1. Definition of motor interface (on
wiper motor)
2. Wiper arm and wiper brush

assembly of rear windshield
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Definition of each interface is seen below:
S/N Name Wiper Fault Description
① Low speed/LOW Fault
② Ground/GND Description Possible Causes
General power 1. Insufficient battery
③ supply/B+ voltage
④ Reset/PARK 2. Front wiper motor fuse
(DF42) in central control box is
⑤ High speed/HIGH broken.
2. Parameters of wiper motor are 3. Poor grounding
seen below: connection of engine compartment
harness end G306 to be connected
• Rated voltage: 12V; Wiper with wiper motor.
motor does 4. The high speed wire/low
• Test voltage: 13.5V; not work speed wire (FW07/FW08) of engine
• Brake torque (low speed): ≥27N.m; compartment harness to be
connected with wiper motor is of
• No-load current: ≤4A; abnormal voltage.
5. The circuit between
• Brake current: ≤30A; interface harness and combination
• Motor noise: <46dB(A) at low switch is open and the combination
speed and ≤ 53dB(A) at high switch is open.
speed; 6. Wiper system damage.
1. Interface (FW09) of
• Revolving speed: In normal load engine compartment harness to be
condition (load of 2. ON.M), it is connected to wiper motor is of
40±4r/min for low speed and abnormal voltage.
60±6r/min for high speed. 2. S end (reset/PARK) of
Wiper
harness to be connected with wiper
motor fails
Fault Inspection and Confirmation to reset
motor is of abnormal voltage.
3. Poor grounding
1. Check the wiper visually for apparent connection of engine compartment
mechanical damage. harness end (G306) to be connected
2. If there is noticeable problem observed with wiper motor.
4. Wiper system damage.
or reported, eliminate the fault before
Wiper is 1. There is foreign material
implementing the next step. dirty and on windshield or rubber strip.
3. If the visual check is passed, confirm vibrating. 2. Wiper arm deformation.
Description Table for help.
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Diagnosis flow for the fault that wiper motor does not work
Carry out fault inspection, determination and maintenance based on the flow of the following
table when the wiper motor does not work.
1. Check the battery voltage.
A. Check the battery voltage for more than 9V or
not?
→Yes Carry out Step 2;
→No Check the battery.
2. Check the wiper motor fuse in central control box.
A. Check the wiper motor fuse (DF42) in central control
box for fracture.
→Yes Replace the fuse;
→No Implement Step 3.
3. Check the engine compartment harness end (G306) connected with wiper motor.
A. Check the end (G306) of engine compartment harness
to be connected with wiper motor for proper
grounding.
→No Check the harness.
4. Check whether the wiper be able to operate at high speed.
A. Place the wiper control lever of combination switch to
high speed (HI) position when the ignition switch is at
ON position. Does the wiper work at high speed?
→Yes Implement Step 5;
→No Implement Step B;
B. Check the engine compartment harness end FW07
(high speed wire) connected with wiper motor for
normal voltage.
→Yes Replace the wiper motor;
→No Check whether there is open circuit
between this interface harness and combination switch
and check the high speed gear of combination switch
is on or off.
5. Check whether the wiper be able to operate at low speed.
A. Place the wiper control lever of combination switch to
low speed (LOW) position when the ignition switch is
at ON position. Does the wiper work at low speed?
→Yes Implement Step 6.
→No Implement Step B;
B. Check the engine compartment harness end FW08
(low speed wire) connected with wiper motor for
normal voltage.
→Yes Replace the wiper motor;
→No Check whether there is open circuit
between this interface harness and combination switch
and check the high speed gear of combination switch
is on or off.
6. Check whether the wiper be able to operate intermittently.
A. Place the wiper control lever of combination switch at
intermittent (INT) position when the ignition switch is
at ON position. Does the wiper work intermittently?
→No Please replace combination switch.
7. Check whether the wiper is able to finish a wiping circle.
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A. Place the wiper control lever of combination switch at
MIST position when the ignition switch is at ON
position. Check whether the wiper is able to finish a
wiping circle.
Yes Wiper motor functions right.
No Please replace the combination switch.
Diagnosis flow for the fault that wiper motor cannot reset
1. Check the harness low speed interface connected with wiper motor for normal voltage.
A. Check the interface FW09 of engine compartment
harness connected with wiper motor for normal
voltage.
Yes Carry out Step 2;
No Please check the circuit.
2. Check the harness end G306 connected with wiper motor for proper grounding.
A. Check the harness end G306 connected with wiper
motor for proper grounding when the ignition switch
is at ON position.
3. Check the harness S interface (reset/PARK) connected with wiper motor for normal voltage.
A. When ignition switch is at ON position, measure the
voltage of S interface of harness connected with wiper
motor. Turn the combination switch to wiper gear and
then reset the switch to check whether there is a
voltage of 12V with multimeter.
Yes Please replace the combination switch;
No Please replace the wiper motor.
Diagnosis flow for the fault that the wiper is dirty and vibrating
1. Check the windshield.
A. Check whether the windshield is clean;
No Clean the windshield with detergent.
2. Check the wiper blade
A. Check whether there is foreign material on wiper
blade;
Yes Wipe out the foreign material on blade edge
with wet towel;
No Carry out Step 3;
3. Check the assembling condition of wiper blade and hanger.
A. Check whether the wiper blade and hanger are
installed in position;
No Install the blade and hanger in position.
4. Check the mounting nut of wiper arm.
A. Check the mounting nut of wiper arm for looseness.
Yes Tighten the mounting nut;
5. Replace the wiper blade.
A. Replace the wiper blade to confirm whether the fault
is eliminated;
Yes Replace the wiper blade;
No Replace the wiper arm.
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Fault Determination and 2. If there is noticeable problem observed

Maintenance of Rear Wiper or reported, eliminate the fault before
implementing the next step.
Connector Definition and Basic
Parameter 3. If the visual check is passed, confirm
1. Motor interface (on wiper motor) Description Table for help.
Wiper Fault Description
Fault
Possible Causes
Description
1. Insufficient battery
voltage
2. Front wiper motor fuse
(DF1) in central control box is
broken.
3. Poor grounding
connection of negative pole (-) of
engine compartment harness to be
Wiper
Definition of each interface connected with wiper motor.
motor does
4. Interface of positive pole
S/N Name not work
(+1) of engine compartment harness
1 (Vacant) to be connected to wiper motor is of
2 Reset (S) abnormal voltage.
3 Positive (+1) 5. The circuit between
4 Negative (-) interface harness and combination
switch is open and the combination
Parameters of rear wiper motor are seen switch is open.
below: 6. Wiper system damage.
• Rated voltage: 12V, test voltage: 13.5V; 1. Interface of positive pole
(+1) of engine compartment harness
• Load: loading moment 0.6N.m, connected to wiper motor is of
revolving speed 38±5rpm; abnormal voltage.
2. Reset end (S) of harness
• No-load: current ≤2.5A, revolving Wiper
to be connected with wiper motor is
speed 40±5rpm; motor fails
of abnormal voltage.
to reset
• Brake: brake torque ≥7N.m, brake 3. Poor grounding
connection of negative pole (-) of
current ≤15A; engine compartment harness to be
• Motor voice: ≤45dB(A) connected with wiper motor.
4. Wiper system damage.
Fault Inspection and Confirmation Wiper is 1. There is foreign material
1. Check the wiper visually for apparent dirty and on windshield or rubber strip.
vibrating. 2. Wiper arm deformation.
mechanical damage.
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Diagnosis flow for the fault that wiper motor fails to work
1. Check the battery voltage.
A. Check the battery voltage for more than 9V or not?
→No Check the battery.
2. Check the front wiper motor fuse (DF1) in instrument fuse box.
A. Check the front wiper motor fuse (DF1) in
instrument fuse box for fracture?
→Yes Replace the fuse;
→No Implement Step 3.
3. Check the negative pole (-) and positive pole (+1) of harness end connectors of rear wiper.
A. When ignition switch is at ON position, place
wiper control lever of combination switch to rear
wiper operating gear. Check the negative pole and
positive pole of harness end connectors of rear
wiper. (Whether the voltage between positive and
negative pole is more than 9V?)
→Yes Please replace the wiper motor;
→No Check the harness.
Diagnosis flow for the fault that wiper motor cannot reset
1. Check the harness positive pole (+1) interface connected with wiper motor for normal voltage.
A. Check the positive interface of engine compartment
harness connected with wiper motor for normal
voltage.
2. Check the harness negative pole (-) interface connected with wiper motor for proper grounding.
A. Check whether the harness negative interface
connected with wiper motor is in normal condition
when the ignition switch is at ON position.
3. Check the harness S interface (reset) connected with wiper motor for normal voltage.
A. When ignition switch is at ON position, measure
the voltage of reset interface of harness connected
with wiper motor. Turn the combination switch to
wiper gear and then reset the switch to check
whether there is a voltage of 12V with multimeter.
Yes Please replace the combination switch;
No Please replace the wiper motor.
Diagnosis flow for the fault that the wiper is dirty and vibrating
1. Check the windshield.
A. Check whether the windshield is clean;
No Clean the windshield with detergent.
2. Check the wiper blade
A. Check whether there is foreign material on wiper
blade;
Yes Wipe out the foreign material on blade edge
with wet towel;
3. Check the assembling condition of wiper blade and hanger.
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A. Check whether the wiper blade and hanger are
installed in position;
No Install the blade and hanger in position.
4. Check the mounting nut of wiper arm.
A. Check the mounting nut of wiper arm for
looseness.
Yes Tighten the mounting nut;
No Please replace wiper arm and wiper blade.
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6.20 Wiper
Contents Page
6.20.1 Front Wiper
Front Wiper System Control Schematic Diagram ........................................................ 4.3.6-11
Front Wiper Motor Operating Schematic Diagram ...................................................... 4.3.6-11
6.20.2 Rear Wiper
Rear Wiper System Control Schematic Diagram ......................................................... 4.3.6-12
Rear Wiper Motor Operating Schematic Diagram ....................................................... 4.3.6-12
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6.20.1 Front Wiper

Front Wiper System Control Schematic Diagram
Front Wiper Motor Operating Schematic Diagram
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6.20.2 Rear Wiper

Rear Wiper System Control Schematic Diagram
Rear Wiper Motor Operating Schematic Diagram
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4.3.7-1 Complete Vehicle Lock Assembly 4.3.7-1
4.3.7 Complete Vehicle Lock START: When the key is rotated to

Assembly this position, the engine is starting. Release
the key and it will immediately return to the
Overview "ON" position.
Complete vehicle lock assembly mainly Key
refer to lock and lock cylinder related to key,
A set of key is in duplicate, with one
which include front door lock cylinder and
foldable remote key and one regular key.
steering lock. Please replace the complete
vehicle lock assembly if the key is lost. Key assembly (straight-shank remote control)
Introductions and Operation of
Steering Lock and Key
Steering Lock
S/N Name
1 Unlocking key
2 Locking key
3 Trunk unlocking key
Key assembly (regular remote control)
There are four positions for operation on the

ignition switch:
LOCK: Normal parking position.
When the key is as this position, the engine
does not start or it stalls. The steering
column will be locked after taking out the
key. Inset the key and rotate to the adjacent
position, and then the steering column will
be unlocked. If it is difficult to rotate the key,
rotate the key after turn the steering wheel
left and right lightly. In order to avoid the
key being pulled out accidentally, it is
required to press the key in for 2mm before
rotating it when switch from ACC to LOCK.
ACC: When the key is rotated to this
position, the engine is not started while
auxiliary facilities are powered on.
ON: When the key is rotated to this
position, all power supplies in the vehicle
are connected, and the engine is about to
start.
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4.3.7-2 Complete Vehicle Lock Assembly 4.3.7-2
Installation and Removal Steering Lock Connector Pins

Steering lock/key

Test
Solution
Condition
1. Test Method and Step
A. Disconnect steering lock harness
connector;
S/N Name B. Rotate the key to ACC position.
1 Steering lock assembly Then, use the on-off position of
2 Hoop multimeter to test the condition
between steering lock connector
3 Anti-theft screw
AM1 and connector ACC. There
Circuit Schematic Diagram and Pin shall be close circuit and full
conduction between these two
Definition conductors.
Steering Lock C. Rotate the key to ON position.
Then use the on-off position of
multimeter to test the condition
among AM1, ACC and IG1, as
well as the condition between
AM2 and IG2. They shall all be
close circuit and full conduction.
D. Rotate and keep the key at ON
position. Then use the on-off
position of multimeter to test the
condition between AM1 and
IG1, as well as the condition
between AM2 and ST2. They
shall all be close circuit and full
conduction.
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4.3.8-1 Complete Vehicle Electric Switch 4.3.8-1
4.3.8 Complete Vehicle Electric switch has two positions of glass ascending
Switch and descending. The first position is manual
regulation and the second position is
Power Window automatic regulation (only for 1.8T 6AT
Instructions and Operation Elite Model and 1.8T 6AT Flagship Model).
Power windows are adopted for this Anti-pinch glass regulator switch at
vehicle model. Press the glass regulator driver's side has two positions of ascending
button to open or close the window when and descending. The first position is manual
needed. There is glass regulator button for regulation and the second position is
all windows of the vehicle at the inner side automatic regulation. The other buttons have
of the door at driver’s side. There is only one position of manual regulation.
regulator button on each door for Removal and Installation
corresponding window glass. Button No.3 is
Main power window switch
the lock button. Press this button to lock or
unlock the other three door windows except
the one at driver's side. Button No.4 is the
door lock switch. Press the right end of the
button to lock the door and the left button to
unlock the door when the door is closed.
Main power window switch
S/N Name
Glass regulator button of rear
1
left door
Glass regulator button of Manner of removal:
2
driver's door
3 Locking button As shown in the figure, when remove
4 Door lock button the main and auxiliary power window
Glass regulator button of front switches, remove the three screws retaining
5
right door the window switch with screwdriver first.
6
Glass regulator button of rear Then press the harness unlocking clip to pull
right door out the harness plug. Then take out the
Auxiliary power window switch switch from the armrest box.
When install the main and auxiliary
power window switches, fasten the three
screws retaining the window switch with
screwdriver first. (Note: The tightening
torque shall not exceed 0.6Nm, otherwise
the armrest box stud may fractures.) Then
insert the harness plug into the switch hole
until there is a click, which indicates it is
Four-door anti-pinch glass regulator connected in position. Pull the harness plug
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backwards and it shall not be loose or pulled Circuit Schematic Diagram of Main Power
out. Window Switch
Circuit Schematic Diagram
Pin Definition of Main Power Window Switch
Circuit Schematic Diagram of Auxiliary Power Window Switch
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Pin Definition of Auxiliary Power Window Switch
Positions of main power window switch
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Positions of auxiliary power window switch
System Inspection and Troubleshooting

Fault Description Solution
1. All power window switches fail to operate
A. Check whether the ignition switch is at ON position: if not,
place the ignition switch to ON position; if so, go to Step II;
B. Check whether the control window motor fuse in dashboard
fuse box burns out: If so, replace the fuse; if not, test the
switch with multimeter.
2. On-off of locking switch
A. Button locking: Pin W-Lock and/or Pin GND of main power
window switch connector are connected.
B. Button unlocking: Pin W-Lock and/or Pin GND of main
power window switch connector are not connected.
C. When all inspection above is done and the switch is
confirmed as normal, if the other switches still function right,
please check the harness connection between the main power
window switch and the other three window switches.
3. On-off of door lock switch
A. Press the door lock end of the button to connect the Pin SET-
LOCK and/or Pin GND of main power window switch. There
will be resistance.
B. Press the door unlock end of the button to connect the Pin
SET-LOCK and/or Pin GND of main power window switch.
There will not be resistance.
C. If all inspections above are done and the door lock switch still
fails to operation, please check the central control lock or the
harness connection between main power window switch and
central control lock.
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Combination Switch This is applicable to defrosting.

Instructions and Operation OFF: Wiper stops operating.
Combination Switch Light Handle INT: Wiper is in intermittent mode,
which quite proper for greasy days and days
with drizzle.
LO: Wiper will operate at a stable low
speed.
HI: Wiper will operate at a stable high
speed.
Wiper intermittence adjustment knob
High beam lamp control lever has two switch: Adjust the intermittence of the INT
positions. When the low beam lamp is mode. The wider part of trapezoid indicates
switched on, push the control lever faster wiping speed.
downwards to high beam position and the Glass Washer Switch
high beam lamp will be switched on and the
indicator on instrument panel will be on;
pull the lever upwards gently to light
shifting position after reset and the high
beam lamp will blink. This is applied at the
time of overtaking. The lever will return to
original position immediately after releasing.
Front lamp switch: When the low beam
lamp is switched on, rotate front fog lamp Pull the switch control lever upwards
switch to turn on the front fog lamp. gently to spray scrubbing solution on
Rear fog lamp: Rotate the rear fog lamp windshield and to conduct wiping for one
switch to turn on the lamp after the front fog time. It resets immediately after releasing.
lamp is on; rotate the rear fog lamp switch Installation and Removal
again after rear fog lamp is on to turn it off.
Left and right turn signal lamps: When
ignition switch is at ON position, push the
control lever rightwards and the right turn
signal lamp will blink; push the lever
leftwards and the left turn signal lamp will
blink.
Combination Switch Wiper Handle 1. Install combination switch light
handle assembly and combination switch
wiper handle assembly on the steering
column based on the directions indicated by
the arrows in the figure. They are installed
in position if the clips on combination
switch handle pop up. Then the combination
switch is not easy to be removed.
Switch control lever is at right side of
2. Drive harness connector into
steering column. Control lever has five
switch connector after ensure their
positions and one wiper intermittence
unanimous positioning directions. Upspring
adjustment knob switch.
of clip means assembly in place of locking
MIST: Wiper operates for one cycle. clip of connector.
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Combination Switch Light Interface
Combination Switch Wiper Interface
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Fault Description Solution

1. Fault of turn lamp switch
A. Turn the combination switch to left turn position or
right turn position and check whether the Pin 11 and
Pin 12, Pin 12 and Pin 13 are connected.
B. No: Please replace the combination switch;
C. Yes: Refer to turn lamp failure diagnosis and
maintenance in lighting system.
2. Fault of light shifting switch
A. Turn the combination switch to high beam shifting
position and check whether the Pin 2 and Pin 8 are
connected; turn to overtaking position and check
whether the Pin 2 and Pin 9 are connected;
C. Yes: Refer to high beam lamp failure diagnosis and
3. Fault of position lamp switch
A. Turn the combination switch to the position lamp
gear. Check whether the Pin 1 and Pin 2 of
combination switch is connected;
C. Yes: Refer to position lamp failure diagnosis and
4. Fault of low beam lamp switch
A. Turn the combination switch to low beam lamp
(headlamp) position. Check whether the Pin 1, Pin 2
and Pin 4 of combination switch is connected;
C. Yes: Refer to low beam lamp failure diagnosis and
5. Fault of front fog lamp switch
position and front fog lamp ON position. Check
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whether the Pin 5 and Pin 6 of combination switch is
connected;
C. Yes: Refer to front fog lamp failure diagnosis and
6. Fault of rear fog lamp switch
position and front fog lamp ON position. Rotate rear
fog lamp switch and check whether the Pin 5, Pin 6
and Pin 7 are connected.
C. Yes: Refer to front fog lamp failure diagnosis and
7. Fault of front wiper
A. Turn the wiper switch of combination switch to the
following positions and check whether the
corresponding pins are connected.
OFF position: Check whether the Pin 2 and Pin 3 of
combination switch are connected
MIST position: Check whether the Pin 1 and Pin 10,
Pin 2 and Pin 3 of combination switch are connected
INT position: Check whether the Pin 2 and Pin 3, Pin
8 and Pin 10 of combination switch are connected
LOW position: Check whether the Pin 2 and Pin 11 of
HI position: Check whether the Pin 3 and Pin 10 of
Spraying position: Check whether the Pin 10 and Pin
11 of combination switch are connected
B No: Please replace the combination switch;
C. Yes: Please check the harness, wiper motor and
spraying motor.
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Pin Definition of Combination Switch Wiper Handle
Button Switch Box

Power mirror switch: Power mirror is internal adjustable and electrical type. Move the
left-right selector of power mirror switch to corresponding position to choose the left or right
power mirror. Then press the up, down, left or right position of button (as show in the figure)
to control the rotating direction of power mirror so as to see objects and vehicle from various
directions.
Light angle adjustment switch: Light angle adjustment switch has 10 positions. Rotate
the button to adjust the light angle of headlamp.
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S/N Name
1 Left and right rear-view mirror regulation
2 Rear-view mirror adjustment button
3 Lighting angle regulator switch
4 Reserved hole cap
Installation and Removal
Button switch mounting box assembly is installed on the instrument panel. Press the clip to
take out the switch.
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Power Mirror Wiring Diagram (not foldable)
Positions of rear-view mirror switch
Lighting angle regulator switch
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Test Condition Solution

1. Check the rear-view mirror switch
A. If the power mirror switch fails to control the rotating
direction of left and right power mirror, carry out the following
inspection.
Step I: Check whether the ignition switch is at ACC position: if not,
turn the ignition switch to ACC position; if so, go to Step II;
Step II: Check whether the power mirror fuse in instrument panel
central control box burns out: if so, replace the fuse; if not, check
whether the Pin E of power mirror is reliably grounded. If it is
properly grounded, use multimeter to measure the voltage between
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the Pin B and Pin E of power mirror and there shall be a working
voltage of power mirror switch. If the voltage is not detected,
please check the harness.
B. Check the ON/OFF condition of each pin based on the position
table.
C. When the inspection above is done, if the power mirror fails to
operate normally, please check other module and connecting
harness.
2. Check the lighting angle regulator switch
A. Check the lighting angle regulator switch for failure.
Step I: Check whether the ignition switch is at ACC position: if not,
turn the ignition switch to ACC position; if so, go to Step II;
Step II: Check whether the Pin POWER of light angle adjustment
switch is properly grounded. If it is reliably grounded, use
multimeter to measure the voltage between the pins of light angle
adjustment switch and there shall be a working voltage of the
switch. If the voltage is not detected, please check the harness.
B. Check the ON/OFF condition between the Pin POWER and the
POER+, M(L) and M(R) as per the wiring diagram.
C. When the inspection above is done, if the light angle adjustment
switch fails to operate normally, please check other module and
connecting harness.
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4.3.9-1 Reversing Radar System 4.3.9-1

Outside view of reversing radar controller is
seen below:

1. Schematic Diagram of Reversing
Radar System
Outside view of reversing radar sensor is

seen below:
2. Parameters of reversing radar

system
Mounting position of reversing radar Operating voltage: 9V ~ 16V
controller on steering support: Operating current: ≤ 200mA;
Detecting angle of reversing radar
sensor: Horizontal: 110 ~ 120; Vertical: 50 ~
60 degree.
3. Interface definition of reversing
radar controller
Mounting position of reversing radar sensor

on rear bumper:
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S/N Interface Definition Signal Type Effective Value Remarks

1
2
3 Rear left sensor signal AD 18mA
4 Rear right sensor signal AD 18mA
Grounded and connected to
5 Sensor ground GND
Pin 15 by harness
6 N/A
Grounded and connected to
7 Sensor ground GND
Pin 15 by harness
8 Power supply for reversing 120mA
9 ~ 14 N/A
15 Sensor ground 18mA
16 System ground 120mA
S/N Interface Definition Signal Type Effective Value Remarks

1 Sensor signal wire AD 18mA
2 Sensor ground GND
System Inspection and Troubleshooting
Fault Description Causes Solution Measures Remarks
1. There is one damaged sensor. 1. Replace sensor.
Buzzer rings for twice
2. There is one sensor without 2. Check the harness for
during self-inspection
voltage or ground connection. normal connection.
Buzzer rings for three 1. There are two damaged 1. Replace sensor.
times during self- sensor. 2. Check the harness for
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inspection 2. There are two or three sensors normal connection.
without voltage or ground
connection.
It will not
1. Check the harness for
1. Controller voltage wire or give alarm of
normal connection.
ground wire is not connected; obstacle if
Reversing radar fails to 2. Replace the battery;
2. Insufficient battery voltage ; self-
operate 3. Turn to R position
3. It is not applied to R position; inspection is
4. Replace the reversing
4. Damage of reversing radar not
radar controller
controller conducted.
1. There is foreign material on 1. Cleaning sensor
sensor 2. Install the sensor
False alarm of
2. Incorrect installation direction correctly
reversing radar
of sensor 3. Unload the vehicle
3. Overloading of vehicle
1. Alarming distance is not 1. Reverse to the operating Self-
achieved. area of reversing radar; inspection is
Reversing radar fails to 2. The obstacle is acoustical 2. Sensor characteristic, no done but it
give alarm material, such as sponge as returning sound wave. will not give
bubble film. 3. The sensor fails to alarm of
3. The obstacle is too small. inspect. obstacle.
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4.3.10-1 Vehicle Body Control System 4.3.10-1

Vehicle Body Controller
Outside view of BCM is seen below:
BCM is installed at passenger side of instrument panel and behind the glove box. The
installation position of BCM on steering support is seen in the figure below:
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Function Instruction and Control System will stop blinking. Activation of emergency
Composition alarm signal is not under control of ignition
switch.
1 Vehicle Locating
(6) Crash alarm: When there is crash
When the ignition switch is pulled out
signal, hazard warning lamp will be
and four doors are closed, if continuously
activated too. Press the emergency alarm
press RC locking button two times within 2s;
switch within 4 seconds after signal
left and right turn lamps will blink and horn
activation will stop the hazard warning lamp.
will ring for two times. The turn lamp will
be off after 10 seconds. If press unlocking (7) Turn lamp activation priority
button or door opens during this period, the a: When ignition switch is at ON
left and right turn signal lamp will switch to position, if emergency alarm switch is
corresponding blinking function. activated before the left or right turn lamp
switch, then the turn signal will take the
priority; if the left or right turn lamp switch
is activated before the emergency alarm
switch, then the emergency alarm signal
takes the priority.
b: When activate left/right lane change
blinking function, if the emergency alarm
switch is activated again, then the alarm
2 Turn and Hazard Warning signal takes the priority. The lamp will not
Lamp blink even after the alarm signal is canceled,
(1) Left turn lamp: When the power until there is activation signal again.
supply is at ON position, left turn switch is c: When activate left/right lane change
activated and left turn lamp blinks at a blinking function, if right or left turn switch
frequency of 360ms-ON/360ms-OFF. is activated again, then the turn signal takes
(2) Right turn lamp: When the power the priority. The left and right lane change
supply is at ON position, right turn switch is blinking function will be canceled within 1
activated and right turn lamp blinks at a second. All turn lamp switch signal of
frequency of 360ms-ON/360ms-OFF. 100ms<t<700ms will be regarded as
common switch signal. The sequential
(3) Lamp filament failure inspection: relationship is seen in the figure below.
If there is filament failure of turn lamp (only
front and rear turn lamps), the blinking
frequency is 2 times of the normal frequency,
which may be 180ms-ON /180ms-OFF;
(4) Lane change blinking: When
power supply is at ON position, if place the
turn switch to OFF-> ON ->OFF within
100ms<t <700ms; the turn lamp on
corresponding side may blink for three times;
meanwhile, if there is switch signal of
100ms < t < 700ms during the blinking,
BCM does not respond.
(5) Hazard warning lamp: if the
emergency alarm switch is activated, both
Except the three conditions mentioned
left and right lamps blink at a frequency of
above, the priority of turn lamp signal is
360ms-ON/360ms-OFF; if hazard warning
seen below:
switch is pressed after activation, the lamp
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1) Emergency alarm; 2) Turn signal; 3) Frequency and duty ratio of each turn
Lock/unlock signal; 4) Feedback signal of lamp signal are seen below:
central control mode change; 5) Service
mode (learning key, etc.)
Function Frequency Priority Level Time Duty Ratio

