LIFAN M7 Service Manual (LF-20171010)

Introduction
This manual is prepared to facilitate maintenance of Lifan vehicles, help managers understand
the construction, working principle and specifications of Lifan M7 models, and serve as
reference for vehicle inspection, failure diagnosis, disassembly, adjustment, service and
maintenance.
This manual is divided into three parts, i.e., Part 1, Part 2 and Circuit Diagram. Readers can
choose the part to read as needed.
At the time of preparation, the maintenance manual was intended to be illustrious and easy
to understand, and ran through a number of maintenance techniques to reduce the man
hours and improve the work efficiency.
Please pay attention to the following when using this manual:
1. When there is any vehicle failure, it is necessary to carry out checking, diagnosis and
removal/installation. Before adjusting and maintaining, please read this manual carefully.
Carry out operation and maintenance according to the requirements, and pay attention
to some contents such as Warning, Caution, Note, and so on.
2. This maintenance manual is suitable for Lifan M7 series Model. Because the model
configurations are different, some devices, facilities or functions introduced in the above
may not be appeared in the model.
3. In order to avoid damage to vehicle devices or even cause any safety accident, do not
allow any user to refit or install any equipment, especially for electrical appliances, braking
system, steering and other systems involving the driving safety.
4. When replacing parts, please purchase and use the genuine fittings provided by Lifan in
Lifan special maintenance service stations.
5. Lifan will not be responsible for any safety incident, other direct or indirect loss resulting
from the violation of the items specified in Serial No. 3 and 4 as the above.
6. With the progress of technology and development, Lifan M7 series Model products
will also be improve and perfect continuously. Therefore, some of the contents in this
maintenance manual may have some discrepancy with the improved products, and
Lifan reserves the right to design improvements without prior notices. In this regard, in
addition to the revision of the second edition, without notice to the users, Lifan will not be
responsible directly or indirectly for the loss caused by the above.
The intellectual property and copyright of the maintenance manual are owned by Lifan. No
company and individual may reproduce or publish it without the permission of Lifan, Lifan
reserves the right to be held accountable under the laws.
LiFan Industry(Group) IMP&EXP Co.,Ltd.

June 2007
Editing date: Jan, 2017
Printing date: Jan, 2017
Volume 1
0 overview Overview 01
Version No.: LF6470-201701
1 Engine Mechanical system (1.5L) 11
Printed in China
Mechanical system (1.8/2.0L) 11
Engine control system (1.5T) 12
Engine control system (Delphi) 12
Engine fuel system (1.5T) 13
Fuel system (1.8/2.0L 1.5LT) 13
Engine exhaust system (1.5T) 14
Intake and exhaust system (1.8/2.0L 1.5LT) 14
Engine cooling system (1.5T) 15
Cooling system (1.8/2.0L 1.5LT) 15
Lubrication system (1.8L) 16A
Lubrication system (2.0L) 16B
Lubrication system (1.5T) 16C
Engine emission control system (1.5T) 17
Exhaust gas emission control (1.8/2.0L 1.5LT) 17
Engine charge system 17
Engine starting system 17
Start charge system (1.8/2.0L 1.5LT) 18
Engine ignition system (1.5T) 19
Ignition coil (1.8/2.0L 1.5LT) 19
Turbocharger and inter-cooler system (1.5T) 20
2 Transmission Transmission (1.5T-5MT) 21
Transmission (2.0L-CVT) 21
Transmission (1.5T-8AT) 21
Transmission (1.8L/2.0L-5MT) 21
Clutch 22
3 Driving system Front suspension 31
Rear suspension 32
Wheel and tire 33
4 Transmission system Drive Shaft 41
Volume 2
5 Braking system Service braking 52
Parking braking(pedal type) 52A
Parking braking(pull type) 52B
Parking braking(electronic) 52C
ABS anti-lock braking system 53A
ESP and ESC brake system 53B
Engine immobilizer (ignition switch) 54A
Engine immobilizer (one-touch start) 54B
6 Steering system Hydraulic steering system 61
7 Electrical system Air conditioner system 71
Safety protection device 72
Stereo set delight system 73
Driver information system 74
Central door lock and body immobilizer 75
Anti-collision radar system 76
Lighting system 77
8 Body and attachments Interior and exterior trims 81
Door and door lock 82
Electric window, rearview mirror, skylight system 83
Seat 84
Dashboard and Sub- dashboard 85
Wiper and washing system 86
Approved by: CHONGQING LIFAN VEHICLE CO., LTD.

Checked by: CHONGQING LIFAN VEHICLE CO., LTD.
Compiled by : CHONGQING LIFAN VEHICLE CO., LTD.
Editing date: Jan, 2017
Printing date: Jan, 2017 Volume 1
Version No.: LF6470-201701 0 overview Overview 01
Printed in China Mechanical system (1.5L)
1 Engine 11
Mechanical system (1.8/2.0L) 11
Engine control system (1.5T) 12
Engine control system (Delphi) 12
Engine fuel system (1.5T) 13
Fuel system (1.8/2.0L 1.5LT) 13
Engine exhaust system (1.5T) 14
Intake and exhaust system (1.8/2.0L 1.5LT) 14
Engine cooling system (1.5T) 15
Cooling system (1.8/2.0L 1.5LT) 15
Lubrication system (1.8L) 16A
Lubrication system (2.0L) 16B
Lubrication system (1.5T) 16C
Engine emission control system (1.5T) 17
Exhaust gas emission control (1.8/2.0L 1.5LT) 17
Engine charge system 17
Engine starting system 17
Start charge system (1.8/2.0L 1.5LT) 18
Engine ignition system (1.5T) 19
Ignition coil (1.8/2.0L 1.5LT) 19
Turbocharger and inter-cooler system (1.5T) 20
2 Transmission Transmission (1.5T-5MT) 21
Transmission (2.0L-CVT) 21
Transmission (1.5T-8AT) 21
Transmission (1.8L/2.0L-5MT) 21
Clutch 22
3 Driving system Front suspension 31
Rear suspension 32
Wheel and tire 33
4 Transmission system Drive Shaft 41
Volume 2
5 Braking system Service braking 52
Parking braking(pedal type) 52A
Parking braking(pull type) 52B
Parking braking(electronic) 52C
ABS anti-lock braking system 53A
ESP and ESC brake system 53B
Engine immobilizer (ignition switch) 54A
Engine immobilizer (one-touch start) 54B
6 Steering system Hydraulic steering system 61
7 Electrical system Air conditioner system 71
Safety protection device 72
Stereo set delight system 73
Driver information system 74
Central door lock and body immobilizer 75
Anti-collision radar system 76
Lighting system 77
8 Body and attachments Interior and exterior trims 81
Door and door lock 82
Electric window, rearview mirror, skylight system 83
Seat 84
Dashboard and Sub- dashboard 85
Wiper and washing system 86
Approved by: CHONGQING LIFAN VEHICLE CO., LTD.

Checked by: CHONGQING LIFAN VEHICLE CO., LTD.
Compiled by : CHONGQING LIFAN VEHICLE CO., LTD.
Overview-Overview
01-a
Overview
How to use this manual�� 1 Vehicle use and maintenance 23
Overview�� 1 Three-way catalytic converter 23
General inspection�� 1 Vehicle use and maintenance� 24
Testing�� 1 Maintenance classification and
Preparations�� 1 basic items�� 24
Maintenance procedures�� 1 Regularly maintenance items� 25
Terms and definitions�� 3 Routine maintenance�� 27
“Warning”, “Caution” and “Tip”� 3
International System of Units (SI) 4
Index�� 4
Abbreviation�� 4
DTC list�� 4
How to perform troubleshooting 5
Fuse inspection and maintenance5
Remove the intermittent fault�� 6
Remove the historical faults�� 7
Precautions before repair�� 8
Safety protection system�� 8
Engine oil�� 8 01
Electrical system maintenance� 9
Vehicle cleaning�� 9
Maintenance guide�� 9
Maintenance Precautions�� 9
Vehicle identification�� 13
VIN�� 13
Technical characteristics and
parameters of vehicle�� 15
Entire vehicle figure�� 15
Vehicle technical parameters� 16
Maintenance data�� 17
Common parameters for inspection
and adjustment�� 17
Oil parameters�� 17
Bulb parameters�� 18
Precautions for use and
maintenance�� 19
Maintenance operation�� 19
Electric system�� 20
Car lifting�� 22
01-b Overview-Overview
Overview-Overview
01-1
How to use this manual

Overview
1. This manual includes mainly Procedure I “Diagnosis” (see “Fault Diagnosis”
in each section), Procedure II “Replacement, Maintenance & Debugging” and
Procedure III “Final Inspection”.
2. In this manual, the maintenance issues are described and analyzed in the
three main sections of the system overview (theoretical support), fault
diagnosis (problem detection), maintenance guidance (troubleshooting).
• System overview:
It includes preparations, maintenance data, precautions, system description,
principles, component drawings, on-board inspection and etc. The system theory is
described and explained and the faults are described from the aspect of the overall
system, to provide the theoretical guidance for the maintenance and analyze and
solve the faults from the aspect of the overall system.
• Troubleshooting:
It includes fault list, fault code list and etc. It mainly includes some common and
possible faults, possible fault locations and solutions, to help you find the fault
causes and locations more quickly.
• Maintenance guidance:
Based on the classification of system components, it includes detailed and correct
maintenance guidance about inspection, testing, demolition, installation of each
component, to improve the maintenance quality and efficiency.
3. The following basic operations are not described in detail in this manual, but
they are indispensable in actual operations.
• How to use a jack; 01
• Clean the disassembled components, if necessary;
• Visual inspection.
4. The precautions in the corresponding maintenance are included in each
section of this manual, and must be understood before the maintenance, to
avoid component damage or personal injury due to any misuse.
General inspection
“General inspection” includes mainly inspection and adjustment of important
positions related to construction and maintenance, as well as other related
inspections (such as, loosening, clearance, cracks, damage, etc.).
Testing
Use the recommended tools and measuring dashboards to perform the
corresponding testing and inspection steps in sensitive mode; however, in actual
maintenance and repair steps, the visual inspection is also used.
Preparations
At the start of each section in this manual, list the recommended tools and
required maintenance data; the full pre-maintenance preparations can improve the
maintenance quality and efficiency.
Maintenance procedures
1. Insert the component drawings as required in the sections, and describe the
system to be maintained in detail.
2. Describe the assembly relationship among components in form of exploded
drawings.
01-2 Overview-Overview
Component assembly relationship
Front differential bearing sleeve Planetary gear shaft

Front differential bearing Planetary gear shaft elastic cylindrical pin
Bolt, differential Differential housing
Axle shaft gear gasket Differential ring gear
Side gear Rear differential bearing
Planetary gear washer Rear differential bearing sleeve
Planetary gear
List of component names

LFWX-6470-01001
3. If the installation steps are just opposite to the removal steps, only the
important components are described.
4. In this manual, only important components and their operations are provided
with illustrations, detail description, operation methods, reference data and
precautions.
5. The procedure is described in the following order:
• Illustration, to show “What to do” and “Where to do”.
• Operation procedure heading, to show “What to do”.
• Operation procedure, to show “How to complete the task” and provide the
operation information, such as “Warning”, “Caution” and “Tip”.
Overview-Overview
01-3
Example:
What to do and where to do

Example:
Illustration
1. Inspect the backlash between the planetary gear and the half-shaft
gear
(a) Measure the backlash between the planetary gear and the half-shaft
gear. If the backlash exceeds the standard value, select the appropriate
spacer and measure the backlash. Standard value: 0.025mm-0.150mm.
Caution
Adjust the backlash to ensure its equality on both sides.
Completion task
Help information
/ ):;
Terms and definitions

Standard value
They refer to the standard values used for component quality determination or assembly 01
inspection or the adjustment values for correction of associated components or assemblies,
expressed as the ranges.
Limit value
They refer to the standard values for component quality determination or assembly
inspection, and maximum or minimum values of components or assemblies that meet the
functional or strength requirements.
Torque
Torques (unit: N•m) refer to the standard value range of tightening torque. For the
tightening torques for bolts and nuts that are not provided, see the list of tightening torques.
“Warning”, “Caution” and “Tip”

Warning
They are bold indications that are required to take the necessary measures to avoid
personal injury or death.
Caution
They are bold indications that emphasize on the necessarily of diagnostic or maintenance
procedure; otherwise it may result in personal injury or damage to components.
△ Tips
They are additional instructions that can improve the maintenance efficiency.
International System of Units (SI)
“Units” in this manual are International System of Units (SI).

For example:
Torque: 30N•m
Index
There is a directory index at the end of this manual for your access during the maintenance
process.
Abbreviation
There is a directory abbreviation at the end of this manual for your access during the
maintenance process.
DTC list
There is a directory DTC list at the end of this manual for your access during the
maintenance process.
Overview-Overview
01-5
How to perform troubleshooting

Fuse inspection and maintenance
1. Inspect the circuit with blown fuse

Storage battery
(a) Remove the blown fuse and measure
the resistance between the blown fuse-
loaded end and the ground. Turn off all
circuit switches connected to this fuse. In
Fuse
this case, if the resistance should be about
0Ω, there may be a short circuit on certain
position between the switch and the load.
Load switch
Short circuit
location
If the resistance is not 0Ω, there may be
no short circuit, but the over-voltage on the
load may cause the fuse to be blown.
Load The main reasons for short circuit include the
following.
• Damage to the outer surface of the wiring
harness due to wear or overheating;
• Water entered into the connector.
• Human factors.
01
(b) When replacing the fuse, make sure that
the new fuse has correct rated current. Do
not use the fuse with the rated current out
of the range.
Remove the intermittent fault

In order to determine the state of intermittent faults, the customer should first provide
vehicle driving conditions, weather conditions, fault frequency and fault symptoms, and
then try to simulate the fault phenomenon, to determine whether the detection circuit
is damaged or normal, and confirm and remove the fault. Referring to the list of fault
symptoms for each system, reduce the range of possible faults.
1. Shaking method
(a) Components and sensors
Gently shake the sensor with a possible
Gently swing fault, to inspect whether the fault is
reproduced.
Note:
If the force is applied too much, it may
result in open circuit of the relay.
(b) Connector
Gently shake the connector in both
horizontal and vertical directions, to
Gently swing
determine whether the fault is reproduced.
(c) Wiring harness

Gently shake the wiring harness and the connector
in both horizontal and vertical directions, to
determine whether the fault has reproduced.
Overview-Overview
01-7
2. Heating method
(a) Use a hair dryer or a similar item to heat
the component with a possible fault, to
determine whether the fault is reproduced.
Note:
• Do not damage the component
structure during heating process.
• Do not heat ECU components directly.
3. Watering method
(a) Water the vehicle, to determine whether
the fault is reproduced.
Note:
•Do not water the engine directly.
•Do not water the electronic components
directly.
Tips:
If the vehicle is water leaked, it may
cause damage to some electrical 01
components. Must carefully water the
vehicle under test.
4. Others
(a) Turn on all loads, to determine whether the fault is reproduced.
Remove the historical faults
Although the fault is not displayed under the current status, the fault did occur. In this case,
the relevant fault may persist.
When there is a historical fault, perform the following test steps.
(a) Determine whether the fuse has been replaced or the connector has been
disconnected.
(b) If the relevant fuse has been replaced or the connector has been disconnected,
clear the fault code and inspect whether the fault code has been reset. If the fault
code is not reset, perform the diagnosis.
(c) If the fault code is reset, perform the relevant diagnostic fault code steps, and then
inspect the wiring harness and the connector, as shown in “How to remove the
intermittent faults”.
Precautions before repair