Emergency alarm switch 360ms-ON/360ms-OFF 1 50%
Crash emergency alarm 360ms-ON/360ms-OFF 2 50%
Turn signal lamp 360ms-ON/360ms-OFF 3 50%
Unlock reminder 360ms-ON/360ms-OFF 4 1 time 50%
Lock reminder 360ms-ON/360ms-OFF 5 2 time 50%
Locating light 360ms-QN/360ms-OFF 6 10 seconds 50%
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2 Roof Lamp blink for two times at the same time.
Roof lamp lights up gradually: If roof (2) If power supply is not at OFF
lamp switch is at door position, the roof position and the vehicle doors are closed
lamp will be on linearly within 1 second in (not including trunk cover), press the lock
any condition. position of central door switch inside the
vehicle, or use the mechanical key to lock
(1) Any of the vehicle doors is open
the four vehicle doors. The turn lamp does
(including truck cover);
not blink.
(2) Ignition switch is at OFF position.
(3) If power supply is at OFF position,
Unlock the vehicle door by pressing
when there is open door (including trunk
"Unlock" button on remote control unit or
cover), press the "Lock" button and the four
unlock the vehicle door with mechanical key
doors will be locked first and then unlocked.
or central lock switch.
Anti-theft horn does not ring and the buzzer
(3) Power supply is turned to OFF beeps for 10 seconds.
position from ON position.
(4) Whichever position the power
Roof lamp goes out gradually: The roof supply is at, if there is open vehicle door
lamp will be off linearly within 1 second no (not including trunk cover), press the lock
matter roof lamp switch is under any position of central door switch inside the
condition. vehicle, or use the mechanical key to lock
(1) When there is no central lock, 25 the four vehicle doors first and then unlock
seconds after all vehicle doors closed them.
(including trunk cover); Four vehicle doors unlocking:
(2) When power supply is at ON (1) If ignition switch is at OFF
position, close all vehicle doors (including position or the power supply of complete
trunk cover) and lock the vehicle doors with vehicle is at OFF position, press the
central lock switch. "unlock" button on remote control unit, or
(3) When power supply is at OFF use the unlock position of central door
position, press "lock" button on remote switch inside the vehicle, or use the
control unit to lock the vehicle doors after mechanical key to unlock the four vehicle
close all vehicle doors (including trunk doors. The turn signal will blink for one
cover). time at the same time.
(4) All vehicle doors are closed and (2) If ignition switch is at ON position,
power supply is at ON position. press the unlock position of central door
switch inside the vehicle, or use the
3 Central Door Lock mechanical key to unlock the four vehicle
All remote control function mentioned doors. The turn lamp will not blink.
below can only be applied when the power
supply is at OFF position and the key is
pulled out. Speed response central door lock (it is
on when the vehicle is sold out):
Lock:
(1) When the power supply is turned
(1) If power supply is at OFF position to ON position from OFF position, and the
and the vehicle doors are closed (including vehicle speeds up to 20Km/h from 0, BCM
trunk cover), press the "lock" button on controls the four vehicle door to implement
remote control unit, or use the lock position automatic locking for once;
of central door switch inside the vehicle (not
including trunk cover), or use the (2) After automatic locking is
mechanical key (not including trunk cover) performed, before the vehicle speeds up to
to lock the vehicle doors. The turn lamp will 20Km/h from 0 (the power supply is still at
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ON position), if the condition of any of the Function release: If the rear defroster switch
four vehicle doors changes or the condition is pressed again within the 14 minutes of
of driver's door lock changes, please rear defrosting operation, or the ignition
implement the automatic locking for another switch is turned to OFF position from ON
time. position, or the activation time reaches 14
minutes, or the battery voltage is lower than
Parking unlocking (it is on when the
9V, the defrosting function will be released.
vehicle is sold out):
When ignition switch is turned to OFF 5 Reminding and Warning
position from other position and the four Function
vehicle doors are locked, BCM will control Lamp on reminding:
the four vehicle doors to implement If ignition switch is pulled out and the
automatic unlocking for one time. position lamp is on, open the door at driver's
Crash unlocking: side and BCM will change the "Buzzer
If BCM receives "Crash" signal from Alarm Mode" in CAN to "Lamp On
SRS EOT and power supply is at ON Reminding" until the lamp goes out, or the
door is closed, or the key is inserted in, or
position, it will carry out automatic
unlocking for 2 times with an interval of 3 the power supply is turned to OFF position
seconds; the alarm light will be activated at from other position.
the same time. Crash signal is 200ms low Alarm for open door:
level, as shown in the figure below.
If ignition switch is at ON position and
any of the doors is open (including trunk
cover), BCM will change the "Buzzer Alarm
Mode" in CAN to "Lamp On Reminding". If
the door is closed during the period, "Buzzer
Alarm Mode" in CAN will be set as "OFF".
During the "alarming" period (during which
corresponding CAN message is sent), BCM
does not ring again (it only alarms for once).
Thermal protection of lock motor: When the alarm is done, if other door is
open, the BCM will alarms once more
If the central door lock implements (sending corresponding CAN message).
locking/unlocking for more than 10 times
continuously within 10 seconds, the central Reminding for unlocked door
door lock motor will be forbidden to operate If ignition switch is at OFF position
for 1 minutes, so as to protect the lock motor. and the key is pulled out, when there is door
However, if it conflicts with crash unlocking open (including trunk cover), press the
function, the crash unlocking shall prevail. "lock" button on remote control unit, all
4 Rear Defrosting and Rear-view vehicle doors will be locked and then
Mirror Heating unlocked, and the buzzer will keep ringing
for 10 seconds. If any of the following
Function description: conditions is satisfied, the buzzer will stop
Function activation: When ignition switch is ringing (the "Buzzer Alarm Mode" in CAN
at ON position, if rear defrosting switch is will be set as "OFF"):
pressed, the rear defrosting function will be 1) Power supply is turned to other position
activated. It will operate for 14 minutes and than OFF. +
then stop. The rear defrosting indicator lamp
on the panel will be activated at the same 2) Vehicle door close (including trunk
time. cover);
3) Press unlocking button of remote
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control unit; Frequen Level Rati
cy o
4) 10 seconds after buzzer alarm Alarm for
activation. 1HZ 1 50%
open door
Alarm for unfastened driver's safety belt: Alarm
for 300s=
If SRS (safety air bag) sends the CAN unfasten (6 s
message indicating "Unfastened Driver's ed ring +
Safety Belt" and the vehicle speed reaches driver's 1HZ 2 50% 9s
7km/h, BCM will change the "Buzzer Alarm stop) ×
IGN is safety
Mode" of CAN message into "Unfastened at ON belt 20
Driver's Safety Belt". During the period, if cycles
position (speed ≥
the CAN message send by SRS indicates . 7km/h)
that the driver's safety belt is fastened, or the Successfu
ignition switch is turned to ACC or OFF l function
position from ON or ST position, then the setting
buzzer alarm stops (the "Buzzer Alarm reminding
1HZ 3 50% 1s
Mode" of CAN message is set as "OFF"). (If of speed
response
the vehicle slows down to 7km, the alarm central
does not stop.) door lock
Successful key learning reminding: Remindin
g alarm
100
If the remote key learning is on through for 1 10s
%
diagnostic apparatus or online key making unlocked
equipment, whenever a key is successfully door
duplicated, BCM will change the "Buzzer Remindin
g of
Alarm Mode" of CAN message to IGN is
lighting
1HZ 2 50%
"Successful Key Learning Reminding". The at ACC
lamp
time is 1s. or OFF
Successfu
position
Function setting reminding of speed l function
setting
response central door lock: reminding
1HZ 3 50% 1s
When the automatic speed locking of speed
function is activated or turned off by response
central
diagnostic apparatus, BCM will change the
door lock
"Buzzer Alarm Mode" of CAN message to
"Activation Reminding of Speed Response Connector Definition
Central Door Lock" or "Cancel Reminding BCM Terminal Definition
of Speed Response Central Door Lock". The
time is 1s.
6 Electric Horn Control
Press the horn switch to start the horn
function and release the switch to turn off
the function. During vehicle locating, the
electric horn will ring for 2 times.
Alarming frequency and priority level of the
alarming function are seen in the table
below.
Conditi Alarmin Priorit Dut Remar
Function
on g y y ks
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Connector A: Model - AMP1318745-2
Model
S/N Interface Definition Signal Type Effective Value Configuration Remarks
JA1 NC DI Low level
JA2 NC DI Low level
JA3 Back door release DI Low level
switch
JA4 NC DI Low level
JA5 Horn switch DI Low level
JA6 Collision signal DI
JA7 DR door unlock state DI Low level
JA8 Rear door condition DI Low level
switch
JA9 Right turn signal lamp DI Low level
switch
JA10 DR door lock state DI Low level
switch
JA11 Ignition switch DI High level
JA12 NC
JA13 NC
JA14 NC
JA15 NC
JA16 CANH CAN Pulse
JA17 NC DI Low level
JA18 Alarm releasing switch DI Low level
JA19 Passenger door state DI Low level
JA20 NC DI Low level
JA21 Front left door state DI Low level
JA22 Position lamp switch DI High level
signal
JA23 KEY-IN signal DI High level
JA24 Hazard warning lamp DI Low level
switch
JA25 Trunk state switch DI Low level
JA26 Left turn signal lamp DI Low level
switch
JA27 Rear defrost switch DI Low level
JA28 Unfastened driver's DI Low level
safety belt
JA29 Central lock switch AD Simulation
JA30 Ground GND
JA31 NC LIN Pulse
JA32 CANL CAN Pulse
Connector B: Model AMP175785-1
JB1 Left turn lamp drive HSD Pulse
JB2 Turn lamp power supply DI High level
JB3 Right turn lamp drive HSD Pulse
JB4 Indoor lamp drive PWM Pulse
JB5 Horn drive HSD High level
JB6 Trunk lock motor drive HSD High level
JB7 Horn power supply DI High level
JB8 Lock motor drive HSD High level
JB9 Unlock motor drive HSD High level
JB10 Controller power DI High level
JB11 Turn lamp audio relay drive PWM Pulse
JB12 NC
JB13 Controller ground GND Low level
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JB14 NC
JB15 Window up (reserve) DO Low level
JB16 Window down (reserve) DO Low level
JB17 Rear defrosting output DO Low level
JB18 NC
JB19 NC DO Low level
JB20 Lock motor power supply DI High level
Maintenance Tool
No.10 sleeve, multimeter, oscilloscope, one moveable lighting device, harness and one
set of special tool.
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Diagnosis of Common Faults of Vehicle Body Controller
Fault
Function Description Causes Solution Measures Remarks
1. No remote controller 1. Make a key online
is made on-line. again or manually
2. Remote controller make a key for the
distance is shorter than 12m or diagnostic scanner.
there is strong interference around 2. /
such as a cellphone or a launcher. 3. Press the remote
3. Remote controller is controller within 12m
powered off. Check the battery to see if it is normal or
All functions of voltage to see if it is higher than to confirm whether
remote 2.9V; there is interference
controller fail 4. Remote controller is source nearby.
in poor connection with the 4. Re-install PCB in the
battery. remote controller.
5. Voltage of the storage 5. Charge the storage
battery is too low. battery.
6. Remote controller is 6. Replace the remote
damaged. Replace the remote controller and relearn
controller and relearn through the the new one with the
diagnostic scanner. diagnostic scanner.
1. Fuse for door lock
power supply has blown out.
2. Door lock motor is in
Functions 1. Replace the fuse for
thermal protection. Wait one
of Remote door lock power
minute and then see if the door
controller supply on the
lock can work normally.
and Door instrument box.
3. Harness connector
Lock 2. Wait one minute and
connecting the door lock to BCM
then see if the door
becomes loose
lock can work
4. Voltage of the storage
All door locks normally.
battery is too low.
do not work 3. Re-connect the
5. Use the remote
harness connector.
controller to unlock and lock to
4. Charge the storage
hear whether the relay in BCM
battery.
works. If it works, the problem is
5. Inspect the harness
within door lock circuit harness or
one by one to see if
the door lock; if it does not work,
short circuit exists or
ground signal of BCM is short to
replace BCM.
the motor output end or the
internal circuit of BCM is
damaged.
A single door 1. Harness connector 1. Re-connect the
lock does not connecting the door lock to BCM harness connector.
work becomes loose 2. Replace the door
2. Door lock is damaged. lock.
Certain door
Replace the door lock or re-
cannot be Fault within the door lock or the
assemble the inner or outer
locked or outer/inner cable
door cable.
opened.
Turning Left and right 1. Fuse of the ignition 1. Re-connect the
and turn lamps do switch signal is damaged or fuse or replace it.
Emergency not work but becomes loose. 2. Check and
Alarm the emergency 2. Ignition switch signal eliminate any fault within
Lamplight alarm lamplight is abnormal. the harness of ignition
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is normal switch signal to BCM or
fault of ignition switch in
the steering lock.
1. Fuse for turn lamp 1. Replace the
power supply has blown out. fuse.
2. Harness connector 2. Re-connect the
connecting the turn lamp to BCM harness connector of BCM.
Both the turn becomes loose 3. Re-connect the
lamp and the 3. Harness connector connector of BCM.
emergency connecting the turn lamp switch 4. Replace the bulb
alarm lamp do and the emergency alarm switch of turn lamp.
not work to BCM is not connected 5. Replace BCM.
properly.
4. Turn lamp is
damaged.
5. BCM fault
The left/right
turn lamp 1. Check and
1. Power of the bulb is
flashes quickly replace the bulb of turn
wrong.
during steering lamp.
2. Fault within BCM
under normal 2. Replace BCM.
condition
Turn signal
lamp failure
detection
function fails.
(Among the
front and the BCM fault Replace BCM.
rear turn lamps,
one does not
flash quickly
when another is
turned off.)
1. Connector connecting
the roof lamp to BCM becomes
loose. 1. Re-connect the
2. Connector of roof connector of BCM.
Indoor roof lamp becomes loose or falls off. 2. Re-connect the
lamp cannot be 3. Fuse of roof lamp is connector of roof lamp.
lighted. damaged or becomes loose. 3. Re-connect the
4. Roof lamp is fuse or replace it.
damaged. 4. Replace the roof
5. BCM is damaged and lamp.
Indoor
needs replacement. 5. Replace BCM.
Lamp
Roof lamp does
Control
not have the
function of
becoming
1. Connector connecting
brighter/dimmer 1. Re-connect
the roof lamp to BCM becomes
gradually. connector B of BCM.
loose.
(Function of the 2. Replace BCM.
2. BCM is damaged.
roof lamp is
normal when it
is at Gear
“ON”)
1. Poor connection or 1. Re-connect the
Rear
Rear defroster fault of the rear defroster harness connector of rear defroster
Defroster
does not work. 2. Voltage of the storage or check for harness fault
Control
battery is too low. step by step.
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3. Fuse for rear defroster 2. Charge the
power supply is damaged or storage battery.
becomes loose. 3. Re-connect the
4. Fuse of the ignition fuse of rear defroster or
switch signal is damaged or replace it.
becomes loose. 4. Re-connect the
5. Ignition switch fault fuse of ignition switch or
6. Rear defroster switch replace it.
fault 5. Check and
7. Connector of BCM replace the ignition switch.
becomes loose or falls off. 6. Check and
8. BCM fault replace the rear defroster
9. Fault of resistance switch.
wire of rear defroster 7. Re-connect the
connector of BCM.
8. Replace BCM.
9. Replace the
resistance wire of rear
defroster.
1. Re-connect the
connector of the horn or
1. Poor connection or check for harness fault step
fault of the horn harness by step.
2. Horn switch fault 2. Replace the horn
Horn The horn does
3. Connector at BCM switch.
Control not work.
end becomes loose or falls off. 3. Re-connect the
4. Horn fault connector of BCM.
5. BCM fault 4. Replace the
horn.
5. Replace BCM.
Warning 1. Re-connect the
1. Connector at BCM connector of BCM.
end becomes loose or falls off. 2. Re-connect the
2. Connector connecting connector at the instrument
All warning BCM to the instrument becomes end.
functions do not loosened or falls off. 3. Check for CAN
work 3. Communication fault communication fault of
of BCM to the instrument BCM harness.
4. Fault of buzzer in the 4. Replace
instrument instrument.
5. BCM fault 5. Replace BCM.
1. CAN communication 1. Replace the air
Only the safety
fault of the air bag controller bag controller.
belt warning
2. Fault of safety belt 2. Replace the
function does
switch safety belt switch.
not work.
3. BCM fault 3. Replace BCM.
For vehicles
without
PEPS,
1. Connector at BCM 1. Re-connect the learning of
end becomes loose or falls off. connector of BCM. remote
Only warning
2. Harness fault of 2. Check the controller
for unclosed
driver’s door switch to BCM. harness connector of BCM key and
door does not
3. Fault of driver's door to the driver’s door switch vehicle
work.
switch harness to see if there is any model
4. BCM fault fault. configuration
3. Replace or refit must be
the driver’s door switch. carried out
4. Replace BCM. again after
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BCM
replacement.
Only warning For vehicles
for still-lighted without
lamp does not PEPS,
work. learning of
remote
controller
1. Connector at BCM 1. Re-connect key and
end becomes loose or falls off. connector C of BCM. vehicle
2. BCM fault 2. Replace BCM. model
configuration
must be
carried out
again after
BCM
replacement.
1. Harness along the
door edge is unreliable; switch
signal at the door edge is short to
ground (The door indicator on the 1. Inspect the fault
instrument is on.) of “Door State" Pin of the
Anti-theft 2. Switch at the door harness connector of BCM.
buzzer is edge is in poor connection (The 2. Replace or refit
activated when door indicator on the instrument the switch at door edge.
entering the is on.) 3. Improve the
defense area 3. Switch signal at the waterproof measure of
without any door edge is short to ground as harness at the door edge.
illegal invasion water enters the harness at door
(door opening edge (The door indicator on the
or ignition) instrument is on.)
Schematic Diagram of Peripheral Wiring
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4.3.11-1 DLC 4.3.11-1
4.3.11 DLC Network, refers to the controller area

network bus. It is used to control the
Description of DLC connection of devices for data exchange.
DLC is a harness connector which Twisted-pair is used as the
vehicle manufacturers all over the world communication medium for CAN bus and
agree to use upon mutual consultation and the communication rate of high-speed CAN
adjustment. This harness connector must be bus is 500kbps.Two resistances of 120Q are
used when building communication between installed in the terminals at both sides of the
a diagnostic scanner and the vehicle or when twisted-pair among which one is within the
programming for the vehicle communication Engine Management System (EMS) and the
system with the diagnostic scanner. other is within the Instrument Panel (IP).
This harness connector must meet the Nodes on the high-speed CAN which
following conditions: have diagnostic functions include Engine
1. It shall be a harness connector with 16 Management System (EMS), Transmission
pins which can be connected with all Control Unit (TCU), Anti-lock Breaking
kinds of diagnostic scanners. System (ABS), Supplementary Restraint
System (SRS), Electric Power Steering
2. It shall always provide power for the (EPS), Instrument Panel (IP) and Body
storage battery of the diagnostic Control Module (BCM).
scanner via No. 16 Terminal.
3. It shall always provide grounding for
Inspection for Completeness of
the diagnostic scanner via No.4 CAN
Terminal and No.5 Terminal. 1. Turn the ignition switch to “LOCK”
4. All the remaining terminals shall be position.
used for communication with the 2. Measure the resistance between No. 6
vehicle system. and No. 14 diagnostic interfaces of
View of Fault Diagnosis Interface DLC.Standard value: 55~63Ω
Terminal
Wiring Terminal Description
No.
1
2
3
4 0. 5 Ground
5 0. 5 Ground 3. If the resistance measured is 110~125Q
6 0. 5 High-speed CAN-H or there is no continuity, it indicates
7 fault of CAN. Please inspect the
8 harness connector of ECM and then
9 that of BCM. Carry out repair work
10 upon discovery of short circuit or poor
11 connection.
12
13 Fault Description, Diagnosis and
14 0. 5 Low-speed CAN-L Test
15
16 0.5 +B power supply General Equipment
Description of CAN 1. Digital multimeter
CAN, abbreviation of Controller Area 2. Diagnostic scanner
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4.3.11-2 DLC 4.3.10-2
1. Confirm problems indicated by
customers.
2. Inspect visually to see if there is an
obvious fault related to the electric
appliance.
3. Inspect the system circuits which are
easy to be seen or can be seen.
4. If the observed or raised problem is
apparent and its cause has been found,
it shall be corrected before next step.
5. If visual inspection passes, confirm the
fault and refer to the fault description
table.
Electric Appliance
Storage battery
Fuse
Loosened or corroded connector of any electric
appliance
Harness
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4.3.11-3 DLC 4.3.11-3
The fault diagnostic process is similar to that
Diagnostic scanner
of ESP.
Communication failure
Reference: Diagnostic Process for
between diagnostic scanner Circuit
Communication Failure between Diagnostic
and EMS
Scanner and ESP
EMS
Diagnostic scanner
of ESP.
and TCU TCU
Scanner and ESP
Diagnostic scanner
Communication failure Reference: Diagnostic Process for
between diagnostic scanner Circuit Communication Failure between Diagnostic
and ESP Scanner and ESP
ESP
Diagnostic scanner
of ESP.
and SRS
Scanner and ESP
SRS
Diagnostic scanner
of ESP.
and SAS
Scanner and ESP
SAS
Diagnostic scanner
of ESP.
and EPB
Scanner and ESP
EPB
Diagnostic scanner
of ESP.
and ALS
Scanner and ESP
SAS
Diagnostic scanner
of ESP.
and IP
Scanner and ESP
IP
Diagnostic scanner
of ESP.
between diagnostic scanner Circuit Communication Failure between Diagnostic
and BCM Scanner and ESP
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4.3.11-4 DLC 4.3.10-4
BCM
Diagnostic scanner
of ESP.
and PEPS
Scanner and ESP
PEPS
Diagnostic scanner
of ESP.
and ESCL
Scanner and ESP
ESCL
Communication failure Diagnostic scanner of ESP.
between diagnostic scanner and Circuit Reference: Diagnostic Process for
TPMS TPMS Communication Failure between Diagnostic
Scanner and ESP
Diagnostic scanner
of ESP.
between diagnostic scanner and Circuit
PAC
Scanner and ESP
PAC
Diagnostic scanner
of ESP.
RRS
Scanner and ESP
RRS
Diagnostic scanner
of ESP.
AC
Scanner and ESP
AC
Diagnostic scanner
of ESP.
PEPS
Scanner and ESP
PEPS
Diagnostic scanner
of ESP.
ESCL
Scanner and ESP
ESCL
Diagnostic scanner
of ESP.
TPMS
Scanner and ESP
TPMS
Diagnostic scanner
of ESP.
between diagnostic scanner and Circuit Communication Failure between Diagnostic
PAC Scanner and ESP
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4.3.11-5 DLC 4.3.11-5
PAC
Diagnostic scanner
of ESP.
RRS
Scanner and ESP
RRS
Diagnostic scanner
of ESP.
AC
Scanner and ESP
AC
Diagnostic scanner
of ESP.
DVD
Scanner and ESP
DVD
Diagnostic Process for Communication Failure between Diagnostic Scanner and ESP
1. Verify fault symptoms.
A. Prepare a normal vehicle.
B. Try to build communication with ESP.
Can communication be built with ESP?
→Yes
Go to Step 2.
→No
Replace the diagnostic scanner with a new one.
2. Inspect whether the diagnostic circuit is connected to ground.
A. Turn the ignition switch to
“LOCK” position.
No.4/No.5 Terminal of DLC harness and the
reliable ground connection respectively
→Yes
Go to Step 3.
→No
Inspect whether grounding of No.4/No.5
Terminal of DLC is normal.
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4.3.11-6 DLC 4.3.10-6
3. Inspect whether power supply connected to the diagnostic circuit is normal.
A. Turn the ignition switch to
“LOCK” position.
No.16 Terminal of DLC harness and the
reliable ground connection respectively
Standard value: 9V-16V
Is the voltage normal?
→Yes
Go to Step 4.
→No
Inspect whether the power supply
connected to No.16 Terminal is normal.
4. Inspect diagnostic circuit CAN-L and ESP circuit.

A. Disconnect the harness connector
of ESP.
No.8 Terminal of ESP harness connector
and No.14 Terminal of DLC.
→Yes
Go to Step 5.
→No
Check and repair the short circuit between
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4.3.11-7 DLC 4.3.11-7
5. Inspect diagnostic circuit CAN-H and ESP circuit.
A. Disconnect the harness connector
of ESP.
→Yes
To Step 6
→No
Check and repair the short circuit between
6. Inspect the power circuit of ESP.

A. Inspect the power circuit of SRS.
Reference: 2.3 Brake System, “ESP
Diagnosis and Test”. Is the power circuit
normal?
→Yes
Go to Step 7.
→No
7. Replace ESP and confirm that the fault has been eliminated.
BENNI 2013.11
Power System
4.3.12 Power System

Contents Page
4.3.12.1 Installation and Removal 4.3.12-1
Common Storage Battery 4.3.12-1
4.3.12.2 Wiring Diagram of Storage Battery 4.3.12-1
Wiring Diagram of Storage Battery 4.3.12-1
Basic Parameters of Storage Battery 4.3.12-2
4.3.12.3 Inspection, Maintenance, Charging and Repair 4.3.12-3
Self-discharge of Storage Battery 4.3.12-3
Capacity Loss after Installation 4.3.12-3
Battery Inspection 4.3.12-3
Description, Causes and Remedial Measures for Storage Battery Fault 4.3.12-4
Charging Manner 4.3.12-4
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4.3.12-1 Power System 4.3.12-1
4.3.12.1 Installation and Removal

Common Storage Battery
The storage battery is installed at the left side of engine compartment.
S/N Comp/part Name

1 Storage battery power wire assembly
2 Storage battery ground wire assembly
3 Storage battery assembly
4 Pressing plate assembly for battery retaining
5 Hexagon flange nut
6 Retaining screw of battery
7 Tray assembly of storage battery
Sequence of removal:
Item 3 is at the left side of the engine compartment. First disconnect Item 2 and then
Item 3 with an M10 sleeve. Screw Item 5 outwards and then take out Item 6 and Item 4.
finally, take Item 3 out from Item 7.
Sequence of installation:
Item 3 is at the left side of the engine compartment. Install Item 7 on the
corresponding metal plate of the vehicle body→Use Item 4 to fasten Item 3 onto Item 7,
as shown in the figure→Fasten Item 3 further with Item 5 and Item 6→Install Item 1 on
the positive pole of the storage battery and tighten it with 8±N.M→Install Item 2 on the
negative pole of the storage battery and tighten it with 8±N.M.
4.3.12.2 Wiring Diagram of Storage Battery
Wiring Diagram of Storage Battery
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4.3.12-2 Power System 4.3.12-2
S/N Comp/part Name

1 Storage battery assembly
2 To generator
3 To vehicle-mounted electric appliances
4 Ignition lock on Gear “Start”
5 Starter motor
Basic Parameters of Storage Battery
Indicator Common storage battery
Exhaust-type (commonly known as maintenance-free) 6-QW-
Specifications
45Ah
Mass 13kg
Nominal voltage D.C.12v
Rated capacity at 20h of discharge rate 45Ah
Idle capacity ≥ 71min
Charge acceptance ≥ 6.75A
Discharge at 225A; Voltage ≥9v after 5s. ≥8.8v at 30s and ≥ 8.4v
Cold-starting ability at -18 °C
at 60s.
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4.3.12-3 Power System 4.3.12-3
4.3.12.3 Inspection, Maintenance, still start the vehicle after being left
Charging and Repair unused for 6 months.
Self-discharge of Storage Battery Battery Inspection
Speaking theatrically, self-discharge of 1. Inspect with a discharge detector.