Safety protection system
1. Precautions in SRS maintenance
(a) After disconnecting the battery negative cable, wait at least 60s before performing
any operation. When disconnecting the battery connection, SRS system can
also provide sufficient voltage for airbag deployment. If repairing SRS system
components within 60 seconds after disconnecting the battery cable, it may activate
SRS system and deploy the airbag, resulting in a serious accident.
(b) Read the appropriate warning/caution label carefully when repairing or servicing
SRS components. The warning label is located on the right sun visor.
(c) Always ensure that the specified special tools and test equipment are used.
(d) Place the removed SRS components on a clean and dry position. Place the airbag
module on a flat surface with its flat face upward. Do not place anything on it.
(e) Do not disassemble or repair SRS components (SRS control unit, airbag module
and clock spring).
(f) After performing SRS maintenance, in order to ensure normal system functions,
inspect the warning indicator for normal operation.
(g) Before handling the airbag module or handling a vehicle equipped with airbags,
must ensure that the airbag is in the deployment status.
2. When operating SRS components (including indirect operations related to
SRS), the following related steps must be followed:
(a) Do not bump or shake SRS components when removing or installing any
component.
(b) During the spraying process, in order to avoid heating damage, must remove
SRS control unit, airbag module, clock spring, front crash sensor and seatbelt with
preload functions.
Engine oil
1. Health warnings
(a) Long-term and repetitive contact with engine oil can cause the reduction of natural
oils and fats on skin, resulting in dry skin, irritation and dermatitis.
(b) The engine oil contains potential dangerous substances that can cause skin cancer.
The appropriate skin protection methods and the corresponding cleaning settings
should be used.
2. Recommended precaution measures
(a) Avoid long-term and repetitive contact with engine oil, especially for used engine oil.
(b) Wear the protective clothing, including practical leak-proof gloves.
(c) Do not place any rags with oil stains in the pocket. To avoid this case, wear a bag-
less clothing.
(d) The working clothing must be kept clean and stored separately.
(e) Wear goggles and face shields during the operation, and also provide appropriate
eye washing facilities.
(f) Do not use oil, kerosene, diesel, gasoline or solvents to clean the skin.
(g) If there is any corresponding skin disease, seek medical attention immediately,
without any delay.
Overview-Overview
01-9
Electrical system maintenance
Before replacing the relevant components in the

electrical system and performing repair operations
on the electrical system, disconnect the battery
negative cable in order to prevent any short circuit.
Before disconnecting or connecting the battery
negative cable, make sure that the ignition switch
and the light switch are turned off (if the switches
are not turned off, it may cause damage to the
semiconductor components).
Vehicle cleaning
When using high-pressure vehicle cleaning equipment or steam vehicle cleaning

equipment for vehicle cleaning, in order to avoid damage to the relevant plastic
components, the following information should be noticed.
• Nozzle distance: ≥40cm
• Pressure: ≤3900kPa
• Temperature: ≤82℃
• Concentrated spray time at one point: 30s.
Applications of preservatives and primer
When a preservative or primer is sprayed onto the sensor or actuator, it can affect the
01
performances of the sensor or actuator. In preservative and primer application, a protective
cover should be used to cover the sensor and actuator.
Maintenance guide
Maintenance Precautions
1. Pre-coating components
(a) The pre-coating components are studs,
nuts and other components painted with a
sealant at factory.
(b) The pre-coating components shall be
repainted with a prescribed sealant after
re-tightening, loosening, or moving in any
other means.
(c). When re-using the pre-coating
components, remove the original sealant
on them, clean them with compressed
air, and then coat their threads with the
specified sealant.
(d) After coating the sealant, wait a time until
the sealant is solidified.
2. Washer
(a). If necessary, install a seal ring on the
gasket, to prevent leakage.
3. Bolts, nuts and screws

(a) Before use, carefully inspect bolts, nuts
and screws for any thread damage with
more than three turns; if any, must replace
them.
(b) Seriously follow the requirements of all bolt
tightening torque specifications.
4. Battery
(a) Before inspecting or repairing the on-board
electrical appliances and electrical circuits,
must first disconnect the battery negative
cable.
(b) To prevent damage to the battery pole,
must loosen the nut on it. Take up the
cable directly and remove it, do not twist or
pry it.
(c) Wipe the battery pole with a rag; do not
scratch it with a file or other abrasive tool.
(d) Loosen the nuts, install the cable terminal
on the battery pole, and then tighten the
nut; do not use a hammer to tap the cable
terminal onto the pole.
5. Electrical components
(a). When pulling the electrical connector, must
pull the connector itself, and do not pull its
wiring harness.
Overview-Overview
01-11
(b) Do not drop the electrical component (such

as sensor or relay); if it drops onto a hard
surface, must replace it.
(c) When inspecting the continuity of the
wiring connector, must carefully insert the
tester probe into it, to prevent the terminal
bending.
(d) After replacing the electrical component,
must inspect the functions of the electrical
component, to ensure its normal functions.
6. Clamp
(a). Must use professional pliers to remove the clamp, and the clamp removal method
for common body components is shown in the following table.
Tips:
If the pliers are damaged in maintenance, must replace it with a new one.
Note:
• If the clamp is damaged in maintenance, must replace it with a new one.
• Some disposable clamps must be replaced and can not be reused.
01
Shape (example) Removal/installation
Thinnose pliers
Clamp pliers
Protective tape
Screw driver
Shape (example) Removal/installation
Protective tape
Scraper
Remove Install
Overview-Overview
01-13
Vehicle identification
VIN
1. Description of Vehicle Identification Number (VIN)
Vehicle Identification Number (VIN) is used for vehicle registration. This number can
help identify the vehicle's identity.
Tips:
A vehicle has many VINs, and here we just show the positions of part of the VINs.
(a). The lower front beam under the co-driver's

seat.
VIN
LFWX-6470-01016
01
(b). The upper left corner of the dashboard on

the driver's side.
XXX XXXX
XXXX XX
XXXX
LFWX-6470-01017
2. Vehicle nameplate description

The nameplate contains the vehicle model, seating capacity, engine model and
vehicle identification number etc.
(a). The nameplate is located at the lower of

right bodywork B pillar vertical plane.
LFWX-6470-01018
3. Position of engine VIN

(a). The engine number is located on the inlet
side of the lower cylinder block.
X
X
X
X
X
X
X
X
X
X
X
X
LFWX-6470-01019
Overview-Overview
01-15
Technical characteristics and parameters of vehicle

Entire vehicle figure
1540
1840 1535
01
1665
19 23
950 2780 990
4720
LFWX-6470-01020
Vehicle technical parameters

Product model and name LF6470 LF6470B LF6470C LF6470G LF6470H
Length (mm) 4720 4720 4720 4720 4720

Overall
Width (mm) 1840 1840 1840 1840 1840
dimensions
Height (mm) 1665 1665 1665 1665 1665
Front (mm) 1540 1540 1540 1540 1540

Tread
Rear (mm) 1535 1535 1535 1535 1535
Wheelbase (mm) 2780 2780 2780 2780 2780
Curb weight (kg) 1540 1540 1540 1540 1540
Maximum authorized total mass

2100 2100 2100 2100 2100
(kg)
Approach Angle (°) 19 19 19 19 19
Departure Angle (°) 23 23 23 23 23
Tire Specification 215/55R17 215/55R17 225/45 R18 225/45 R18 215/55R17
Spare tire T135/90R16 T135/90R16 T135/90R16 T135/90R16 T135/90R16
Front Suspension (mm) 950 950 950 950 950
Rear Suspension (mm) 990 990 990 990 990
Number of passengers 5/7 persons 6/7 persons 6/7 persons 6/7 persons 6/7 persons
Maximum Vehicle Speed (km/h) 180 180 180 180 180
Engine model LFB479Q LF483Q LF477ZLQ LF477ZLQ LF483Q
Type Straight Straight Straight Straight Straight

4-cylinder, 4-cylinder, 4-cylinder, 4-cylinder, 4-cylinder,
16-valve, 16-valve, 16-valve, 16-valve, 16-valve,
water- water- water- water- water-
cooled cooled cooled cooled cooled
Displacement (ml) 1794 1988 1452 1452 1988
Maximum Torque N•m (r/min) 168 185 234 234 185
Idle Speed (r/min) 750±50 750±50 750±50 750±50 750±50
Combined fuel consumption

(L/100km) 8.0 7.8 8.2 8.2 8.2
Maximum gradability (%) ≥30% ≥30% ≥30% ≥30% ≥30%
Emission Standards National V National V National V National V National V
Maximum net power (kW) 92 100 100 100 100
Brake pedal free stroke (mm) 15~20 15~20 15~20 15~20 15~20
Overview-Overview
01-17
Brake lining Front / rear

Front: 10 / Front: 10 / Front: 10 / Front: 10 / Front: 10 /
standard
rear: 10.7 rear: 10.7 rear: 10.7 rear: 10.7 rear: 10.7
thickness (mm)
Front / rear
Front: 8 / Front: 8 / Front: 8 / Front: 8 / Front: 8 /
effective
rear: 8.7 rear: 8.7 rear: 8.7 rear: 8.7 rear: 8.7
thickness (mm)
Clearance to the
0.2~0.4 0.2~0.4 0.2~0.4 0.2~0.4 0.2~0.4
brake (mm)
No-load (kg) 850/690 850/690 860/700 900/730 890/690

Axle weight
Full Load (kg) 980/1120 980/1120 980/1120 980/1120 980/1120
Maintenance data
Common parameters for inspection and adjustment
To make the search easy in maintenance, the common parameters for inspection and
adjustment
Item Normal parameter

Ti r e p r e s s u r e ( n o Front wheel 230kPa/250kPa
load / full load) Rear wheel 230kPa/250kPa
Toe-in of front wheels 1.3±0.5mm

01
Front wheel outer camber -0.05°±0.5°
Kingpin caster angle 5.5°±0.5°
Kingpin inclination angle 11.65°±0.5°
Left turn of left wheels: 39.7° Right turn of right wheels: 33.5°
Steering angle
Left turn of right wheels: 33.5° Right turn of left wheels: 39.7°
Oil parameters
To ensure the normal operation of vehicles during maintenance and repair, various oils
must be properly chosen and can not be replaced by other inadequate fluids. The grade
and usage for various oils of Lifan M7 series:
Refueling capacity
Item Brand
LF6470
SN 5W-30 (2.6±0.2) L
Engine Oil
SN 5W-40 (4.3±0.2) L
Cold countries and regions: SAE 75W-90 (API

GL-4) gear oil (applicable temperature: -40℃
or above);
Common countries and regions: SAE 80W-90
Manual transmission gear
(API GL-4) gear oil (applicable temperature: (2.0±0.1) L
oil
-26℃ or above);
Tropical countries and regions: SAE 85W-90
(API GL-4) gear oil (applicable temperature:
-12℃ or above).
Manual transmission gear

DAPHNE ATFSP III 8.0L
oil
Automatic transmission
ATFSS Ⅷ -L (7.5±0.2) L
gear oil (8AT)
Brake fluid D0T4 (800±20) ml
Power steering fluid ATF220 (1100±50) ml
(1.5T) Glycol type: select freezing point based

(7.4±0.2)L
on temperature
Coolant
(1.8L/2.0L) Glycol type: select freezing point
( 6± 0.2) L
based on temperature
Fuel Car unleaded gasoline of 92# or above 60L
Detergent SFFC-1 3L
Air-conditioningrefrigerant R134a 710±20g
Bulb parameters
Parameters of various lighting and signal lamps of Lifan M7 series:
Name Model Qty.
Curve auxiliary lamp H7 12V 55W 2
High beam BIR2
Combination 2
Low beam BIR2
headlamp
Front position lamp Light band 1X0.5W 2
Front turn lamp PY21 12V 21W 2
Rear turn lamp PY21 12V 21W 2
Combination Rear position lamp LED(18X 0.2W) 2
tail lamp Reverse lamp W16W 12V 16W 2
Brake lamp LED(8X 0.5W+18X0.2W) 2
High-mounted stop lamp LED(8X 0.5W) 1
License plate lamp LED(3X 0.5W) 2
Side turn lamp LED(3X 0.5W) 2
Front roof lamp W5W 12V 5W 1
Front roof lamp (Available for openable
LE D (2X 0.5W ) 1
skylight models)
Rear roof lamp W5W 12V 5W 2
Overview-Overview
01-19
Name Model Qty.

Front fog lamp H8 12V 55W 2
Rear fog lamp P21W 12V 21W 2
Daytime running light LED(6X 0.5W) 2
Trunk light W5W 12V 5W 1
Door lamp W5W 12V 5W 4
Glove box lamp W1.2W 12V 1.2W 1
Make-up Mirror Light 2X0.5W 1
Precautions for use and maintenance

Maintenance operation
1. Precautions during disassembly and assembly
A car is composed of a large number of parts and assemblies by bolts and nuts. In repair,
the car needs to be disassembled and installed. In operation, the following precautions
should be noted to ensure safe operation, not damage parts, and guarantee the normal
connection of these parts after repair:
(a). Use appropriate wrench or sleeve to remove fasteners such as bolts and nuts. You
cannot use a monkey wrench, because it may damage the parts or cause personal
injury due to slipping in disassembly.
(b). Soak the bolts or nuts in loosening fluid if they cannot be unscrewed. Do not use
excessive force when disassembling the parts to avoid accidents caused by the
damage to parts or support unbalance when lifting the car with a jack.
(c). Some parts are closely connected, so don't pry or knock them rudely using 01
inappropriate tools avoid damage.
(d). Use appropriate tension and compression tools when removing or installing
bearings or oil seals, so as to avoid damage to bearings and oil seals as well as the
connection and sealing of relevant parts.
(e). Bolts and nuts must be tightened based on the specified torque.
2. Other considerations in maintenance
(a). Pay attention to the reliability of car when doing maintenance operations under the
lifted car.
(b). Vehicle maintenance shop should be laid out reasonably, the parts removed should
be placed by standard, and the oils on floor should be cleaned in time, so as to
avoid stumbling or slipping by the parts.
(c). Smoking is prohibited during vehicle maintenance in case of fire.
(d). The maintenance shop should be well ventilated, so as to avoid that the harmful
substances from exhaust gas may cause personal injury.
(e). Don't check or repair the car unless the engine stops and temperature falls, so as to
avoid burns by the cylinder or exhaust pipe and other hot parts. Sheet metal parts
should be removed at normal temperature so as to avoid deformation.
(f). In maintenance, try to avoid long-time direct contact of skin with various oils. Rinse
off with water when the body paint has brake fluid or anti-freezing liquid so as to
avoid damage to paint.
Electric system
1. Precautions for maintenance operation of electric system
(a). Disconnect the power first before disconnecting or connecting the plug-ins of electronic
devices, electrical equipment or lines, so as to avoid instantaneous voltage damage to the
electronic components.
(b). Starter, generator, some electrical and electronic system components as well as the power
circuits directly connected to the battery cannot be disconnected from the power supply after
turning off the ignition switch. The negative cable must be removed when it's necessary to
disconnect from the battery.
(c). Spark test cannot be used to check the line continuity, so as to avoid transient voltage
impulse damage to electronic components.
(d). Don't puncture the insulating layer of wire to check the line continuity, so as to avoid poor
line connection or poor insulation.
(e). Don't pull the wire directly when unplugging the harness or plug-ins of electrical
components, so as to avoid breaking the wire or internal wire of the plug.
(f). Use a digital multimeter whose internal resistance is not less than 10MΩ when testing the
voltage or resistance of ECU and electronic control circuit.
(g). Disconnect the power first before testing the circuit continuity, and the resistance of electrical
and electronic components using a multimeter, so as not to damage the instrument.
2. Precautions for use and maintenance of battery
(a). Precautions for use:
• The battery contains strong corrosive electrolyte, so try to protect the eyes and face in
disassembly and handling process. Once the electrolyte is in contact with the skin, rinse
immediately with plenty of water.
• Recharge the battery using a charger if the starting speed decreased significantly (battery
power is not sufficient). If not, the battery plates may be vulcanized to shorten the service
life of battery.
• Regularly check the liquid level of the electrolyte. If it is too low, add distilled water (excluding
maintenance-free batteries).
• Ensure that the battery cable clamp is installed firmly so as to avoid the clamp becomes
loose or falls off when the car is moving. If not, the overvoltage generated from the electrical
system may damage the electronic equipment.
• The surface of battery poles, cable clamps and covers should be kept clean to avoid poor
contact or electric leakage.
• If the car is out of service for more than one month, the negative cable should be
disconnected.
(b). Precautions for disassembly:
• When disassembling the battery, make sure all electrical equipment on the car are in the
disconnected state.
• When removing the battery cable, you should remove the negative cable clamp first and
then the positive cable clamp, so as to avoid the fact that unmeant touch to nearby parts
during disassembly may result in power short-circuit accident; the battery cables should be
installed in the reverse order.
• Note: the positive and negative cable connectors must not be connected wrong; otherwise,
the generator rectifier diode may burn.
(c). Precautions when recharging the battery:
• Disconnect the positive and negative cable connectors when recharging the battery.
• Connect the wire well before recharging, and then turn on the power switch; turn off the
power first when stopping recharging.
• The cable clamp must be reliably connected to the battery poles, so as to avoid the
accidents caused by the spark that ignites the hydrogen and oxygen generated during
recharging.
• When recharging the battery at constant voltage, the constant voltage cannot be greater
than 16V, and the charging current can not be greater than 20% of the set value of battery,
Overview-Overview
01-21
or it may result in over-charging or damage to the plates.