the storage battery is inevitable. Though Press the corresponding contacts onto
self-discharge of fully maintenance-free the positive/negative pole of the storage
battery is far less than that of common battery respectively. When the pointer of the
battery, self-discharge to a certain extent discharge detector is within the green scope
still exists anyway. If the storage battery is and keeps there for about 2 seconds, it
left open for a long time, quantity of indicates that the capacity can meet the
electricity stored in the storage battery will requirement of starting the vehicle at high
decrease obviously.Self-discharge of storage current; if the pointer is within the red scope
battery is affected mainly by the following without any other abnormalities, it indicates
factors: that capacity is insufficient and charging
1. The self-discharge rate increases shall be carried out.
as the temperature increases. Generally, the 2. Use a voltmeter to inspect the
self-discharge rate increases approximately storage battery with the front lamp as the
2.7 folds each time when the temperature load.
increases by 10°C. Therefore, the self-
Connect the voltmeter onto the storage
discharge rates of the same vehicle stored in
battery in a way same as that to test the
winter and in summer are greatly different.
battery voltage, read the voltage value, and
2. Conditions of the storage places then open the front lamp. If the voltage of
can also affect the self-discharge rate. Self the storage battery does not drop quickly
discharge speed of the storage battery will and remains greater than 10V, then the
quicken in dusty environment with high storage battery can be used to start the
humidity. vehicle when it is fully charged.If the
Capacity Loss after Installation voltage of the storage battery drops quickly
after the front lamp is opened, charge the
After the storage battery is installed in battery till its function is restored. For
the vehicle, its electricity is consumed storage battery which has been unused for a
mainly through the following aspects: long time, relevantly extend the charging
1. Certain amount of electricity will time. It is better to conduct charging and
be consumed during commissioning. discharging for several times so as to fully
activate the battery.
2. Some electric appliances on the
vehicle continuously consume Note: It is inappropriate to use a
electricity, such as anti-theft buzzer. discharge detector to inspect storage battery
3. Elements on the vehicle cause which is under charge/discharge, or was
electric leakage due to poor insulating fully charged just now.This is because a
property. large amount of hydrogen gas will be
produced during charging. At this time, if
4. The negative connecting wire is you use a discharge detector or a resistance
not pulled off which causes quiescent wire to inspect the storage battery, the
current and leakage current, sparks will make the gas explode, causing
accumulating the amount of electricity personal injuries and damages to relevant
that is lost.Therefore, standing time of materials.
the storage battery can be affected by
many factors. Generally, the fully
charged storage battery with the
negative connecting wire pulled off can
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4.3.12-4 Power System 4.3.12-4
Description, Causes and Remedial Measures for Storage Battery Fault
Fault Causes Troubleshooting Supplementary Measure
Description Method
Caused by frequent start, continuous Charge the storage
start for a long time, not timely charged battery in time.
storage battery which is seriously out of
power
Inspect relevant circuit
Electric leakage of circuit installed on of the vehicle,
the vehicle or the lamp on the vehicle is eliminate electric
not turned off. leakage and charge the
storage battery.
Manage not to leave the
Power carried
vehicle unused for a
by the storage
long time. If the vehicle
battery is Storage battery is used without charging
is to be left unused,
insufficient when the vehicle has not been used for
charge the storage
and the a long time.
battery fully and charge
engine does
it once every other
not run or
month afterwards.
runs very
Output voltage of the
slowly
Output voltage of the vehicle engine is vehicle engine shall be
too low or the engine fails to work. 13.2~14.4V under
loading condition.
Abrasive wear (caused by bottoming) of
carbon brush surface of the engine Inspect and repair the
(starter motor)causes excessive starting carbon brush inside the
current. engine.
Connector at the positive or negative
Fasten the connecting
pole of the storage battery becomes
post.
loose.
Connection at certain position of the Fasten the terminal Reduce inner damage of
terminal post is poor, causing the post. storage battery caused by
Terminal post
terminal post burnt out due to sparks sudden start.
burns out.
generated when starting the
vehicle(high current discharge).
Charging Manner
Before starting the engine, please first check the voltage. If the voltage is lower than 12.6V,
charge the storage battery and then start the engine. This can assure that the vehicle can be started
after it is stored in a garage of another place for a greatly longer time. The charging manner is as
following:
1. Constant-voltage charge:
Charge the storage battery at a constant voltage of 14.8V and continue to charge it for 3
hours after the current drops to 2.25A. Note that the charge current shall not be higher than 25A.
2. Constant-current charge: First charge the storage battery at 4.5A and then continue to
charge it for 3 hours at 2.25A after the voltage increases to 14.8V.
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Part 5
Vehicle Body
Section Title Page
5.1 Vehicle Body and Accessories
5.1.1 Fixed Glass of Complete Vehicle 5.1.1-1
5.1.2 Door System 5.1.2-1
5.1.3 Roof-mounted Sunvisor Frame Assembly 5.1.3-1
5.1.4 Instrument Panel and Console 5.1.4-1
5.1.5 Door Inner Trim Panel 5.1.5-1
5.1.6 Interior Trim Panel and Trims 5.1.6-1
5.1.7 Rear-view Mirror 5.1.7-1
5.1.8 Front/Rear Quarter Window Exterior Garnish Assembly 5.1.8-1
5.1.9 Bumper 5.1.9-1
5.1.10 Front Hood Garnish 5.1.10-1
5.1.11 Front Wheelhouse Lining Plate Assembly 5.1.11-1
5.1.12 Washer 5.1.12-1
5.1.13 Back Door Handle Assembly 5.1.13-1
5.1.14 NVH Parts 5.1.14-1
5.1.15 Seat 5.1.15-1
5.1.16 Safety Belt System 5.1.16-1
5.1.17 Air Bag System 5.1.17-1
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Contents Page
5.1.1 Fixed Glass of Complete Vehicle
Instructions and Operations 5.1.1-1
Part Description 5.1.1-1
Front Windshield Assembly 5.1.1-2
Back Door Window Glass Assembly 5.1.1-5
Skylight Glass Assembly 5.1.1-8
5.1.2 Door System
Torque Specification 5.1.2-1
Door Window Glass 5.1.2-1
Door Window Glass 5.1.2-2
Front door power window regulator 5.1.2-3
Rear Door Power Window Regulator 5.1.2-4
Front Door Window Glass Run 5.1.2-5
Rear Door Window Glass Run 5.1.2-6
Front Door Glass Run Channel 5.1.2-7
Rear Door Glass Run Channel 5.1.2-8
Front Door Stop 5.1.2-9
Rear Door Stop 5.1.2-10
5.1.3 Roof-mounted Sunvisor Frame Assembly
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5.1.1-1 Fixed Glass of Complete Vehicle 5.1.1-1
5.1.1 Fixed Glass of Complete Vehicle

Specifications
Name Specification
Front windshield assembly 2.0+0.76+2.0 laminated clear glass with transparent film
Back door window glass assembly 3.2 tempered glass
Back door window glass assembly (with 3.2 tempered glass
defroster)
Skylight glass assembly 2.1+0.76+2.1 laminated green glass with grey film
Instructions and Operations

System Overview
Fixed Glass of Complete Vehicle includes the front windshield assembly, the back door
window glass assembly and the skylight glass assembly. The Fixed Glass of Complete Vehicle,
together with the vehicle body closing/opening components and other door window glasses, forms
a closed space for driving and riding which can transmit light at the same time, offering the driver
a good view.
The Fixed Glass of Complete Vehicle is fixed in the window frame on the vehicle body by
adhesive. Solidified adhesive has a certain degree of hardness and elasticity which has the
functions of sealing and water proofing at the same time.
If it is necessary to replace the fixed glass, please first take down the original glass, remove
the remaining adhesive in the window frame, and then install the new glass and fix it properly
with adhesive.
Part Description
Front Windshield Assembly
The front windshield assembly consists of interlayer glass which has not been tempered. So
compared with other tempered glass, the windshield is more likely to crack. When suffers
destructive impact and becomes cracked, most of the windshield will stick to the central film other
than fall off to hurt someone.
Back Door Window Glass Assembly
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The back door window glass assembly is made of tempered glass. Like all other tempered
glass, it has a relatively high degree of strength and shock resistance. When the glass suffers
destructive impact and becomes cracked, the fragment shows no blade scratches and the size of
fragment is comparatively small.
Back Door Window Glass Assembly (with Defroster)
The back door window glass assembly (with defroster) is made of tempered glass. Like all
other tempered glass, it has a relatively high degree of strength and shock resistance. When the
glass suffers destructive impact and becomes cracked, the fragment shows no blade scratches and
the size of fragment is comparatively small.
There is a heating line for removal of frost and fog in the back door window glass assembly
(with defroster) and the vehicle-mounted generator supplies power to this heating line. The
heating line for removal of frost and fog is formed by solidified silver paste on the glass surface
and connectors welded onto the glass.
Skylight Glass Assembly
The skylight glass assembly consists of interlayer glass which has not been tempered. So
compared with other tempered glass, the skylight glass is more likely to crack. When suffers
destructive impact and becomes cracked, most of the skylight glass will stick to the central film
other than fall off to hurt someone.
Front Windshield Assembly
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Special Tools
Name Qty.
Glass adhesive cutter 1
Adhesive removal tool 1
Hot air gun 1
Glass adhesive gun 1
First coat brush 1
Glass sucker 2
Removal
1. Support the front hood assembly upwards.
2. Disconnect the wire on the negative pole of the storage battery.
Reference: Storage Battery (4.1.8 Storage Battery System, “Removal and Installation”)
3. Remove the front windshield wiper.
Reference: Wiper (4.3.7 Wiper and Washer, “Removal and Installation”)
4. Remove the front hood garnish.
Reference: Front Hood Garnish (5.1.10 Exterior Trims, “Removal and Installation”)
5. Lower the front hood assembly downwards.
6. Remove the inner rear-view mirror on the front windshield assembly.
Reference: Rear-view Mirror (5.1.5 Rear-view Mirror, “Removal and Installation”)
7. Remove the Interior Trim Panel on both the right and the left sides of Column A.
Reference: Interior Trim Panel of Column A (5.1.9 Interior Trim Panel and Trims, “Removal
and Installation”)
8. Cut apart the front windshield adhesive with a glass adhesive cutter along the door window
metal plate.
Warning: Please wear gloves and goggles when using the special tool because fragments will
be produced during cutting. Please wear earplugs during cutting. Personal injuries will be
caused if these instructions are not conformed to.
Note: Please be careful during cutting so as not to damage the vehicle body or the trim
panel.
9. Use glass sucker to remove the front windshield assembly with the assistance of other
technicians.
Installation
Note: Please pay attention to not allow the adhesive to get in contact with surface that
has been cleaned or painted with first coat, because this will reduce the adhesivity to the glass.
Note: Please paint the adhesive after the first coat solidifies completely and then stick the
glass onto the adhesive within one hour so as to ensure good adhesivity to the glass.
Note: If the ambient temperature is lower than 10 °C, the adhesive or the first coat may
condensate and agglomerate. In this case, you can use hot air gun or heating furnace to heat
the adhesive or the first coat up to about 25 °C so as to improve the fluidity of the adhesive
and the first coat.
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1. Clean up the waste adhesive remained on the metal plate of door window.
Note: If the remaining waste adhesive is not cleaned up, the adhesivity to the glass will
decrease.
Note: Please be careful when you clean the remaining waste adhesive so as not to
damage paint layer of the vehicle body.
2. Please prepare the PU adhesive, the first coat for glass adhesive, the new glass and other
accessories as well as such special tools as the adhesive gun and the first coat brush.
3. Place the new front windshield assembly on a special console with the convex side facing
downwards.
Note: Surface of the console shall be soft and please be careful when placing the front
windshield assembly so as not to damage it.
4. Install the inner rear-view mirror on the front windshield assembly.
Reference: Rear-view Mirror (5.1.5 Rear-view Mirror, “Removal and Installation”)
5. Use a brush to paint first coat on bonding position of the new front windshield assembly and
that of the corresponding metal plate. Wait the first coat to condensate or use a hot air gun to
dry the first coat quickly.
6. Use an adhesive gun to paint adhesive at the four corners of the front windshield assembly.
The painted adhesive shall be on the inner side of the edge protector and the outer side of the
adhesive stopper, forming a triangle of 10mm wide and13mm high.

1 Edge protector 1
2 Adhesive stopper 1
3 Adhesive 1
7. Use a sucker to turn over the front windshield assembly so that the convex side faces
upwards with assistance of other technicians. Align the positioning columns on the right and
left sides of the upper front windshield assembly with the mounting holes along both sides of
the door window and then engage the glass onto the metal plate of the door window.
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Note: Please open the doors when engaging the glass onto the metal plate because the
pressure within the vehicle will increase and the adhesivity will be reduced consequentially if
the doors are closed.
8. Move the glass right and left to ensure the clearances between the glass and both sides of the
side panel are the same.
9. Pat the front windshield assembly softly to ensure that it is firmly stuck to the metal plate.
Wind the front windshield with adhesive tape and adhere the tape onto the metal plate so that
the tape can impose pressing force on the glass. You can place sponge between the adhesive
tape and the glass in which way the tape will not get in contact with the glass and the pressing
force will increase.
10. Install the Interior Trim Panel on both the right and the left sides of Column A.
Reference: Interior Trim Panel of Column C (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
Note: Please be careful when installing the Interior Trim Panel to prevent pollution may
be caused by the glass adhesive.
11. Support the front hood upwards.
12. Install the front hood garnish.
Reference: Front Hood Garnish (5.1.10 Exterior Trims, “Removal and Installation”)
13. Install the front wiper.
14. Connect the negative harness of storage battery.
16. Put the whole vehicle for 24—48 hours to allow the adhesive to solidify completely.
Back Door Window Glass Assembly
Special Tools
Name Qty.
Hot air gun 1
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First coat brush 1

Glass sucker 2
Removal
1. Support the front hood assembly upwards.
3. Remove the Interior Trim Panel of rear rack.
Reference: Interior Trim Panel of Rack (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
4. Pull out the harness connector of the defrosting and defogging line on the back door window
glass assembly.
Note: This step only applies to back door window glass assembly with defroster.
5. Use a glass adhesive cutter to cut apart the adhesive along the metal plate of door window.
Note: Please be careful during cutting so as not to damage the vehicle body or the trim
panel.
6. Use glass sucker to remove the back door window glass assembly with the assistance of other
technicians.
Installation
and the first coat.
1. Clean up the waste adhesive remained on the metal plate of back door frame.
decrease.
Note: Please be careful when you clean the remaining waste adhesive so as not to damage
paint layer of the vehicle body.
3. Place the new back door window glass assembly on a special console with the convex side
facing downwards.
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Note: Surface of the console shall be soft and please be careful when placing the back door
window glass assembly so as not to damage it.
4. Use a brush to paint first coat on bonding position of the new back door window glass
assembly and that of the corresponding metal plate. Wait the first coat to condensate or use a
hot air gun to dry the first coat quickly.
5. Use an adhesive gun to paint adhesive at the four corners of the back door window glass
assembly. The painted adhesive shall be on the inner side of the edge protector and the outer
side of the adhesive stopper, forming a triangle of 10mm wide and13mm high.

1 adhesive 1
3 Connector 2
6. Partially open the back door assembly.

7. Use a sucker to turn over the back door window glass assembly so that the convex side faces
upwards with assistance of other technicians. Align the positioning columns on the right and
left sides of the upper back door window glass assembly with the mounting holes along both
sides of the metal plate of the back door and then engage the glass onto the metal plate of the
back door.
8. Move the glass right and left to ensure the clearances between the glass and both sides of the
side panel are the same.
9. Pat the back door window glass assembly softly to ensure that it is firmly stuck to the metal
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plate. Wind the back door window glass assembly with adhesive tape and adhere the tape
onto the metal plate so that the tape can impose pressing force on the glass. You can place
sponge between the adhesive tape and the glass in which way the tape will not get in contact
with the glass and the pressing force will increase.
10. Connect the defrosting and defogging connectors on both sides of the glass.
11. Install the Interior Trim Panel of the rack.
Reference: Interior Trim Panel of Rack (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
12. Connect the negative harness of storage battery.
Skylight Glass Assembly
Special Tools
Name Qty.
Hot air gun 1
First coat brush 1
Glass sucker 2
Removal
1. Remove the front windshield assembly.
Reference: Front Windshield Assembly (5.1.1-3 Fixed Glass of Complete Vehicle, “Removal
2. Remove the roof lining assembly.
Reference: Roof Lining Assembly (x.x.x Roof Lining Assembly, “Removal and Installation”)
3. Remove the roof-mounted sunvisor frame assembly.
Reference: Roof-mounted Sunvisor Frame Assembly (XXX Roof-mounted Sunvisor Frame
Assembly, “Removal and Installation”)
4. Cut apart the skylight glass assembly adhesive with a glass adhesive cutter along the door
window metal plate.
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Note: Please be careful during cutting so as not to damage the vehicle body or the trim panel.
5. Use glass sucker to remove the skylight glass assembly with the assistance of other
technicians.
Installation
and the first coat.
1. Clean up the waste adhesive remained on the metal plate of door window.
decrease.
Note: Please be careful when you clean the remaining waste adhesive so as not to
damage paint layer of the vehicle body.
3. Place the new skylight glass assembly on a special console with the convex side facing
downwards.
Note: Surface of the console shall be soft and please be careful when placing the skylight
glass assembly so as not to damage it.
4. Use a brush to paint first coat on bonding position of the new skylight glass assembly and
that of the corresponding metal plate. Wait the first coat to condensate or use a hot air gun to
dry the first coat quickly.
5. Use an adhesive gun to paint adhesive at the four corners of the skylight glass assembly. The
painted adhesive shall be on the inner side of the edge protector and the outer side of the
adhesive stopper, forming a triangle of 10mm wide and13mm high.

1 Edge protector 1
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3 Adhesive 1
6. Use a sucker to turn over the skylight glass assembly so that the convex side faces upwards
with assistance of other technicians. Align the positioning columns on the right and left sides
of the upper skylight glass assembly with the mounting holes along both sides of the door
window and then engage the glass onto the metal plate of the door window.
7. Move the skylight glass right and left to ensure the clearances between the glass and both
sides of the side panel are the same.
8. Pat the skylight glass assembly softly to ensure that it is firmly stuck to the metal plate. Wind
the back door window glass assembly with adhesive tape and adhere the tape onto the metal
plate so that the tape can impose pressing force on the glass. You can place sponge between
the adhesive tape and the glass in which way the tape will not get in contact with the glass
and the pressing force will increase.
9. Install the roof-mounted sunvisor frame assembly.
Reference: Roof-mounted Sunvisor Frame Assembly (XXX Roof-mounted Sunvisor Frame
Assembly, “Removal and Installation”)
10. Install the roof lining assembly.
Reference: Roof Lining Assembly (XXX Roof Lining Assembly, “Removal and
Installation”)
11. Install the front windshield assembly.
Reference: Front Windshield Assembly (5.1.1-3 Fixed Glass of Complete Vehicle, “Removal
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5.1.8-1 Handle, Lock and Latch 5.1.8-1
5.1.8 Handle, Lock and Latch

Back Door Lock Assembly
Removal
1. Remove inner trims of the back door.
Reference: Inner Trims of Back Door (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
2. Separate the back door lock assembly and the back door harness assembly.
3. Separate the back door lock assembly (remove the three screws).
4. Separate the back door lock assembly and the signal lamp connector of the back door harness
assembly.
5. Take down the back door lock assembly.

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5.1.8-2 Handle, Lock and Latch 5.1.8-2
• Disconnect the harness at the outside of the mechanical lock of the trunk and remove the
clip from the inner plate of the trunk.
• Take down the mechanical lock of the trunk.
Installation
Install according to steps in opposite sequence of removal.
Engine Hood Lock
Removal
1. Remove the fixed bolts on the engine hood lock.
2. Remove the release cable of engine hood.
Installation
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5.1.2-1 Door System 5.1.2-1
5.1.2 Door System

Specifications
Name Nm lb-ft lb-in
Fixed bolt of door window regulator 5 - 44
Fixed bolt of door window regulating
8 - 71
motor

System Overview
The door system mainly consists of door window glass, door outer handle, door inner handle,
door lock assembly, power window regulator assembly, door rubber seal strip, door window run,
front and rear mounting run channel assemblies, door tierod, door hinge, door Interior Trim Panel
and other accessories. These parts together form an organic door system.
Main functions of the door system includes allowing driver and passengers to get on and off
the vehicle via opening and closing of doors and realizing communication between the interior and
exterior environments via opening and closing of door windows. Meanwhile, the door system can
also protect the interior space effectively upon occurrence of any side impact, minimizing the
damages that may be caused to passengers. Besides, as an enclosed system, the door system can
prevent such substances as ash, noise and water from entering the vehicle. It provides a pleasant
interior environment for both the driver and the passengers.
As an essential part of the vehicle, the door system must be removed and installed according
to the following operations so as to ensure that it can work normally.
Part Description
Door Window Glass

1 Front door window glass (left/right) 2
2 Glass bracket 8
3 Rear door window glass (left/right) 2
The door window glass is made of tempered glass. Like all other tempered glass, it has a
relatively high degree of strength and shock resistance. When the glass suffers destructive impact
and becomes cracked, the fragment shows no blade scratches and the size of fragment is
comparatively small.
The front door window is equipped with two brackets while on the rear door window, there
are two glass connector mounting holes one of which is connected with the bracket bolt of the
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5.1.3-2 Door System 5.1.3-2
front power window regulator and the other with the mounting bolt of rear door window regulator.
The front door window is adhered firmly to the brackets via adhesive and they are not
detachable.
Door Window Glass
Removal
2. Remove the door inner trims.
Reference: Door Inner Trims (5.1.9 Interior Trim Panel and Trims, “Removal and Installation”)
3. Use proper tools to remove the armrest box and the waterproof membrane.
4. Pull out the door harness connector.
Reference: Door Harness Connector (6.3.6 Repair and Maintenance of Harness Terminal)
5. Remove the two bolts which connect the door window brackets and the regulator.
6. Take out the front door glass run channel
Note: Lift the window regulator to the central position so that the assembling holes on the
metal plate will be in line with the regulator bracket. The glass can be removed more easily in
this way.
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5.1.2-3 Door System 51.2-3
Installation
Front door power window regulator
Removal
1. Disconnect the negative harness of the storage battery.
2. Remove the front door inner trims.
Reference: Front Door Inner Trims (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
3. Use a proper tool to take down the waterproof membrane.
4. Remove the front door window glass.
Reference: Front and Rear Door Window Glasses (5.1.2 Door Window Glass, “Removal and
Installation”)
5. Remove the front door power window regulator.
6 Take out the front door power window regulator.
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5.1.3-4 Door System 5.1.3-4
Installation
Rear Door Power Window Regulator
Removal
2. Remove the rear door inner trims.
Installation”)
4. Remove the rear door window glass.
Reference: Rear Door Window Glass (5.1.2 Door Window Glass, “Removal and
Installation”)
5. Remove the rear door window regulator.
6. Take out the power window regulator.
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5.1.2-5 Door System 51.2-5
Front Door Window Glass Run

Reference: Front and Rear Door Window Glasses (5.1.2 Door Window Glass, “Removal and
Installation”)
2. Remove the front door window glass regulator.
Reference: Front Door Window Glass Regulator (5.1.2 Front Door Window Glass Regulator,
“Removal and Installation”)
3. Remove the power rear-view mirror assembly.
Reference: Power Rear-view Mirror (4.3.8 Power Rear-view Mirror, “Removal and
Installation”)
4. Remove the retaining screws of front door outer weatherstrip.
5. Take down both the inner and outer weatherstrips of the front door.
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5.1.3-6 Door System 5.1.3-6
6. Remove the front door glass run.
Rear Door Window Glass Run

1. Remove the rear door window glass.
Reference: Rear Door Window Glass (5.1.2 Door Window Glass, “Removal and
Installation”)
2. Remove the rear door window glass regulator.
Reference: Rear Door Window Glass Regulator Assembly (5.1.2 Front Door Window Glass
Regulator, “Removal and Installation”)
3. Remove the retaining screws of rear door outer weatherstrip.
4. Take down both the inner and outer weatherstrips of the rear door.
5. Remove the rear door glass run.
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5.1.2-7 Door System 51.2-7
Front Door Glass Run Channel

Removal
Reference: Door Inner Trims (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
Installation”)
4. Remove the mounting bolts of front door glass run channel.
5. Take out the front door glass run channel.
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5.1.3-8 Door System 5.1.3-8
Installation
Rear Door Glass Run Channel
Removal
2. Remove the rear door inner trims.
Reference: Rear Door Inner Trims (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
4. Remove the mounting bolts of rear door glass run channel.
5. Take out the rear door glass run channel.
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5.1.2-9 Door System 51.2-9
Installation
Front Door Stop
Installation”)
3. Remove the mounting bolt of the front door stop on the side panel.
5. Remove the mounting bolt of the front door stop at the front door.
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5.1.3-10 Door System 5.1.3-10
6. Take out the front door stop.
Rear Door Stop

See steps for removal and installation of front door stop.
Front Door Lock Assembly
Reference: (5.1.9 Interior Trim Panel and Trims, “Removal and Installation”)
Reference: Removal and Installation of Front Door Window Glass.
5. Remove the front door inner handle.
Reference: Removal and Installation of Inner Handle.
6. Take down the inner locking cable and inner unlocking cable from the clip on the inner panel.
7. Disconnect the inner unlocking cable and the inner locking cable from the inner handle.
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5.1.2-11 Door System 51.2-11
8. Remove the outer handle rod and the lock cylinder rod of the front door.
(1) First remove the outer handle rod connected to the lock body end.
(2) Remove the lock cylinder rod connected to the lock body end.
(3) Remove the outer connecting rod connected to the handle end.
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5.1.3-12 Door System 5.1.3-12
(4) Remove the lock cylinder rod connected to the lock body end.
9. Remove the bolts on the lock body of the front door.
9. Remove the motor harness connector on the lock body of the front door.
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5.1.2-13 Door System 51.2-13
Installation
Rear Door Lock Assembly
Installation and removal of the rear door lock body is the same as that of the front door lock
body.
External Door Handle
Installation”)
4. Use special tools to remove the mounting hole cover of the external door handle.
Remove the mounting bolts on the external door handle cover.
5. Pull the door handle to the maximum position.
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5.1.3-14 Door System 5.1.3-14
6. Take down the external door handle cover.
7. Take out the door handle from the outer side of the door.
Installation
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5.1.3-1 Door System 5.1.3-1
5.1.3 Roof-mounted Sunvisor Frame Assembly.

Specifications
Name Nm
Retaining nut of roof-mounted sunvisor frame 8~10
Fixing bolt for guide rail mounting bracket of the abat vent 8~10

System Overview
The roof-mounted sunvisor frame assembly consists of the roof-mounted sunvisor frame and
the guide rail mounting bracket of abat vent. The roof-mounted sunvisor frame assembly, together
with the white vehicle body, the skylight glass assembly, the roof cover lining assembly, forms the
panoramic skylight system. This system has functions of transmitting rays and shrouding the
sunlight at the same time. It can provide excellent visibility and rays, offering a pleasant visual
field to the passengers.
If it is necessary to replace the roof-mounted sunvisor frame assembly, please first remove
the roof cover lining and then replace the assembly with a new one.
Part Description
Roof-mounted Sunvisor Frame
The roof-mounted sunvisor frame consists of the front and the rear abat vent protectors, the
abat vent assembly, the guide rail assembly, etc. These parts are riveted together, making the
sunvisor frame an integrated unit which is not detachable.
Mounting Bracket of Abat Vent Guide Rail
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5.1.3-2 Door System 5.1.3-2
At the right and the left sides of the vehicle, there is one abat vent guide rail mounting
bracket. These two brackets are in common use and they support the roof-mounted sunvisor
frame. Before replacing the roof-mounted sunvisor frame assembly, please first remove the abat
vent guide rail mounting brake and then replace the roof-mounted sunvisor frame. As to the abat
vent guide rail mounting bracket, it is unnecessary to replace it if it is not deformed.
Removal
1. Remove the roof lining.
Reference: Roof Lining (4.1.8 Roof Lining, “Removal and Installation”)
2. Remove the retaining nut on the left side of the roof-mounted sunvisor frame (one).
3. Remove the fixing bolts (two) of the left-side abat vent guide rail mounting bracket and then
take down the bracket.

4. Remove the right-side abat vent guide rail mounting bracket. Please refer to Step 2 and Step
3.
5. Remove the retaining nuts of the roof-mounted sunvisor frame at the front beam and middle
beam of the roof cover one by one according to sequence (①-②-③-④) shown in the
following figure the right portion of which shows the front of the vehicle and the left portion
shows the rear of the vehicle.
Warning: When removing the four mounting nuts on the roof-mounted sunvisor frame at the
front beam and the middle beam of the roof cover, tow men must cooperate with each other
with one man supporting the roof-mounted sunvisor frame and the other removing the nuts so
as to avoid personal injuries which may be caused due to falling off of the roof-mounted
sunvisor frame.
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5.1.2-3 Door System 51.2-3
6. Remove the roof-mounted sunvisor frame.
Note: Please be careful during removal so as not to damage the vehicle body or the trim
panel.
Installation
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Part 5.1
Interior and Exterior Trims
Section Title Page
5.1.4 Instrument Panel and Console 5.1.4-1
5.1.5 Door Inner Trim Panel 5.1.5-1
5.1.6 Interior Trim Panel and Trims 5.1.6-1
5.1.7 Rear-view Mirror 5.1.7-1
5.1.8 Front/Rear Quarter Window Exterior Garnish Assembly 5.1.8-1
5.1.9 Bumper 5.1.9-1
5.1.10 Front Hood Garnish 5.1.10-1
5.1.11 Front Wheelhouse Lining Plate Assembly 5.1.11-1
5.1.12 Washer 5.1.12-1
5.1.13 Back Door Handle Assembly 5.1.13-1
5.1.14 NVH Parts 5.1.14-1
5.1.15 Seat 5.1.15-1
5.1.16 Safety Belt System 5.1.16-1
5.1.17 Air Bag System 5.1.17-1
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5.1.4-1 Instrument Panel and Console 5.1.4-1
5.1.4 Instrument Panel and Console

Manner of Removal
Special Tools
Tools to remove exterior and interior trims
Name Nm lb-ft lb-in
Fastening of upper portion of the 3 - 27
instrument panel
Fastening of side face of the instrument 19 14 -
panel
Fastening of lower portion of the 9 14 -
instrument panel
Warning: Before removing or replacing the air bag system, please first disconnect the
system power supply and then carry out removal or replacement at least 60s thereafter.
Note: Please confirm that the steering wheel is locked.
Note: Please confirm that the wheels are in the straight front position.
Reference: Inspection of Storage Battery (3.1.10 Charging System, “General Inspection”)
2. Remove the trim panels of Column A at both the left and the right sides.
Reference: Trim Panel of Column A (5.1.6 Interior Trim Panel and Trims, “Removal and
Installation”)
3. Remove the instrument.
Reference: Instrument Assembly (4.3.2 Instruments, “Removal and Installation”)
4. Remove the driver air bag and the steering wheel.
Reference: Driver Air Bag and Steering Wheel (5.1.17 Air Bag Restraint System, “Removal
5. Remove the passenger air bag.
Reference: Passenger Air Bag (5.1.17 Air Bag Restraint System, “Removal and Installation”)
6. Remove the lamplight combination switch.
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Reference: Lamplight Combination Switch (4.3.6 Lighting System, “Removal and

Installation”)
7. Remove the wiper combination switch.
Reference: Wiper Combination Switch (4.3.7 Wiper and Washer, “Removal and
Installation”)
8. Remove the air conditioner control module.
Reference: Air Conditioner Control Module (4.1.1 Air Conditioner System—Manual,
9. Remove the DVD player.
Reference: DVD Player (4.3.5 Information and Entertainment System, “Removal and
Installation”)
10. Remove the USB adaptor and the power outlet.
Reference: (4.3.4 USB Adaptor/Power Outlet, “Removal and Installation”)
11. Remove the gear cover plate.
12. Remove the fixing bolt in the middle of the control cabinet. Torque: 3N.m.
13. Remove the fixing bolt at left and right sides of the rear portion of the control cabinet.
Torque: 3N.m.
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14. Remove the trim panel at the front end on the right side of the control cabinet.
15. Remove the two retaining screws on the right side of the front portion of the control cabinet.
Torque: 3N.m.
16. Remove the trim panel at the front end on the left side of the control cabinet.
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17. Remove the two retaining screws on the left side of the front portion of the control cabinet.
Torque: 3N.m.
18. Remove the control cabinet assembly.