(d). Precautions for use in winter: It's cold in winter, so the capacity of the battery is reduced and
the internal resistance is increased, and there is risk of electrolyte freezing.If the electrolyte
is frozen, the battery can not be used, and the active material on the plate may fall off and
container may break. Therefore, these matters should be noted in cold regions in winter:
• Properly increase the density of the electrolyte, because low density of electrolyte is easy
to freeze in winter.
• Make sure the the battery is in fully-charged state in winter, because the density of battery
electrolyte is lowered after discharge which increases the chances of freezing.
• Add distilled water when recharging the battery, so water quickly mixes with the electrolyte,
thus reducing the risk of electrolyte freezing.
• The battery should be insulated and preheated in winter when starting the engine so as to
improve the battery capacity and reduce the resistance, making it easier to start the engine.
(e). Precautions when using emergency battery: When the starter cannot start the engine due to
serious loss of power of battery, a cart cannot start the engine in most cases, because the
Electronic Control Unit (ECU) of engine does not work properly in such a case. If the engine
must be started, another car's battery or standby battery may be used to start the engine. To
ensure a safety start, comply with the following operation methods and precautions:
• Connect the emergency battery in the order shown in
the figure. Ensure that the power line is securely
connected, and prevent the clamp from loosening to
create a spark.
• If using another car's battery, connect the two
batteries first and then start the rescue car's engine; let
the engine run at a relatively high speed, and then start
the car whose battery lacks of power.
• The rescue car cannot contact with the car whose
Emergency battery
01
battery lacks of power. Stop the engine when
Grounding point on the car
connecting the clamp. Do not touch the clamp or lean
Battery of failed car
against the battery in starting process.
• Remove the clamp in the reverse order of the
connection.
LFWX-6470-01021
3. Precautions for use and maintenance of
generator
(a). Check if the tension of the generator driving belt is appropriate when the generator cannot
be charged or charged poorly, because slipping of belt is one of the common reasons.
(b). Don't disconnect the battery when the engine and generator are running, or it will cause
over-voltage, burn the rectifier diodes inside the generator, and damage other electronic
components on the car.
(c). While the generator is running, it is not allowed to check the generator by spark test
because this can easily burn out the rectifier diodes and other electronic components on the
car.
(d). Disconnect the rectifier diodes from the armature windings first when checking the insulation
performance of armature windings using a 220V AC test lamp or ohmmeter, or the rectifier
diodes will be burnt.
(e). When the engine goes off, the ignition switch should be disconnected in time, because the
battery will continue to discharge to the generator's field winding if the ignition switch is still
on. This will consume the battery power for nothing, and may burn out the generator's field
winding after a long time.
4. Precautions for use and maintenance of starter
(a). When the engine is difficult to start, the starting time once cannot be too long (generally not
greater than 5s), and the other start should be made 15s later. This cannot only make the
battery electrolyte have time to penetrate into the inner layer of the plates to recover the
electromotive force of battery for easier start, but can also avoid burning out the starter for
long-time running.
(b). Do not use the starter to drive the car, so as to avoid damage to the starter due to excessive
load.
(c). Release the ignition switch in time after the engine starts, and let the ignition switch
automatically return to the ignition gear, so as to avoid the wear when starting the electric
motor and one-way clutch after the starter idles at high speed for a long time.
(d). Do not turn the ignition switch to the starting gear when the engine is running, so as to avoid
the fact that the driving gear of starter collides with the flywheel ring gear of engine.
(e). he performance testing time of the starter in maintenance shall not exceed 5s to avoid
damage to the starter.
Car lifting
In some cases, a car needs to be partly or wholly lifted. Select the correct support points
during the lifting process so as to ensure the safety of the car.
Key points for lifting of M7 series vehicles:
1. Position of strength
(a). Lift the vehicle with the lifting machine or
jack at the front.
LFWX-6470-01022
(b). Lift the vehicle with the lifting machine or

jack at the rear.
Note:
Lifting at the chassis position is not
recommended since lifting the bodywork will
be more stable.
LFWX-6470-01023
Overview-Overview
01-23
Vehicle use and maintenance

1. Precautions for driving
The following matters should be noted for normal operation of engine and other systems:
(a). Observe the indicators on the instrument and instrument panel. If some warning indicator
lights, stop the car, and check to remove the faults.
(b). Make sure the radiator cap is tight to ensure that the engine cooling system runs properly.
(c). Start the car by the first gear. Don't drive the car when the gear shift lever is at the neutral
position.
(d). When the electric fuel injection engine starts, the injection system, under the control of
ECM, controls the spraying based on the starting switch signal, so it's unnecessary to stamp
on the accelerator pedal.
(e). After the engine starts, the car needs to warm up before driving; do not accelerate the car
suddenly; allow the car to move a distance smoothly; let the engine idle before it goes out,
so that the engine temperature declines gently.
(f). Regularly check the liquid level of engine coolant, braking fluid, windshield washer fluid, and
engine oil.
(g). Check and maintain the normal idle speed of the engine, so as to give play to the engine
performance.
(h). The spark plugs for electronic fuel injection engine and carburetor engine cannot be
exchanged.
2. Precautions for tire use
(a). Regularly check the tire pressure. Keep the tire at normal pressure. When the tire pressure
is too low, the tire side is easy to form early cracking, the crown has uneven wear, the tire
shoulder encounters premature wear, and the rolling resistance of the tire increases. All
these factors increased the fuel consumption. When the tire pressure is too high, the tire
tread will encounter premature wear, adhesion property decreases, braking distance is
prolonged, so the car may sideslips; in severe cases, the car may have tire punctured when
moving at high speed.
01
(b). Use the tire changer to unscrew the tire, and make dynamic balance test using a dynamic
balancer. Improper operation tends to deform or damage the tire bead, influence tire
airtightness or cause swelling on tire side, and even break the tire cord and retire the
tire in a series case. Without dynamic balance correction, the car may wobble and make
increasingly larger noise when running, and the tires will suffer from uneven wear to shorten
the service life of tires.
(c). Regularly interchange the tires in use to reduce the eccentric wear, ensure the car's driving
performance, and extend the service life of tires.
(d). Note that the car needs to use Lifan M7 tires. The tires of different specifications and
patterns cannot be used in one single car.
(e). Rinse off the sticky mud and sand on the tire in time, so as to avoid wheel shaking and
damage to tires when moving at high speeds.
3. Precautions when cleaning a car
(a). Don't clean the car's paint and polymethyl methacrylate using dry cloths, gasoline, kerosene,
trichlorethylene, strong alkaline water and alcohol, so as to avoid damage to the surface.
(b). When a car will run on the roads unfrozen by salt, the lower part of engine compartment and
bottom of the car should be cleaned in time so as not to cause corrosion.
Three-way catalytic converter

Three-way catalytic converter may fail for deposition of lead, zinc, sulfur, phosphorus and other
impurities on surface because of impure fuel, or for aging or damage because of over-reaction (high
HC content in exhaust gas). To ensure the normal work of catalytic converter and extend its service
life, try not to use the emissions of lead, zinc, sulfur, phosphorus and hydrocarbons into catalytic
converter during use and maintenance.
1. Precautions for use
(a). Use 92# or better unleaded gasoline.

(b). Don't use the gasoline additives and oil additives Lifan hasn't recognized or recommended.
(c). Do not use the starter to drive the car.
(d). Do not drive or park on roads with inflammables (such as hay, gasoline, alcohol and some
organic solvents, etc.), so as to avoid the hot three-way catalytic converter ignites the
inflammables and causes the fire.
(e). Check and remove the cold start problems when it's difficult to start the engine, to avoid the
unburned gasoline in the cylinder being discharged into the three-way catalyst converter
after multiple starts which burns the catalyst converter due to over-reaction.
(f). When the warning light works because the fuel is too low, fill the fuel as soon as possible
in order to avoid that the fuel level of fuel tank is too low to normally supply oil, resulting in
poor combustion in engine to increase the load of three-way catalytic converter.
2. Precautions for maintenance
Do not let excessive HC discharge into the three-way catalytic converter in maintenance,
and the following matters should be noted:
(a). Don't cut out cylinders to identify each cylinder's working conditions.
(b). Unplug the injector connectors when measuring the cylinder pressure using the starter to
drive the engine.
(c). Regularly check and clean the injector, and promptly solve the injector's oil drippage,
channel blockage, surface carbon and other failures.
(d). Regularly check the ignition system, and promptly solve the fall-off or poor contact of
hightension cables, carbon deposit or burn of spark plug, poor ignition coil and circuit, and
other failures.
Vehicle use and maintenance

Maintenance classification and basic items
In use, a car's technical performance will gradually change with the increase of mileage and
a variety of factors, thus reducing the power performance, economical efficiency, safety and
reliability, while increasing the exhaust pollution, noise and failure rate. Therefore, the car should
be repaired in time to eliminate the hidden dangers, prevent failures, improve the serviceability rate
and technical performance, and effectively extend the life of the car.
According to the technical requirements and use of vehicles, Lifan M7 series can be divided into
different categories in maintenance.
1. First maintenance
First maintenance, also known as breaking-in period maintenance, refers to the first check and
maintenance after a new car or a repaired car has reached a breaking-in period of 1500~2500km.
Basic items:
(a). Check if the engine, transmission and differential mechanism leaks, and solve the problems
if any.
(b). Replace the engine oil filter and the engine oil.
(c). Check the level of coolant, braking fluid, windshield detergent and battery electrolyte (except
maintenance-free battery), and check if there has leakage. Add more fluids if the level is too
low; repair the vessel if there has leakage.
(d). Check if the oscillating arm and ball pin, and the diverter's connecting ball are damaged or
loose. Repair or replace the parts if any.
(e). Check if the oil system, and front/rear shock absorbers have oil leakage, and solve the
problems if any.
(f). Check the tire pressure: the standard air pressure of front and rear wheels when the car
takes no load is 230kPa, and that for full load is 250kPa.
(g). Check if the self-diagnostic system has fault codes, and remove the fault codes if any.
Overview-Overview
01-25
(h). Tighten the chassis bolts and nuts according to the specified torque.
(i). Check is the whole car's lighting and electrical systems work properly, and check and repair
them if not.
2. Periodic maintenance
The car enters the normal period of use after the first maintenance. During the normal period of
use, the car should be regularly checked and repaired based on the actual conditions.
(a). Periodic maintenance in harsh conditions: the maintenance period of a car is 3000km. One
of the following circumstances is considered as a harsh condition;
• Frequently started.
• Often operates in dusty environments.
• Often operates in hot areas (greater than 40℃ ).
• Often running at low temperature (the temperature of engine often can not reach the
normal operating temperature when short-trip operation predominates).
(b). Periodic maintenance in general conditions: the maintenance period of a car is 5000km.
Note:
Periodic maintenance should be carried out at Lifan Service Station.
(c) Periodic maintenance items:
• Meanings of I, R, C
I—Inspect these items and related parts. Make correction, cleaning, replenishment,
adjustment or replacement when necessary.
R—Replace.
C—Clean.
• For cars operating in severe conditions, for short distance and always driving at idle
speed or in dusty environment, shorten the period for replacing the engine oil and filter as
01
necessary;
• For cars operating in hills or mountainous areas or often being towed, the braking fluid
should be replaced every 20000km.
• Unleaded gasoline of 92# or above only.
Regularly maintenance items

Maintenance First Second The reading on the odometer or the number of months that comes first
intervals maintenance maintenance prevails.
×1000Km 3 8 13 18 23 28 33 38 43 48 53 58 63
Maintenance Month 3 9 15 21 27 33 39 45 51 57 63 69 75
items
Engine
Oil and oil filter R R R R R R R R R R R R R
Air / A/C filter element I R I R I R I R I R I R I
Fuel filter I R I R I R I
I I I I I I I I I I I I I
Spark plugs
Replace it every 1 year or every 20,000km
Throttle body C C C C C C C C C C C C
Fuel injection nozzle C C C C C C C C C C C C
I Replace it every 2 year or every 40,000km
Engine coolant
Add some in accordance with specific conditions
Cooling system piping and

fittings
Fuel lines and fittings I I I I I I I I I I I I I

Fuel tank, vaporizer tube,
carbon tube
Intake / exhaust manifold
I I I I I I I
status
Screw the fastening bolts for
engine
Engine harness and sensor I I I I I I I
Positive crankcase ventilation
system
Transmission belt and
tensioning device
Engine timing chain Must be replaced every 100,000km
Chassis and Body
Parking brake function and
stroke
Check the free travel of brake
I I I I I I I I I I I I
pedal
I I I I R I I I R I I I I
Brake fluid/clutch fluid
Replace it every 2 year or every 40,000km
Braking line (with vacuum
booster)
Brakes and related work
components
Steering function and steering
track rod
Power steering fluid I I I I R I I I R I I I R
Power-assisted steering line I I I I I I I I I I I I I
Propeller shaft I I I I I I I I I I I I
Manual transmission gear oil I R Replace it every 2 year or every 40,000km
Automatic transmission gear
I R Replace it every 2 year or every 40,000km
oil
Front and rear shock
absorbers
Tighten the bolt and nuts of
chassis and body bottom
Ti r e c o n d i t i o n s a n d t i r e
pressure (including spare tire)
Fasten the wheel nuts I I I I I I I I I I I I I
Wheel alignment Check if there is an abnormal running condition
Seat belt, latch and bracket
I I I I I I I
status
Door lock, hinges, and limiting
stopper should be lubricated I I I I I I I I I I I I
as necessary
Electrical and air conditioning
Storage battery I I I I I I I I I I I I I
Lighting and signaling devices I I I I I I I I I I I I I
Windshield Washer System
(including wiper and washer)
Wire harness connector and
I I I I I I I
ground wire harness
A/C system (including cooling
fan, A/C control switch)
Overview-Overview
01-27
Routine maintenance
Routine maintenance is to make vehicle inspection, cleaning, fastening, supplementing and other
operations depending on vehicle usage and status, so as to make sure the vehicles are in good
condition. Routine maintenance should be made by the driver before or after the driving.
1. Maintenance of air cleaner
(a). The air filter filters the air entering the engine cylinder and the dust and other impurities
filtered out gather in the filter element. The the dust and other impurities must be removed in
time.
(b). Disassemble the filter to remove the dust and impurities from the filter element. Under
normal circumstances, the filter should be cleaned once every 5000km; and it should be
cleaned once every three days when driving in dusty roads.
(c). Determine the number of times the air filter is serviced based on the cleanness of roads
during the replacement cycle of filter element. When servicing a filter, remove the filter
element and blow the dust away from the element using compressed air, and remove the
impurities from the filter housing.
Note:
Don't clean the element using wet cloth, water or liquid cleanser. Make sure the connection
is well sealed when installing the filter.
2. Battery maintenance
The battery is used to start the engine and supply power for equipment, and its status will directly
influence the normal use of the vehicles, especially those equipped with electronic control devices.
Battery should be often inspected and maintained as follows in routine use:
(a). Externally clean the battery: Regularly check if the battery housing and cover are dirty.
Clean the dust, oil, or other dirts in a timely manner, if any. And keep the battery cover dry,
so as to avoid battery cover leakage.
(b). Check the battery connection: poor connection between terminal posts and cable may result
in the fact that the engine is difficult to start or can not be started; fall-off of battery cable 01
may damage the electrical components. Therefore, regularly check if the cable connectors
are well connected with the posts.
3. Tire maintenance
It's important to control the fuel consumption and driving safety by keeping the tire in good
condition, so regular inspection and maintenance should be carried out.
(a). Tire pressure: Regularly check the tire pressure. Inflate the tires to ensure standard air
pressure when necessary.
(b). Tire damage: Visually check if the tire has abnormal wear, cracking, or swelling; repair or
replace the tires, if any. The tires embedded with hard debris should be removed in time, so
as not to damage the tires.
(c). Interchanging of tires: Interchange the tires
every 10000km so as to ensure the vehicle's
driving performance, and extend the service
life of tires. Tires are interchanged as below.
(d). Normal wear criteria: Tires should be replaced
when tire tread depth is less than 1.6 mm
or when there are two or more wear marks
Driving direction
between adjacent tire grooves.
LFWX-6470-01024
4. Maintenance of wiper and washer

The conditions lf wiper and washer have a direct impact on the driver's line lf sight and the
service life of the windshield. Therefore, it's necessary to regularly maintain the wiper and
washer.
(a). Wiper: Check if the wiper blade has defects or deformation. Make timely repair or
replacement if there is poor contact between wiper blade and windshield or the wiper motor
is not working properly.
(b). Washer: Check the liquid volume of the washer's liquid storage tank, and replenish the
detergent in time. For the best washing performance, use the specified detergent. Slowly
inject the detergent and do not get impurities mixed.
5. Headlamp detection and adjustment
Improper beam of headlamp will affect the driving safety at night, so regular inspection
should be carried out. See Chapter 75 for more information about headlamp detection and
adjustment.
6. Interior maintenance
Interior maintenance refers to the cleaning work inside a car so as to keep the car clean
and tidy and provide a fresh and comfortable driving environment. Key points for interior
maintenance:
(a). Stains cleaning method: Remove the dust first, and then remove the stains using
appropriate cleaning solution, and lastly repeatedly wipe the car using clean, soft and
moderately wet cloth.
(b). Cleaner: Try using the water solution with soap solution and surfactant to remove stains
from fabrics or synthetic leather. Use alcohol to remove the ballpoint pen and lipstick stains.
Use low-grade gasoline to remove the grease stains. Use commercial aqueous solution of
ammonia to remove the chocolate and sugar stains. And use special resolutions to remove
the asphalt stains. All kinds of solvents have more or less corrosive effects on the synthetic
materials of interiors, so they should be used with caution.
(c). Long-time exposure to sunlight may discolor, distort the interiors or accelerate the aging.
Therefore, it is preferable to cover the places exposed to sunlight.
7. Exterior maintenance
Exterior maintenance keeps the exterior of a car clean and bright, giving a beautiful,
pleasant feeling to us. Such maintenance can also help avoid corrosion and abnormal fall-
off of paint. Key points for exterior maintenance:
(a). Body washing:
• After flushing the surface dirt with pressure flow, wipe the body using a soft cloth or sponge
from top to bottom.
• If using detergent to clean the body, rinse the detergent with clean water.
• Wipe the surface of the body with a fine cheese.
Note:
After the washing, step on the brake pedal for a few times when driving the car to eliminate
the moisture in the friction pair.
(b). Windshield cleaning: Do not use silicon copper based products. Use special cleaning fluid
for better cleaning effects.
(c). Asphalt cleaning: Clean the asphalt on the body and bumper instead of scraping.
(d). Paint repair: Go to Lifan authorized repair station to repair the paint injury in time, if any.
(e). Body polishing and waxing:
• Paint polishing should be carried out at the end of winter. Before polishing, the body must
be absolutely clean and dry. Use liquid or creamy polishing agent for polishing.
• Before waxing, the body paint surface must be absolutely dry and clean. Evenly apply
the wax over the paint surface using waxing tool (or a soft napkin or a soft, lint-free napped
cotton fabric). Judge the waxing effect via droplet test: Spray some water onto the paint
surface to be tested, and if there are droplets, the wax layer has been formed; otherwise,
clean the surface and re-do the process.
Note:
Do not do it in direct sunlight or in cold weather.
Engine mechanical system - mechanical system (1.5T)
21-a
Mechanical system
Mechanical systems��1 Piston and piston pin noise 25
Technical specifications��1 Air valve drive unit noise� 27
Material specifications��1 Engine can not be started - the
Part specifications��1 crankshaft can not be rotated
General specifications��2 freely�� 29
Torque specifications��3 Removal and Installation�� 31
Structure and installation location Attachment belt�� 31
��4 Disassembly�� 31
Part Location Drawing��4 Inspection�� 31
Accessory gear trains��4 Installation�� 31
Part exploded view��5 Tensioner assembly�� 32
Accessory gear train��5 Disassembly�� 32
Timing cap, chain and sprocket Inspection�� 32
components��6 Installation�� 33
Valve components��7 Tensioner bracket�� 33
Camshaft and cylinder head Disassembly�� 33
components��8 Installation�� 33
Flywheel components��9 Crankshaft front oil seal� 34
Piston, piston rings and Disassembly�� 34
connecting rod components 10 Installation�� 35 21
Main bearing, crankshaft, Crankshaft rear oil seal� 37
cylinder block components� 11 Disassembly�� 37
Fault diagnosis and inspection 12 Installation�� 38
Cylinder compression pressure Timing chain and sprocket
check�� 12 components�� 39
List of fault symptoms�� 13 Disassembly�� 39
There is an abnormal noise Inspection�� 43
below the engine�� 16 Installation�� 46
Attachment belt noise diagnosis Camshaft cover�� 51
�� 17 Disassembly�� 51
Diagnosis about engine non- Installation�� 52
firing�� 18 Camshaft and hydraulic rock
Engine firing�� 20 arm components.�� 54
Exhaust abnormity (blue smoke) Disassembly�� 54
�� 21 Inspection�� 54
Exhaust abnormity (black Installation�� 57
smoke)�� 23 Cylinder head and air valve
Connecting rod and connecting components�� 58
rod bearing noise symptoms 24 Disassembly�� 58
21-b Engine mechanical system - mechanical system (1.5T)
Inspection�� 59
Installation�� 63
Piston, piston rings and
connecting rod components64
Disassembly�� 64
Inspection�� 66
Main bearing, crankshaft and
cylinder block assembly� 73
Inspection�� 74
Flywheel�� 78
Maintenance Tools�� 79
Special tools�� 79
General tool�� 81
21-1
Mechanical systems
Technical specifications
Material specifications
Name Size Volume
Sealant 1596 -
Sealant 1515 -
Pipe thread sealant 1567 -
Volume: SN-5W40
Engine oil -
Winter: SN-5W40
Part specifications
Name Size
Camshaft diameter 24mm

Camshaft
Camshaft axial clearance 0.05 ~ 0.3 mm
Upper surface: 0.05

mm
Cylinder head surface flatness
Lower surface: 0.04
Cylinder Head mm
Minimum total height after machining 108.5 mm
Total height 108.5 mm

21
Valve spring Valve spring free length 47.19 mm
Intake valve diameter 29.5 mm
Exhaust valve diameter 26 mm
Exhaust valve 5.953 mm

Valve tappet diameter
Intake valve 5.973 mm
Valve
Clearance between the Intake valve 0.02 ~ 0.046 mm
valve tappet and the
catheter Exhaust valve 0.04 ~ 0.066 mm
Intake valve 2.8±0.15 mm

Valve head thickness
Exhaust valve 2.7±0.15 mm
Valve guide inner Intake valve 6 ~ 6.012 mm

diameter Exhaust valve 6 ~ 6.012 mm
Valve guide
Valve catheter length out of cylinder head 15±0.2 mm
Total valve catheter length 39 mm

21-2 Engine mechanical system - mechanical system (1.5T)
Standard piston diameter (mm) 76.465 mm
Piston Piston and cylinder matching clearance (cylinder

diameter/or piston skirt maximum diameter in 0.04 ~ 0.06 mm
thrust direction)
Piston ring groove Top ring 1.225 ~ 1.250 mm

Piston ring groove
clearance The second ring 1.22 ~ 1.24 mm
Top ring 0.2 ~ 0.35 mm
Piston ring End clearance The second ring 0.4 ~ 0.6 mm
Oil ring 0.2 ~ 0.7 mm
Piston pin diameter 18.998 mm
Piston pin Clearance between piston pin and piston pin hole 0.012 mm
Piston pin hole diameter 19.01 mm
1 47.763 ~ 47.768 mm
Connecting rod journal
Crankshaft 2 47.768 ~ 47.763 mm
diameter
3 47.773 ~ 47.778 mm
Axial clearance of connecting rod bearing 0.04 mm
Axial clearance of main shaft 0.06 ~ 0.24 mm
Standard thickness of crankshaft thrust piece 2.47 mm
Clearance between main bearing and the main

Crankshaft 0.025 ~ 0.055 mm
journal
1 49.963 ~ 49.968 mm
Main journal diameter 2 49.968 ~ 49.973 mm
49.973 ~ 49.978 mm
1 55.025 ~ 55.031 mm
Main bearing hole diameter
in cylinder block (no 2 55.031 ~ 55.037 mm
bearing)
3 55.037 ~ 55.043 mm
Flatness 0.04 mm
Cylinder block
Cylinder diameter limit 76.530 mm
General specifications
Name Size
Engine model LF477ZLQ
Fuel supply mode Direct injection
Timing driving mode Timing chain
Cylinder diameter 76.5mm

21-3
Piston stroke 79mm
Displacement 1.452L
Compression ratio 10
Maximum power 104kw
Maximum torque 234 N.m
Minimum fuel consumption rate 265 g/KW.h
Idle speed 750±50 rpm

Ignition order 1-3-4-2
Spark plug type F6HI332
Torque specifications
Name Nm Lb-ft Lb-in
Flywheel assembly fastening bolt 95 70 -
Tensioner bracket fastening bolt 23 17 -
Connecting rod cap fixing bolts 30 N•m + 90° 22 -
Cylinder head bolt I 30 N•m +90°+90° 22 -
Rear crankshaft end cap fixing

11 8 -
bolts
10 bolts on both sides: 18 10 bolts on both 21

Camshaft cap fixing bolts 5 bolts in the middle:11 sides: 13 -
5 bolts in the middle:8
Crankshaft positioning bolt 23 17 -
Tensioner assembly bolt 50 37 -
Idler wheel bolt 50 37 -
Timing chain tensioner fixing bolts 11 8 -
Water pump pulley fixing bolts 18 13 -
Crankshaft pulley fixing bolts 230 170 -
Exhaust timing sprocket fixing

90 67 -
bolts
Intake phaser assembly bolt 90 67 -
Timing cap component bolt (M10) 50 37 -
Timing cap component bolt(M6) 11 8 -
Main bearing cap fixing bolts 50 N•m + 90° 37 -

Structure and installation location

Part Location Drawing
Accessory gear trains
3
1
6
5
LFWX-6470-04001
1 Water pump pulley 4 Tensioner assembly
2 Idler wheel 5 Compressor assembly
3 Alternator assembly 6 Crankshaft pulley

21-5
Part exploded view

Accessory gear train
1 2
6
3
21
5
4
LFWX-6470-04002
1 Water pump pulley 4 Tensioner assembly
2 Idler wheel 5 Compressor assembly
3 Alternator assembly 6 Crankshaft pulley

Timing cap, chain and sprocket components
7
4 6
3
8
5 9
1 2
10
11
14
12
13
LFWX-6470-04003
1 Crankshaft pulley 8 Exhaust timing sprocket
Orbit determination components of

2 Crankshaft sleeve O-ring 9
timing chain
3 Timing cover component 10 Oil pump chain
Oil pump chain and moving rail

4 Timing cap gasket 11
components
5 Timing chain rail components 12 Oil pan assembly
6 Air intake phaser assembly 13 Timing chain tensioner
7 Timing chain 14 Crankshaft front oil seal

21-7
Valve components
1
8 3
7 6
21
LFWX-6470-04004
1 Roller rocker and hydraulic tappet 6 Exhaust valve
2 Valve collet 7 Intake valve
3 Spring of exhaust valve 8 Oil seal of exhaust valve
4 Valve guide 9 Valve spring seat
5 Cylinder head assembly

Camshaft and cylinder head components
1 2
8
7
3
6
LFWX-6470-04005
1 Phaser control valve 6 Exhaust camshaft
2 Camshaft cover 7 Air intake camshaft
3 Rear camshaft end cap 8 Exhaust timing sprocket
4 Cylinder head assembly 9 Air intake phaser assembly
5 Gasket, cylinder head

21-9
Flywheel components
1 2
21
4
5
LFWX-6470-04006
1 Crankshaft pulley 4 Rear crankshaft end cover
2 Crankshaft front oil seal 5 Rear crankshaft oil seal
3 Flywheel assembly
Piston, piston rings and connecting rod components
1
2
3
3 4
7 6
6
8
9
10
11
12 LFWX-6470-04007
1 Piston ring I 7 Piston pin
2 Piston ring II 8 Body, connecting rod
3 Film ring 9 Upper connecting rod tile
4 Backing ring 10 Lower connecting rod tile
5 Piston 11 Cap, connecting rod
6 Snap ring, piston pin 12 Bolt, connecting rod

21-11
Main bearing, crankshaft, cylinder block components
3 7
4
6
21
LFWX-6470-04008
1 Main bearing cap 5 Cylinder block assembly
2 Lower main bearing shell 6 Rear crankshaft end cover
3 Crankshaft timing sprocket 7 Upper thrust plate
4 Upper main bearing shell

Fault diagnosis and inspection

Cylinder compression pressure check
(a). Preheat and shutdown the engine.
Note:
After the engine is preheated, place the
transmission shift lever in “N neutral” position,
and enable the parking brake.
(b). Disconnect the ignition coil plug and all fuel
injector plugs.
(c). Remove the ignition coil.
(d). Remove the spark plug.
(e). Install the pressure gauge into the spark
plug mounting hole.
LFWX-6470-03020
(f). Depress the throttle pedal to the end.
(g). Operate the starter motor, until the pressure on the gauge is not increased, read the
value on the gauge.
Standard cylinder pressure: 8 ~ 14 bar
Tips:
Before starting, check whether the battery is in full charge status; otherwise change
or replace the battery.
(h). Test the pressure in other cylinders with the same method, and calculate the
maximum cylinder pressure difference.
Maximum cylinder pressure difference: 1 bar
Note:
All tests should be completed within a short time (about 15 s), in order to avoid
damage to the starter.
21-13
List of fault symptoms

Recommended
Symptom Possible Cause
Measures
● The oil sump is deformed
● The oil strainer is deformed or damaged
● There is an abnormal
There is an abnormal interior noise ● The oil pressure is too low
interior noise below the
below the engine ● The fitting clearance between the crankshaft
engine diagnosis
and bearing is too big
● The axial clearance of the crankshaft is too big
● Electronic control system

● Fuel system
● Ignition system
● Mechanical system
- Carbon accumulated in combustion chamber
- Camshaft ● That the engine is not
The engine is not fired
- Intake and exhaust valves fired is an integration fault.
- Piston
- Piston ring
- Cylinder
- The intake is clogged
- The exhaust is clogged
● Accessory belt
● Related fasteners
● Tensioner assembly
● Crankshaft pulley ● Attachment belt noise
Attachment belt noise diagnosis
● Water pump assembly diagnosis.
● Idler wheel
● Generator assembly
● Air conditioning compressor assembly
21
● Electric control system fault
● Engine timing
Engine firing
● The ignition is too late
Note:The fuel in the exhaust ● Diagnosis about engine
● The mixture is too thick
system is ignited, resulting in a blasting.
● Exhaust valve components
serious blasting noise.
● Exhaust system leakage
● Engine control module
●Diagnosis about abnormal

Exhaust abnormity (blue smoke) ● The oil is burned
exhaust (blue smoke)
● Diagnosis about that

● The coolant is fed into the combustion
Abnormal exhaust (white smoke) the coolant is fed into the
chamber
combustion chamber.
● Diagnosis about
Exhaust abnormity (black smoke) ● The mixture is too thick abnormal exhaust (black
smoke).
● Reference: Control
● Electric control system failure
system diagnosis.
Under cold engine status, the ● Fill the oil with the
knocks occur and last for 2~3 min viscosity in line with
● The engine oil viscosity is too low
and/or the knocks are increased expected seasonal
with the increase of engine torque temperature requirements.
● The clearance between the piston and cylinder ● Reference: Mechanical

wall is too big system diagnosis.
Recommended
Measures
● Connecting rod positioning conditions (end ● Reference: Control
clearance, bending, twisting) system diagnosis.
● Fill the oil with the

viscosity in line with
● The piston pin clearance is too big
expected seasonal
temperature requirements.
● Must use 93# or above

When the vehicle is heated at idle ● Fuel quality
fuel.
speed, the knocks occur.
● Engine timing ● Reference: Timing check.
● The clearance between the piston and cylinder

wall is too big ● Reference: Removal and
installation of piston, piston
● Connecting rod positioning conditions (end
rings and connecting rod
clearance, bending, twisting)
components.
● Reference: Oil pressure

Main bearing noise ● The oil pump pressure is too low
check.
Note: Remove the accessory
drive belt, to eliminate noise
caused by the accessory device;
use a stethoscope to determine the
position of the engine noise.
Note: the main bearing noise
can be heard when the engine is
operated under load, the sound is
big and heavy, the greater is the ● The axial clearance of the crankshaft is too big ● Reference: Removal and
load, the greater is the noise. ● The crankshaft journal is out of round installation of main bearing,
Note: the beat sound is regular, ● The clearance between the crankshaft and crankshaft and cylinder
and changes with the rotational bearing is too bi block.
speed.
Note: the noise also occurs
under the low oil pressure.
Note: There is a beat noise from
the bearing when the oil is too thin
or there is no oil on the bearing.
● The oil pump pressure is too low

● The big end clearance of the connecting rod is
beyond the scope
● Tightening torque for connecting rod bolts
● Noise diagnosis about
Connecting rod and connecting rod ● The connecting rod bending/twisting is beyond
connecting rod and
bearing noise symptoms the scope
connecting rod bearing.
●The piston pin clearance is too big
●The clearance between the piston and cylinder
wall is too big
● The piston ring groove clearance is too big

● The connecting rod and the piston are installed
improperly
● The connecting rod bending/twisting is beyond
● Noise diagnosis about
Piston and piston pin noise the scope
piston and piston pin.
● The clearance between the piston and cylinder
wall is too big
● The piston ring groove clearance is too big
21-15
Recommended
Measures
● The hydraulic tappet is stuck
● The roller rocker is damaged
● The cam angle is damaged
● The camshaft journal clearance is too big ● Noise diagnosis about
Air valve drive unit noise
● The valve spring is too soft valve drive shaft.
● The valve is stuck
● The clearance between the valve stem and the
valve duct is too big
● The valve seat is loosened
● The accessory drive system components is

stuck
● The cylinder is stuck due to the hydraulic
reason.
● The camshaft is stuck or broken
● Engine can not be
Engine can not be started - the ● The valve system component is stuck or
started - the crankshaft can
crankshaft can not be rotated freely broken
not be rotated freely
● There is the foreign body in the cylinder
● The crankshaft and connecting rod bearing is
stuck
● The connecting rod is bent or broken
● The crankshaft is broken.
● The engine is overheated

● Reference: Fault
- The coolant level is too low
symptom table (cooling
- The cooling fan does not action
The cooling fluid enters into the system).
- The thermostat has a fault
combustion chamber
Note: The white smoke beyond ● Replace the cylinder
the acceptable scope and/or the head gasket.
● The cylinder head gasket is damaged
gas with coolant smell is exhausted ● Replace the cylinder
● The cylinder head is warped
head and liner.
21
from the exhaust pipe. ● The cylinder head is cracked
Note: Remove the spark plug, ● Replace the cylinder
● The cylinder liner or the cylinder block is
and there is some cooling fluid on head and liner.
cracked
the spark plug. ● Replace the cylinder
● There are pores on the cylinder head or
block.
cylinder block
● Replace the cylinder
head or the cylinder block.
● Engine overheating
- The cylinder head has cold cracks and the
cooing fluid level is too low ● Reference List of fault
- The cooling fan does not action symptoms(cooling system)
- The thermostat has a fault
The cooling fluid enters into the
engine oil ● Replace cylinder head
Note: the oil contains bubbles ● The cylinder head gasket is damaged sealing gasket
and its color is changed. ● The cylinder head is warped ● Replace cylinder head
Note: the engine oil is ● The cylinder head is cracked and gasket
“Excessive”. ● The cylinder liner or the cylinder block is ● Replace cylinder head
cracked and gasket
● There are pores on the cylinder head or ● Replace cylinder block
cylinder block ● Replace cylinder head or
cylinder block
There is an abnormal noise below the engine

Note: The use of stethoscope will help you to determine the engine noise position.
Note: Remove the accessory belt, to eliminate the noise caused by these devices.
Test conditions Details/results/measures

1. Check the oil sump.
A. Check the oil sump.
Is it deformed?
→ Yes
Repair or replace it, and then go to Step 2.
→ No
To step 2.
2. Check the oil filter.
A. Check the oil filter for deformation or damage.
Is the oil filter deformed or damaged?
→ Yes
Repair or replace it.
→ No
To step 3.
3. The oil pressure is too low.
A. check the oil pressure.
If is the pressure too low?
→ No
To step 5.
→ Yes
To step 4.
4. Check the oil pump.
A. Remove the oil pump.
B. Check the oil pump.
Is the oil pump normal?
→ Yes
Replace the oil pump.
→ No
To step 5.
5. Check the shaft tile fitting clearance and the crankshaft axial clearance.
A. Decompose the main shaft tiles and the connecting
rod shaft tiles.
B. Check the fitting clearances of the main shaft tiles
and the connecting rod shaft tiles and the crankshaft
thrust piece wear.
Are the fitting clearances and the crankshaft axial clear-
ance normal?
→ No
Repair the fitting clearances of the main shaft tiles and
the connecting rod shaft tiles and the crankshaft axial
clearance to achieve the normal scope.
→ Yes
Test the system for normal operation.
21-17
Attachment belt noise diagnosis

Note: Must use the correct accessory belt.
Note: The poor flatness (the crank pulley is not aligned with related accessory pulley) may cause abnormal
wear, abnormal noise or falling off of accessory belt.
Note: the sudden increase of the load may cause a noise due to the belt slipping, for example, the air con-
ditioning compressor is started, the throttle is opened rapidly during the engine operation, etc.
Note: Too big load also causes the belt abnormal noise, for example: air conditioning system is filled ex-
cessively, the power steering hose is deformed, and the power steering fluid is excessive.
1. Check the attachment belt.
A. Check the attachment belt.
2. Check the related fasteners.
A. Check all fasteners related to the accessory belt for

loosening or deformation.
Is any fastener loosened or deformed?
→ Yes
Fasten or replace it.
→ No
To step 3.
3. Check the tensioner assembly.