Installation
19. Remove the bolt cover in the middle of the front end of the instrument panel.
20. Remove the fixing bolt at the front end of the instrument panel. Torque: 3N.m.
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21. Remove the trim covers at both the left and the right sides of the instrument panel.
22. Remove the 8 fixing bolts at both the left and the right sides of the instrument panel. Torque:
19N.m
23. Remove the 2 fixing bolts at the front end of the left side of the instrument panel. Torque:
19N.m.
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24. Remove the 2 retaining nuts at the upper portion of the lower bracket of the steering wheel
and the 2 fixing bolts at the lower portion. Torque: 12N.m.
25. Remove the instrument panel assembly.

Installation
1. Remove the trim strip on the gear cover plate.
2. Remove the 4 screws on the knob type electronic gear shifter.
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3. Remove the knob type electronic gear shifter.
5. The way to remove the fixing bolts at the front and the rear of the control cabinet is the same
as that of the MT control cabinet.
Installation
1. Remove the central control panel. First use special tools to pry out the cellphone box cover at
each side.
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Pry out the clips at the middle and the lower portions of the central control panel from the
crevices between the central control panel and the trim covers and then pull out the clip at the
upper portion.
2. Remove the right-side air outlet coverplate. First remove the 2 retaining screws at the left
side of the air outlet coverplate, and then pry out the clip at the left side of the coverplate with
a special tool and finally pull out the clips one by one with your hand from the left to the
right.
3. Remove the instrument cluster mask. First use s special tool to pry out the clips at the left and
the right lower corners of the instrument cluster mask and then pull out the mask with your
hand.
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4. Remove the upper shell of the steering lock. First adjust the steering column to the lowest
position, and then use a special tool to pry the clips on both sides of the lock shell until they
are loose and finally pull out the lock shell with your hand.
5. Remove the 3 retaining screws on the power shell of the steering lock. Before removing the
screws below the lock shell, please first turn the adjusting handle of the steering column to
the lowest position so as to leave space for the tool.
6. Remove the lower shell of the steering lock.
Installation
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5.1.5-1 Door Inner Trim Panel 5.1.5-1
5.1.5 Door Inner Trim Panel

Front Door Inner Trim Panel
Manner of Removal
Special Tools
1. Use proper tools to remove the trims of the front door quarter window.
2. Remove the hole cover of the front door inner handle.
3. Use a proper tool to remove the mounting screw in the inner handle.
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4. Remove the inner handle box.
5. Remove the cover on the screw hole of the front door armrest box.
6. Use a proper tool to remove the screw in the armrest box.
7. Use a proper tool to remove the front door inner trim panel. Special tool: tools to remove
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exterior and interior trims.
8. Disconnect the harness connector of the power window switch.
Note: It is possible that the clip of front door inner trim panel will be damaged during
removal, so please replace the damaged clip during installation.
Installation Method
Special Tools
1. Connect the harness connector of the power window switch.
2. Install the inner trim panel of the front door.
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3. Install the inner handle box.
4. Use a special tool to install the retaining screw in the inner handle box.
5. Install the cover on the screw hole of the inner handle box.
6. Use a proper tool to install the mounting screw of armrest box.
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7. Install the screw coverplate of armrest box.
8. Install the trims of front door quarter window properly.
Rear Door Inner Trim Panel

Manner of Removal
1. Use proper tools to remove the trims of the rear door quarter window.
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2. Remove the cover on the screw hole of the rear door inner handle box.
2. Use a proper tool to remove the mounting screw of the rear door inner handle box.
3. Remove the rear door inner handle box.
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4. Use special tools to remove the screw coverplate of the rear door armrest plate.
5. Remove the mounting screw on the armrest plate of the rear door inner trim panel.
6. Use a special tool to remove the rear door inner trim panel.
7. Disconnect the harness connector of the rear door power window switch.
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Installation Method
The method for installation is the same as that of the front door inner trim panel.
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5.1.6-1 Interior Trim Panel and Trims 5.1.6-1
5.1.6 Interior Trim Panel and Trims

Front Sill Trim Panel
Manner of Removal
Special Tools
1. Remove the clip connecting structure at the front/rear end of the front sill trim panel.
2. Use a special tool to remove the V-type clip on the front sill trim panel.
Installation
Rear Sill Trim Panel
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Manner of Removal
Special Tools
1. Remove the retaining screw of rear sill trim panel.
2. Remove the clip connecting structure at the front/rear end of the rear sill inner trim panel.
3. Use a special tool to remove the V-type clip on the rear sill trim panel.
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Installation
Back Sill Trim Panel
Manner of Removal
Special Tools
1. Use proper tools to remove the retaining screws on both sides of the back sill trim panel.
2. Use proper tools to remove ISO FIX retaining screws and the snap fastener in the middle at
both ends of the back sill trim panel.
3. As is shown below, remove the clip connecting structures at both ends of the back sill trim
panel.
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4. Use a special tool to remove the fixing clip on the back sill trim panel.
Installation
Trim Panel of Column A
Manner of Removal
Special Tools
1. Use a special tool to remove the cover on the trim panel of Column A.
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2. Remove the retaining bolts on the trim panel of Column A.
3. Use a special tool to remove the trim panel on Column A.
4. Disconnect connectors of the loudspeaker.
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5. Use a proper tool to remove the disc-type nut on the trim panel of Column A.
6. Use a special tool to remove the 2 fixing clips on the lower trim panel of Column A.
Installation
Trim Panel of Column B
Manner of Removal
Special Tools
1. Use a special tool to remove the 3 front fixing clips on the lower trim panel of Column B.
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2. Use a special tool to remove the 2 rear fixing clips on the lower trim panel of Column B.
3. Use a special tool to remove the lower trim panel of Column B.
4. Positions of clips on the lower trim panel of Column B are shown in the figure below.
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5. Use a special tool to remove the retaining bolts under the front-row safety belt.
7. Remove the trim cover of the mounting bolt on the upper trim panel of Column B.
8. Remove the mounting bolt on the upper trim panel of Column B.
8. Use a special tool to remove the 2 fixing clips on the upper trim panel of Column B.
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9. Use a special tool to remove the fixing clip on the lower portion of the upper trim panel of
Column B.
10. Positions of the clips on the upper trim panel of Column B are shown in the figure below.
11. Use a special tool to remove the upper trim panel of Column B.
Installation
Trim Panel of Column C
Manner of Removal
Special Tools
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1. Remove the trim cover of the mounting bolt on the upper trim panel of Column C.
2. Remove the mounting bolt on the upper trim panel of Column C.
3. Use a special tool to remove the 4 fixing clips on the trim panel of Column C.
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4. Use a special tool to remove the trim panel of Column C.

Installation
Quarter Trim Panel
Manner of Removal
1. Remove the 4 mounting screws on the quarter trim panel.
Remove the 2 mounting nails on the lower portion of the quarter trim panel.
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Installation
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5.1.7-1 Rear-view Mirror 5.1.7-1
5.1.7 Rear-view Mirror

System Overview
Rear-view mirror includes interior rear-view mirror and exterior rear-view mirror. The mirror
can be adjusted manually or electrically, depending on the specific configuration of the vehicle.
Manual adjustment is realized via the rear-view mirror adjusting handle at the inner side of the
front door and electrical adjustment is realized via a button on the instrument panel.
Interior Rear-view Mirror
Removal
1. Turn the retaining screw on the rear-view mirror counterclockwise to make it loose.
2. Move the rear-view mirror upwards to take it down.
Installation
Exterior Rear-view Mirror
Removal
1. Remove the trims of the front door quarter window.
Note: Refer to 5.1.2-6 for the manners of removal and installation.
2. Disconnect harness of the exterior power rear-view mirror.
3. Remove the 3 nuts at the mounting plate of front rear-view mirror.
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4. Take the rear-view mirror down according to the direction shown in the figure below.
Installation
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5.1.8-1 Quarter Window Exterior 5.1.8-1
Garnish
5.1.8 Front/Rear Quarter Window Exterior Garnish Assembly

Removal
1. Remove the exterior garnish assembly of front quarter window.
2. Remove the exterior garnish assembly of front quarter window according to the direction
shown in the figure below.
3. Remove the exterior garnish assembly of quarter window.
Note: It is possible that the clip on the front/rear quarter window exterior garnish
assembly will be damaged during removal, so please replace the damaged one during installation.
Installation
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5.1.9-1 Bumper 5.1.9-1
5.1.9 Bumper
Front Bumper
Removal
2. Disconnect the harness connector of the combination headlamp.
Reference: Combination Headlamp (4.3.6 Lighting System, “Removal and Installation”)
3. Remove the 3 fixing bolts at the upper portion of the bumper.
4. Remove the 2 fixing clips at the upper portion of the bumper.
5. Remove the 2 retaining screws at the wheel housing on each side of the bumper.
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5.1.9-2 Bumper 5.1.9-2
6. Remove the 2 fixing bolts at the bottom of the bumper.
7. Remove the 4 plastic retaining snap fasteners at the bottom of the bumper.
8. Use proper tools to pry the 4 clips connecting the bumper and the bumper bracket and the 2
clips connecting the bumper and the front headlamp on the left side and the right side
respectively to make the clips loose and then pull outwards the bumper according to the
direction the right-side arrow in the figure below shows.
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5.1.9-3 Bumper 5.1.9-3
9. Disconnect the harness connectors at the left and the right sides of the front foglamp.
Reference: Front Foglamp (4.3.6 Lighting System, “Removal and Installation”)
10. Remove the bumper.
Installation
Rear Bumper
Removal
2. Remove the s on both the left and the right sides.
Reference: (4.3.6 Lighting System, “Removal and Installation”)
3. Remove the fixing clips and the self-tapping screws on both the left and the right sides on the
upper portion of the bumper.
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5.1.9-4 Bumper 5.1.9-4
5. Remove the 2 plastic retaining clips and the 2 bolts at the bottom of the bumper.
6. Disconnect the harness connector of the license lamp.

Reference: License Lamp (4.3.6 Lighting System, “Removal and Installation”)
7. Use a proper tool to pry the 4 clips connecting the bumper and the bumper bracket at both the
left and the right sides respectively and then pull the bumper outwards according to the
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5.1.9-5 Bumper 5.1.9-5
8. Take the rear bumper down.

Installation
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5.1.10-1 Front Hood Garnish 5.1.10-1
5.1.10 Front Hood Garnish

Removal
3. Remove the 5 clips connected to the vehicle body.
4. Remove the clip connecting structure of the front end covers (left and right) of the front hood
and the fender.
5. Move the main locating pin out of its corresponding hole on the vehicle body.
6. Remove the front hood garnish assembly as per the direction shown in the figure below.
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6. Lower the front hood.

Installation
2. Install the main locating pin into its corresponding hole on the vehicle body.
3. Push the front hood garnish assembly as per the direction shown in the figure below.
4. Connect the clip on the front hood garnish body with the front windshield.
5. Connect the front end covers (left and right) of the front hood and the fender with a clip.
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6. Connect the front hood garnish and the hole on the vehicle body with a clip.
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5.1.11-1 Front Wheelhouse Lining Plate 5.1.11-1
5.1.11 Front Wheelhouse Lining Plate Assembly

Removal
1. Remove the 5 fixing clips and 1 screw which connect the front wheelhouse lining plate with
the front bumper and the vehicle body.
2. Remove the four clips and one screw which connect the front wheelhouse lining plate with
the fender and the vehicle body.
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3. Take down the front wheelhouse lining plate after all clips and screws are removed.
Installation
Rear Wheelhouse Lining Plate Assembly
Removal
1. Remove the 3 fixing clips and 2 screws which connect the rear wheelhouse lining plate with
the rear bumper and the vehicle body.
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2. Take down the rear wheelhouse lining plate after all clips and screws are removed.
Installation
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5.1.12-1 Washer 5.1.12-1
5.1.12 Washer
Removal
1. The washer reservoir is located at the left lower corner of the engine room. It can be seen
when you open the front hood. It is shown in the figure below.
2. Remove the two bolts and one nut on the washer reservoir.
3. Take down the washer reservoir.

Installation
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5.1.13-1 Back Door Handle Assembly 5.1.13-1
5.1.13 Back Door Handle Assembly

Removal
1. Open the back door.
2. Use a special tool to remove the 10 clips on the back door lining.
3. Remove the harness of the point-contact switch of the back door.
4. Use a special tool to remove the two screws on the point-contact switch of the back door.
Installation
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5.1.14-1 NVH Parts 5.1.14-1
5.1.14 NVH Parts

1. Sunvisor Assembly (Left/Right)
Removal
1. Screw the mounting screw marked as “1” out with a crosshead screwdriver and then pull out
the sunvisor body from the mounting seat marked as “2”.Take down the sunvisor body.
2. Pry out the core (marked as “3”) inserted in the mounting seat with a flat head screwdriver
and then pull out the sunvisor mounting seat marked as “2” from the mounting hole.
Installation
2. Safety Handle
Removal
Turn over the safety handle marked as “1” and the screw coverplates marked as “2” and “3”,
screw out the mounting screw with a crosshead screwdriver and then remove the safety handle.
Installation
3. Glasses Case
Removal
screw out the mounting screw with a crosshead screwdriver and then remove the glasses case.
Installation
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5.1.14-2 NVH Parts 5.1.14-2
4. Roof Lining
Removal
1. Before removing the roof lining, please confirm that all the following parts have been
removed:
1) Sealing strips for five doors
Reference: Sealing Strip (x.x.x Sealing Strip System, “Removal and Installation”)
2) Interior trim panel on Column A
Reference: Interior Trim Panel (x.x.x Interior Trim Panel and Trim Panel, “Removal and
Installation”)
3) Interior trim panel on Column B
Installation”)
4) Interior trim panel on Column C
Installation")
5) Sunvisor assembly (left/right)
Reference: Sunvisor (x.x.x Sunvisor, “Removal and Installation”)
6) Safety handle
Reference: Safety Handle (x.x.x Safety Handle, “Removal and Installation”)
7) Glasses case
Reference: Glasses Case (x.x.x Glasses Case, “Removal and Installation”)
8) Front roof lamp
Reference: Front Roof Lamp (x.x.x Front Roof Lamp, “Removal and Installation”)
9) Front windshield has been removed completely.
Reference: Glass (x.x.x Glass System, “Removal and Installation”)
2. Remove the mounting nails (9 in total) on the roof lining and then take the roof lining out of
the front windshield frame.
Installation
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5.1.15-1 Seat 5.1.15-1
5. Roof Lining (Panoramic Sunroof)

Removal
removed:
Installation”)
Installation”)
Installation”)
6) Safety handle
7) Glasses case
8) Front roof lamp
2. Remove the mounting nail “1” (3 in total) on the roof lining
3. Disconnect the dual lock (12 in total) which connects the roof lining and the abat vent;
4. Pull the roof lining back a little toward the rear portion of the vehicle, take out the plastic part
on the front end of the roof lining from lap joint of the abat vent metal plate and then take the
roof lining out of the front windshield frame.
Installation
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5.1.14-2 NVH Parts 5.1.14-2
Install according to Step 4, 2, 3 of the removal.
5.1.15 Seat
Specification
Name N.m
Front fixing bolt of front-row seat 40±5
Rear fixing bolt of front-row seat 40±5
Outside bolt of rear-row backrest 25±3
Middle nut of rear-row backrest 25±3
Middle hinge of rear-row seat 30±3
Fixing bolt used on both the rear-row seat and the safety belt 65±5

System Overview
This vehicle is equipped with two rows of seats. All the front-row seats can slide back and
forth with adjustable armrest angle and headrest height. Besides, the height of the driver’s seat is
adjustable and this allows the driver to get a comfortable position for driving. Space between the
rear-row seats is large, providing a comfortable man-machine riding environment. When the seat
cushion is folded, the backrest can be put down and thus more storing space is acquired.
Removal and Installation of Seat
Front-row Manual Seat
Removal
1. Pull the sliding rail unlocking rod upwards and then move the seat forward to the utmost
position;
2. Remove the two fixing bolts on the back side of the seat;
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5.1.15-3 Seat 5.1.15-3
3. Refer to Step 1 and move the seat backwards to the utmost position;
4. Remove the two fixing bolts on the front side of the seat;
5. Turn the seat backwards, disconnect the harness connector of the safety belt at the bottom of
the seat and then take the seat down.(There is a harness only at the bottom of the driver’s
seat.)
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5.1.14-4 NVH Parts 5.1.14-4
Installation
Rear-row Seat
Removal
Rear-row Seat Cushion
1. Lift the seat cushion up to unlock it and then turn the cushion over;
2. Bend a little the steel wire on the 60% portion of seat cushion, take out part of cushion at one
side and then that at the other side. Take out the 40% portion of the seat cushion in the same
way;
Rear-row Backrest
1. Remove the bolts which connect the safety belt buckle assembling unit on the 60% portion of
the backrest and the vehicle body;
2. Pull up the unlocking button on the 60% portion of the backrest and then put the backrest
down and onto the floor of the vehicle body;
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5.1.15-5 Seat 5.1.15-5
3. Remove the step bolt at the outer side of the 60% portion of the backrest, then remove the
connecting nut in the middle and finally take down the 60% portion of the backrest;
4. Remove the step bolt at the outer side of the 40% portion of the backrest and take this portion
down.
Installation
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5.1.14-6 NVH Parts 5.1.14-6
Middle Hinge of Rear-row Seat

Removal
1. After both the 40% portion and the 60% portion of the backrest are removed, remove the two
bolts connecting the middle hinge of rear-row seat and the vehicle body directly.
Installation
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5.1.16-1 Safety Belt System 5.1.16-1
5.1.16 Safety Belt System

Specifications
Name Nm
Lower fixing bolt of front-row safety belt 39±5
Fixing bolt on height adjuster of front-row safety belt 39±5
Fixing bolt on guide ring of front-row safety belt 39±5
Lower fixing bolt on retractor of front-row safety belt 39±5
Upper fixing bolt on retractor of front-row safety belt 9±3
Fixing bolt on buckle of front-row safety belt 39±5
Fixing bolt on retractor of rear-row safety belt 39±5
Lower fixing bolt on left side of rear-row safety belt 39±5
Lower fixing bolt on right side of rear-row safety belt 39±5
Lower fixing bolt in the middle of rear-row safety belt 69±5
Fixing bolt of rear-row buckle 69±5
System Overview
Safety belt is a main way to protect passengers. Both the front-row and the rear-row seats are
equipped with safety belts. Three-point diagonal-fixing safety belt is adopted for both the front-
row and the rear-row seats.
The safety belt buckle of front-row seat is put in the seat slide. While the safety belt buckle of
rear-row seat is fastened onto the floor.
All the safety belts of the front-row seats have the emergency locking function. The locking
function will be activated when the safety belt is pulled quickly out of the retractor. The locking
function can prevent the safety belt from being pulled out to an extent not allowed, i.e. surpassing
the allowable retraction position.
When the pre-tensioners of the front-row safety belts work, working sound will be heard and
a small amount of smoke will be generated. Such smoke is harmless, and it does not indicate a
fire.
Force Limit Safety Belt
Front-row safety belt retractors are equipped with force limit devices. In case of head-on
crash, the retractor will release a certain length of braid to reduce the compression of the braid on
the passenger’s chest when the tension of the chest braid exceeds the set value.
Warning for Unfastened Safety Belt
The front-row safety belt has the function of warning for unfastened safety belt. It reminds
the user to fasten the safety belt by offering visual and audial information.
Reference: Warning for unfastened safety belt (4.2.1 Air Bag System)
Exploded View of Parts
Front-row Safety Belt Assembly
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S/N Name Qty. S/N Name Qty.

Upper fixing bolt on retractor of
1 Front-row retractor assembly 1 7 1
front-row safety belt
Lower fixing bolt on retractor of
2 Front-row buckle assembly 1 8 1
Lower fixing bolt of front-row
3 Height adjuster assembly 1 9 1
safety belt
Fixing bolt on guide ring of front- Washer at the lower fixing point of
4 1 10 1
row safety belt front-row safety belt
5 Fixing bolt of height adjuster 2 11 Front-row buckle washer 1
Fastening bolt of braid buckle on
6 1
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Rear-row Safety Belt

Lower fixing washer of rear-row
1 Rear-row retractor assembly (left) 1 6 2
safety belt
Retractor assembly in the middle of Fixing bolt on guide ring of rear-
2 1 7 2
rear row row safety belt
Guide ring washer of rear-row
3 Rear-row retractor assembly (right) 1 8 2
safety belt
Rear-row double buckle assembly Fixing bolt on retractor of rear-row
4 1 9 4
(left) safety belt
Lower fixing bolt of rear-row safety Fixing washer on retractor of rear-
5 2 10 4
belt row safety belt

Front-row Safety Belt
Removal
Warning: The pre-tensioner of safety belt works under the control of air bag system. Such
operations as removing or remodeling the air bag system without permission, knocking the
air bag control unit or the sensor and damaging the control circuit of air bag can cause the
pre-tensioner to work suddenly or make it fail to work.
Warning: It is strictly prohibited to refit, take off, knock or open the pre-tensioner
components of the safety belt or remove or damage its connection; otherwise, sudden
functioning or malfunction of the pre-tensioner of the safety belt will be probably caused,
leading to serious safety and casualty accidents.
Warning: Please check the safety belt system after each crash. Safety belt of which the pre-
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tensioner has worked before shall be replaced immediately other than used again. Newly
fixed safety belts must be checked by professional technician to make sure that the safety
belts do not have faults and can work normally.
1. Remove the lower fixing bolt of safety belt
Open the trim cover of lower fixing bolt and remove the lower fixing bolt of the safety belt.
Torque: 39Nm
3. Remove the interior trim panel of Column B.

Reference: Trim Panel of Column B (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
4. Withdraw the braid from the interior trim panel of Column B.
Installation”)
5. Remove the guide ring of the safety belt.

Torque: 39Nm
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6. Remove the retractor of the safety belt.

Remove the fixing bolt on the retractor of the safety belt. Torque: 39Nm
7. Remove the height adjuster of the safety belt.

Torque: 39Nm
Installation
Safety Belt Buckle
Removal
1. Stop the engine and turn the key to position “OFF”.
2. Disconnect the connector which is connected to the harness of the buckle.
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3. Remove the seat.

4. Remove the buckle of the safety belt.
Torque: 39Nm
Installation
Removal
1. Remove the rear-row seat cushion.
Reference: Rear-row Seat (5.1.3 Rear-row Seat, “Removal and Installation”)
2. Remove the lower fixing bolt of rear-row safety belt.
Remove the fixing point bolt at the left side.
Torque: 39 Nm
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Remove the fixing point bolt at the right side.

Torque: 39Nm
Remove the fixing bolt in the middle.

Torque: 69Nm
Remove the fixing bolt of the buckle.
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3. Remove the rear-row backrest.

4. Remove the interior trim panel of Column C.
Reference: Interior Trim Panel (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
5. Withdraw the rear-row safety belt from the interior trim panel.
6. Remove the rear-row safety belt.

Torque: 39Nm
Installation
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5.1.17-1 Air Bag System 5.1.17-1
5.1.17 Air Bag System

Contents Page
Locations of Parts of Air Bag System 5.1.17-2
Definition of Pins on Air Bag Controller 5.1.17-2
Fault Code Table 5.1.17-5
Troubleshooting 5.1.17-6
Driver Air Bag 5.1.17-11
Passenger Air Bag 5.1.17-14
Air Bag Controller 5.1.17-15
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5.1.17-2 Air Bag System 5.1.17-2

Specifications
Name Nm lb-ft lb-in
Fixing bolt of air bag for passenger 23±3
Fixing bolt of air bag controller 9±3

System Overview
Air bag on vehicle (AIR BAG) is a Supplemental Restraint System (SRS).
Air bag system includes the crash sensor, the air bag controller and all kinds of air bags
(including air bag for the driver and air bag for the assistant driver).
When a crash occurs, the sensor will transmit a crash signal to the air bag controller which
will decide whether the severity of crash reaches the minimum requirement for explosion; if it
does, the controller will send an ignition command to detonate the air bags. The exploded air bags
will form a soft air cushion quickly among the passengers and the structural parts in the vehicle
such as the steering wheel, the instrument panel and the interior trim panel. The impact will be
mitigated and the collision energy will be absorbed through the damping effect of the air cushion
during air discharging and thus injuries to the passengers will be reduced.
Warning: Only under the condition that the safety belt is used, can the SRS
protect the passengers to the fullest extent. Reference: 5.1.4 Safety Belt System
Warning: Please check the air bag system after each crash. The air bag and the air bag
controller shall not be used again after crash. They must be replaced immediately. The new
air bag system shall be checked by professional technician and confirmed to be able to work
normally without any defect.
Warning: It is strictly prohibited to place a child seat facing backward in the front row
and the rear-row seats are the safe position for children.
Warning: It is strictly prohibited to place any substance at the place where the air bag
locates.
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5.1.17-3 Air Bag System 5.1.17-3
Circuit Diagram of Air Bag System

Air bag ECU (ECU) can carry out real-time monitoring over the air bag system to see if it
works normally. If a fault occurs, the air bag warning lamp will be on, reminding the user to carry
out inspection and repair in time.
Warning: If the air bag alarm lamp is always on, it is necessary to inspect and repair the
air bag.
Reminding Logic for Unfastened Safety Belt

Safety belt is the most important protection device for passenger’s safety. The warning for
unfastened safety belt will remind the passengers to fasten the safety belt and thus safety during
driving is guaranteed.
Warning for unfastened safety belt of driver seat is made in visual and acoustic ways:
1. If the safety belt buckle is not fastened when the power gear is at “ON” or “START”, the
indicator will be always on;
2. If the safety belt buckle is not fastened when the vehicle speed reaches 7km/h, the warning
sound will last for 300s.
Locations of Parts of Air Bag System
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5.1.17-4 Air Bag System 5.1.17-4

1 Driver air bag assembly 1 8 Air bag controller assembly 1
2 Steering wheel 1 9 Floor assembly 1
Assembling unit of cross recessed
3 pan head self tapping screw and big 3
washer
4 Passenger air bag assembly 1
5 M8 hexagon flange bolt 2
6 Instrument panel assembly 1
Part Description
Driver Air Bag Assembly
The air bag for driver is connected to the interior of the steering wheel by two steel clips and
three plastic clips. The bag will open and form a soft air cushion between the driver and the
steering wheel to protect the driver in case of a front crash. The bag is called DAB for short.
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5.1.17-5 Air Bag System 5.1.17-5
Passenger Air Bag Assembly

The coverplate of passenger air bag assembly is hitched to the instrument panel. The lower
edge of the coverplate is connected to the instrument panel through three screws and the lower air
bag body is fixed to the steering support column through two bolts. The bag will open and form a
soft air cushion between the assistant driver and the instrument panel to protect the passenger in
case of a front crash. The bag is called PAB for short.
Air Bag Controller

The air bag controller is installed on the floor of the central channel which is below the
central control cabinet. It is between the parking brake and the gear shift. There is a direct impact
sensor in the air bag controller which can sense the signal of front crash. The air bag controller can
monitor the whole air bag system. It is called ECU for short.
Definition of Pins on Air Bag Controller
S/N Definition Description S/N Definition Description

1 Vbat Power supply 17 CAN_H CAN_H
2 CAN_L CAN_L 18 NC NC
3 ABFD+ Air bag before the driver + 19 NC NC
Safety belt buckle for the
4 ABFD- Air bag before the driver - 20 BLFP
assistant driver (reserved)
Air bag before the assistant
5 ABFP- 21 NC NC
driver -
6 ABFP+ 22 NC NC
driver +
Safety belt pre-tensioner for the
7 BTFDBelt+ 23 NC NC
driver + (reserved)
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5.1.17-6 Air Bag System 5.1.17-6
Safety belt pre-tensioner for the

8 BTFDBelt- 24 NC NC
driver - (reserved)
Safety belt buckle of the
9 NC NC 25 BLFD
driver
10 NC NC 26 CRO Crash output
11 NC NC 27 NC NC
12 NC NC 28 NC NC
13 NC NC 29 NC NC
14 NC NC 30 NC NC
15 NC NC 31 NC NC
16 GND Ground wire 32 NC NC

General Inspection
Air Bag Alarm Lamp:
After the air bag system is installed, turn the ignition switch to “ON” or “START” and
connect power supply of the air bag system. At this time, alarm lamp of the air bag system on the
instrument shall be on for approximately 4 seconds before it turns out.
Warning for unfastened safety belt:

Warning for unfastened safety belt of driver seat is made in a visual way:
1. If the safety belt buckle is not fastened when the power gear is at “ON” or “START”,
the indicator will be always on;
2. If the safety belt buckle is not fastened when the vehicle speed reaches 7km/h, the
warning sound will last for 300s.
If the above mentioned logic is conformed to, it indicates that the air bag system works
normally; if not, it indicates that the system fails to work normally and must be inspected and
repaired.
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5.1.17-7 Air Bag System 5.1.17-7
Diagnosis Procedure
Inspection and repair shall be carried out immediately upon discovery that the alarm lamp is
always on or that warning of unfastened safety belt is abnormal. First use a diagnostic scanner to
read the fault code stored in the air bag controller to confirm the fault location and the fault causes
and then carry out repair.
S/N Step
1 Alarm lamp is not normal
2 Connect the diagnostic scanner
3 Read the fault code
4 Handle the fault
5 Clear the fault code
Note: Fault elimination must be conducted after the fault is removed.

General Equipment
S/N Name
1 Diagnostic scanner

2. Conduct visual inspection to see whether there are signs of any obvious mechanical or
electrical damages.
3. Conduct visual and manual inspection to see whether the harness connectors are connected
reliably and whether the positive wire and the negative wire are connected oppositely.
List for Visual Inspection
Air bag Harness
Air bag controller Connector
Air bag controller
4. If the apparent cause of an observed or raised problem has been found, it shall be corrected
before next step.
5. If the fault cannot be found easily, use a diagnostic scanner to diagnose the system.
DTC Reading Program
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5.1.17-8 Air Bag System 5.1.17-8
1. Conduct necessary preparations and appearance inspection.

2. Connect the diagnostic scanner to the diagnosis interface in the cab.
3. Enter the diagnosis procedure of air bag system and read the DTC.
Fault Code Table
Code Fault Code Description Code Fault Code Description
B1B00 Fault within ECU B1B14 Air bag at the driver’s side makes contact
B1B01 Configuration fault B1B14 Air bag at the driver’s side is short to ground
Peripheral sensor at the driver’s side is Air bag at the driver’s side is short to power
B1B02 B1B14
not installed correctly supply
Peripheral sensor at the driver’s side is
B1B02 B1B14 Circuit of air bag at the driver’s side is open.
damaged
Communication fault of peripheral Resistance of air bag at the driver’s side is too
B1B02 B1B14
sensor at the driver’s side is damaged low.
Peripheral sensor at the passenger’s side
B1B03 B1B15 Air bag at the passenger’s side makes contact
is not installed correctly
Reliability fault of peripheral sensor at Air bag at the passenger’s side is short to
B1B03 B1B15
the passenger’s side ground.
Communication fault of peripheral Air bag at the passenger’s side is short to power
B1B03 B1B15
sensor at the passenger’s side supply.
B1B03 B1B15 Circuit of air bag at the passenger’s side is open.
is damaged
Peripheral sensor at the driver’s side Resistance of air bag at the passenger’s side is
B1B08 B1B15
makes contact. too low.
Peripheral sensor at the driver’s side is Air curtain at the passenger’s side makes
B1B08 B1B16
short to ground. contact.
Peripheral sensor at the driver’s side is Air curtain at the passenger’s side is short to
B1B08 B1B16
short to power supply. ground.
Peripheral sensor at the passenger’s side Air curtain at the passenger’s side is short to
B1B02 B1B16
makes contact. power supply.
Peripheral sensor at the passenger’s side Circuit of air curtain at the passenger’s side is
B1B02 B1B16
is short to ground. open.
Peripheral sensor at the passenger’s side Resistance of air curtain at the passenger’s side
B1B02 B1B16
is short to power supply. is too low.
B1B10 Air bag before the driver makes contact. B1B17 Air curtain at the driver’s side makes contact
Air bag before the driver is short to Air curtain at the driver’s side is short to
B1B10 B1B17
ground. ground.
Air bag before the driver is short to Air curtain at the driver’s side is short to power
B1B10 B1B17
power supply. supply.
Circuit of air bag before the driver is
B1B10 B1B17 Circuit of air curtain at the driver’s side is open.
open.
Resistance of air bag before the driver is Resistance of air curtain at the driver’s side is
B1B10 B1B17
too low. too low.
Air bag before the passenger makes
B1B11 B1B20 Safety belt buckle of the driver makes contact.
contact.
Air bag before the passenger is short to Resistance of safety belt buckle of the driver is
B1B11 B1B20
ground. too low.
Air bag at the passenger’s side is short Resistance of safety belt buckle of the driver is
B1B11 B1B20
to power supply. undefined.
Circuit of air bag before the passenger Resistance of safety belt buckle of the driver is
B1B11 B1B20
is open. too high.
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5.1.17-9 Air Bag System 5.1.17-9
Resistance of air bag before the Safety belt buckle of the driver is short to power
B1B11 B1B20
passenger is too low. supply.
Safety belt pre-tensioner of the driver Safety belt buckle of the passenger makes
B1B12 B1B21
makes contact. contact.
Safety belt pre-tensioner of the driver is Resistance of safety belt buckle of the passenger
B1B12 B1B21
short to ground. is too low.
B1B12 B1B21
short to power supply. is undefined.
Circuit of the safety belt pre-tensioner Resistance of safety belt buckle of the passenger
B1B12 B1B21
of the driver is open. is too high.
Resistance of safety belt pre-tensioner Safety belt buckle of the passenger is short to
B1B12 B1B21
of the driver is too low. power supply.
Safety belt pre-tensioner of the
B1B13 B1B34 Crash output is short to ground.
passenger makes contact.
B1B13 B1B34 Crash output is short to power supply.
passenger is short to ground.
B1B13 B1B40 Supply voltage is too high.
passenger is short to power supply.
Circuit of safety belt pre-tensioner of
B1B13 B1B40 Supply voltage is too low.
the passenger is open.
Resistance of safety belt pre-tensioner
B1B13 U1585 No communication is built with ABS.
of the passenger is too low.
Front-row air bag and safety belt pre-
B1B50 U1581 No communication is built with the instrument.
tensioner have been detonated.
Air curtain of the side air bag has been
B1B51 U1582 Transmit information fault
detonated.
ECU is locked and the controller shall
B1B52 U1583 Vehicle speed state is invalid.
be replaced.
U1580 CAN communication fault U1584 Warning lamp state fault
Troubleshooting
Warning: If the air bag warning lamp is always on, it is necessary to inspect and repair the air
bag. Before inspecting and repairing the air bag system, please first confirm that the system is
disconnected from the power supply. Hot-line operation is strictly prohibited.
Warning: Improper handling of the air bag system can make the system open unexpectedly,
probably causing serious accident. All connectors must be connected properly and firmly.
Such conditions as short circuit, virtual circuit and contact making will make the air bag
system explode suddenly as the circuit thereof becomes unstable.
Warning: It is very dangerous to check the air bag module with a multimeter as serous
personal injuries are likely to be caused. Therefore, it is strictly prohibited to use such
electrical equipment as multimeter to inspect the air bag system. Instead, ECU diagnostic
scanner shall be used to inspect the system.
When the ignition switch is at “ON”, the air bag system enters self-inspection mode which
will last for about 4 seconds. During this short period, the air bag warning lamp will be on
continuously. If the lamp turns out afterwards, it indicates no fault; if it does not, it indicates a
fault. If the warning lamp does not lighten during self-inspection, please inspect and repair
according to the following steps:
Diagnostic Procedure for Not Lightened Air Bag Warning Lamp when Ignition Switch Is at “ON”
Fault Code U1584 Description Warning lamp state fault
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5.1.17-10 Air Bag System 5.1.17-10
Possible
A. Warning lamp fault
Causes
Step Detection Operation
1 General inspection Yes Repair is completed.
A. Turn the ignition switch to “ON” position, the No Continue to Step 2.
air bag system enters self-inspection mode and the
warning lamp will be on continuously for about 4
seconds.
B. Is the air bag warning lamp on constantly?
2 Test the warning lamp Yes Replace the warning lamp.
Reference: 4.3.2 Instrument, “Fault Description Reference: 4.3.2 Instrument,
Diagnosis and Test” “Removal and Installation”
A. Is there anything wrong with the air bag No Repair is completed.
warning lamp?
If the air bag warning lamp is still on after the self-inspection, inspect and repair according to
the following steps:
Diagnostic Procedure for Air Bag Warning Lamp That Is Still on when Ignition Switch Is at “ON”
Fault Code U1584, B1B00 Description Warning lamp state fault; fault
within ECU
Possible A. Warning lamp fault
Causes B. Air bag system fault
1 General inspection Yes Continue to Step 2.
A. Turn the ignition switch to “ON” position, the No Repair is completed.
air bag system enters self-inspection mode, the warning
lamp will be on continuously for about 4 seconds and
then it turns out.
A. Is there anything wrong with the air bagNo Continue to Step 3.
warning lamp?
3 Inspect the connection between the air bag system and the Yes Replace harness.
complete vehicle harness
No Continue to Step 4.
A. Turn the ignition switch to “LOCK” position.
B. Inspect the corresponding circuits of the air
bag system to see if such faults have occurred as bonding,
being short to the power supply or being open.
Reference: 4.2.1 Air Bag System, “Removal and
Installation”
4 Connect the fault diagnostic scanner Yes Use the diagnostic scanner to
A. Turn the ignition switch to “ON” position, read the fault code, carry out
connect the diagnostic scanner and enter the air bag repair correspondingly and
system. then confirm that repair is
B. Select the function of “Fault Code completed.
Elimination”. No Use the diagnostic scanner to
C. First turn the ignition switch to “LOCK” clear previous fault records
position, keep it there for 10 seconds and then switch it to and then confirm that the
“ON” position. repair is completed.
D. Is the air bag warning lamp on constantly?
You can read the causes for faults of the air bag system with the diagnostic scanner and then
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5.1.17-11 Air Bag System 5.1.17-11
carry out inspection and repair according to the specific causes.

Internal Fault
Fault Code B1B00 Description Internal fault
Possible A. Fault within the air bag controller
Causes
Troubleshooting
1 Inspect the connection between the air bag controller and Yes Replace harness.
the complete vehicle harness No Replace the air bag controller
A. Turn the ignition switch to “LOCK” position. Reference: 4.2.1 Air Bag
B. Inspect the corresponding circuits of the air System, “Removal and
bag controller to see if such faults have occurred as Installation”
bonding, being short to the power supply or being open.
Installation”
Power Failure
Fault Code B1B40 DescriptionPower voltage is too high or too
low.
Possible A. Supply voltage is too high.
Causes B. Supply voltage is too low.
C. Fault occurs in the harness between the air bag controller and the storage battery.
Troubleshooting
1 Test the storage battery Yes Continue to Step 2.
A. Measure the voltage of the storage battery to No Inspect the
see if it is within the normal range. charging/discharging system.
Reference: 3.1.10 Charging System, “Fault Reference: 3.1.10 Charging
Description, Diagnosis and Test” System, “Fault Description,
Diagnosis and Test”
2 Inspect the connection between the air bag controller and Yes Use the diagnostic scanner to
the complete vehicle harness clear previous fault records and
A. Turn the ignition switch to “LOCK” position. then confirm that the repair is
B. Loosen the connectors of all parts of the air completed.
bag system. No Replace harness.
Installation”
C. Turn the ignition switch to “ON" position,
measure the voltage between the power supply pin (1) of
the complete vehicle harness corresponding to the air bag
controller and the grounding pin (16) to see if it is in the
normal range.
Driver Air Bag Fault
Short circuit, open circuit,
Fault Code B1B10 Description
excessively low resistance
Possible A. Drive air bag module fault
Causes B. Fault within the clock spring
C. Fault of circuit connectors between the clock spring and the air bag controller
D. Harness between the clock spring and the air bag controller is open or short.
E. Connector of the driver air bag generator of SRS air bag system is not connected properly.
Troubleshooting
1 Inspect the clock spring. Yes Continue to Step 2.
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5.1.17-12 Air Bag System 5.1.17-12
A. Turn the ignition switch to “LOCK” position. No Replace the clock spring.
B. Inspect all parts related to the clock spring to
see if they are all normal? (The relationship between all
pins is normal without short circuit or open circuit?)
Replace the clock spring with a good one if it allows.
2 Inspect the driver air bag. Yes Continue to Step 3.
A. Replace the air bag module with a good one No Replace the driver air bag.
or connect a resistance of 2 ohmages. Reference: 4.2.1 Air Bag
Reference: 4.2.1 Air Bag System, “Removal and System, “Removal and
Installation” Installation”
B. Install the negative cable of storage battery
back.
C. Turn the ignition switch to “ON” position.
D. Is the air bag warning lamp still on?
3 Inspect the harness connection between DAB and ECU. Yes Replace harness.
A. Turn the ignition switch to “LOCK” position. No Use the diagnostic scanner to
B. Loosen the connectors of all parts of the air clear previous fault records and
bag system. then confirm that the repair is
Reference: 4.2.1 Air Bag System, “Removal and completed.
Installation”
B. Inspect the harness and connectors between
the air bag controller and DAB to see whether such
conditions as bonding, being short to the power supply or
being open exist.
Passenger Air Bag Fault
Short circuit, open circuit,
Fault Code B1B11 Description
Possible A. PAB air bag module fault
Causes B. Fault of circuit connectors between PAB and the air bag controller
C. Harness between PAB and the air bag controller is open or short.
D. Connector of PAB generator is not connected properly.
Troubleshooting
1 Inspect the passenger air bag. Yes. Continue to Step 2.
A. Turn the ignition switch to “LOCK” position. No. Replace the passenger air bag
B. Replace PAB with a good one or connect a module.
resistance of 2 ohmages. Reference: 4.2.1 Air Bag
D. Is the warning lamp still on?
2 Inspect the harness connection between PAB and ECU. Yes. Replace harness.
A. Turn the ignition switch to “LOCK” position. No. Use the diagnostic scanner to
Installation”
C Inspect the harness and connectors between
the air bag controller and PAB to see whether such
being open exist.
A Crash Happens
Fault Code B1B50, B1B51 DescriptionAir bag detonation, safety belt
detonation
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5.1.17-13 Air Bag System 5.1.17-13
Possible A. A crash happens.

Causes
Troubleshooting
1 A. Turn the ignition switch to “LOCK” position.
B. Replace the air bag controller; replace the air
bag or the safety belt.
Installation”
Diagnostic Procedure for Not Lightened Warning Lamp when Driver Safety Belt Is Not Fastened with
Ignition Switch at “ON”
Fault Code U1584 DescriptionWarning lamp fault
Possible
A. Fault of warning lamp for unfastened safety belt
Causes
A. Turn the ignition switch to “ON” position and No Continue to Step 2.
the air bag system enters self-inspection mode.
B. Is the warning lamp for unfastened safety belt
on constantly?
2 Test the warning lamp Yes Replace the warning lamp for
Reference: 4.3.2 Instrument, “Fault Description unfastened safety belt.
Diagnosis and Test” Reference: 4.3.2 Instrument,
A. Is there anything wrong with the warning “Repair and Installation”
lamp for unfastened safety belt?
Diagnostic Procedure for Warning Lamp That Is Still on when Safety Belt is Fastened with Ignition
Switch at “ON”
normal?
2 Test the warning lamp. Yes Replace the warning lamp.
Reference: 4.3.2 Instrument, “Fault Description, Reference: 4.3.2 Instrument,
A. Is there anything wrong with the warning No Continue to Step 3.
lamp?
3 Test the buckle. Yes Replace the buckle.
A. Is there anything wrong with the buckle? Reference: 5.1.4 Safety Belt
System, “Removal and
Installation”
4 Inspect the harness connection between the buckle Yes Repair is completed.
harness and the air bag controller. No Replace harness.
B. Inspect the connection of circuits
corresponding to the air bag system.
Installation”
C. Is the warning lamp for unfastened safety belt
normal?
Diagnostic Procedure for No Reminding Sound Issued when Safety Belt is Unfastened with Ignition
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5.1.17-14 Air Bag System 5.1.17-14
Switch at “ON”
Possible A. BCM fault
Causes B. Instrument fault
C. Air bag controller is not installed.
D. Connection fault between safety belt buckle harness and the air bag controller
A. Is the reminding sound for unfastened safety
belt normal?
lamp?
3 Test BCM. Yes Replace BCM.
Reference: 3.1.14 Electronic Control System, “Fault Reference: 3.1.14 Electronic
Description, Diagnosis and Test” Control System, “Removal and
A. Is there anything wrong with BCM? Installation”
4 Test the air bag controller Yes Continue to Step 5.
A. Turn the ignition switch to “LOCK” position. No Install air bag controller.
B. Check whether the air bag controller has been
installed?
Installation”
the complete vehicle harness No Repair is completed.
bag controller to see if such faults have occurred as
Installation”

probably causing serious accident. Before inspecting and repairing the air bag system, please
first confirm that the system is disconnected from the power supply.
Warning: It is strictly prohibited to refit, take off, knock or open components of the air bag
system or remove or damage its connection; otherwise, sudden functioning or malfunction of
the air bag system will be probably caused.
Warning: After installation, please confirm that all connectors have been connected properly
and firmly. Such conditions as short circuit, virtual circuit and contact making will make the
air bag system explode suddenly as the circuit thereof becomes unstable.
Driver Air Bag
Installation
1. Connect the connector of driver air bag.
2. Wind the harness around the center of steering wheel to prevent it from being pressed by the
BENNI 2013.11
5.1.17-15 Air Bag System 5.1.17-15
spring.
3. Align the two steel clips and the three plastic clips on DAB with the five mounting hooks in
the steering wheel and then press DAB down.
Removal
2. Turn the steering wheel 90° clockwise.
3. Stretch a small screwdriver from the upper of the steering lock case to the steel wire on the
steel clip foot of air bag and then press the screwdriver down with force to release the steel
wire from the clip foot.
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5.1.17-16 Air Bag System 5.1.17-16
4. Turn 180° counterclockwise and repeat Step 3.

5. Turn 90° further counterclockwise, stretch the small screwdriver through the upper of the
steering lock case to make it touch the upper of the plastic clip of the air bag and then press
the screwdriver down to release the plastic clip from the hook.
6. Take down the connector of air bag.

Passenger Air Bag
Removal
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5.1.17-17 Air Bag System 5.1.17-17
1. Remove the glove box.

Reference: 5.1.4 Instrument Panel and Console, “Installation and Removal”
2. Remove the central control panel and the air outlet coverplate at the right side.
3. Remove the fixing bolt connecting the passenger air bag and the steering support column.
Torque: 23±3Nm
4. Remove the three screws connecting PAB coverplate and the instrument panel.
5. Remove the passenger air bag hook from the air bag frame on the instrument panel.
Installation
Air Bag Controller
Removal
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5.1.17-18 Air Bag System 5.1.17-18
1. Remove the central control cabinet.

2. Remove the mounting bolt of air bag controller.
Torque: 9±3Nm
3. Disconnect the connector of air bag.
Installation
Warning: The air bag controller shall be taken and put back gently. Please be careful not to
bump during assembly of air bag controller. It is also prohibited to open the controller shell.
When the controller is fastened, please check and confirm that torque of the fastening bolt is
not less than 9N•m.
Warning: The product bar code on each part of the air bag system is the permanent
identification which shall not be torn up or contaminated so as to help the manufacturer carry
out quality tracing and performance inspection.
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Interior and Exterior Trims
Section Title Page
5.1.4 Instrument Panel and Console ................................................................... 5.1.4-1
5.1.5 Door Inner Trim Panel .............................................................................. 5.1.5-1
5.1.6 Interior Trim Panel and Trims ................................................................... 5.1.6-1
5.1.7 Rear-view Mirror ...................................................................................... 5.1.7-1
5.1.8 Front/Rear Quarter Window Exterior Garnish Assembly ........................... 5.1.8-1
5.1.9 Bumper ..................................................................................................... 5.1.9-1
5.1.10 Front Hood Garnish ................................................................................ 5.1.10-1
5.1.11 Interior Trim Panel and Trims ................................................................. 5.1.11-1
5.1.12 Washer .................................................................................................... 5.1.12-1
5.1.13 Back Door Handle Assembly .................................................................. 5.1.13-1
5.1.14 NVH Parts .............................................................................................. 5.1.14-1
5.1.15 Seat ......................................................................................................... 5.1.15-2
5.1.16 Safety Belt System .................................................................................. 5.1.16-1
5.1.17 Air Bag System ...................................................................................... 5.1.17-2
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Vehicle Body and Accessories

Contents
Page
Manner of Removal 5.1.4-1
Front Door Inner Trim Panel 5.1.5-1
Rear Door Inner Trim Panel 5.1.5-6
Front Sill Trim Panel 5.1.6-1
Rear Sill Trim Panel 5.1.6-1
Back Sill Trim Panel 5.1.6-3
Trim Panel of Column A 5.1.6-4
Trim Panel of Column B 5.1.6-6
Trim Panel of Column C 5.1.6-9
Quarter Trim Panel 5.1.6-11
Interior Rear-view Mirror 5.1.7-1
Exterior Rear-view Mirror 5.1.7-1
5.1.9 Bumper
Front Bumper 5.1.9-1
Rear Bumper 5.1.9-3
Removal 5.1.10-1
Installation 5.1.10-3
Removal 5.1.11-1
5.1.12 Washer
Removal 5.1.12-1
Removal 5.1.13-1
5.1.14 NVH Parts
1. Sunvisor Assembly (Left/Right) 5.1.14-1
2. Safety Handle 5.1.14-3
3. Glasses Case 5.1.14-1
4. Roof Lining 5.1.14-3
5. Roof Lining (Panoramic Sunroof) 5.1.14-1
5.1.15 Seat
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Vehicle Body and Accessories

Removal and Installation of Seat 5.1.15-1
Front-row Manual Seat 5.1.15-1
Rear-row Seat 5.1.15-3
Middle Hinge of Rear-row Seat 5.1.15-4
Force Limit Safety Belt 5.1.16-1
Warning for Unfastened Safety Belt 5.1.16-1
Exploded View of Parts 5.1.16-1
Front-row Safety Belt Assembly 5.1.16-1
Rear-row Safety Belt 5.1.16-2
Front-row Safety Belt 5.1.16-3
Safety Belt Buckle 5.1.16-5
Rear-row Safety Belt 5.1.16-6
Locations of Parts of Air Bag System 5.1.17-2
Definition of Pins on Air Bag Controller 5.1.17-2
Fault Code Table 5.1.17-5
Troubleshooting 5.1.17-6
Removal and Installation 11
Driver Air Bag 5.1.17-11
Passenger Air Bag 5.1.17-14
Air Bag Controller 5.1.17-15
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Manner of Removal
Special Tools
Name Nm lb-ft lb-in
Fastening of upper portion of the 3 - 27
instrument panel
Fastening of side face of the instrument 19 14 -
panel
Fastening of lower portion of the 9 14 -
instrument panel
Warning: Before removing or replacing the air bag system, please first disconnect the
system power supply and then carry out removal or replacement at least 60s thereafter.
Note: Please confirm that the steering wheel is locked.
Note: Please confirm that the wheels are in the straight front position.
2. Remove the trim panels of Column A at both the left and the right sides.
Reference: Trim Panel of Column A (5.1.6 Interior Trim Panel and Trims, “Removal and
Installation”)
3. Remove the instrument. Reference: Instrument Assembly (4.3.2 Instruments, “Removal and
Installation”)
4. Remove the driver air bag and the steering wheel.
Reference: Driver Air Bag and Steering Wheel (5.1.17 Air Bag Restraint System, “Removal
5. Remove the passenger air bag.
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Reference: Passenger Air Bag (5.1.17 Air Bag Restraint System, “Removal and Installation”)
6. Remove the lamplight combination switch.
Reference: Lamplight Combination Switch (4.3.6 Lighting System, “Removal and
Installation”)
7. Remove the wiper combination switch.
Reference: Wiper Combination Switch (4.3.7 Wiper and Washer, “Removal and
Installation”)
8. Remove the air conditioner control module.
Reference: Air Conditioner Control Module (4.1.1 Air Conditioner System—Manual,
9. Remove the DVD player.
Reference: DVD Player (4.3.5 Information and Entertainment System, “Removal and
Installation”)
10. Remove the USB adaptor and the power outlet.
Reference: (4.3.4 USB Adaptor/Power Outlet, “Removal and Installation”)
11. Remove the gear cover plate.
13. Remove the fixing bolt at left and right sides of the rear portion of the control cabinet.
Torque: 3N.m.
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5.1.4-3 Instrument Panel and Console 51.4-3
14. Remove the trim panel at the front end on the right side of the control cabinet.
15. Remove the two retaining screws on the right side of the front portion of the control cabinet.
Torque: 3N.m.
16. Remove the trim panel at the front end on the left side of the control cabinet.
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17. Remove the two retaining screws on the left side of the front portion of the control cabinet.
Torque: 3N.m.

Installation
19. Remove the bolt cover in the middle of the front end of the instrument panel.
20. Remove the fixing bolt at the front end of the instrument panel. Torque: 3N.m.
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21. Remove the trim covers at both the left and the right sides of the instrument panel.
22. Remove the 8 fixing bolts at both the left and the right sides of the instrument panel. Torque:
19N.m
23. Remove the 2 fixing bolts at the front end of the left side of the instrument panel. Torque:
19N.m.
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24. Remove the 2 retaining nuts at the upper portion of the lower bracket of the steering wheel
and the 2 fixing bolts at the lower portion. Torque: 12N.m.
25. Remove the instrument panel assembly.

Installation
1. Remove the adjusting coverplate of parking brake. Hold the rear end, pull out the clips at the
rear end and then hold both sides to pull out the clips at the front end.
2. Remove the trim strip on the gear cover plate.
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3. Remove the 4 screws on the knob type electronic gear shifter.
4. Remove the knob type electronic gear shifter.
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6. The way to remove the fixing bolts at the front and the rear of the control cabinet is the same
as that of the MT control cabinet.
Installation
1. Remove the central control panel. First use special tools to pry out the cellphone box cover at
each side.
Pry out the clips at the middle and the lower portions of the central control panel from the
crevices between the central control panel and the trim covers and then pull out the buckle at
the upper portion.
2. Remove the right-side air outlet coverplate. First remove the 2 retaining screws at the left
side of the air outlet coverplate, and then pry out the buckle at the left side of the coverplate
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with a special tool and finally pull out the buckles one by one with your hand from the left to
the right.
3. Remove the instrument cluster mask. First use s special tool to pry out the buckles at the left
and the right lower corners of the instrument cluster mask and then pull out the mask with
your hand.
4. Remove the upper shell of the steering lock. First adjust the steering column to the lowest
position, and then use a special tool to pry the buckles on both sides of the lock shell until
they are loose and finally pull out the lock shell with your hand.
5. Remove the 3 retaining screws on the power shell of the steering lock. Before removing the
screws below the lock shell, please first turn the adjusting handle of the steering column to
the lowest position so as to leave space for the tool.
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6. Remove the lower shell of the steering lock.