A. Remove the accessory belt.
B. The tensioner assembly bearing cannot be stuck or
loosened.
C. Turn the tensioner assembly, there should be no ab-
normal noise.
D. The tensioner can not displaced, bent, distorted and 21
cracked.
E. There should be abnormal scratches, edges and cor-
ners and other abnormalities on the tensioner surface.
Whether to meet the requirements above?
→ No
→ Yes
To step 4.
4. Check the crankshaft pulley and pulleys of related accessories.
A. The pulley can not be displaced, bent, distorted,
cracked or loosened.
B. There should be abnormal scratches, edges and cor-
ners and other abnormalities on the pulley surface.
C. There should be no foreign body in pulley groove.
Can it meet the above requirements?
→ No
Clean the foreign bodies, fasten or replace the part.
→ Yes
To step 5.

5. Check the bearings of generator assembly, water pump assembly, and air conditioning compressor as-
sembly.
A. The bearings can not be stuck or loosened.
B. Turn the bearings, there should be no abnormal
noise.
Whether to meet the requirements above?
→ No
→ Yes
Verify that the system is operated normally.
Diagnosis about engine non-firing

1. Check the engine DTC.
A. Use the fault diagnosis instrument to detect the en-

gine DTC.
Is there a DTC?
→ Yes
Reference: DTC diagnosis process indexes.
→ No
To step 2.
2. Check the vacuum degree of air intake system.
A. Check the vacuum degree of the air intake system, to

verify the air intake system for leakage.
→ Yes
Repair it.
→ No
To step 3.
3. Check the engine timing.
3. Check whether the engine timing is correct.

→ No
Repair it.
→ Yes
To step 4.
4. Check the fuel pressure.
A. Check the fuel pressure.

Is the fuel pressure too low?
→ Yes
Implement the measures for symptoms.
Reference: List of fault symptoms.
→ No
To step 5.
21-19

5. Check the fuel injector.
A. Check the fuel injector.
If is it clogged?
→ Yes
Clean or replace it.
→ No
To step 6.
6. Test the spark plug.
A. Test the spark plug.
If does it meet the requirement?
→ No
→ Yes
To step 7.
7. Check the cylinder pressure.
A. Check the cylinder pressure. Is it within the standard
scope?
→ Yes
To step 8.
→ No
Repair it.
8. Check the exhaust system.
A. Test the exhaust back pressure, to check whether the
exhaust system is clogged.
If is it clogged?
→ Yes 21
Implement the exhaust system clogging diagnosis pro-
cedure.
→ No
To step 9.
9. Replace ECM.
A. Replace ECM.
Engine firing


gine DTC.
Is there a DTC?
→ Yes
→ No
To step 2.
2. Check the engine timing.
A. Check the engine timing.

If is it normal?
→ No
Repair it.
→ Yes
To step 3.

Is the fuel pressure too low?
→ Yes
Implement the measures for symptoms.
Reference: List of fault symptoms.
→ No
To step 4.

If is it clogged?
→ Yes
→ No
To step 5.

If does it meet the requirement?
→ No
→ Yes
To step 6.
21-21

6. Check the cylinder pressure.
A. Check the cylinder pressure.
Is the pressure normal?
Reference: the cylinder compression pressure check.
→ Yes
To step 7.
→ No
Repair it.
7. Check the exhaust system
A. Test the exhaust back pressure, to check whether the
exhaust system is clogged.
If is it clogged?
→ Yes
Implement the exhaust system clogging diagnosis proce-
dure.
→ No
Repair it.
8. Replace ECM.
A. Replace ECM.
Exhaust abnormity (blue smoke)

Note: Use the oil in line with the requirements of the specification.
Note: Usually, the spark plug is attached with carbon deposition.

21
1. Check the spark plug.
A. Check the spark plug.

If is there some carbons?
→ Yes
→ No
To step 2.
2. Check the engine oil level.
A. Check the engine oil level.

Is the oil level too high?
→ Yes
Maintain the oil level.
→ No
To step 3.

3. Check the oil-gas separator.
A. Check the oil-gas separator.

If is it normal?
→ No
Replace the oil-gas separator.
→ No
To step 4.
4. Check the cylinder compression pressure.
A. Check the cylinder compression pressure.

Can it meet the requirements?
→ Yes
To step 5.
→ No
To step 6.
5. Check the piston rings or valve for fault.

After adding an appropriate volume of the oil in the cylin-
der.
→ If the pressure is increased significantly, and
check the piston rings.
→ If the pressure is increased slightly, check the air
valve.
6. Check the carbon deposition in the combustion chamber.
A. Check the combustion chamber.
If is there some carbons?
→ Yes
Clean it.
→ No
To step 7.
7. Check the valve seal.
A. Check the valve seal.

If is there a leakage?
→ Yes
Replace it.
→ No
21-23
Exhaust abnormity (black smoke)

gine DTC.
Is there a DTC?
→ Yes
→ No
To step 2.
Is it too high?
→ Yes
The fuel pipe is clogged; repair the pipe.
→ No
To step 3.
If is there a leakage?
→ Yes
Replace it.
→ No
To step 4.
21
Does it meet the requirement?
→ No
→ Yes
To step 5.
5. Replace ECM.
A. Replace ECM.
Connecting rod and connecting rod bearing noise symptoms

Note: After the attachment belt is removed, the engine running time should be strictly limited; oth-
erwise it may result in any engine damage from high temperature.
Note: Remove the attachment belt to eliminate the noise caused by attachment device.
Note: This noise may be isolated after one fuel injector wiring harness plug is removed. If the
noise is reduced or disappeared, the noise must be related to the cylinder.
Note: Too big connecting rod clearance can cause a knock noise under various engine speed; it
the oil pressure is too low, the noise also occurs.
1. Confirm the fault is not the noise caused by the accessory device.
A. Remove the attachment belt.
Does the noise exist?
→ No
The noise is caused by the accessory; check the acces-
sory and accessory belt.
→ Yes
To step 2.
2. Check the oil pump pressure.
A. Check the oil pump pressure.

Is the oil pump pressure too low?
→ Yes
Repair it.
→ No
To step 3.
3. Broken cylinder inspection.
A. Use the cylinder disconnection test with removal of

the fuel injector wiring harness plug, to confirm the en-
gine cylinder associated with the noise.
→ Yes
Repair it.
→ No
To step 4.
4. Check the big end clearance of the connecting rod.
A. Check the big end clearance of the connecting rod.

→ No
Replace the connecting rod.
→ Yes
To step 5.
5. Check the connecting rod bolt tightening torque.

A. Check the connecting rod bolt tightening torque.
→ No
Record the tightening torque and replace the bolt.
→ Yes
To step 6.
21-25

6. Check the connecting rod distortion /bending degree.
A. Check whether the connecting rod distortion/bending is
within the specified scope.
→ No
→ Yes
To step 7.
7. Check the crankshaft roundness and taper.
A. Check the crankshaft roundness and taper.
→ No
Repair or replace the crankshaft.
→ Yes
To step 8.
8. Check the clearance between the connecting rod and the crankshaft.
A. Check the clearance between the connecting rod and the
crankshaft.
→ No
Repair it to meet the specification requirements.
→ Yes
Piston and piston pin noise

Note: Remove the accessory belt and strictly limit the engine operation time; otherwise the en-
gine may be damaged due to the high temperature.
Note: The use of stethoscope will help you to determine the engine noise position. 21
Note: The knock sound due to too big clearance between the piston and the cylinder wall often
can be heard when the engine is operated at idle speed. If the fuel r injector wiring harness plug on
the cylinder is removed, the knock sound may be changed obviously.

1. Confirm that the noise is not caused by the attachment device.
Reference: Attachment belt removal and installation.
If is there a noise?
→ No
If the noise is caused by any attachment, check the at-
tachment belt and other accessories.
→ Yes
To step 2.

2. Check the oil pressure.
A. Check the oil pressure.

→ Yes
Repair it.
Reference: Oil pump removal and installation.
→ No
To step 3.
3. Broken cylinder inspection.
A. Use the cylinder disconnection test with removal of

the fuel injector wiring harness plug, to confirm the en-
gine cylinder associated with the noise.
→ Yes
Repair it.
→ No
To step 4.
4. Check the installation of the connecting rod and the piston.
A. Check the installation of the connecting rod and the

piston.
→ No
Reinstall it.
→ Yes
To step 5.
5. Check the connecting rod tortion/bending degree.

A. Check the connecting rod tortion/bending degree.
→ No
→ Yes
To step 6.
6. Check the piston pin clearance.
A. Check the piston pin clearance.
→ No
Repair it.
→ Yes
To step 7.
21-27

7. Check the piston ring groove clearance.
A. Check the piston ring groove clearance.
→ No
Repair it to meet the requirement.
→ Yes
To step 8.
8. Check the clearance between the piston and the cylinder wall.
A. Check the clearance between the piston and the cyl-
inder wall.
→ No
Repair it to meet the requirement.
→ Yes
Air valve drive unit noise

Note: After the attachment belt is removed, the engine running time should be strictly limited; oth-
erwise it may result in any engine damage from high temperature.
1. Confirm that the noise is not caused by the attachment device.
Reference: Attachment belt removal and installation. 21
If is there a noise?
→ No
If the noise is caused by any attachment, check the at-
tachment belt and other accessories.
→ Yes
To step 2.
2. Check the oil pressure.
A. check the oil pressure.
→ Yes
Repair it.
Reference: Oil pump removal and installation.
→ No
To step 3.

3. Check the hydraulic rocker component.
A. Check the hydraulic tappet and the rocker compo-
nents.
Can they meet the requirements?
→ No
Replace the hydraulic tappet.
Reference: Camshaft and hydraulic rocker compo-
nent.
→ Yes
To step 4.
4. Check the camshaft cam height.
A. Check the camshaft cam height.
→ No
Replace the camshaft
→ Yes
To step 5.
5. Check the camshaft journal clearance.
A. Check the camshaft journal clearance.
→ No
→ Yes
To step 6.
6. Check the camshaft axial clearance.
A. Check the camshaft axial clearance.
→ No
→ Yes
To step 7.
7. Check the valve spring.
A. Check whether the valve spring can meet the specifi-
cation requirements.
→ No
Replacement
→ Yes
To step 8.
21-29

8. Check whether the air valve is stuck.
A. Check whether the air valve is stuck.
Is it stuck?
→ Yes
Repair or replace relevant parts.
→ No
To step 9.
9. Check the clearance between the valve stem and the valve duct.
A. Check the clearance between the valve stem and the
valve duct.
→ No
→ Yes
To step 10.
10. Check whether the valve seat is loosened.
A. Check whether the valve seat is loosened.
→ Yes
→ No
Engine can not be started - the crankshaft can not be rotated

freely 21
1. Check the accessory drive system components.
Remove the accessory belt, and try to turn the crank-
shaft with a wrench.
Reference: Attachment belt removal and installation.
Is the crankshaft rotated freely?
→ Yes
Repair or replace the accessory drive system compo-
nents.
→ No
To step 2.
2. Check whether the cylinder is stuck due to the hydraulic pressure.
A. Remove all spark plugs and check whether there is
water/oil/antifreeze attached on them.
→ Yes
Check the cylinder block, cylinder head, cylinder gasket
for cracks; if necessary, check or repair it.
→ No
To step 3.

3. Check the cylinder head assembly.
A. Remove the timing mechanism.
B. Check the cylinder head.
- The camshaft is stuck or broken
- The valve rocker is stuck or broken.
- The valve or valve spring is stuck or broken.
If are there the above circs?
→ Yes
→ No
To step 4.
4. Check the cylinder block assembly.

A. Check the cylinder block assembly.
- The piston is broken.
- There is the foreign body in the cylinder
- The crankshaft is broken.
- The connecting rod is bent or broken
If are there the above circs?
→ Yes
→ No
21-31
Removal and Installation

Attachment belt
Disassembly
1. Remove the accessory belt.
(a). Rotate counterclockwise the tensioner

assembly locking pin (1) to lock the
tensioner, and then remove the accessory
belt.
1
LFWX-6470-04009
Inspection
1. Check the attachment belt.
Damaged or aged drive belt

(a). The check should be performed when the
engine is under cold status or after 30 min
from the engine shutdown.
(b). Visually check the accessory belt for
Drive belt installation
excessive wear, cord wear, cracks and other 21
damages; if any defect is found, replace the
accessory belt.
Correct fit
LFWX-6470-04010
Installation
1. Install the accessory belt.
(a). Install the accessory belt onto the pulley,

with the belt installation direction as shown
on the left figure.
Warning:
● When installing the accessory belt, please
ensure that it is combined correctly with the
pulley groove.
● Do not allow the engine oil or the engine
coolant to attach on the accessory belt.
LFWX-6470-04011
● Do not excessively twist or bend the
accessory belt.
(b). Use a wrench to counterclockwise rotate the

belt tensioner assembly, and then pull out
the tensioner locking pin (1), to loosen the
1
belt tensioner assembly.
LFWX-6470-04009
Tensioner assembly
Disassembly
1. Remove the tensioner assembly.
(a). Remove the accessory belt.

Reference: Attachment belt removal and
installation.
(b). Remove the tensioner assembly fixing
bolts and remove the tensioner assembly.
LFWX-6470-04012
Inspection
1. Check the tensioner assembly.
(a). Turn the tensioner assembly, to check if for

any noise or damage; If any, replace it in a timely
manner.
LFWX-6470-04013
21-33
Installation
1. Install the tensioner assembly.
(a). Install the tensioner assembly on the

tensioner bracket, install and tighten
tensioner assembly fixing bolts.
Torque: 50 N•m
(b). Install the accessory belt.
LFWX-6470-04012
Tensioner bracket
Disassembly
1. Remove the tensioner bracket.

installation.
(b). Remove the tensioner assembly.
Reference: Tensioner assembly removal
and installation.
(c). Remove the compressor assembly. 21
Reference: Compressor assembly
removal and installation.
(d). Remove the fixing bolts and remove the
tensioner bracket.
LFWX-6470-04014
Installation
1. Install the tensioner bracket.
(a). Install the tensioner bracket and tighten the

fixing bolts.
Torque: 23 N•m
(b). Install the compressor assembly.
(c). Install the tensioner bracket assembly.
(d). Install the accessory belt.
LFWX-6470-04014
Crankshaft front oil seal

Disassembly
1. Remove the front crankshaft oil seal.

installation.
(b). Use the crankshaft tooling bolt to fix the
crankshaft.
LFWX-6470-04015
(c). Remove the crankshaft pulley fixing bolts,

and remove the crankshaft pulley.
LFWX-6470-04016
(d). Take down crankshaft sleeve.

21-35
(e). Use the seal extractor to remove the

crankshaft oil seal.
Note:
The removed oil seal can not be used again;
when installation, please replace the new oil
seal.
LFWX-6470-04018
Installation
1. Install the front crankshaft oil seal.
(a). Install the bearing sleeve onto the crankshaft

journal, and push the front crankshaft oil seal
on the bearing sleeve.
Tips:
Before installation, coat a layer of clean oil on the
oil seal lip.
Note:
Vertically install the oil seal; do not install it
21
aslant.
(b). Use the oil seal tool to press the crankshaft

oil seal to the check position into the timing
cap housing and use a hammer to tap it, to
make it smooth and even.
LFWX-6470-04020
(c). Install crankshaft sleeve on crankshaft.
LFWX-6470-04021
(d). Use the crankshaft tooling bolt to fix the

crankshaft.
Torque: 23 N•m
LFWX-6470-04015
(e). Install the crankshaft pulley and tighten the

fixing bolts.
Pre-tightening torque: 150 N.m
Tightening torque: 230 N.m
(f). Install the accessory belt.
(g). Remove the crankshaft tooling bolt and
install the cylinder block plug bolt.
Torque: 23 N•m
LFWX-6470-04016
21-37
Crankshaft rear oil seal

Disassembly
1. Remove the rear crankshaft oil seal.
(a). Remove the flywheel.