Installation
1. Stick a piece of adhesive cloth on the place (shown in the figure as a frame formed by dotted
line) at the right lower corner of the glove box sin case that the glove box will damage the
lower trim panel of Column A.
2. Open the glove box and push inwards both sides of the box with your hands to make the
limiting pin come out of the instrument panel.
3. Take the damper wire down from the hook as shown in the figure below, turn the glove box
downwards continuously to remove it and then tear down the adhesive cloth at the right lower
corner.
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Installation
1. Remove the fixing bolt on each side of the lower portion of the fuse box coverplate assembly.
Torque: 3N.m.
2. Hold the upper and the lower ends of the fuse box coverplate assembly with your hands and
pull outwards to take out the clip.
3. Open the front hood unlocking handle and rotate the handle to take out the front hood
unlocking cable assembly shown in dotted lines in the figure.
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4. Take out the front hood unlocking cable assembly shown in dotted lines in the figure from
the fuse box coverplate.
Installation
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Front Door Inner Trim Panel
Manner of Removal
Special Tools
1. Use proper tools to remove the trims of the front door quarter window.
2. Remove the hole cover of the front door inner handle.
3. Use a proper tool to remove the mounting screw in the inner handle.
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4. Remove the inner handle box.
5. Remove the cover on the screw hole of the front door armrest box.
6. Use a proper tool to remove the screw in the armrest box.
7. Use a proper tool to remove the front door inner trim panel. Special tool: tools to remove
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exterior and interior trims.
8. Disconnect the harness connector of the power window switch.
Note: It is possible that the buckle of front door inner trim panel will be damaged during
removal, so please replace the damaged buckle during installation.
Installation Method
Special Tools
1. Connect the harness connector of the power window switch.
2. Install the inner trim panel of the front door.
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3. Install the inner handle box.
4. Use a special tool to install the retaining screw in the inner handle box.
5. Install the cover on the screw hole of the inner handle box.
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6. Use a proper tool to install the mounting screw of armrest box.
7. Install the screw coverplate of armrest box.
8. Install the trims of front door quarter window properly.
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Rear Door Inner Trim Panel

Manner of Removal
1. Use proper tools to remove the trims of the rear door quarter window.
2. Remove the cover on the screw hole of the rear door inner handle box.
2. Use a proper tool to remove the mounting screw of the rear door inner handle box.
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3. Remove the rear door inner handle box.
4. Use special tools to remove the screw coverplate of the rear door armrest plate.
5. Remove the mounting screw on the armrest plate of the rear door inner trim panel.
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6. Use a special tool to remove the rear door inner trim panel.
7. Disconnect the harness connector of the rear door power window switch.
Installation Method
The method for installation is the same as that of the front door inner trim panel.
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Front Sill Trim Panel
Manner of Removal
Special Tools
1. Remove the clip connecting structure at the front/rear end of the front sill trim panel.
2. Use a special tool to remove the V-type clip on the front sill trim panel.
Installation
Rear Sill Trim Panel
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Manner of Removal
Special Tools
1. Remove the retaining screw of rear sill trim panel.
2. Remove the clip connecting structure at the front/rear end of the rear sill inner trim panel.
3. Use a special tool to remove the V-type clip on the rear sill trim panel.
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5.1.6-3 Interior Trim Panel and Trims 51.6-3
Installation
Back Sill Trim Panel
Manner of Removal
Special Tools
1. Use proper tools to remove the retaining screws on both sides of the back sill trim panel.
2. Use proper tools to remove ISO FIX retaining screws and the snap fastener in the middle at
both ends of the back sill trim panel.
3. As is shown below, remove the clip connecting structures at both ends of the back sill trim
panel.
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4. Use a special tool to remove the fixing clip on the back sill trim panel.
Installation
Trim Panel of Column A
Manner of Removal
Special Tools
1. Use a special tool to remove the cover on the trim panel of Column A.
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2. Remove the retaining bolts on the trim panel of Column A.
3. Use a special tool to remove the trim panel on Column A.
4. Disconnect connectors of the loudspeaker.
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5. Use a proper tool to remove the disc-type nut on the trim panel of Column A.
6. Use a special tool to remove the 2 fixing clips on the lower trim panel of Column A.
Installation
Trim Panel of Column B
Manner of Removal
Special Tools
1. Use a special tool to remove the 3 front fixing clips on the lower trim panel of Column B.
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2. Use a special tool to remove the 2 rear fixing clips on the lower trim panel of Column B.
3. Use a special tool to remove the lower trim panel of Column B.
4. Positions of clips on the lower trim panel of Column B are shown in the figure below.
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5. Use a special tool to remove the retaining bolts under the front-row safety belt.
7. Remove the trim cover of the mounting bolt on the upper trim panel of Column B.
8. Remove the mounting bolt on the upper trim panel of Column B.
8. Use a special tool to remove the 2 fixing clips on the upper trim panel of Column B.
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9. Use a special tool to remove the fixing clip on the lower portion of the upper trim panel of
Column B.
10. Positions of the clips on the upper trim panel of Column B are shown in the figure below.
11. Use a special tool to remove the upper trim panel of Column B.
Installation
Trim Panel of Column C
Manner of Removal
Special Tools
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1. Remove the trim cover of the mounting bolt on the upper trim panel of Column C.
2. Remove the mounting bolt on the upper trim panel of Column C.
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4. Use a special tool to remove the trim panel of Column C.

Installation
Quarter Trim Panel
Manner of Removal
1. Remove the 4 mounting screws on the quarter trim panel.
Remove the 2 mounting nails on the lower portion of the quarter trim panel.
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Installation
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System Overview
Rear-view mirror includes interior rear-view mirror and exterior rear-view mirror. The mirror
can be adjusted manually or electrically, depending on the specific configuration of the vehicle.
Manual adjustment is realized via the rear-view mirror adjusting handle at the inner side of the
front door and electrical adjustment is realized via a button on the instrument panel.
Interior Rear-view Mirror
Removal
1. Turn the retaining screw on the rear-view mirror counterclockwise to make it loose.
2. Move the rear-view mirror upwards to take it down.
Installation
Exterior Rear-view Mirror
Removal
1. Remove the trims of the front door quarter window.
Note: Refer to 5.1.2-6 for the manners of removal and installation.
2. Disconnect harness of the exterior power rear-view mirror.
3. Remove the 3 nuts at the mounting plate of front rear-view mirror.
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4. Take the rear-view mirror down according to the direction shown in the figure below.
Installation
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5.1.8-1 Quarter Window Exterior 5.1.8-1
Garnish

Removal
1. Remove the exterior garnish assembly of front quarter window.
2. Remove the exterior garnish assembly of front quarter window according to the direction
shown in the figure below.
3. Remove the exterior garnish assembly of rear quarter window.
Note: It is possible that the clip on the front/rear quarter window exterior garnish
assembly will be damaged during removal, so please replace the damaged one during installation.
Installation
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5.1.9-1 Bumper 5.1.9-1
5.1.9 Bumper
Front Bumper
Removal
2. Disconnect the harness connector of the combination headlamp.
Reference: Combination Headlamp (4.3.6 Lighting System, “Removal and Installation”)
3. Remove the 3 fixing bolts at the upper portion of the bumper.
4. Remove the 2 fixing clips at the upper portion of the bumper.
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5.1.9-2 Bumper 5.1.9-2
6. Remove the 2 fixing bolts at the bottom of the bumper.
7. Remove the 4 plastic retaining snap fasteners at the bottom of the bumper.
8. Use proper tools to pry the 4 clips connecting the bumper and the bumper bracket and the 2
clips connecting the bumper and the front headlamp on the left side and the right side
respectively to make the clips loose and then pull outwards the bumper according to the
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5.1.9-3 Bumper 5.1.9-3
9. Disconnect the harness connectors at the left and the right sides of the front foglamp.
Reference: Front Foglamp (4.3.6 Lighting System, “Removal and Installation”)
10. Remove the bumper.
Installation
Rear Bumper
Removal
2. Remove the s on both the left and the right sides.
Reference: (4.3.6 Lighting System, “Removal and Installation”)
3. Remove the fixing clips and the self-tapping screws on both the left and the right sides on the
upper portion of the bumper.
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5.1.9-4 Bumper 5.1.9-4
5. Remove the 2 plastic retaining clips and the 2 bolts at the bottom of the bumper.
6. Disconnect the harness connector of the license lamp.

Reference: License Lamp (4.3.6 Lighting System, “Removal and Installation”)
7. Use a proper tool to pry the 4 clips connecting the bumper and the bumper bracket at both the
left and the right sides respectively and then pull the bumper outwards according to the
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5.1.9-5 Bumper 5.1.9-5
8. Take the rear bumper down.

Installation
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Removal
3. Remove the 5 clips connected to the vehicle body.
4. Remove the clip connecting structure of the front end covers (left and right) of the front hood
and the fender.
5. Move the main locating pin out of its corresponding hole on the vehicle body.
6. Remove the front hood garnish assembly as per the direction shown in the figure below.
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Installation
2. Install the main locating pin into its corresponding hole on the vehicle body.
3. Push the front hood garnish assembly as per the direction shown in the figure below.
4. Connect the clip on the front hood garnish body with the front windshield.
5. Connect the front end covers (left and right) of the front hood and the fender with a clip.
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6. Connect the front hood garnish and the hole on the vehicle body with a clip.
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Removal
1. Remove the 5 fixing clips and 1 screw which connect the front wheelhouse lining plate with
the front bumper and the vehicle body.
2. Remove the four clips and one screw which connect the front wheelhouse lining plate with
the fender and the vehicle body.
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3. Take down the front wheelhouse lining plate after all clips and screws are removed.
Installation
Rear Wheelhouse Lining Plate Assembly
Removal
1. Remove the 3 fixing clips and 2 screws which connect the rear wheelhouse lining plate with
the rear bumper and the vehicle body.
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2. Take down the rear wheelhouse lining plate after all clips and screws are removed.
Installation
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5.1.12-1 Washer 5.1.12-1
5.1.12 Washer
Removal
1. The washer reservoir is located at the left lower corner of the engine room. It can be seen
when you open the front hood. It is shown in the figure below.
2. Remove the two bolts and one nut on the washer reservoir.
3. Take down the washer reservoir.

Installation
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5.1.13-1 Back Door Handle Assembly 5.1.13-1

Removal
1. Open the back door.
2. Use a special tool to remove the 10 clips on the back door lining.
3. Remove the harness of the point-contact switch of the back door.
4. Use a special tool to remove the two screws on the point-contact switch of the back door.
Installation
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5.1.14-1 NVH Parts 5.1.14-1
5.1.14 NVH Parts

1. Sunvisor Assembly (Left/Right)
Removal
1. Screw the mounting screw marked as “1” out with a crosshead screwdriver and then pull out
the sunvisor body from the mounting seat marked as “2”.Take down the sunvisor body.
2. Pry out the core (marked as “3”) inserted in the mounting seat with a flat head screwdriver
and then pull out the sunvisor mounting seat marked as “2” from the mounting hole.
Installation
2. Safety Handle
Removal
screw out the mounting screw with a crosshead screwdriver and then remove the safety handle.
Installation
3. Glasses Case
Removal
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5.1.14-2 NVH Parts 5.1.14-2
screw out the mounting screw with a crosshead screwdriver and then remove the glasses case.
Installation
4. Roof Lining
Removal
removed:
Installation”)
Installation”)
Installation”)
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5.1.14-3 NVH Parts 5.1.14-3
6) Safety handle
7) Glasses case
8) Front roof lamp
2. Remove the mounting nails (9 in total) on the roof lining and then take the roof lining out of
the front windshield frame.
Installation
5. Roof Lining (Panoramic Sunroof)
Removal
removed:
Installation”)
Installation”)
Installation”)
6) Safety handle
7) Glasses case
8) Front roof lamp
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5.1.14-4 NVH Parts 5.1.14-4
2. Remove the mounting nail “1” (3 in total) on the roof lining.

3. Disconnect the dual lock (12 in total) which connects the roof lining and the abat vent;
4. Pull the roof lining back a little toward the rear portion of the vehicle, take out the plastic part
on the front end of the roof lining from lap joint of the abat vent metal plate and then take the
roof lining down and out of the front windshield frame.
Installation
Install according to Step 4, 2, 3 of the removal.
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5.1.15-1 Seat 5.1.15-1
5.1.15 Seat
Specifications
Name N.m
Front fixing bolt of front-row seat 40±5
Rear fixing bolt of front-row seat 40±5
Outside bolt of rear-row backrest 25±3
Middle nut of rear-row backrest 25±3
Middle hinge of rear-row seat 30±3
Fixing bolt used on both the rear-row seat and the safety belt 65±5

System Overview
This vehicle is equipped with two rows of seats. All the front-row seats can slide back and
forth with adjustable armrest angle and headrest height. Besides, the height of the driver’s seat is
adjustable and this allows the driver to get a comfortable position for driving. Space between the
rear-row seats is large, providing a comfortable man-machine riding environment. When the seat
cushion is folded, the backrest can be put down and thus more storing space is acquired.
Removal and Installation of Seat
Front-row Manual Seat
Removal
1. Pull the sliding rail unlocking rod upwards and then move the seat forward to the utmost
position;
2. Remove the two fixing bolts on the back side of the seat;
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5.1.15-2 Seat 5.1.15-2
3. Refer to Step 1 and move the seat backwards to the utmost position;
4. Remove the two fixing bolts on the front side of the seat;
5. Turn the seat backwards, disconnect the harness connector on the safety belt at the bottom of
the seat and then take the seat down.(There is a harness only at the bottom of the driver’s
seat.)
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5.1.15-3 Seat 5.1.15-3
Installation
Rear-row Seat
Removal
Rear-row Seat Cushion
1. Lift the seat cushion up to unlock it and then turn the cushion over;
2. Bend a little the steel wire on the 60% portion of seat cushion, take out part of cushion at one
side and then that at the other side. Take out the 40% portion of the seat cushion in the same
way;
Rear-row Backrest
1. Remove the bolts which connect the safety belt buckle assembling unit on the 60% portion of
the backrest and the vehicle body;
2. Pull up the unlocking button on the 60% portion of the backrest and then put the backrest
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5.1.15-4 Seat 5.1.15-4
down and onto the floor of the vehicle body;
3. Remove the step bolt at the outer side of the 60% portion of the backrest, then remove the
connecting nut in the middle and finally take down the 60% portion of the backrest;
4. Remove the step bolt at the outer side of the 40% portion of the backrest and take this portion
down.
Installation
Middle Hinge of Rear-row Seat
Removal
1. After both the 40% portion and the 60% portion of the backrest are removed, remove the two
bolts connecting the middle hinge of rear-row seat and the vehicle body directly.
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5.1.15-5 Seat 5.1.15-5
Installation
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Specifications
Name Nm
Lower fixing bolt of front-row safety belt 39±5
Fixing bolt on height adjuster of front-row safety belt 39±5
Fixing bolt on guide ring of front-row safety belt 39±5
Lower fixing bolt on retractor of front-row safety belt 39±5
Upper fixing bolt on retractor of front-row safety belt 9±3
Fixing bolt on buckle of front-row safety belt 39±5
Fixing bolt on retractor of rear-row safety belt 39±5
Lower fixing bolt on left side of rear-row safety belt 39±5
Lower fixing bolt on right side of rear-row safety belt 39±5
Lower fixing bolt in the middle of rear-row safety belt 69±5
Fixing bolt of rear-row buckle 69±5

System Overview
Safety belt is a main way to protect passengers. Both the front-row and the rear-row seats are
equipped with safety belts. Three-point diagonal-fixing safety belt is adopted for both the front-
row and the rear-row seats.
The safety belt buckle of front-row seat is put in the seat slide. While the safety belt buckle of
rear-row seat is fastened onto the floor.
All the safety belts of the front-row seats have the emergency locking function. The locking
function will be activated when the safety belt is pulled quickly out of the retractor. The locking
function can prevent the safety belt from being pulled out to an extent not allowed, i.e. surpassing
the allowable retraction position.
When the pre-tensioners of the front-row safety belts work, working sound will be heard and
a small amount of smoke will be generated. Such smoke is harmless, and it does not indicate a
fire.
Force Limit Safety Belt
Front safety belt retractors are equipped with force limit devices. In case of head-on crash,
the retractor will release a certain length of braid to reduce the compression of the braid on the
chest when the tension of the chest braid exceeds set value.
Warning for Unfastened Safety Belt
The front-row safety belt has the function of warning for unfastened safety belt. It reminds
the user to fasten the safety belt by offering visual and audial information.
Reference: Warning for Unfastened Safety Belt (4.2.1 Air Bag System)
Exploded View of Parts
Front-row Safety Belt Assembly
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Upper fixing bolt on retractor of
1 Front-row retractor assembly 1 7 1
Lower fixing bolt on retractor of
2 Front-row buckle assembly 1 8 1
Lower fixing bolt of front-row
3 Height adjuster assembly 1 9 1
safety belt
Fixing bolt on guide ring of front- Washer at the lower fixing point of
4 1 10 1
row safety belt front-row safety belt
5 Fixing bolt of height adjuster 2 11 Front-row buckle washer 1
Fastening bolt of braid buckle on
6 1
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Lower fixing washer of rear-row
1 Rear-row retractor assembly (left) 1 6 2
safety belt
Retractor assembly in the middle of Fixing bolt on guide ring of rear-
2 1 7 2
rear row row safety belt
Guide ring washer of rear-row
3 Rear-row retractor assembly (right) 1 8 2
safety belt
Rear-row double buckle assembly Fixing bolt on retractor of rear-row
4 1 9 4
(left) safety belt
Lower fixing bolt of rear-row safety Fixing washer on retractor of rear-
5 2 10 4
belt row safety belt

Front-row Safety Belt
Removal
Warning: The pre-tensioner of safety belt works under the control of air bag system. Such
operations as removing or remodeling the air bag system without permission, knocking the
air bag control unit or the sensor and damaging the control circuit of air bag can cause the
pre-tensioner to work suddenly or make it fail to work.
Warning: It is strictly prohibited to refit, take off, knock or open the pre-tensioner
components of the safety belt or remove or damage its connection; otherwise, sudden
functioning or malfunction of the pre-tensioner of the safety belt will be probably caused,
leading to serious safety and casualty accidents.
Warning: Please check the safety belt system after each crash. Safety belt of which the pre-
tensioner has worked before shall be replaced immediately other than used again. Newly
fixed safety belts must be checked by professional technician to make sure that the safety
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belts do not have faults and can work normally.

1. Remove the lower fixing bolt of safety belt
Open the trim cover of lower fixing bolt and remove the lower fixing bolt of the safety belt.
Torque: 39Nm
3. Remove the interior trim panel of Column B.

Installation”)
4. Withdraw the braid from the interior trim panel of Column B.
Installation”)
5. Remove the guide ring of safety belt.

Torque: 39 Nm
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6. Remove the retractor of the safety belt.

7. Remove the height adjuster of the safety belt.

Torque: 39Nm
Installation
Safety Belt Buckle
Removal
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2. Disconnect the connector which is connected to the harness of the buckle.
3. Remove the seat.

4. Remove the buckle of the safety belt.
Torque: 39Nm
Installation
Removal
1. Remove the rear-row seat cushion.
2. Remove the lower fixing bolt of rear-row safety belt.
Remove the fixing point bolt at the left side.
Torque: 39Nm
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Remove the fixing point bolt at the right side.

Torque: 39Nm
Remove the fixing bolt in the middle.

Torque: 69Nm
Remove the fixing bolt of the buckle.
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3. Remove the rear-row backrest.

4. Remove the interior trim panel of Column C.
Reference: Interior Trim Panel (5.1.9 Interior Trim Panel and Trims, “Removal and
Installation”)
5. Withdraw the rear-row safety belt from the interior trim panel.
6. Remove the rear-row safety belt.

Torque: 39Nm
Installation
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5.1.17-1 Air Bag System 5.1.17-1

Specifications
Name Nm lb-ft lb-in
Fixing bolt of air bag for passenger 23±3
Fixing bolt of air bag controller 9±3

System Overview
Air bag on vehicle (AIR BAG) is a Supplemental Restraint System (SRS).
Air bag system includes the crash sensor, the air bag controller and all kinds of air bags
(including air bag for the driver and air bag for the assistant driver).
When a crash occurs, the sensor will transmit a crash signal to the air bag controller which
will decide whether the severity of crash reaches the minimum requirement for explosion; if it
does, the controller will send an ignition command to detonate the air bags. The exploded air bags
will form a soft air cushion quickly among the passengers and the structural parts in the vehicle
such as the steering wheel, the instrument panel and the interior trim panel. The impact will be
mitigated and the collision energy will be absorbed through the damping effect of the air cushion
during air discharging and thus injuries to the passengers will be reduced.
Warning: Only under the condition that the safety belt is used, can the SRS protect the
passengers to the fullest extent.
Reference: 5.1.4 Safety Belt System
Warning: Please check the air bag system after each crash. The air bag and the air bag
controller shall not be used again after crash. They must be replaced immediately. The new
air bag system shall be checked by professional technician and confirmed to be able to work
normally without any defect.
Warning: It is strictly prohibited to place a child seat facing backward in the front row and
the rear-row seats are the safe position for children.
Warning: It is strictly prohibited to place any substance at the place where the air bag
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5.1.17-2 Air Bag System 5.1.17-2
locates.
Circuit Diagram of Air Bag System
Air bag ECU (ECU) can carry out real-time monitoring over the air bag system to see if it
works normally. If a fault occurs, the air bag warning lamp will be on, reminding the user to carry
out inspection and repair in time.
Warning: If the air bag warning lamp is always on, it is necessary to inspect and repair
the air bag.
Reminding Logic for Unfastened Safety Belt

Safety belt is the most important protection device for passenger’s safety. The warning for
unfastened safety belt will remind the passengers to fasten the safety belt and thus safety during
driving is guaranteed.
1. If the safety belt buckle is not fastened when the power gear is at “ON” or “START”, the
indicator will be always on;
2. If the safety belt buckle is not fastened when the vehicle speed reaches 7km/h, the warning
sound will last for 300s.
Locations of Parts of Air Bag System
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5.1.17-1 Air Bag System 5.1.17-1

1 Driver air bag assembly 1 8 Air bag controller assembly 1
2 Steering wheel 1 9 Floor assembly 1
Assembling unit of cross recessed
3 pan head self tapping screw and big 3
washer
4 Passenger air bag assembly 1
6 Instrument panel assembly 1
Part Description
Driver Air Bag Assembly
The air bag for driver is connected to the interior of the steering wheel by two steel clips and
three plastic clips. The bag will open and form a soft air cushion between the driver and the
steering wheel to protect the driver in case of a front crash. The bag is called DAB for short.
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5.1.17-2 Air Bag System 5.1.17-2
Passenger Air Bag Assembly

The coverplate of passenger air bag assembly is hitched to the instrument panel. The lower
edge of the coverplate is connected to the instrument panel through three screws and the lower air
bag body is fixed to the steering support column through two bolts. The bag will open and form a
soft air cushion between the assistant driver and the instrument panel to protect the passenger in
case of a front crash. The bag is called PAB for short.
Air Bag Controller

The air bag controller is installed on the floor of the central channel which is below the
central control cabinet. It is between the parking brake and the gear shift. There is a direct impact
sensor in the air bag controller which can sense the signal of front crash. The air bag controller can
monitor the whole air bag system. It is called ECU for short.
Definition of Pins on Air Bag Controller

S/N Definition Description S/N Definition Description
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5.1.17-3 Air Bag System 5.1.17-3
1 Vbat Power supply 17 CAN_H CAN_H

2 CAN_L CAN_L 18 NC NC
3 ABFD+ Air bag before the driver + 19 NC NC
Safety belt buckle for the
4 ABFD- Air bag before the driver - 20 BLFP
assistant driver (reserved)
5 ABFP- 21 NC NC
driver -
6 ABFP+ 22 NC NC
driver +
Safety belt pre-tensioner for
7 BTFDBelt+ 23 NC NC
the driver + (reserved)
Safety belt pre-tensioner for
8 BTFDBelt- 24 NC NC
the driver - (reserved)
Safety belt buckle of the
9 NC NC 25 BLFD
driver
10 NC NC 26 CRO Crash output
11 NC NC 27 NC NC
12 NC NC 28 NC NC
13 NC NC 29 NC NC
14 NC NC 30 NC NC
15 NC NC 31 NC NC
16 GND Ground wire 32 NC NC

General Inspection
Air Bag Alarm Lamp:
After the air bag system is installed, turn the ignition switch to “ON” or “START” and
connect power supply of the air bag system. At this time, alarm lamp of the air bag system on the
instrument shall be on for approximately 4 seconds before it turns out.
Warning for Unfastened Safety Belt:

Warning for unfastened safety belt of driver seat is made in a visual way:
1. If the safety belt buckle is not fastened when the power gear is at “ON” or “START”,
the indicator will be always on.
2. If the safety belt buckle is not fastened when the vehicle speed reaches 7km/h, the
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5.1.17-4 Air Bag System 5.1.17-4
warning sound will last for 300s.

If the above mentioned logic is conformed to, it indicates that the air bag system works
normally; if not, it indicates that the system fails to work normally and must be inspected and
repaired.
Diagnosis Procedure
Inspection and repair shall be carried out immediately upon discovery that the alarm lamp is
always on or that warning of unfastened safety belt is abnormal. First use a diagnostic scanner to
read the fault code stored in the air bag controller to confirm the fault location and the fault causes
and then carry out repair.
S/N Step
1 Alarm lamp is not normal
2 Connect the diagnostic scanner
3 Read the fault code
4 Handle the fault
5 Clear the fault code
Note: Fault elimination must be conducted after the fault is removed.

General Equipment
S/N Name
1 Diagnostic scanner

2. Conduct visual inspection to see whether there are signs of any obvious mechanical or
electrical damages.
3. Conduct visual and manual inspection to see whether the harness connectors are connected
reliably and whether the positive wire and the negative wire are connected oppositely.
List for Visual Inspection
Air bag Harness
Air bag controller Connector
Air bag controller
4. If the apparent cause of an observed or raised problem has been found, it shall be corrected
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5.1.17-5 Air Bag System 5.1.17-5
before next step.

5. If the fault cannot be found easily, use a diagnostic scanner to diagnose the system.
DTC Reading Program
1. Conduct necessary preparations and appearance inspection.
2. Connect the diagnostic scanner to the diagnosis interface in the cab.
3. Enter the diagnosis procedure of air bag system and read the DTC.
Fault Code Table
Code Fault Code Description Code Fault Code Description
B1B00 Fault within ECU B1B14 Air bag at the driver’s side makes contact
B1B01 Configuration fault B1B14 Air bag at the driver’s side is short to ground
Peripheral sensor at the driver’s side is Air bag at the driver’s side is short to power
B1B02 B1B14
not installed correctly supply
Peripheral sensor at the driver’s side is
B1B02 B1B14 Circuit of air bag at the driver’s side is open.
damaged
Communication fault of peripheral Resistance of air bag at the driver’s side is too
B1B02 B1B14
sensor at the driver’s side is damaged low.
B1B03 B1B15 Air bag at the passenger’s side makes contact
is not installed correctly
Reliability fault of peripheral sensor at Air bag at the passenger’s side is short to
B1B03 B1B15
the passenger’s side ground.
Communication fault of peripheral Air bag at the passenger’s side is short to power
B1B03 B1B15
sensor at the passenger’s side supply.
B1B03 B1B15 Circuit of air bag at the passenger’s side is open.
is damaged
Peripheral sensor at the driver’s side Resistance of air bag at the passenger’s side is
B1B08 B1B15
makes contact. too low.
Peripheral sensor at the driver’s side is Air curtain at the passenger’s side makes
B1B08 B1B16
short to ground. contact.
Peripheral sensor at the driver’s side is Air curtain at the passenger’s side is short to
B1B08 B1B16
short to power supply. ground.
Peripheral sensor at the passenger’s side Air curtain at the passenger’s side is short to
B1B02 B1B16
makes contact. power supply.
Peripheral sensor at the passenger’s side Circuit of air curtain at the passenger’s side is
B1B02 B1B16
is short to ground. open.
Peripheral sensor at the passenger’s side Resistance of air curtain at the passenger’s side
B1B02 B1B16
is short to power supply. is too low.
B1B10 Air bag before the driver makes contact. B1B17 Air curtain at the driver’s side makes contact
Air bag before the driver is short to Air curtain at the driver’s side is short to
B1B10 B1B17
ground. ground.
Air bag before the driver is short to Air curtain at the driver’s side is short to power
B1B10 B1B17
power supply. supply.
Circuit of air bag before the driver is
B1B10 B1B17 Circuit of air curtain at the driver’s side is open.
open.
Resistance of air bag before the driver is Resistance of air curtain at the driver’s side is
B1B10 B1B17
too low. too low.
Air bag before the passenger makes
B1B11 B1B20 Safety belt buckle of the driver makes contact.
contact.
Air bag before the passenger is short to Resistance of safety belt buckle of the driver is
B1B11 B1B20
ground. too low.
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5.1.17-6 Air Bag System 5.1.17-6
Air bag at the passenger’s side is short Resistance of safety belt buckle of the driver is
B1B11 B1B20
to power supply. undefined.
Circuit of air bag before the passenger Resistance of safety belt buckle of the driver is
B1B11 B1B20
is open. too high.
Resistance of air bag before the Safety belt buckle of the driver is short to power
B1B11 B1B20
passenger is too low. supply.
Safety belt pre-tensioner of the driver Safety belt buckle of the passenger makes
B1B12 B1B21
makes contact. contact.
B1B12 B1B21
short to ground. is too low.
B1B12 B1B21
short to power supply. is undefined.
Circuit of the safety belt pre-tensioner Resistance of safety belt buckle of the passenger
B1B12 B1B21
of the driver is open. is too high.
Resistance of safety belt pre-tensioner Safety belt buckle of the passenger is short to
B1B12 B1B21
of the driver is too low. power supply.
B1B13 B1B34 Crash output is short to ground.
passenger makes contact.
B1B13 B1B34 Crash output is short to power supply.
passenger is short to ground.
B1B13 B1B40 Supply voltage is too high.
passenger is short to power supply.
Circuit of safety belt pre-tensioner of
B1B13 B1B40 Supply voltage is too low.
the passenger is open.
Resistance of safety belt pre-tensioner
B1B13 U1585 No communication is built with ABS.
of the passenger is too low.
Front-row air bag and safety belt pre-
B1B50 U1581 No communication is built with the instrument.
tensioner have been detonated.
Air curtain of the side air bag has been
B1B51 U1582 Transmit information fault
detonated.
ECU is locked and the controller shall
B1B52 U1583 Vehicle speed state is invalid.
be replaced.
U1580 CAN communication fault U1584 Warning lamp state fault
Troubleshooting
Warning: If the air bag warning lamp is always on, it is necessary to inspect and repair the air
bag. Before inspecting and repairing the air bag system, please first confirm that the system is
disconnected from the power supply. Hot-line operation is strictly prohibited.
Warning: improper handling of the air bag system can make the system open unexpectedly,
probably causing serious accident. All connectors must be connected properly and firmly.
Such conditions as short circuit, virtual circuit and contact making will make the air bag
system explode suddenly as the circuit thereof becomes unstable.
Warning: It is very dangerous to check the air bag module with a multimeter as serous
personal injuries are likely to be caused. Therefore, it is strictly prohibited to use such
electrical equipment as multimeter to inspect the air bag system. Instead, ECU diagnostic
scanner shall be used to inspect the system.
When the ignition switch is in “ON”, the air bag system enters self-inspection mode which
will last for about 4 seconds. During this short period, the air bag warning lamp will be on
continuously. If the lamp turns out afterwards, it indicates no fault; if it does not, it indicates a
fault. If the warning lamp does not lighten during self-inspection, please inspect and repair
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5.1.17-7 Air Bag System 5.1.17-7
according to the following steps:

Diagnostic Procedure for Not Lightened Air Bag Warning Lamp when Ignition Switch Is at “ON”
Fault Code U1584 DescriptionWarning lamp state fault
Causes
A. Turn the ignition switch to “ON” position, the No Continue to Step 2.
air bag system enters self-inspection mode and the
warning lamp will be on continuously for about 4
seconds.
A. Is there anything wrong with the air bag No Repair is completed.
warning lamp?
If the air bag warning lamp is still on after the self-inspection, inspect and repair according to
the following steps:
Diagnostic Procedure for Air Bag Warning Lamp That Is Still on when Ignition Switch Is at “ON”
Fault Code U1584, B1B00 DescriptionWarning lamp state fault; fault
within ECU
Causes B. Air bag system fault
1 General inspection Yes Continue to Step 2.
A. Turn the ignition switch to “ON” position, the No Repair is completed.
air bag system enters self-inspection mode, the warning
lamp will be on continuously for about 4 seconds and
then it turns out.
A Is there anything wrong with the air bag No Continue to Step 3.
warning lamp?
3 Inspect the connection between the air bag system and the Yes Replace harness.
complete vehicle harness No Continue to Step 4.
bag system to see if such faults have occurred as bonding,
being short to the power supply or being open.
Installation”
4 Connect the fault diagnostic scanner Yes Use the diagnostic scanner to
A. Turn the ignition switch to “ON” position, read the fault code, carry out
connect the diagnostic scanner and enter the air bag repair correspondingly and
system. then confirm that repair is
B. Select the function of “Fault Code completed.
Elimination”. No Use the diagnostic scanner to
C. First turn the ignition switch to “LOCK” clear previous fault records
position, keep it there for 10 seconds and then switch it to and then confirm that the
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5.1.17-8 Air Bag System 5.1.17-8
“ON” position. repair is completed.