1 2
Reference: Removal and installation of
8 3 the flywheel.
(b). Remove the rear crankshaft end cap fixing
bolts and oil pan bolt in the order as shown,
7 4 and use an appropriate tool to remove the
rear crankshaft end cap.
5
6
LFWX-6470-04022
(c). Remove the rear crankshaft end cap seal.
21
LFWX-6470-04023
(d). Use oil seal tool - 351149 to remove the rear

crankshaft oil seal from the rear end cap.
Note:
The removed oil seal can not be used again;
must replace the new oil seal when installation.
LFWX-6470-04024
Installation
1. Install the rear crankshaft oil seal.
(a). Place the rear crankshaft end cap on the

pressure machine positioning plate and
position it, and install the rear crankshaft oil
seal on the pressure machine head. Use
the oil seal tool - 351149 to install the rear
crankshaft oil seal. Before the installation,
check the oil seal outer surface and the lip
for scratches, folding, pressing and other
damages.
LFWX-6470-04024
(b). Install the rear crankshaft end cap seal on

the rear crankshaft end cap positioning pin.
(c). Install the rear crankshaft end cap onto the
cylinder block, and align the positioning pins
with the pin holes.
LFWX-6470-04023
(d). As shown, install and tighten the rear

1 2
crankshaft end cap fixing bolts and oil pan
8 3 bolt. During the installation, clean the glue
residue on the exposed part of the oil pan
assembly, coat the glue against, and then
7 4 install the rear crankshaft end cap.
Torque: 11 N•m
(e). Install the flywheel.
5
6
LFWX-6470-04022
21-39
Timing chain and sprocket components

Disassembly
1. Timing chain, sprocket components

installation.
(b). Remove oil inlet pipe bolt and water-outlet
hard pipe bolt of supercharger.
turbocharger assembly.
(c). Remove the generator assembly.
Reference: Generator assembly removal
and installation.
(d). Install the crankshaft tooling bolts to fix the
crankshaft pulley.
(e). Remove the crankshaft pulley fixing bolts,

and then remove the crankshaft pulley.
21
LFWX-6470-04016
(f). Remove the idler wheel.
LFWX-6470-04026
(g). Use the water pump removal wrench -

351147 to fix the water pump pulley, and
use an appropriate tool to remove the water
pump pulley fixing bolts. Remove the water
pump pulley.
(h). Remove the electronic pump inlet pipe fixing
bolts.
LFWX-6470-04027
(i). Remove oil-gas separation tube bolt, and

take out the oil-gas separation tube.
LFWX-6470-04028
(j). As shown in the left figure, remove the four

oil sump fixing bolts.
LFWX-6470-04029
(k). Remove the timing cap fixing bolts and

remove the timing cap and the timing cap
gasket.
Tips:
Use a rubber hammer tap gently the timing cap
components to remove it.
LFWX-6470-04030
21-41
(l). Remove the upper inlet water pipe

component fixing bolts.
LFWX-6470-04031
(m). R e m o v e t h e l o w e r w a t e r i n l e t p i p e
LFWX-6470-04032
(n). Remove the rear camshaft end cap fixing

bolts and remove the rear camshaft end cap.
21
LFWX-6470-04033
(o). Remove the timing chain tensioner fixing

bolts (1) and remove the timing chain
tensioner.
1
LFWX-6470-04034
(p). Remove the timing chain moving rail

component (1), the timing chain (2), and the
2 timing chain fixed rail component (3).
LFWX-6470-04035
(q). Install the camshaft anti-rotating tool (1),

remove the intake phaser assembly fixing
1
bolts (2) and the exhaust timing sprocket
fixing bolts (3), and remove the intake phaser
assembly and the exhaust timing sprocket.
Tips
3
2
There is a left-hand thread in the intake phaser
assembly fixing bolt.
LFWX-6470-04036
21-43
Inspection
1. Check the exhaust timing sprocket.
(a). Install the chain onto the exhaust timing

sprocket.
(b). Use a vernier caliper to measure the exhaust
timing sprocket diameter with the timing
chain. If it is less than the specified value,
replace the exhaust timing sprocket.
Minimum diameter: 102.1 mm
Note:
In measurement, the two measuring points of
the vernier caliper must be contacted with the
chain roller.
LFWX-6470-04037
2. Check the intake phaser assembly.
(a). Fix the camshaft on the vise.

Note:
Do not bruise the camshaft on the vise.
(b). If the intake phaser assembly rotor has a
movement related to the housing, replace
the air intake phaser assembly.
21
LFWX-6470-04038
(c). Check and confirm that there is no clearance

between the intake phaser assembly and
the camshaft flange surface, and tighten the
intake phaser assembly flange fixing bolts.
Torque: 90 N•m
Note:
Do not bruise the camshaft.
LFWX-6470-04039
(d). As shown, Use a rubber seal to plug one

of oil holes in the oil duct at advance side,
and ensure that the opposite oil hole on the
same oil duct is opened.
Note:
Oil duct at advance side
Delay side fuel channel
When blowing the opened oil hole, use a cloth

to shield to oil duct, to prevent the oil splash.
Plugged with a
rubber seal Opened
Opened Plugged with a
rubber seal
LFWX-6470-04040
(e). As shown, use a rubber seal to plug one

of the oil holes in the oil duct at the delay
side, and ensure that the opposite oil hole
Oil duct at advance side on the same oil duct is opened, and use the
Delay side fuel channel compressed air with pressure of about 200
Kpa (2.0 kgf/cm2, 28 psi) to blow the two
opened holes.
LFWX-6470-04041
(f). When the air pressure into the oil holes at

the relay side is decreased, check whether
the intake phaser assembly is moved to
Oil duct at advance side the advance side; when the intake phaser
Delay side fuel channel
assembly arrives at the most advance
location, decrease the air pressure into the
oil holes at the relay side and the oil holes at
the advance side in specified order.
Note:
Don decrease the air pressure in the oil hole at
the advance side; the intake VVT may suddenly
LFWX-6470-04042 be rotated to the relay side, resulting in the
damage to the locking pin.
(g). Check whether the rotation is free.
Note:
Rotate the intake phaser assembly to the left and right about 21° three times, but
don't rotate it to the most delay position, to ensure the intake phaser assembly can
be rotated freely.
(h). Check whether it is locked at the most delay position.
Note:
Confirm that the intake phaser assembly is locked in the most delay position.
21-45
(i). Remove intake phaser assembly fixing bolt.

Note:
Flange bolt Don't remove other intake phase assembly
bolts.
Don't touch the bolts
LFWX-6470-04043
3. Check the timing chain tensioner.
(a). Check the timing chain tensioner for

damage, if there is any abnormality, replace
it.
LFWX-6470-04044
21
4. Check the crankshaft timing sprocket.
(a). As shown, install the chain onto the

crankshaft timing sprocket.
(b). Use a vernier caliper to measure the
crankshaft timing sprocket diameter with the
timing chain. If it is less than the specified
value, replace the crankshaft sprocket.
Minimum diameter: 56. 18 mm
Note:
chain roller.
LFWX-6470-04045
5. Check the timing chain moving rail components.
(a). Use a vernier caliper to measure the

thickness of the timing chain moving rail. If
the rail thickness is less than the minimum
thickness, replace the timing chain moving
rail component.
Minimum thickness: 3 mm
LFWX-6470-04046
Installation
1. Install the timing chain and sprocket components.
(a). Install the intake phaser assembly, screw

manually the bolt into the intake phaser
assembly, and ensure that the intake phase
is rotated freely.
LFWX-6470-04046
(b). Check the crankshaft, to ensure that the 1st

engine cylinder at TDC position.
(c). Remove the cylinder block plug bolt, and
install and tighten the crankshaft positioning
bolt.
Torque: 23 N•m
(d). Clockwise rotate the crankshaft, until the
crankshaft can not be rotated.
LFWX-6470-04015
21-47
(e). Install the camshaft timing tool into the

camshaft hole to fix the camshaft.
Tips:
The surface with a gap is upward.
LFWX-6470-04048
(f). Install 2 bolts in holes shown in the left

Figure, so as to fix camshaft timing tooling.
21
LFWX-6470-04049
(g). Align the timing chain fixed rail component

2 (3) with the moving rail positioning bolt and
install it in place.
(h). Install the timing chain (2) on the crankshaft
timing sprocket, and install it at the moving
1 rail positioning bolt inside, on inlet phaser
3 assembly and in the position groove in turn
from down up, and then align the exhaust
timing sprocket with the installation position
at inside of the timing chain and install it in
place, tighten the exhaust timing sprocket
bolt, and ensure the exhaust timing sprocket
LFWX-6470-04050
can be rotated freely.
(i). Align the timing chain moving rail (1) with the
moving rail positioning bolt and install it, to
allow the timing chain moving rail to fall of
and install it in place.
(j). Install the timing chain tensioner and install

the fixing bolt (1), pull out the timing chain
tensioner locking tool (2), and coat the paint
1 marking on the timing chain tensioner bolt
joint surface.
1
2
Torque: 11 N•m
LFWX-6470-04051
(k). Install the camshaft anti-rotating tool (1).

1 (l). Tighten the exhaust sprocket fixing bolts (3).
Pre-tightening torque: 50 N•m
Tightening torque: 90 N•m
(m). Tighten the intake phaser assembly fixing
bolts (2).
2 3 Tightening torque: 90 N•m
(n). Remove the camshaft anti-rotating tool (1).
LFWX-6470-04052
(o). Remove the fixing bolts on the camshaft

cap timing fixed bolts for the tooling tool and
remove the camshaft cap timing tool.
LFWX-6470-04053
(p). Install the rear camshaft end cap and tighten

the fixing bolts.
Note:
Check the rear camshaft end cap sealing ring.
(t). Install the oil air separator pipe and pipe bolt.
LFWX-6470-04033
21-49
(q). Install and tighten the lower water pipe

Torque: 18 N•m
LFWX-6470-04032
(r). Install and tighten the upper water pipe

Torque: 11 N•m
LFWX-6470-04031
21
(s). Align the timing cap seal with the locating
pin and install it in place, align the timing cap
with the positioning pin and install it on the
engine, and install and tighten the bolts.
M10 bolt tightening torque: 50 N•m
M6 bolt tightening torque: 11 N•m
Note:
● Coat the sealant on the joint surfaces of
the cylinder head and the camshaft cap, the
cylinder head and the cylinder block, the
timing cap components and the oil sump
assembly; before coating the new sealant,
LFWX-6470-04030 must clean the old sealant.
● First tighten M10 bolts and then tighten M6
bolts.
(t). Install the oil air separator pipe and pipe bolt.
Torque: 11 N•m
LFWX-6470-04028
(u). Install and tighten 4 fixing bolts on the oil

sump.
Torque: 11 N•m
LFWX-6470-04029
(v). Install and tighten the fixing bolts on the

water pump pulley. Use the water pump
installation wrench - 351147 to fix the water
pump pulley, and use and appropriate tool to
install the water pump pulley fixing bolts.
Torque: 18 N•m
LFWX-6470-04027
(w). Install and tighten the fixing bolts on the idler

wheel.
Torque: 50 N•m
LFWX-6470-04026
21-51
(x). Install the crankshaft pulley and tighten the

fixing bolts.
(y). Mount the bolts for supercharger oil inlet
pipe and supercharger water outlet rigid
pipe.
(z). Remove the crankshaft locating bolts, mount
and tighten the cylinder blocking bolts.
Torque: 23 N•m
(aa). Install the generator assembly.
LFWX-6470-04016 (ab). Install the accessory belt.
Camshaft cover
Disassembly
1. Remove the camshaft cap.
(a). Remove the engine ignition coil assembly.

2
the engine ignition coil assembly.
(b). Remove the turbocharger assembly.
(c). Remove the high pressure fuel pump.
21
1
Reference: High pressure fuel pump
removal and installation.
(d). Remove the timing chain and sprocket
components. Reference: Removal and
LFWX-6470-04054 installation of the timing chain and sprocket
components.
(e). Disconnect the vacuum pipe (2) and the
cooling fluid hose (1).
1 (f) Remove the fixing bolt (1) and remove the

1 intake manifold gland.
(g). Loosen the clamp (2), and pull out the intake
pipe from the throttle.
LFWX-6470-04055
(h). Remove oil-gas separation valve assembly

bolt (1) as well as oil-gas separation valve
breather pipe and carbon tank solenoid valve
1 composite pipe joint, and take down oil-gas
separation tube (2).
2
1
LFWX-6470-04056
(I). Remove the camshaft cap fixing bolts in

1 7 13 9
the order as shown, and then remove the
4
camshaft cap.
Note:
5 ● Must remove evenly the camshaft cap fixing
6
11 14 12
bolts.
● The camshaft cap can not be removed easily
2 10 15 8
3 due to the sealant; must use the appropriate
tool to remove it.
LFWX-6470-04057
Installation
1. Install the camshaft cap.
(a). Before installation, must clean the oil sealant

on the camshaft cap and coat a layer of new
sealant on it.
LFWX-6470-04058
(b). Based on the positioning pin position, place

the camshaft cap in the installation position,
7 1 5 3 9 and pre-tighten the fixing bolts in the order
as shown.
14
15 (c). Tighten the camshaft cap fixing bolts in the
12 11 13 order as shown.
10 2
Tightening torque:
6
10 bolts on both sides: 18 N• m
4
8
5 bolts in the middle: 11 N•m
LFWX-6470-04059
21-53
(d) Connect the oil-gas separation pipe (2);

install and tighten the oil-gas separation
valve assembly fixing bolts (1).
1 (e). Install the turbocharger assembly.
2
1
LFWX-6470-04056
1 (f). Install the intake manifold onto the throttle,

1 and install the clamp (2).
(g). Install the intake manifold gland, and install
and tighten the fixing bolts (1).
LFWX-6470-04055
2
(h). Install the vacuum pipe (2), the cooling fluid 21
hose (1) into the intake manifold.
LFWX-6470-04054
(I). Install the air intake hose and install the

spring clamp.
(j). Install the intake pipe.
(k). Install the timing chain and sprocket
components.
(l). Install the high pressure fuel pump.
(m). Install the ignition coil assembly.
LFWX-6470-04060
Camshaft and hydraulic rock arm components.

Disassembly
1. Remove the camshaft and hydraulic rocker components.
(a). Remove the timing chain and sprocket components. Reference: Removal and
installation of the timing chain and sprocket components.
(b). Remove the high pressure fuel pump. Reference: High pressure fuel pump removal
and installation
(c). Remove the camshaft cap. Reference: Camshaft cover removal and installation.
1 (d). Remove the intake and exhaust camshaft

assemblies from the camshaft cap.
Note:
Must distinguish the intake and exhaust
camshafts; (1) exhaust camshaft assembly, (2)
2
intake camshaft assembly.
LFWX-6470-04061
(e). Remove the roller rocker and hydraulic

tappet.
Note:
Remove the roller rocker and the hydraulic
tappet, mark them, and place them on the
corresponding position.
LFWX-6470-04062
Inspection
1. Check the camshaft rocker runout.
(a). Put the camshaft on a V-shaped block, use a

dial indicator to measure the circular rocker
runout at the middle shaft journal. If the
rocker runout is greater than the maximum
value, must replace the camshaft.
Maximum value: 0.02 mm
LFWX-6470-04063
21-55
2. Check the maximum strokes of the inlet and exhaust camshafts.
(a). As shown, use a spiral micrometer to

measure the maximum strokes of the intake
and exhaust camshafts, if the values are
beyond the scope, replace them.
Intake: 4.7230 mm
Exhaust: 4.5953 mm
LFWX-6470-04064
3. Check the roller rocker
(a). Check the roller rocker surface for scratches

cracks or abnormal wear; if necessary,
replace the roller rocker.
(b). Rotate manually the roller rocker to check
if for free rotation; if the rotation is stuck,
replace the roller rocker.
Note:
Must replace the circlip to connect the roller
rocker and hydraulic tappet; it can not be
reused. 21
LFWX-6470-04065
4. Check the hydraulic tappet.
(a). Use the appropriate pin (wire) to press the

ball valve, to ensure the pin top and the ball
center are on the same axis.
Pin
Hydraulic tappet Small ball
LFWX-6470-04066
(b). Immerse the hydraulic tappet into clean oil,

repeatedly press the plunger 5 ~ 6 times and
remove it from the oil.
LFWX-6470-04067
(c). Manually press the plunger to check the

plunger resistance. If after three times of
tries, the plunger can be pressed down,
please replace the new hydraulic tappet.5.
LFWX-6470-04068
5. Check the camshaft axial clearance.
(a). If it is more than the wear limit, replace the

camshaft.
Wear limit: 0.05 ~ 0.3 mm
LFWX-6470-04069
21-57
Installation
1. Install the camshaft and the hydraulic rocker components.
(a). Use an oil pot to coat evenly layer of oil in

the hydraulic tappet hole.
(b). Install the roller rocker onto the hydraulic
tappet, and then install it into the hydraulic
tappet hole in the cylinder head.
Note:
● Install it with the corresponding mark, and
LFWX-6470-04062
confirm that the roller rocker and the hydraulic
tappet are installed reliably.
● Do not install the rocker aslant.
● Coat a little oil on the roller of the roller
rocker and in the shaft hole.
(c). Install the inlet and exhaust camshaft

assemblies onto the camshaft cap.
Note:
● Coat evenly a layer of now oil on the contact
surface of the camshaft assembly.
● Must distinguish the intake and exhaust
camshaft assemblies.
LFWX-6470-04070
21
(d). Put camshaft cover stably, then coat plane
1
sealant 1596 as track and line shown in item
(1), and coat anaerobic plane sealant 1515
on the periphery of high pressure oil hole of
2 2 camshaft cover and on the periphery of the
middle 5 bolt holes as track shown in item (2).
2
Note:
2 2
The sealant width is 1. 5 - 3. 0 m m . A f t e r

the application, check the sealant bar for
holiday, discontinuity or unevenness. Finish
LFWX-6470-04071 the components assembly within 3 minutes
after the sealant application.
(e). Install the camshaft cover.
(f). Install the high pressure fuel pump.
(g). Install the timing chain and sprocket
components.
Cylinder head and air valve components