D. Is the air bag warning lamp on constantly?
You can read the causes for faults of the air bag system with the diagnostic scanner and then
carry out inspection and repair according to the specific causes.
Internal Fault
Fault Code B1B00 Description Internal Fault
Possible A. Fault within the air bag controller
Causes
Troubleshooting
the complete vehicle harness No Replace the air bag controller
A. Turn the ignition switch to “LOCK” position. Reference: 4.2.1 Air Bag
B. Inspect the corresponding circuits of the air System, “Removal and
bag controller to see if such faults have occurred as Installation”
Installation”
Power Failure
Fault Code B1B40 Description Power voltage is too high or
too low.
Possible A. Supply voltage is too high.
Causes B. Supply voltage is too low.
C. Fault occurs in the harness between the air bag controller and the storage battery.
Troubleshooting
1 Test the storage battery Yes Continue to Step 2.
A. Measure the voltage of the storage battery to No Inspect the
see if it is within the normal range. charging/discharging system.
Reference: 3.1.10 Charging System, “Fault Reference: 3.1.10 Charging
Description, Diagnosis and Test” System, “Fault Description,
Diagnosis and Test”
2 Inspect the connection between the air bag controller and Yes Use the diagnostic scanner to
the complete vehicle harness clear previous fault records and
A. Turn the ignition switch to “LOCK” position. then confirm that the repair is
B. Loosen the connectors of all parts of the air completed.
bag system. No Replace harness.
Installation”
C. Turn the ignition switch to “ON" position,
measure the voltage between the power supply pin (1) of
the complete vehicle harness corresponding to the air bag
controller and the grounding pin (16) to see if it is in the
normal range.
Driver Air Bag Fault
Fault Code B1B10 Description Short circuit, open circuit,
Possible A. Drive air bag module fault
Causes B. Fault within the clock spring
C. Fault of circuit connectors between the clock spring and the air bag controller
D. Harness between the clock spring and the air bag controller is open or short.
E. Connector of the driver air bag generator of SRS air bag system is not connected
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5.1.17-9 Air Bag System 5.1.17-9
properly.
Troubleshooting
1 Inspect the clock spring. Yes Continue to Step 2.
A. Turn the ignition switch to “LOCK” position. No Replace the clock spring.
B. Inspect all parts related to the clock spring to
see if they are all normal? (The relationship between all
pins is normal without short circuit or open circuit?)
Replace the clock spring with a good one if it allows.
2 Inspect the driver air bag. Yes Continue to Step 3.
A. Replace the air bag module with a good one No Replace the driver air bag.
or connect a resistance of 2 ohmages. Reference: 4.2.1 Air Bag
B. Install the negative cable of storage battery
back.
D. Is the air bag warning lamp still on?
3 Inspect the harness connection between DAB and ECU. Yes Replace harness.
Installation”
B. Inspect the harness and connectors between
the air bag controller and DAB to see whether such
being open exist.
Passenger Air Bag Fault
Fault Code B1B11 Description Short circuit, open circuit,
Possible A. PAB air bag module fault
Causes B. Fault of circuit connectors between PAB and the air bag controller
C. Harness between PAB and the air bag controller is open or short.
D. Connector of PAB generator is not connected properly.
Troubleshooting
1 Inspect the passenger air bag. Yes Continue to Step 2.
A. Turn the ignition switch to “LOCK” position. No Replace the passenger air bag
B. Replace PAB with a good one or connect a module.
resistance of 2 ohmages. Reference: 4.2.1 Air Bag
D. Is the warning lamp still on?
2 Inspect the harness connection between PAB and ECU. Yes Replace harness.
Installation”
C. Inspect the harness and connectors between
the air bag controller and PAB to see whether such
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5.1.17-10 Air Bag System 5.1.17-10
being open exist.

A Crash Happens
Fault Code B1B50, B1B51 Description Air bag detonation, safety belt
detonation
Possible A. A crash happens.
Causes
Troubleshooting
1 A. Turn the ignition switch to “LOCK” position.
B. Replace the air bag controller; replace the air
bag or the safety belt.
Installation”
Diagnostic Procedure for Not Lightened Warning Lamp when Driver Safety Belt Is Not Fastened with
Ignition Switch at “ON”
Fault Code U1584 Description Warning lamp fault
Possible A. Fault of warning lamp for unfastened safety belt
Causes
on constantly?
2 Test the warning lamp Yes Replace the warning lamp for
Reference: 4.3.2 Instrument, “Fault Description, unfastened safety belt.
Diagnosis and Test” Reference: 4.3.2 Instrument,
A. Is there anything wrong with the warning “Repair and Installation”
lamp for unfastened safety belt?
Diagnostic Procedure for Warning Lamp That Is Still on when Safety Belt is Fastened with Ignition
Switch at “ON”
normal?
lamp?
3 Test the buckle. Yes Replace the buckle.
A. Is there anything wrong with the buckle? Reference: 5.1.4 Safety Belt
System, “Removal and
Installation”
4 Inspect the harness connection between the buckle Yes Repair is completed.
harness and the air bag controller. No Replace harness.
B. Inspect the connection of circuits
corresponding to the air bag system.
Reference: 5.1.4 Safety Belt System, “Removal and
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5.1.17-11 Air Bag System 5.1.17-11
Installation”
C. Is the warning lamp for unfastened safety belt
normal?
Diagnostic Procedure for No Reminding Sound Issued when Safety Belt is Unfastened with Ignition
Switch at “ON”
Possible A. BCM fault
Causes B. Instrument fault
C. Air bag controller is not installed.
D. Connection fault between safety belt buckle harness and the air bag controller
A. Is the reminding sound for unfastened safety
belt normal?
lamp?
3 Test BCM. Yes Replace BCM.
Reference: 3.1.14 Electronic Control System, “Fault Reference: 3.1.14 Electronic
Description, Diagnosis and Test” Control System, “Removal
A. Is there anything wrong with BCM? and Installation”
4 Test the air bag controller Yes Continue to Step 5.
A. Turn the ignition switch to “LOCK” position. No Install air bag controller.
B. Check whether the air bag controller has been
installed?
Installation”
the complete vehicle harness No Repair is completed.
bag controller to see if such faults have occurred as
Installation”

probably causing serious accident. Before inspecting and repairing the air bag system, please
first confirm that the system is disconnected from the power supply.
Warning: It is strictly prohibited to refit, take off, knock or open components of the air bag
system or remove or damage its connection; otherwise, sudden functioning or malfunction of
the air bag system will be probably caused.
Warning: After installation, please confirm that all connectors have been connected properly
and firmly. Such conditions as short circuit, virtual circuit and contact making will make the
air bag system explode suddenly as the circuit thereof becomes unstable.
Driver Air Bag
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5.1.17-12 Air Bag System 5.1.17-12
Installation
1. Connect the connector of driver air bag.
2. Wind the harness around the center of steering wheel to prevent it from being pressed by the
spring.
3. Align the two steel clips and the three plastic clips on DAB with the five mounting hooks in
the steering wheel and then press DAB down.
Removal
2. Turn the steering wheel 90° clockwise.
3. Stretch a small screwdriver from the upper of the steering lock case to the steel wire on the
steel clip foot of air bag and then press the screwdriver down with force to release the steel
wire from the clip foot.
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5.1.17-13 Air Bag System 5.1.17-13
4. Turn 180° counterclockwise and repeat Step 3.

5. Turn 90° further counterclockwise, stretch the small screwdriver through the upper of the
steering lock case to make it touch the upper of the plastic clip of the air bag and then press
the screwdriver down to release the plastic clip from the hook.
BENNI 2013.11
5.1.17-14 Air Bag System 5.1.17-14
6. Take down the connector of air bag.

Passenger Air Bag
Removal
1. Remove the glove box.
2. Remove the central control panel and the air outlet coverplate at the right side.
3. Remove the fixing bolt connecting the passenger air bag and the steering support column.
Torque: 23±3Nm
4. Remove the three screws connecting PAB coverplate and the instrument panel.
5. Remove the passenger air bag hook from the air bag frame on the instrument panel.
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5.1.17-15 Air Bag System 5.1.17-15
Installation
Air Bag Controller
Removal
1. Remove the central control cabinet.
2. Remove the mounting bolt of air bag controller.
Torque: 9±3Nm
3. Disconnect the connector of air bag.
Installation
Warning: The air bag controller shall be taken and put back gently. Please be careful not to
bump during assembly of air bag controller. It is also prohibited to open the controller shell.
When the controller is fastened, please check and confirm that torque of the fastening bolt is
not less than 9N•m.
Warning: The product bar code on each part of the air bag system is the permanent
identification which shall not be torn up or contaminated so as to help the manufacturer carry
out quality tracing and performance inspection.
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Part 6
Circuit Diagram
Section Title Page
6.1 Description
6.1.1 General ..................................................................................................... 6.1.1-1
6.1.2 Purposes.................................................................................................... 6.1.2-1
6.1.3 Reading Method ........................................................................................ 6.1.3-1
6.2 Symbols
6.2.1 Symbols .................................................................................................... 6.2.1-1
6.3 Safety System
6.3.1 Safety System ........................................................................................... 6.3.1-1
6.4 Speed Control System
6.4.1 1.4IMT System ......................................................................................... 6.4.1-1
6.5 Vehicle Body Control System
6.5.1 Vehicle Body Control System ................................................................... 6.5.1-1
6.6 Reversing Radar System
6.61 Reversing System....................................................................................... 6.5.1-1
6.7 Chassis System
6.7.1 Brake System ............................................................................................ 6.7.1-1
6.8 Power Rearview Mirror System
6.8.1 Power Rearview Mirror System ................................................................ 6.8.1-1
6.9 Ignition Power System
6.9.1 Ignition Power System .............................................................................. 6.9.1-1
6.10 Electronic Fuel Injection System
6.10.1 Electronic Fuel Injection System ............................................................. 6.10.1-1
6.11 Electronic Power Steering System
6.11.1 EPS System............................................................................................. 6.11.1-1
6.12 Grounding System
6.12.1 Grounding System................................................................................... 6.12.1-1
6.13 Air Conditioner System
6.13.1 Air Conditioner System ........................................................................... 6.13.1-1
6.14 Diagnosis Interface and Small System
6.14.1 Diagnosis Interface and Small System ..................................................... 6.14.1-1
6.15 Instrument System
6.15.1 Instrument System................................................................................... 6.15.1-1
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6.16 Audio-Visual (AV) System
6.16.1 Audio-Visual (AV) System ..................................................................... 6.16.1-1
6.17 Lighting System
6.17.1 Lighting System ...................................................................................... 6.17.1-1
6.18 Power Distribution
6.18.1 Power Supply Distribution of Electric Appliances in Engine Room ......... 6.18.1-1
6.18.2 Power Supply Distribution of Indoor Electrical Appliances ..................... 6.18.2-1
6.19 Detailed Information of Fuse
6.19.1 SB1—SB6 .............................................................................................. 6.19.1-1
6.19.2 EF1—EF22 ............................................................................................. 6.19.1-1
6.19.3 DF1—DF43 ............................................................................................ 6.19.1-1
6.20 Grounding Distribution
6.20.1 Grounding Distribution ........................................................................... 6.20.1-1
6.21 Harness Connector Location Plan
6.21.1 Instrument Harness Connector Location Plan .......................................... 6.21.1-1
6.21.2 Roof Harness Connector Location Plan ................................................... 6.21.2-1
6.21.3 Door Harness Connector Location Plan ................................................... 6.21.3-1
6.21.4 Harness Connector Location Plan of Engine Room ................................. 6.21.4-1
6.21.5 Chassis Harness Connector Location Plan ............................................... 6.21.5-1
6.21.6 Engine Harness Connector Location Plan ............................................... 6.21.6-1
6.22 Harness End Face View
6.22.1 Harness Connection................................................................................. 6.22.1-1
6.22.2 Engine Room Harness ............................................................................. 6.22.2-1
6.22.3 Engine Harness Connector ...................................................................... 6.22.3-1
6.22.4 Instrument Harness Connector................................................................. 6.22.4-1
6.22.5 Floor Harness Connector ......................................................................... 6.22.5-1
6.22.6 Door Harness Connector ......................................................................... 6.22.6-1
6.22.7 Indoor Harness Connector and Other Harness Connectors ....................... 6.22.7-1
6.23 Fault Diagnosis
6.23.1 Fault Diagnosis Equipment ..................................................................... 6.23.1-1
6.23.2 Fault Diagnosis Procedure....................................................................... 6.23.2-1
6.23.3 Fault Detection ........................................................................................ 6.23.3-1
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Description
6.1 Description
Contents Page
6.1.1 General
General ................................................................................................................................ 6.1.1-1
6.1.2 Purposes
Purposes .............................................................................................................................. 6.1.2-1
6.1.3 Reading Method
Reading Method ................................................................................................................. 6.1.3-1
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6.1.1-1 Description 6.1.1-1
6.1.1 General whole composition and connection

relationship of vehicle circuits in detail,
Vehicle circuit diagram uses the circuit
without consideration for the actual
symbols specified in the national standard to
location.
illustrate the structure, working principle,
working process and installation The circuit diagram has the following
requirements of vehicle electric appliances, characteristics:
and the diagram also includes legends and 1. It involves the completeness conception
simple structure diagram. The circuit for the circuits of the whole vehicle.
diagram shows the mutual relationship and The circuit diagram is a complete
connection between different circuits. vehicle circuit diagram as well as a
Through reading of the circuit diagram, the partial circuit diagram with mutual
name, model and specification of the electric connection, and the diagram has
components in the circuit diagram can be highlighted important and difficult
recognized and determined, and the points, with proper level of detail.
composition, inner mutual relationship,
working principle and installation location 2. The potential concept is reflected in the
of the vehicle electric system can be clearly diagram. The potential at the negative
mastered. The circuit diagram facilitates ground is the lowest, which is
maintenance, inspection, installation, wiring, represented with the wire at the bottom
etc. of the vehicle diagram. in the diagram; the potential of the
positive live wire is the highest, which
Due to complex appearance and is represented with the wire at the top.
structure of vehicle electric components, The current direction is basically from
the nationally unified graphic symbols and top to bottom: positive pole of power
letter symbols are used to represent the supply—switch—electric appliance—
electric components of different types, ground—negative pole of power supply;
specifications and installation methods. otherwise, more time will be spent in
In order to show all the basic twists and turns along the current
composition and connection relationship of direction.
the circuits of actual equipment or 3. Twists and turns and crossings are
complete sets of devices in detail, and to reduced as many as possible. With
understand the specific action principle, the properly adjusted locations and
schematic circuit diagram (also circuit reasonable layout, the diagram is
diagram or electric circuit diagram) shall simple and clear, and the graphic
be drawn. symbols are fit for the appearance and
In the circuit diagram, the graphic internal structure of components, so as
symbols and letter symbols are drawn to facilitate association and analysis,
according to the unified method and based and make it easy to draw and read.
on the relevant national technical standard. 4. The mutual relationships in the circuit
The circuit diagram is an important and system are clear. The original position
simple circuit diagram which is most of the connection points between the
widely used in electric technology generator and battery room, and
application, and of which the circuit between each circuit system is
principle is easy to be understood, with maintained if possible. The connection
clear and simple circuits. methods of the fuse, switch and
The vehicle circuit diagram is a instrument are the same as those in the
simple diagram, in which, the graphic original diagram. The disadvantage is
symbols of electric appliances are drawn that the graphic symbols are not
according to the working sequence or standard, which make it difficult for
functional distribution, so as to show the communication.
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6.1.2 Purposes
The circuit diagram has the following
purposes:
1. It shows the circuit layout of the
object in detail and makes it understood by
people.
2. The circuit diagram provides
information for detection, fault locating
and fault clearing.
3. The circuit diagram provides data for
drawing the wiring diagram (sometimes,
the added information of structural
diagram shall be referred to).
As the connection relationships
described in the circuit diagram are only
functional relationships instead of the
actual wiring relationships, the wire laying
diagram cannot be replaced with the circuit
diagram.
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6.1.3 Reading Method positive and negative poles of the

power supply, the same pole of the
Due to different drawing methods,
power supply is equipotential
graphic symbols, letter symbols and
without voltage. This “positive to
technical standards of vehicle circuit
diagrams in different countries, great positive” circuit will not generate
current.
difference exists among the drawing
methods of vehicle circuit diagrams of the • In the vehicle circuit, the generator
different vehicle manufacturers, and even and battery are both power
great difference exists among the supplies, and different circuits
representing methods in circuit diagrams of cannot be mixed. The current will
different companies in the same country, not starts from the positive pole of
which causes much trouble to diagram a power supply and return to the
reading. Therefore, it is very important to negative pole of another power
master the basic reading method of vehicle supply after passing through
circuit diagram. several electric equipment. A true
circuit will not be like this, nor
1. Reading Diagram Notes Carefully
will current be generated.
Read diagram notes carefully, learn Therefore, it shall be emphasized
the name and technical specification of the that the circuit refers to that the
circuit diagram, know the definite meaning current starts from the positive
of the graphical symbols, establish the one- pole of a power supply and returns
to-one corresponding relationship between to the negative pole of the same
the components and graphic symbols, so as power supply after passing
to read the diagram quickly and accurately. through electric appliances.
2. Mastering circuit principle 3. Getting Familiar with Switch
In electricity, the circuit is the most Functions
basic and important and simplest concept. The switch is the key to
Any complete circuit consists of the power controlling switch on/off of the
supply, electric appliances, switch, wires, circuit. The main switches in the
etc. To work normally, an electric circuit always gather lots of wires,
appliance has to attain electric energy. For such as the ignition switch and
a DC circuit, the current always starts from main lamp switch. During
the positive pole of the power supply and diagram reading, the 5 questions
reaches the electric appliance after passing related to switches shall be paid
through the wire, fuse and switch, and attention to:
returns to the negative pole of the same
• Among the many terminals of the
power supply after passing through the
switch, which are directly
wire (or ground). During this process, the
connected to power supply, and
circuit will not work correctly and
which are connected to electric
effectively if one link goes wrong. For
example: appliances? Is there wiring
symbols beside the terminals? Are
• The current starts from the the symbols common?
positive pole of the power supply
and returns to the positive pole of • How many positions of switch are
there? At each position, which
the same power supply after
passing through a certain electric terminals are energized and which
appliance (or more electric are de-energized?
appliances). As the potential • Through which route does the
difference (voltage) of the power incoming current to the battery or
supply only exists between the generator reach this switch? Are
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there any other switches and fuses independent circuit systems

along the route? Is the switch according to different functions
manual or electric? and working principles, so as to
facilitate analysis of the complex
• Which electric appliance is
vehicle circuits. Now the vehicle
controlled by each switch
circuits are generally drawn
respectively? What are the
according to different circuit
functions of the controlled electric
systems, such as the power system,
appliances?
starting system, ignition system,
• Among the controlled electric lighting system, signal system, etc.
appliances, which are normally These units of circuits have
energized? Which circuits are different characteristics. It will be
energized temporarily? Which easy to understand the vehicle
should be energized at first and circuits after the characteristics,
which should be energized later? structure and principle of each unit
Which should work independently? circuit are mastered.
Which should work
5. General Diagram Reading Method
simultaneously? Which electric
appliances are allowed to be At first, look at the whole diagram and
energized simultaneously? circle the independent systems respectively.
Generally, the power supply and main
4. Learning General Rules of
switch of power supply of each electric
Vehicle Circuit Diagram
system are for common use, and any
• The wire from the power supply to system should be a complete circuit and in
each electric appliance fuse or accordance with the circuit principle.
switch is the common live wire of
• Analyze the working process and
electric equipment, and is
inner mutual connection of each
generally drawn at the upper part
system. Before analyzing a certain
of the schematic circuit diagram.
electric system, the functions,
• In the circuit diagram which is technical parameters, etc. of each
drawn according to the standard component contained in the
drawing method, the switch electric system should be made
contact is at the zero position or in clear. During analysis, pay special
the static state, namely that the attention to the working state of
switch is turned off or the relay the switch and relay contact. In
coil is de-energized. The most electric systems, the circuit is
energizing or de-energizing of changed to realize different
transistors, thyristors and other functions through different
components which are of the working states of the switch and
switching characteristic will relay.
depend on the particular facts.
• Through analysis of a typical
• The single wire system is adopted circuit, get to know other similar
for the vehicle circuits. The circuits. Many parts of the
electric appliances are in parallel schematic circuit diagrams of
connection, and the relay and many vehicle models are similar.
switch are in series connection. Thus, some common rules of
• Most electric equipment is vehicles can be mastered through
provided with fuses for protection. analysis of a specific example and
comparison with other similar
• The circuits of the whole vehicle circuits. While learning the circuit
can be divided into several principles of other vehicle models
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with these common characteristics The color and code of the wire shall
in consideration, more common conform to in the following table:
characteristics and the difference Wire Color Common Abbreviation Chinese
among different vehicle models Black B 黑色
can be found.
Blue Bl 蓝色
6. Wire Color Brown Br 棕色
• Terminology Yellow Y 黄色
Green G 绿色
Single-color wire: the wire with
Gray S 灰色
one color on the insulated surface.
Light Green Lg 浅绿
Double-color wire: the wire with
two colors on the insulated surface. Orange O 橙色
Main color: the color with a larger Pink P 粉红
area proportion in the two colors Purple V 紫色
of the double-color wire. Red R 红色
Auxiliary color: the color with a White W 白色
smaller area proportion in the two
colors of the double-color wire.
• The color and code of the wire
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• Composition of wire color

The color of a single-color wire
consists of one color specified in
the above table.
The color of a double-color wire
consists of two colors specified in
the above table.
The single color shall be chosen in
preference to the double colors.
• Ground Wire
The ground wires of various
vehicle electric appliances shall be
black. The black wires shall be
only used as ground wires without
any other purposes.
• Marking of Wire Color
The color codes are used to mark
the wire color. For example, the
single-color wire with red color
shall be marked as “R”; The
double-color wire, with red as the
main color and white as the
auxiliary color, shall be marked as
“RW” (the first color is the main
color and the second color is the
auxiliary color).
7. Sectional Area of Wire
The sectional area of the wire is
selected according to the working current.
For some electric appliance circuits with
extremely little current, such as the
indicator lamp circuit, in order to ensure
the suitable mechanical strength, the
sectional area of the wire shall be no less
than 0.5mm2. The sectional area of the
wire shall be marked in front of the color
code and not marked if the unit is mm. For
example, 1.25R means that the wire is red
with the sectional area of 1.25mm2;
1.0G/Y means that the wire is double
colored with the sectional area of 1.0 mm2
(the main color: green, the auxiliary color:
yellow).
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Symbols
6.2 Symbols
Contents Page
6.2.1 Symbols
Symbols .............................................................................................................................. 6.2.1-1
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6.2.1-1 Symbols 6.2.1-1
6.2.1 Symbols
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6.2.1-2 Symbols 6.2.1-2
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Safety System
6.3 Safety System
Contents Page
6.3.1 Safety System
Safety System ..................................................................................................................... 6.3.1-1
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6.3.1-1 Safety System 6.3.1-1
6.3.1 Safety System
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Speed Control System
6.4 Speed Control System
Contents Page
6.4.1 1.4IMT System
1.4IMT System................................................................................................................. 6.4.1-1
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6.4.1-1 1.4MT System 6.4.1-1
6.4.1 1.4IMT System
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Vehicle Body Control System
6.5 Vehicle Body Control System
Contents Page
Vehicle Body Control System ......................................................................................... 6.5.1-1
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Reversing Radar System
6.6 Reversing Radar System
Contents Page
Reversing System ............................................................................................................... 6.6.1-1
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Chassis System
6.7 Chassis System
Contents Page
6.7.1 Chassis System
Brake System...................................................................................................................... 6.7.1-1
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6.7.1-1 Chassis System 6.7.1-1
6.7.1 Chassis System
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Power Mirror System
6.8 Power Rearview Mirror System
Contents Page
6.8.1 Power Rearview Mirror System
Power Rearview Mirror System ............................................................................... 6.8.1-1
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6.8.1-1 Power Mirror System 6.8.1-1
6.8.1 Power Rearview Mirror System
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Ignition Power Supply System
6.9 Ignition Power System
Contents Page
6.9.1 Ignition Power System
Ignition Power System ....................................................................................................... 6.9.1-1
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6.9.1-1 Ignition Power Supply System 6.9.1-1
6.9.1 Ignition Power System
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Electronic Fuel Injection System
6.10 Electronic Fuel Injection System
Contents Page
6.10.1 Electronic Fuel Injection System
Electronic Fuel Injection System ...................................................................................... 6.10.1-1
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6.10.1-1 Electronic Fuel Injection System 6.10.1-1
6.10.1 Electronic Fuel Injection System
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Electronic Power Steering System
6.11 Electronic Power Steering System
Contents Page
6.11.1 Electronic Power Steering System
EPS System ............................................................................................................... 6.11.1-1
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6.11.1-1 Electronic Power Steering System 6.11.1-1
6.11.1 EPS System
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Grounding System
6.12 Grounding System
Contents Page
6.12.1 Grounding System
Grounding System.............................................................................................................. 6.12.1-1
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6.12.1-1 Grounding System 6.12.1-1
6.12.1 Grounding System
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6.12.1-2 Grounding System 6.12.1-2
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Air Conditioner System
6.13 Air Conditioner System
Contents Page
6.13.1 Air Conditioner System
Air Conditioner System ..................................................................................................... 6.13.1-1
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6.13.1-1 Air Conditioner System 6.13.1-1
6.13.1 Air Conditioner System
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Diagnosis Interface and Small System
6.14 Diagnosis Interface and Small System
Contents Page
6.14.1 Diagnosis Interface and Small System
Diagnosis Interface and Small System ............................................................................. 6.14.1-1
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6.14.1-1 Diagnosis Port and Small System 6.14.1-1
6.14.1 Diagnosis Interface and Small System
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Instrument System
Contents Page
Instrument System.............................................................................................................. 6.15.1-1
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6.15.1-1 Instrument System 6.15.1-1
6.15.1 Instrument System
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Audio-Visual (AV) System
6.16 Audio-Visual (AV) System
Contents Page
6.16.1 Audio-Visual (AV) System
Audio-Visual (AV) System........................................................................................ 6161-1
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6.16.1-1 Audio-Visual (AV) System 6.16.1-1
6.16.1 Audio-Visual (AV) System
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Lighting System
6.17 Lighting System
Contents Page
Lighting System ................................................................................................................. 6.17.1-1
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Power Distribution
6.18 Power Distribution
Contents Page
6.18.1 Power Supply Distribution of Electrical Appliances in Engine Room
Power Supply Distribution of Electrical Appliances in Engine Room......................... 6.18.1-1
6.18.2 Power Supply Distribution of Indoor Electrical Appliances
Power Supply Distribution of Indoor Electrical Appliances ........................................... 6.18.2-1
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6.18.1-1 Power Distribution 6.18.1-1
6.18.1 Power Supply Distribution of Electrical Appliances in Engine Room