Disassembly
1. Remove the cylinder head and the air valve components.
(a). Remove intake manifold assembly. Reference: Removal and installation of the intake
manifold assembly.
(b). Remove exhaust manifold assembly. Reference: Removal and installation of the
exhaust manifold assembly.
(c). Remove the thermostat assembly. Reference: Removal and installation of the
thermostat assembly.
(d). Remove the timing chain and sprocket components. Reference: Removal and
installation of the timing chain and sprocket components.
(e). Remove the camshaft cap. Reference: Camshaft cover removal and installation.
(f). Remove the camshaft and hydraulic rocker components. Reference: Removal and
installation of the camshaft and the hydraulic rocker components.
1 5 9 7 4
(g). Remove the cylinder head assembly
fixing bolts and remove the cylinder head
assembly and the cylinder pad.
Note:
When removing the cylinder head assembly
fixing bolts, loosen the fixing bolts in the order
as shown.
3 8 10 6 2
LFWX-6470-04072
(h). Use a special tool to remove the air valve

lock piece; remove in turn the air valve,
valve spring holder, valve spring, and valve
oil seal.
Note:
The removed air valve seal can not be used
again; must use the new oil seal during
installation.
LFWX-6470-04073
(i). Heat the cylinder head to 80~100℃ .
LFWX-6470-04074
21-59
(j) place the cylinder head on a wooden board,

and use the special tool to take out the air
valve duct from the cylinder head.
Note:
● The removed air valve duct can not be used
again.
● Because there is an interference fit between
the valve duct and the cylinder head, when
installing a new duct, must increase the size.
LFWX-6470-04075
Inspection
1. Check the cylinder head.
(a). Clean the sealant and the oil on the cylinder head.
(b). Clean the carbon deposition in the combustion chamber of the cylinder head.
Note:
Do not use any sharp tool to scrape the carbon deposition; during removing the
carbon deposition, do not scratch or damage the metal surface.
(c). Use a high pressure water jet to clean the cylinder head, especially, the water duct
and the oil duct.
(d). Use compressed air to dry the cylinder head.
Note:
When using compressed air, it is suggested to wear goggles and protective mask, to
avoid any injury from flying debris or dirt.
21
(e). Check the cylinder head bolts for any
damage; if necessary, replace them.
(f). Use a ruler and feeler gauge to measure
the cylinder head joint surface flatness in 6
directions as shown in the left figure.
Maximum flatness: 0.04 mm
LFWX-6470-04076
(g). Use a ruler and thickness gauge to check

the flatness at intake and exhaust sides;
if the flatness is more than the maximum
value, replace the cylinder head.
Maximum flatness: 0.05 mm
LFWX-6470-04077
2. Check the air valve components.
(a). Check the air valve locking piece for cracks

or damage, if necessary, replace it.
(b). Use a vernier caliper to measure the valve
spring length under the free status;, if it is
beyond the scope, replace it.
Free length: 47.19 mm
LFWX-6470-04078
(c). Use a spring dynamometer to measure the

spring force under the standard compression
length of elasticity; if it can not meet the
requirements, replace it.
Installation spring force: 236 N•m
Maximum working force: 424 N•m
LFWX-6470-04079
(d). Use a ruler and tablet to check the spring

verticality based on the clearance between
the air valve spring end and the ruler; if it is
beyond the specified value, replace it.
Maximum deviation value: 1.3 mm
The maximum deviation angle: 1.
58°
(e). Remove all carbon deposition on the air
valve, check the working surface of the valve
LFWX-6470-04080 and the air valve stem for wear, ablation or
deformation; if any, repair it; if necessary,
replace the air valve.
(f). Use a square angle ruler to measure the air

valve edge thickness; if the measured value
is less than the minimum value, replace the
air valve.
Intake valve thickness: 1.4±0.05 mm
Minimum thickness: 1.5±.05 mm
LFWX-6470-04081
21-61
(g). Use a vernier caliper to measure the

air valve length, if it can not meet the
requirement, replace it.
Intake valve length: 100.6 mm
Exhaust valve length: 100.57mm
LFWX-6470-04082
(h). Use a spiral micrometer to measure the

air valve stem diameter, if it can not the
Intake valve: 5.973±0.007 mm
Exhaust valve: 5.953±0.007 mm
LFWX-6470-04083
(i). Check the air valve seat contact width.

Note: 21
Coat a layer of the marking membrane on the
air valve seat, and then install the air valve on
the cylinder head. Use the air valve grinding
tool to rotate the air valve 1/4 turns several
times, and then remove the air valve.
LFWX-6470-04084
Note:
The marking produced on the air valve mating
surface must be a continuous closed trace,
and its width must be within the prescribed
scope. If the marking is uneven, or the mark
width is beyond the specified scope, must
grind and fine grind and polish the air valve
seat.
Intake valve holder width: 2.40 ~ 3.25 mm
Intake valve seat: use a air valve seat reamer

to repair it two times. Must use two reamers to
60
45
repair it: the first reamer has an angle of 15°,

and the second reamer has an angle of 45°. In
the second repair, must achieve the required
air valve seat width.
Intake valve holder width: 2.40 ~ 3.25 mm
Exhaust valve seat: the repair procedure is the
same as one for the intake valve.
LFWX-6470-04086 Exhaust valve seat width: 2.19 ~ 2.90 mm
(j) Grind the air valve. First coat a layer of

coarse grinding paste on the surface of the
valve seat, and use the grinding tool to grind
the air valve; and then coat a layer of fine
grinding paste to grind it, until a perfect fit
between the air valve and the air valve seat
is obtained.
LFWX-6470-04087
(k). After grinding, thoroughly clean the air valve,

air valve seat, and use an inside diameter
micrometer to measure the air valve duct
inner diameter.
Air valve duct inner diameter: 6~6.012 mm
(l). Deduce the air valve stem diameter from the
air valve duct, to obtain the air valve guide
duct clearance. If the oil clearance value is
greater than the maximum value, replace the
air valve and the air valve duct.
LFWX-6470-04088 Intake valve: 0.027 mm
Exhaust valve: 0.047 mm
Intake valve: 0.047 mm
(m). Use the inside micrometer to measure the

air valve installation hole diameter.
Inside diameter: 11 ~ 11.018 mm
LFWX-6470-04089
21-63
Installation
1. Install the cylinder head and the air valve components.
(a). Heat the cylinder head to 80 ~ 100℃ .
LFWX-6470-04074
(b). Remove the cylinder head and place it on a

wooden board, use the special tool to press
the new valve duct to the specified value
into the duct hole, until the special tool is
contacted with cylinder head.
Specified pressing value: 30 mm
Note:
Use the tool (11 mm reamer) to ream the duct
hole, to remove burrs.
LFWX-6470-04075
(c). Use the special tool (5. 5 mm reamer), 21

to ream the air valve duct hole to achieve the
standard oil clearance.
Intake valve: 0.027 mm
LFWX-6470-04090
(d). In turn, install air valve seal, air valve, air

valve spring, air valve spring seat, and use
the special tool to install the air valve locking
piece.
Note:
In installation, it is prohibited to use a hammer
or other objects to tap the special tool; when
installing the oil seal onto the duct, only
manually press the special tool, the tapping on
LFWX-6470-04073 the special tool may cause the air valve seal
damage or deformation.
(e). Install the new cylinder pad. Before the

installation, use a paper to clean the upper
cylinder bock surface, to ensure that there is
no dirt.
Note:
The marked surface should be upward; the
positioning pin hole position should be
noticed.
LFWX-6470-04091
1 5 9 7 4
(f). Align the cylinder head positioning pin hole
with the positioning pin on cylinder block and
then gently place the cylinder head.
(g). Install the cylinder head fixing bolts, and re-
tighten them in the order as shown in the left
figure, and tighten them in 3 times.
Tightening torque: 30 N•m + 90° + 90 °
(h). Install the camshaft and the hydraulic rocker
3 8 10 6 2 components.
LFWX-6470-04072 (i). Install the camshaft cover.
(j). Install the the timing chain and sprocket
components.
(k). Install the thermostat assembly.
(l). Install the exhaust manifold assembly.
(m). Install the intake manifold assembly.
Piston, piston rings and connecting rod components
Disassembly
1. Remove the piston, piston rings, and connecting rod components.
(a). Remove the cylinder head. Reference: Removal and installation of cylinder head and
air valve components.
(b). Remove the oil sump assembly. Reference: Oil sump assembly removal and
installation.
(c). Remove the oil pump assembly. Reference: Removal and installation of the oil pump
assembly.
(d). Rotate the crankshaft to allow 1st and 4th
cylinder pistons at BDC position, remove
the connecting rod cap fixing bolts, remove
the connecting rod and connecting rod tile.
Remove other connecting rod caps and
connecting rod tiles with the same method.
Note:
Mark the removed connecting rod caps and
connecting rod tiles, for easy installation.
LFWX-6470-04092
21-65
(e). Remove the piston assembly.

Note:
Use a wood or rubber object to push out
the piston, do not use any metal object, to
avoid damage to the connecting rod end
surface. Place the piston and connecting rod
components in the correct order,; don't mix
them.
LFWX-6470-04093
(f). Use the piston ring expander to remove

the piston ring I, the piston ring II and the
combination oil ring.
Note:
Mark the removed piston rings, for easy
installation.
LFWX-6470-04094
21
(g). Use the circlip pliers to remove two piston
pin snap rings.
LFWX-6470-04095
(h). Use a punch to remove the piston pin
LFWX-6470-04096
Inspection
1 Check the connecting rod components.
(a). Check that the connecting rod and the

connecting rod cap for marks, cracks, burrs,
scratches or wear.
Note:
If there is a significant wear and tear on any
part of the connecting rod or the connecting
rod cap, must replace them as an assembly.
LFWX-6470-04097
(b). Use the connecting rod gauge and the

feeler gauge to measure the connecting rod
crossing degree.
Standard crossing degree value: 0.04 mm
(in 100 mm length)
Note:
If the connecting rod cross degree is
greater than the standard value, replace the
connecting rod.
(c). Check the connecting rod distortion degree.

Standard distortion value: 0.08 mm (in 100 mm
length)
Note:
If the connecting rod distortion is greater
than the standard value, must replace the
connecting rod.
LFWX-6470-04099
(d) Use a thickness gauge to measure the

axial clearance between the piston and
the connecting rod; if the axial clearance is
greater than the maximum axial clearance,
replace the connecting rod components.
Standard axial value: 4.252 ~ 4.548 mm
LFWX-6470-04100
21-67
(e). Check the fit clearance between the

connecting rod and the bearing, place a
plastic clearance gauge on the connecting
rod journal. Install the connecting rod cap (the
connecting rod cap forward marking should
be toward the front side of the engine and
the connecting rod bolts should be tightened
to the specified tightening torque); remove
the connecting rod cap and use the plastic
clearance gauge to measure the maximum
clearance width.
LFWX-6470-04101
2. Check the piston and piston rings.
(a). Check the piston skirt, pin hole, piston top

and piston ring groove for damage and wear;
if necessary, replace them.
(b). Measure the piston outer diameter at the
position with the distance of 10 mm (0.39 in)
to the bottom of the piston skirt at the angle
of 90°.
Note:
If It is beyond the scope of specifications,
LFWX-6470-04102 replace the piston.
Measure the clearance between the piston and 21
the cylinder.
If It is beyond the scope of specifications,
replace the piston.
Standard clearance: 0.02 ~ 0.08 mm
(c). Along the circumference, measure the

clearance between the piston ring and the
ring groove.
Note:
If it is beyond the specified scope, must
replace the piston and piston rings as an
assembly.
1st piston ring clearance:0.08 ~ 0.035 mm
2nd piston ring clearance: 0.07 ~ 0.025
LFWX-6470-04103 mm
Combination fuel rings: 0.186 ~ 0.06 mm
(d). Insert manually the piston ring into the

cylinder, use the piston to push it into the
bottom of the piston ring stroke. User a feeler
gauge to measure the end clearance of each
Piston ring
piston; if it is beyond the specified scope,
must replace the piston and the piston rings
as an assembly.
1st piston ring end clearance: 0.2~0.35 mm
LFWX-6470-04104 2nd piston ring clearance: 0.4 ~ 0.6 mm
Combination fuel rings: 0.2 ~ 0.7 mm
3. Check the piston pin oil clearance.
(a). Use a caliper gauge to measure the inner

diameter of the piston pin hole.
Standard values:
Group A: 19.006 ~ 19.010 mm
Group B: 19.010 ~ 19.013 mm
LFWX-6470-04105
(b). Deduce the outer diameter of piston pin

from the inner diameter of piston pin hole, to
obtain the oil clearance between the piston
and the piston pin.
5 mm (0.20 in.)
Standard values:
Group A: 0.008~0.016 mm
Group B: 0.0089~0.015 mm
Note:
If the oil clearance is greater than the maximum
28 mm (1.10 in.)
5 mm (0.20 in.) value, must replace the piston and the piston
LFWX-6470-04106 pin.
(c). Use a caliper gauge to measure the inner

diameter of the connecting rod small end
hole.
Standard value: 19.002 ~ 19.010 mm
(d). Deduce the outer diameter of the piston pin
from the inner diameter of the connecting rod
small end hole, to obtain the oil clearance
between the piston pin and the connecting
rod small end hole.
LFWX-6470-04107
21-69
Note:
If the clearance is greater than the standard value, replace the connecting rod
components.
4. Select the connecting rod shaft tiles.
A2 Unit: mm
Connecting rod shaft tile selection principle
Connecting rod tile Connecting rod shaft diameter grouping

group number 1# 2# 3#
Connecting 1# 1# 1# 1#
rod big end
2# 2# 2# 1#
hole group
number 3# 3# 2# 2#
The size group and fit clearance of crankshaft connecting rod journal, connection rod big
end hole, and connecting rod shaft are shown in table A.2.
Installation
1. Install the piston, piston rings, connecting rod components.
1 (a). During the assembly, note the direction of

piston and link assembly. The direction of
piston forward mark (1) should be consistent
with that of link assembly forward mark (2). 21
LFWX-6470-04108
(b). Use the circlip pliers to install new piston pin

snap ring at the piston pin hole end.
LFWX-6470-04109
Note:
As shown, the piston pin snap ring (1) end can
not be at the piston pin hole opening (2).
LFWX-6470-04110
(c). Coat evenly a layer of oil on the piston pin,

align the connecting rod small end with the
piston pin hole, and insert the piston pin
into the piston pin hole. When installing the
piston connecting rod, the single convex of
connecting rod is toward the piston direction
shown with the arrow.
Tips:
If the piston pin is installed difficulty in winter, it
can be heated for installation (during operation,
the heated position should be noticed, to avoid
LFWX-6470-04111 burns).
Note:
After installation turn the piston pin, to ensure its free rotation. When installation,
align the forward marks on the piston and the connecting rod.
(d). Use the circlip pliers to install the new snap
ring at the other end of the piston pin.
LFWX-6470-04109
3 (e). Use a clean oil to lubricate the piston ring and

the piston skirt, and use the piston ring expander
to install the piston rings (1), (2) and (3) in turn.
2
① .Combination oil ring, ② .2nd piston ring
③ .1st piston ring clearance:
1 Note:
● Install them correctly based on the marks when
removal.
● The gas ring surface with marking should be
upward.
● Coat the oil on the piston ring surface, an check
the piston ring for free rotation in the ring groove.
LFWX-6470-04112
21-71
(f). Install the upper connecting rod tile, and use

clean oil to lubricate the inner side of the
upper connecting rod tile.
Note:
● Ensure that the connecting rod and the
connecting rod tile surface are clean and no
any debris and damage.
● Do not lubricate the back of the connecting
rod tile, and coat clean oil on the inner side of
LFWX-6470-04113 the connecting rod tile.
(g). Use the piston ring compression tool to press

the piston ring to the operation position.
LFWX-6470-04114
21
Note:
0
12
Before compression, adjust the piston ring

opening to the angle as shown in the left
figure, each ring opening cannot be aligned
120
with the piston pin opening or other ring

openings; otherwise the piston ring cannot be
sealed fully.
(h). Tu r n t h e c r a n k s h a f t t o a l l o w t h e t h e
connecting rod journal to be installed to the
DTC position; use the piston installation
tool and a wooden bar to push each piston
respectively into each cylinder.
Note:
Before installation, coat a layer of oil on the
inner cylinder wall; do not use any metal object
to push the pistons.
LFWX-6470-04116
Note:
As shown on the left figure: ensure that the
mark on the piston is forward (at the crankshaft
pulley side); don not install it incorrectly.
(i). Install the lower connecting rod tile onto the

tile cap, and use clean oil to lubricate the
inner side of the lower connecting rod tile.
Note:
● Ensure that the connecting rod tile surface is
clean and no debris and damage.
● Do not lubricate the back of the connecting
rod tile, and coat clean oil on the inside of the
connecting rod tile.
LFWX-6470-04118
(j). Install the connecting rod cap onto the

installation location and install and pre-
tighten the connecting rod bolts.
Pre-tightening torque: 30 N. m.
Note:
Ensure that connecting rod cap is installed
in place, to allow the digital side of the
connecting rod cap to correspond with the
digital side of the connecting rod.
(k) Use a digital angle wrench, 10# and 12#
socket wrenches to tighten the connecting
LFWX-6470-04092 rod bolts respectively; and install other
connecting rod caps with the same method.
Torque: 30 N.m + 90°
(l). Install the oil pump assembly.
(m). Install the oil sump assembly.
(n). Install the cylinder head and the air valve
components.
21-73
Main bearing, crankshaft and cylinder block assembly