Fuse Box in Engine Room
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6.18.2-1 Power Distribution 6.18.2-1
6.18.2 Power Supply Distribution of Indoor Electrical Appliances

Fuse Box for Instruments
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Detailed Information of Fuse
6.19 Detailed Information of Fuse
Contents Page
6.19.1 SB1—SB6
SB1—SB6 ................................................................................................................. 6.19.1-1
6.19.2 EF1—EF22
EF1—EF22 ............................................................................................................... 6.19.2-1
6.19.3 DF1—DF43
DF1—DF43 .............................................................................................................. 6.19.3-1
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6.19.1-1 Detailed Information of Fuse 6.19.1-1
6.19.1 SB1—SB6
Detailed Information of Fuse in Engine Room
Fuse Current Connected Electric Appliance
To fan relay (high)
SB1 30A
To fan relay (low)
SB2 30A To ignition switch B1
SB3 30A To ignition switch B2
SB4 60A To EPS
SB5 40A To instrument fuse box
SB6 40A To ABS
6.19.2 EF1—EF22
EF1 10A To ECU-20
EF2 25A To ABS-25
EF3 30A To main relay
EF4 10A To compressor relay
EF5 15A To front fog lamp relay
EF6 10A To brake lamp switch
EF7 15A To front left high/low beam lamp
EF8 15A To front right high/low beam lamp
EF12 10A To fuel pump relay
EF13 30A To blower
EF14 15A To ignition coil
EF15 10A To ECU-15/ECU-16/front/rear oxygen sensor
EF16 10A To fuel spray nozzle/canister control valve
6.19.3 DF1—DF43
DF1 30A To
DF2 10A To starting relay
DF3 10A To right position lamp/license plate lamp
DF4 10A To left position lamp/background light power
DF12 30A To blower relay
DF13 30A To rear defroster relay
DF17 10A To electric horn power BCM-B7
DF18 15A To door lock power BCM-B20
DF20 15A To turn signal lamp power BCM-B2
DF21 7.5A To BCM power B10/key reminder power BCM-A23
DF22 10A To diagnosis interface power
DF23 15A To DVD/radio power
DF25 15A To lamp switch power
DF28 15A To power mirror power/DVD radio ACC power
DF29 15A To power socket power
DF30 10A To generator power
DF31 15A To BCM-A11/instrument/A/C controller
DF32 10A To air bag ECU
DF33 15A To reversing lamp switch/brake lamp switch
DF34 10A To ECU-35
DF35 10A To ABS power
DF36 10A To EPS power
DF37 15A To TCU power
DF39 20A To front wiper power
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6.19.1-2 Detailed Information of Fuse 6.19.1-2
DF40 15A To rear wiper power
DF41 10A To rear defroster relay/blower relay
DF42 35A To power window power
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6.20 Grounding Distribution
Contents Page
6.20.1 Grounding Distribution
Grounding Distribution.............................................................................................. 6.20.1-1
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6.20.1-1 Grounding Distribution 6.20.1-1
6.20.1 Grounding Distribution
A301 Grounding Distribution
Grounding Parts and
S/N Grounding Point Location
Components
Front left position lamp
Front left turn signal lamp
Front left high beam lamp
Front section outer plate (left) of Front left low beam lamp
1 G101
front component Front left Fog Lamp
Left dimmer motor
Water tank fan
Left side turn signal lamp
Front left position lamp
Front right turn signal lamp
Front right high beam lamp
Front right low beam lamp
Supporting plate of front upper
2 G102 Front right fog lamp
component (right)
Left dimmer motor
Left side turn signal lamp
Electric horn
Three-state pressure switch
Front section inner plate (left) of
3 G103 Engine ground
front component
Front section inner plate (left) of
4 G104 Battery negative pole ground
front component
Connection plate (right) of Front
5 G105 ABS
mounting support of fender
6 G106 Upper mounting support of TCU ECU
7 G107 Lower mounting support of TCU ECU
8 G108 Inner plate (left) of A column EPS
Brake fluid level switch
9 G109 Inner plate (left) of A column
Front wiper motor
Combination instrument
BCM
10 G201 Mounting support of dash panel
TRIP switch
Reversing radar controller
Emergency alarm switch
Light combination switch
Wiper combination switch
Power socket
Lighting angle regulator
11 G202 Mounting support of dash panel
switch
Blower relay
Backup power supply
Rear wiper relay
Rear defroster background
light switch
12 G203 Central connection support DVD
HVAC module
13 G204 Inner plate (right) of A column Blowing rate switch
Right power mirror
Front roof lamp
Dimmer motor switch
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Power mirror switch

14 G205 Inner plate (left) of A column
Power window switch
Central door lock switch
Diagnosis interface
15 G301 Front floor passage Air bag ECU
16 G302 Inner plate (right) of C column
17 G303 Inner plate of back door Rear defroster
Turn signal lamp (rear left)
Rear position lamp (left)
Brake lamp (rear left)
Rear fog lamp
18 G304 Inner plate (left) of C column License plate lamp
Back door release switch
Back door lock motor
Rear wiper motor
Turn signal lamp (rear right)
Brake lamp (rear right)
19 G305 Inner plate (right) of C column Rear position lamp (right)
Reversing lamp (rear right)
Camera
Fuel pump motor
Driver’s door lock state
20 G306 Inner plate (left) of B column
switch
Main seat belt switch
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Harness Connector Location
6.21 Harness Connector Location
Contents Page
6.21.1 Instrument Harness Connector Location Plan
Instrument Harness Connector Location Plan........................................................... 6.21.1-
6.21.2 Roof Harness Connector Location Plan
Roof Harness Connector Location Plan ..................................................................... 6.21.2-
6.21.3 Door Harness Connector Location Plan
Door Harness Connector Location Plan ..................................................................... 6.21.3-
6.21.4 Harness Connector Location Plan of Engine Room
Harness Connector Location Plan of Engine Room.................................................. 6.21.4-
6.21.5 Chassis Harness Connector Location Plan
Floor Harness Connector Location Plan ................................................................... 6.21.5-
6.21.6 Engine Harness Connector Location Plan
Engine Harness Connector Location Plan .................................................................. 6.21.6-
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6.21.1-1 Harness Connector Location 6.21.1-1
6.21.1 Instrument Harness Connector Location Plan
Dashboard Harness Assy

S/N Name S/N Name
1 To left chassis harness 21 To DVD
2 To front left door harness assy 22 To A/C controller B
3 To left engine room harness 23 To blowing rate switch
4 To engine room harness 2 24 A/C controller A
5 To treble horn (left) 25 To BCM B
6 To roof harness assembly 26 To BCM A
7 To power mirror 27 To HVACA
8 To dimmer motor 28 To HVAC B
9 To light combination switch 29 To emergency alarm switch
10 To clock spring 1 30 To assistant driver side air bag
11 To clock spring 2 31 To treble horn (right)
12 To wiper switch 32 To reversing radar controller
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13 To ignition switch 33 To engine room harness 4

14 To key reminder switch 34 To front right door harness
15 To TRIP switch 35 To engine room harness 3
16 To combination instrument 36 To engine room harness 2
17 Dashboard fuse box 37 To air bag ECU
18 Diagnosis interface 38 To hand brake switch
19 To EPS signal wire 39 To electronic gear shifter
20 To power socket
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6.21.2 Roof Harness Connector Location Plan
Roof Harness Assembly

S/N Name S/N Name
1 To instrument harness 2 To front roof lamp
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6.21.3 Door Harness Connector Location Plan

Front Door Harness Connector Location Plan
Front Left Door Harness Assembly

S/N Name S/N Name
1 To instrument harness (left) 5 To front left window switch
To front left loudspeaker To central control lock of front left
2 6
(bass) door
To front left window
3 7 To front left door lock motor
regulator motor
To left rear-view mirror
4
motor
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Front Right Door Harness Assembly

S/N Name S/N Name
To instrument harness
1 4 To right rear-view mirror motor
(right)
To front right loudspeaker
2 5 To front right window switch
(bass)
To front right window
3 6 To front right door lock motor
regulator motor
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Rear Door Harness Connector Location Plan
Rear Door Harness Assembly

S/N Name S/N Name
1 To floor harness 4 To rear left window switch
2 To loudspeaker 5 To rear left door lock motor
To rear window regulator
3
motor
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Back Door Transition Harness Connector Location Plan
Back Door Transition Harness Assembly

S/N Name S/N Name
Back door transition harness to floor
1 4 To camera
harness
2 To high-mounted brake lamp 5 To back door harness 1
3 To rear defroster (+) 6 To back door harness 2
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Back Door Harness Connector Location Plan
Back Door Harness Assembly

S/N Name S/N Name
Back door harness to back door transition
1 4 To rear wiper motor
harness 1
Back door harness to back door transition
2 5 To back door lock motor
harness 2
3 To trunk release switch 6 To back door lock switch
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6.21.4 Harness Connector Location Plan of Engine Room
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Engine Room Harness Assembly

S/N Name S/N Name
Front compartment to
1 19 To GD101 (anti-rotary)
instrument harness 1
Front compartment to
2 20 To front left fog lamp
instrument harness 2
3 To GD108 (anti-rotary) 21 To radiator fan motor
4 To GD109 (anti-rotary) 22 To disc type horn +
5 To electronic accelerator pedal 23 To disc type horn -
6 To brake lamp switch 24 To GD102 (anti-rotary)
7 To EPS power 25 To front spray motor
8 To brake fluid level switch 26 To rear spray motor
9 To front wiper motor 27 To front right fog lamp
10 To engine harness 28 To front right combination lamp
11 To ECU 29 To GD105 (anti-rotary)
12 To positive pole of battery 30 To right side wheel speed sensor
13 Front compartment fuse box 31 To right side turn signal lamp
14 To front left wheel speed sensor 32 To ABS EOT
15 To left side turn signal lamp 33 To three-state pressure switch
16 To front left combination lamp 34 Front compartment to instrument harness 3
17 To TCU 1 35 Front compartment to instrument harness 4
18 To TCU 2
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6.21.5 Chassis Harness Connector Location Plan
Chassis Harness Assembly

S/N Name S/N Name
1 Floor to instrument harness 1 13 To front right door contact switch
2 To main seat belt switch 14 To rear right door harness
3 To GD306 (anti-rotary) 15 To rear right wheel speed sensor
4 To front left door contact switch 16 To rear right door contact switch
5 To rear left door harness 17 To GD305 (anti-rotary)
6 To rear left wheel speed sensor 18 To GD302 (anti-rotary)
7 To fuel pump and fuel sensor 19 To rear right combination lamp
8 To rear left door contact switch 20 To reversing radar probe (right)
9 To GD304 (anti-rotary) 21 To right license plate lamp
10 To back door transition harness 22 To left license plate lamp
11 To rear left combination lamp 23 To reversing radar probe (left)
12 Floor to instrument harness 2
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6.21.6 Engine Harness Connector Location Plan
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Engine Harness Assembly

S/N Name S/N Name
1 To GD106 (anti-rotary) 14 To fuel spray nozzle 1
2 Engine to front compartment harness 15 To OVC valve
3 Engine to ECU 16 Front oxygen sensor
4 To rear oxygen sensor 17 To compressor
5 To water temperature sensor 18 To oil pressure switch
6 To ignition coil 4 19 To electronic throttle
7 To ignition coil 3 20 To canister control valve
8 To ignition coil 2 21 To reversing lamp switch
9 To ignition coil 1 22 To starter
10 To phase sensor 23 To generator
11 To fuel spray nozzle 4 24 To intake air pressure sensor
12 To fuel spray nozzle 3 25 Knock sensor
13 To fuel spray nozzle 2 26 To crankshaft position sensor
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Harness End Face View
6.22 Harness End Face View
Contents Page
6.22.1 Harness Connection
Harness Connection ................................................................................................... 6.22.1-1
6.22.2 Engine room Harness
Engine Room Harness ............................................................................................... 6.22.2-1
6.22.3 Engine Harness Connector
Engine Harness Connector......................................................................................... 6.22.3-1
6.22.4 Instrument Harness Connector
Instrument Harness Connector ................................................................................... 6.22.4-1
6.22.5 Floor Harness Connector
Floor Harness Connector ........................................................................................... 6.22.5-1
6.22.6 Door Harness Connector
Door Harness Connector............................................................................................ 6.22.6-1
6.22.7 Indoor Harness Connector and Other Harness Connectors
Indoor Harness Connector and Other Harness Connectors ......................................... 6.22.7-1
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6.22.1-1 Harness End Face View 6.22.1-1
6.22.1 Harness Connection
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6.22.2 Engine Room Harness
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6.22.3 Engine Harness Connector
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6.22.4 Instrument Harness Connector
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6.22.5 Floor Harness Connector
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6.22.6 Door Harness Connector
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6.22.7 Indoor Harness Connector and Other Harness Connectors
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Fault Diagnosis
6.23 Fault Diagnosis

Applicable to A301
Contents Page
6.23.1 Fault Diagnosis Equipment
Equipment Description .............................................................................................. 6.23.1-1
Complete Machine Description .......................................................................... 6.23.1-1
Interface Description.......................................................................................... 6.23.1-1
Technical Parameters ................................................................................................. 6.23.1-1
Power Supply Method ............................................................................................... 6.23.1-2
Maintenance and Service ........................................................................................... 6.23.1-2
Storage Environment ......................................................................................... 6.23.1-2
Touch Screen Maintenance ................................................................................ 6.23.1-2
CF Card Maintenance ........................................................................................ 6.23.1-2
6.23.2 Fault Diagnosis Procedure
Fault Diagnosis Procedure ......................................................................................... 6.23.2-1
6.23.3 Fault Detection
Basic Test .................................................................................................................. 6.23.3-1
Reading Vehicle Computer Model...................................................................... 6.23.3-1
Reading Fault Code ........................................................................................... 6.23.3-1
Clearing Fault Code ........................................................................................... 6.23.3-1
Component Control Test .................................................................................... 6.23.3-1
Reading Dynamic Data Flow ............................................................................. 6.23.3-2
Auxiliary Functions ................................................................................................... 6.23.3-2
Data Capture ...................................................................................................... 6.23.3-2
Data Comparison ............................................................................................... 6.23.3-2
Data/Wave Form Display ................................................................................... 6.23.3-3
Data Scope Reference ........................................................................................ 6.23.3-3
Traveling Data Recorder .................................................................................... 6.23.3-3
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6.23.1-1 Fault Diagnosis 6.23.1-1
6.23.1 Fault Diagnosis Equipment Power supply switch of

3
host machine
Equipment Description
2. Lower Interface View
Complete Machine Description
The name of each marked point is as follows:

S/N Name
S/N Name
1 RS232 serial port
1 Power indicator lamp
2 Network cable socket
2 Display screen
3 CF card slot
3 Contact pen
Technical Parameters
The above is the description of KT300
host machine. The part inside the housing 1. Host Machine
mainly consists of two big modules: Item Indicator
KT300ARM mainboard and KT300IO Supply voltage 11 ~14V DC
board, which form an integral whole and Working
work as a diagnostic tool during -10°C~50°C
temperature
maintenance. In addition, KT300 is Relative
Less than 90%
equipped with some accessories for vehicle humidity
diagnosis and online updating, such as RJ45 network
10M
extension line for testing, power extension interface
PS/2 interface Standard PS/2 interface
line, vehicle crocodile clip, cigarette lighter
For plugging in/pulling out
connectors, 14V power supply, CF card, CF card slot
CF card
CF card reader and testing connectors, etc.
2. Hardware Configuration
Interface Description
System
1. Upper Interface View Indicator
Hardware
CPU 32-bit embedded chip
Dominant
80MHz
frequency
FLASH with extra large
Flash memory
capacity, rewritable
External CF card, for arbitrary
memory extension
5.6 ” LCD true color touch
Display
screen
Power Supply Method
The name of each marked point is as follows: There are 4 power supply methods for
KT300 host machine, and you may select
S/N Name
one from them as necessary:
1 Test port
Power supply port of host 1. AC power supply: the power adapter in
2
machine KT300 standard configuration is
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adopted. One terminal is connected to when there is no cross cursor.

the power supply port of the instrument 2. Please use the contact pen at the right
and the other terminal is connected to upper corner of the instrument to touch
the 100-240V AC socket. the touch screen. Please do not use your
2. Vehicle battery power supply: the fingernail and other sharp objects (hard
power extension line and vehicle objects) to touch the screen surface, so
crocodile clip in KT300 standard as to avoid damaging the surface.
configuration are adopted. One 3. Please do not put any abnormal object
terminal is connected to the power on the touch screen, so as to prevent
supply port of the instrument and the misalignment of the touch screen and
other terminal is connected to the damage of internal components due to
vehicle battery. heavy pressure.
3. Cigarette lighter power supply: the 4. Please do not expose the touch screen
power extension line and vehicle directly in the sunlight or UV light, so
cigarette lighter in KT300 standard as to lengthen the service life.
configuration are adopted. One
terminal is connected to the power 5. Please do not put the product beside the
supply port of the instrument and the electric equipment which generates
other terminal is connected to the electromagnetic wave interference, so
vehicle cigarette lighter. as to avoid affecting the oscillography
effect.
4. Power supply through diagnostic
seat. 6. The LCD is likely to attract dust due to
the static electricity on the surface. It is
Maintenance and Service suggested to purchase the special
Storage Environment cleaning agent and wiping cloth for
LCD. Do not use other chemical
1. When not in use, the machine shall be
cleaning agents or finger to scrub the
put at a flat and dry place with
touch screen.
appropriate temperature and little dust.
CF Card Maintenance
2. Do not put the machine at a place
which is in the direct sunlight or is 1. Please do not pull out CF card during
close to a heating device. operation of the host machine. Please
pull out CF card after turning off the
3. Do not put the machine near a stove or
machine, and take antimagnetic
at a place which is susceptible to
measures.
damage by fume or where water and oil
are easy to get in. 2. When you are using CF card for
updating online, do not pull out CF
4. Please do not open the host machine in
card arbitrarily during operation of the
private. If the host machine is very
card reader. Otherwise, the data may be
dirty, please turn off the machine at
lost. The proper method for pulling out
first and unplug the power cable, and
CF card is as follow: at Windows
then wring dry a soft wet cloth to scrub
desktop, open “My Computer” window,
the housing or screen.
right click on “Removable Disc” and
5. If the vehicle has not been tested for a select “pop out” item in the menu
long time, please regularly operate column which just popped out, and
KT300 host machine to prevent the then pull out CF card.
host machine from becoming damp.
3. When the CF card of KT300 is
Touch Screen Maintenance damaged and the program in the card
1. During calibration of the touch screen, cannot operate, CF card can be
please do not click on the touch screen recreated according to the following
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steps:
• You may use your user name
(product serial number) and
password to log in:
http://www.kingtec.net:86/down/n
ew zh cn/?u=3 Bosch (Shenzhen)
KT300 download center. Select
the diagnostic program or
complete updating package of the
corresponding vehicle model
according to your specific needs
and download it to your PC.
• Format the CF card of KT300.
• Operate the downloaded updating
program in your CF card.
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1. Determine the location and shape of the
diagnostic seat, and decide whether an
external power supply is needed.
2. Choose the corresponding connector
according to the vehicle model and the
shape of diagnostic seat.
3. Insert one terminal of the testing
extension line into the test port of
KT300 and connect the other terminal
to the test connector.
4. Insert the testing connector (connected
with the testing extension line) into the
diagnostic seat of the vehicle.
Note: please first connect the host
machine, testing extension line and
diagnostic connector, and then connect
the testing connector to the diagnostic
seat. Otherwise, the fuse of diagnostic
seat is likely to blow out due to short
circuit.
Refer to the following diagram for detailed
connection:

S/N Name
1 Test port of KT300
2 Extension line for testing
3 Special testing connector
4 KT300 power interface
5 Power extension line
6 Twin-caliper power line
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Basic Test
Reading Vehicle Computer Model
This function is used to read the
computer information of the tested system,
including the version number, CODING
number, service station code and the
relevant information.
In the system function selection menu,
select 01-read vehicle computer model.
The screen display is as follow: This function is used to clear the fault
code recorded in the ECU of the tested
system. For the general vehicle model,
please operate strictly according to the
regular sequence: read and record (or print)
the fault code at first, then clear the fault
code, conduct test run, re-read the fault
code to verify, repair the vehicle, clear the
fault code, and re-conduct test run to
confirm that the fault code will no longer
occur.
Reading Fault Code The current rigid fault code cannot be

cleared. Although the technical code of the
Select 02-read fault code in the system oxygen sensor, knock sensor, mixed gas
function selection menu, and the system correction, cylinder misfire and the like can
will start to detect the fault memory be immediately cleared, it will reappear
information recorded in RAM of the within a certain period. Only after the fault
computer. After testing, the test result will has been completely removed will the fault
be displayed on the screen as shown below: code not appear again.
Component Control Test
This function is used to check the
circuit working condition of the actuating
component. During component control test,
you may observe and determine whether
this component works normally. If the
actuating component does not work
normally, you need to check whether faults
exist in the relevant electric components,
plug harnesses or mechanical locations. In
the system function selection menu, select
Clearing Fault Code 03-component control test to enter the
operation interface as below:
In the system function selection menu,
select 05-clear fault code to enter the
operation interface:
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system will record all the currently tested

data. You may turn the pages to record all
the data; if you do not turn the pages, the
equipment may only record the data on the
current screen. Click on the record button
to enter the interface saving function, and
the specific operation is as follows:
Click on the record button. If the
equipment allows inputting and saving of
files, the file name input dialog box will
pop out as shown below, and meanwhile,
The instrument panel system will the saved data flow file is displayed to
conduct simulate display. You may observe prevent inputting the same file name,
and determine whether the instrument is causing the original file to be covered. If
faulted. Press any button or click on the the inputted file name exists, the equipment
screen to conduct component test, and all will automatically cover the original file,
the alarm lamps on the instrument panel without any prompt.
will be indicated, so as to determine
whether the instrument alarm lamps or
circuits are faulted.
Click on the “continue” button to
conduct test of the next component. The
method is the same as that of the previous
test. After the test of all the system
components is finished, press ESC to
return to the system function selection
menu.
Reading Dynamic Data Flow
In the system function selection The file name is displayed as: inputted
menu, select 08-read dynamic data flow to file name + a suffix which equals 1
enter the operation interface. character. For example, the inputted file
name is: E800, and the displayed file name
is: E8001. Please input the correct file
name and press OK button, and the system
will automatically save the file to NOTE
folder of CF card.
If the record button is pressed and
there are already three record files related
to the data flow, a prompt dialog box will
pop out as show below, requiring the user
to delete certain files. The number of saved
files related to each data flow is at most
three. Select the names of files to be
Auxiliary Functions deleted and click on the delete button to
delete the files.
Data Capture
After entering the data flow test
interface, click on ? help button to enter
data flow help function menu. After
selecting the data capture function, the
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Data Comparison
After saving the file, press ? help
button. Select data comparison in the help
menu, and the system will call out the
saved data flow file to conduct data
The comparison scope value displayed
comparison, as shown below:
in the interface is: the product of the
reference value and an offset. The offset
can be set through clicking on the data flow
result offset setting item in data flow
setting function in the data flow help
function menu.
Data/Wave Form Display
All files related to the data flow are After entering the data flow test
listed in the above picture. You may select interface, select data/wave form display in ?
the corresponding data flow as necessary help function menu and the following
and select the display method: single-frame value/wave form display picture will pop
comparison and automatic judgment. After out. This function is used to visually
the single-frame comparison is selected, the display the value change rule of a certain
following interface will be displayed. You data flow in a graphical manner, so as to
may determine whether the input is correct help you to quickly determine the fault of
according to the interface: vehicle electronic equipment. You may
click on the inverted triangle button on the
interface to select different data flow items
for wave form display.
After selecting automatic judgment

and the following interface will be
displayed:
Click on the print button and the print
and save button will pop out. Click on the
print button to print directly. Click on the
save button and the file name input dialog
box will pop out. Input the file name and
click on OK, and the data flow wave form
display picture will be saved in the xx.bmp
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file format in the temp folder of CF card. The F: 1/ at the left lower corner of
The longest file name is 8 characters and the interface represents the sampling rate,
32 files can be recorded at most. which is determined by the rate of
communication between the diagnostic
Data Scope Reference
equipment and ECU and the parameter. For
In the data flow help function menu, example, during data flow reading of a
select data flow scope reference to enter certain ECU, the communication rate with
data flow reference function page. The the diagnostic equipment is 8/second.
reference data is at the middle of the page, Meanwhile, when F: 1/ is set as 2, data
and the data is saved in the system after the recording will be conducted 4 times per
user has captured it. The equipment will second.
automatically compare the test data with
Exit—exit from the waveform and
this scope. If the current test value is
record waveform—conduct real-time
beyond the scope, the data are wrong and
monitoring and saving of the waveform—
will be displayed in the red font for future
waveform data saving. The waveform data
checking.
is saved in the xx.osc file format in the
Meanwhile, the equipment is temp folder of CF card. The longest file
recording data. If the user clicks on the name is 8 characters, and 32 files can be
record button, the equipment will use the recorded at most.
current test value to correct the current data
2. Waveform real-time monitoring. Select
scope.
“waveform” at the interface above to
Traveling Data Recorder enter the waveform real-time
1. During reading of a certain ECU data monitoring interface as shown below:
flow, you may record the traveling data
through the “traveling data recorder”
function in the help menu. Click on
“traveling data recorder” to enter the
following interface. The first 6 data
items in the data flow will be
automatically recorded. You may click
on the inverted triangle button on the
left to select different data items. The
name, current value and unit of the
recorded data flow item will be
displayed, with the recording progress
displayed at the same time. If the The recorded data will be displayed in
recording bar in the record progress waveform. The waveform can be browsed
column occupies the full column, the at any time by moving the slider on the
recording is finished. interface. In one time, 6 waveforms can be
displayed at most. During browsing, the
system is still recording data, but the
interface will not refresh automatically.
The data flow name and the
maximum/minimum value are on the left of
the above picture. The recorded data flow
in the interface cannot be changed. The
data flow can be saved.
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After exiting from the traveling data

recorder, you may conduct waveform
playback in “traveling record playback” in
the help menu. Select the file to be played
back and enter the interface indicated in the
waveform real-time monitoring picture to
conduct waveform playback.
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Part 1

Installation or Connection ..................................................................................................102

Chapter II Engine Cooling System

S/N Comp/part No. Comp/part Name

Coolant pipe of engine is as shown in the

Chapter III Electronic Control System

Tightening torque for the oxygen sensor is 50 N·m±10N·m.

Figure 1 Sensor Output Waveform Diagram

the sensor for a long time, causing corrosion to the sensor;

Figure 1 Sensor Output Waveform Diagram

General Fault Causes

Profile of DS-S/TF Pressure/Temperature Sensor

Figure1 Product Structure Diagram of EA14FF Fuel Manifold Assembly

Inspection and Maintenance

Pinion Return Test

Fault Description, Diagnosis and Test

Replace a new battery.

and terminal 5# of the ignition switch

Diagnosis Process for Starter Motor Stop Failure

A. Turn the ignition switch to “OFF” position,

Integral AC Generator Assembly

1. Confirm problems indicated by customers.

• Accessory drive • Fuse

A. Conduct inspection process for parasitic

A. Start the engine to increase its speed to

Diagnosis Process for Charge Lamp Off

2. Inspect resistance of circuit from instrument and voltage regulator

2. Inspect charging voltage of generator

3. Take out the electric brush.

6. Take out the rubber pad.

7. Remove the generator pulley.

8. Separate the front and rear covers.

• Fault description: start failure, etc.

Diagnostic scanner for electronic fuel injection system

Chapter IV Mechanical Maintenance of Engine

3) Disconnect the harness connectors of the

8) Compression pressure value for each

Inspection of Oil Pressure

6) Shut down the engine and take off the oil

Tightening torque: 21N·m + 2N·m

Inspection and Adjustment of Valve

3) Replace corresponding valve tappet if

Cold state (coolant The valve clearance shall be inspected once

S/N D ±T No. S/N D ±T No. S/N D ±T No.

3) Assemble the selected standard tappet

Cylinder Head Cover Assembly

Requirements on installation of PCV valve:

Oil Pan Assembly, Oil Filter

Note: On the oil strainer assembly there is

Oil Filter Assembly

Front Gear Train

Detection method of generator belt tension: Installation

qualification. support assembly and the mounting bolts

As shown in the picture, rotate the crankshaft

2) Installation of Timing System

3) Install the oil pump front housing as per

Water Pump Assembly

clean without oil dirt and scratch. The gluing

Oil Pump Front Housing

26 1010010-H03 Oil strainer assembly

4) Install the oil strainer assembly as

foreign matters and its underside is smooth

Wear of Camshaft Bearing Bush

Wear of Camshaft Journal