Disassembly
1. Main bearing, crankshaft and cylinder block assembly
(a). Remove the timing chain and sprocket components. Reference: Removal and
installation of timing chain and sprocket components.
(b). Remove the rear crankshaft oil seal. Reference: Removal and installation of the rear
crankshaft oil seal.
(c). Remove the piston, piston rings and connecting rod components. Reference:
Removal and installation of piston, piston rings, and connecting rod components.
(d). Remove the main bearing cap fixing bolts in

turn in the order as shown.
3 7 9 5 1
4 8 10 6 2
LFWX-6470-04119
(e). In turn, remove the main bearing cap, lower

main shaft tile, crankshaft, upper thrust
piece, and upper main shaft tile. 21
Note:
Place the main bearing cap, lower main shaft
tile and upper main shaft tile in turn, for easy
subsequent installation.
LFWX-6470-04120
(f). Remove the cooling nozzle component

fixing bolts and remove the cooling nozzle
component, and remove other cooling
nozzles with the same method.
LFWX-6470-04121
Inspection
1. Check the main bearing cap fixing bolts.
(a). Measure the length of the fixing bolts. If it is

beyond the specified scope, replace the bolt.
Main bearing cap fixing bolt length:
65±0.5 mm
LFWX-6470-04122
2. Check the main bearing cap.
(a). Check the main bearing cap for cracks

or abnormal wear and tear; if necessary,
replace it.
3. Check the crankshaft main journal circular runout.
(a). Use a dial indicator to measure the

crankshaft main journal circular runout.
Maximum runout: 0.04 mm
Note:
If the circular runout is unqualified, replace the
crankshaft.
LFWX-6470-04124
21-75
4. Check the crankshaft axial clearance.
(a). Install the crankshaft and upper thrust plate

of crankshaft.
(b). Install the main bearing cap with the lower
shaft tile and the main bearing cap bolts, and
ensure that the forward marks on the main
bearing cap is toward the front of the engine.
(c). Use a screwdriver to spry the crankshaft
and use a dial indicator to measure the axial
clearance.
Standard axial clearance: 0.06 ~ 0.24 mm
Note:
If the thrust clearance can not meet the
requirement, must replace the thrust piece as
a whole.
LFWX-6470-04125
5. Crankshaft journal diameter.
A B (a). As shown, measure the journal diameter

at two points (Points A and B) in X and Y
X
directions. If they are beyond the specified
scope, replace the crankshaft or grind the
journal and install the increased bearing.
Y
Main journal diameter: 49.963 ~ 49.978 21
mm
Connecting rod journal diameter: 47.763
~ 47.778 mm
Maximum runout of connecting rod
LFWX-6470-04126
journal: 0.05 mm
6. Check the crankshaft main journal circular runout.
(a). As shown, measure the distortion on

the cylinder block top surface in the six
directions.
If one of them is more than the maximum value,
replace the cylinder block.
LFWX-6470-04127
Maximum distortion of cylinder block: 0.04 mm
LFWX-6470-04128
(b). Measure the cylinder diameter in X and Y

directions at the position of 10 mm (0.39in)
below the cylinder top surface.
If one of them is beyond the specified scope,
replace the cylinder block.
Standard diameter scope: 76.500 ~ 76.530
X mm
Y
10 mm (0.39 in)
10 mm (0.39 in)
LFWX-6470-04129
7. Select the shaft tile.

A1 Unit: mm
Main shaft tile selection principle
Main shaft tile group Main journal group number

number 1# 2# 3#
Main journal 1# 2# 2# 1#
hole group 2# 3# 2# 2#
number 3# 3# 3# 2#
21-77
Installation
1 Install the cylinder block, crankshaft, and main bearing.
(a). Ensure that the cooling nozzle towards the

cylinder hole, install and tighten the cooling
nozzle fixing bolts, and install other cooling
nozzle components in turn.
Torque: 32 N•m
LFWX-6470-04130
(b) Install the upper main shaft tile on the

cylinder block.
Note:
● Install them in the order when removal.
● Ensure the main shaft tile surface is clean,
no damage or foreign body; do not use the oil
to lubricate the back of the main shaft tile.
● In the installation, ensure that the positioning
LFWX-6470-04131 tongue on the main shaft tile is aligned with
the positioning tongue groove on the cylinder
block. 21
(c). Install 2 upper thrust pieces into 3rd shaft

hole in the cylinder block, with its oil groove
surface outward, and ensure that the thrust
piece is installed in place.
Note:
As shown, the oil groove on the upper thrust
piece is outward.
LFWX-6470-04132
(d). Place the clean crankshaft on the cylinder

block, and coat a little oil on the main journal.
LFWX-6470-04133
10 6 2 4 8
(a). Ensure that the cooling nozzle towards the
cylinder hole, install and tighten the cooling
nozzle fixing bolts, and install other cooling
nozzle components in turn.
Torque: 32 N•m
9 5 1 3 7
LFWX-6470-04134
Flywheel
Disassembly
1. Remove the flywheel.
(a). Install the flywheel check tool.

1
(b). Remove the flywheel fixing bolts in the order
3
5 as shown and remove the flywheel and the
tool. Install the upper main shaft tile on the
cylinder block.
6
2
4
Note:
In order to prevent the flywheel falling off when
removing the last fixing bolt, the flywheel
LFWX-6470-04135
should be held by the assistant.
Installation
1. Install the flywheel.
(a). Install the positioning pin and the flywheel

assembly, hold the flywheel by hand, and
1
5 coat the sealant on the flywheel fixing bolts,
and pre-tighten the flywheel fixing bolts in
3
the order as shown.

6 4 Torque: 40 N•m
2
(b). Install the flywheel check tool.
(c). Tighten the flywheel fixing bolts in the order
as shown in the left figure.
LFWX-6470-04135
Torque: 95 N•m
(d). Remove the flywheel check tool.
21-79
Maintenance Tools
Special tools
S/N Tool name Tool figure Tool code Notes
Fix the
1 Retainer 351133
flywheel
Lock the
2 Camshaft timing tool 351134
camshaft
Position the
Crankshaft pulley
3 351135 crankshaft
positioning wrench
pulley
21
Position the
Crankshaft positioning
4 351136 crankshaft
bolt
bolt
Position the
5 Pin 351138
tensioner
Remove
the front
6 Seal extractor 351139
crankshaft
oil seal
/1
Install
the front
7 Combination tool 351140
/2 crankshaft
oil seal
Water
Water pump removal pump pulley
8 351147
wrench removal
tool
Install
the rear
9 Oil seal tool 351149
crankshaft
oil seal
21-81
General tool
S/N Tool name Tool figure Notes
Quick wrench,
Remove/install the
1 connecting rod and
fixing bolts and nut
socket
Remove/install the
2 Screwdriver
fixing screw
Measure the part

3 Screw micrometer
diameter
Measure the part

4 Thickness gauge 21
clearance
5 Dial indicator Measure the part
Measurement gauge
6 Auxiliary measuring device
adapter
Auxiliary measuring
7 Dial gauge holder
device
Inner diameter dial Measure the part

8
indicator inner diameter
Measurement the part

9 Vernier caliper
length
Remove/install the
10 Circlip pliers
circlip
11 Piston ring compressor Install the piston
12 Spring dynamometer Measure the spring force

21-83
Measure the
Connecting rod
13 connecting rod
collimator
distortion
14 Piston ring expander Install the piston rings
Cylinder diameter Measure the cylinder

15
measuring gauge diameter
Air valve lock piece

Remove/install the air
16 removal and installation
tool valve lock piece
21
17 Reamer Ream the air valve duct
Air valve duct removal / Remove/install the air

18
installation tool valve duct
Engine mechanical system - Mechanical system (1.8L 2.0L) 11-a
Mechanical system
Engine mechanical system��1
Preparations��1
Maintenance data��5
Precautions�� 12
General inspection�� 13
System inspection�� 13
Inspect the cylinder pressure� 13
Fault phenomenon table�� 15
Fault diagnosis�� 18
Engine assembly�� 44
Change�� 44
Engine wiring harness and sensor
�� 48
Change�� 48
Intake manifold�� 50
Component drawing�� 50
Repair�� 51
Timing sprocket�� 54 11
Repair�� 55
Camshaft�� 66
Repair�� 67
Cylinder Head�� 70
Repair�� 70
Valve�� 73
Adjustment�� 74
Repair�� 75
11-b Engine mechanical system - Mechanical system (1.8L 2.0L)
Engine mechanical system - Mechanical system (1.8L 2.0L) 11-1
Engine mechanical system

Preparations
1. Special tools
S/N Tool External view NOTE
1 Oil pan puller Remove the oil pan
Valve cotter Remove and install the valve

2
replacer cotter
Air valve duct 11

3 removal /installation Remove and install air valve
tool
4 Reamer Ream the air valve duct
5 Oil filter puller Remove and install the oil filter

11-2 Engine mechanical system - Mechanical system (1.8L 2.0L)
Crankshaft front oil Install the front crankshaft oil

6
seal mounting tool seal.
Crankshaft rear oil Install the rear crankshaft oil

7
seal mounting tool seal.
Piston mounting
8 Install the piston
tool
Cylinder pressure
9 To test the cylinder pressure
gauge
10 Hanger Hang the engine
Spring
11 To test the valve spring force
dynamometer
To test the part radial run-out

6 Dial gauge
and gap
7 Inside micrometer To test the part inside diameter
8 Vernier caliper To measure the part length
11
Connecting rod To test the connecting rod

9
collimator distorsion degree
10 Circlip pliers Remove/install the circlip
Piston ring
11 Install the piston
expander
12 Thickness gauge Measure the part clearance
Cylinder diameter
13 To measure the cylinder bore
measuring gauge
Quick wrench
Dismounting the fixing bolts and
13 and flashlight
nuts
components
13 Screw driver Remove the pipe clamp

Maintenance data
1. Technical specifications (1.8L)
Engine model LFB479Q
Total displacement 1794mL
Idle speed 750±50
Rated power 98
Maximum torque 168 N·m
Fuel consumption under comprehensive working

8L/100km
condition
Maximum cylinder pressure 1.3MPa
Standard cylinder pressure 1.2MPa

Cylinder pressure Minimum cylinder pressure 1.0MPa
Maximum cylinder pressure

0.1MPa
difference
Maximum elongation of timing chain 122.6mm
Minimum diameter of exhaust cam timing sprocket

97.3mm
(with timing chain)
Minimum diameter of crankshaft timing sprocket (with

51.6mm 11
timing chain)
Maximum thickness of timing chain movable rail 1.0mm
Cylinder block junction plane 0.05mm

Cylinder head
Intake side 0.10mm
flatness
Exhaust side 0.10mm
Maximum radial runout of camshaft 0.03mm
Intake and exhaust Intake camshaft 44.168~44.268mm

camshaft maximum lift Exhaust camshaft 43.705~43.805mm
Cylinder block junction

0.05mm
Cylinder head flatness plane
Intake side 0.08mm
Camshaft radial run-out 0.04mm
Intake and exhaust Intake camshaft 8.353mm

camshaft maximum lift Exhaust camshaft 7.55mm
1# exhaust 24.949~24.965mm
Camshaft journal
Other 22.949~22.965mm
Standard axial clearance 0.040~0.095mm

Camshaft axial clearance
Maximum axial clearance 0.10mm
Free length 43.40mm
Valve spring Installation force 153N~169N(33.88mm)
Max. working force 335.3N~370.7N(24.1mm)
Max. deviation ￠ 1.3mm

Air valve spring verticality Maximum deviation angle
2°
of 2°
Standard thickness 1.0mm

Valve edge thickness
Minimum thickness 0.7mm
Standard length 88.65mm

Intake valve
V a l v e Minimum length 88.35mm
length Exhaust Standard length 88.69mm
valve Minimum length 88.39mm
Intake valve 5.470~5.485mm

Exhaust valve 5.465~5.480mm
Intake valve seat width 1.0~1.4mm

Valve seat contact width
Exhaust valve seat width 1.0~1.4mm
Air valve duct inner diameter 5.510~5.530mm
Mechanical tappet top thickness 5.055~6.005mm
Standard oil
0.025~0.060mm
Intake clearance
valve Maximum oil
0.08mm
clearance
Valve oil clearance
Standard oil
0.030~0.065mm
Exhaust clearance
valve Maximum oil
0.10mm
clearance
Valve guide mounting hole inside diameter 10.285~10.306mm
Valve guide designated pressing-in amount 8.7~9.1mm
Standard clearance of
0.20~0.25mm
intake valve (cold status)
Air valve clearance Standard clearance
of exhaust valve (cold 0.30~0.35mm
status)
Piston diameter standard value 78.925~78.935mm
Standard oil clearance 0.065~0.085mm

Piston oil clearance
Maximum oil clearance 0.085mm
Piston pin mounting hole diameter 20.006~20.015mm
Piston pin top circle diameter 20.004~20.013mm
Connecting rod axial Standard axial clearance 0.16~0.34mm

clearance Maximum axial clearance 0.34mm
Connecting rod oil Standard oil clearance 0.030~0.054mm

clearance Maximum oil clearance 0.08mm
Piston pin oil clearance Standard oil clearance 0.002~0.011mm

(piston pin mounting hole) Maximum oil clearance 0.011mm
Connecting rod small end bore 20.012~20.021mm
First ring groove 0.20~0.35mm

Piston ring groove gap
Second ring groove 0.40~0.55mm
Top ring 0.20~0.35mm

Standard
Second ring 0.40~0.55mm
opening gap
Piston
Film ring 0.20~0.70mm
ring notch
Top ring 1.05mm
clearance
Maximum
Second ring 1.20mm
opening gap
Film ring 1.10mm
Connecting rod maximum distortion degree 0.05mm/100mm

11
Connecting rod maximum bending degree 0.05mm/100mm
Connecting rod bolt Nominal diameter 7.30~7.40mm

diameter Minimum diameter 7.20mm
Crankshaft maximum radial run-out 0.03mm
Crankshaft main journal diameter 47.982~48.000mm
Maximum oval of crankshaft 0.02mm
Crankshaft connecting rod neck diameter 43.992~44.000mm
Crankshaft connecting rod neck maximum ellipticity 0.02mm

Crankshaft oil clearance
Cylinder block main Nominal diameter 8.80~9.00mm

bearing cap fixing bolt
Minimum diameter 8.70mm
diameter
Cylinder block top surface warpage (maximum

0.05mm
warpage)
Cylinder block cylinder hole diameter 79.00~79.13mm

2. Tightening torque
Item N•m
Left engine mounting fixing bolt/ nut 85~105
Right engine mounting fixing bolt/ nut 65~85
Front engine mounting fixing bolt/ nut 65~85
Rear engine mounting fixing bolt/ nut 85~105
Throttle body mounting bolt and nut 10~12
Intake manifold mounting bolt and nut 30
Exhaust timing sprocket mounting bolt 54
Phaser fixing bolt 60
Timing chain movable rail assembly mounting bolt 23
Timing chain fixing rail assembly mounting bolt 11
Timing cover mounting bolt 23

Timing chain tensioner mounting nut 11
Crankshaft pulley bolt assembly 138
Water pump mounting bolt 11
Tensioner assembly mounting bolt and nut 69(bolt); 29(nut)
Generator fixing bolts 5(short bolt); 54(long bolt)
Cylinder head cover mounting bolt 11
1# camshaft cover
Vehicle speed sensor 23
mounting bolt
mounting bolt
Other bolts 13
Cylinder head fixing bolt (tightened twice) 60(the first time); 90(the second time)
Bolt, connecting rod 50
Cylinder block drain bolt 23
Oil filter 25~30
Oil filter mounting bolt 25
Oil pan mounting bolt 10
Crankshaft main bearing cover fixing bolt (tightened

40(the first time); 60(the second time)
twice)
Upper and lower cylinder block fixing bolt 18
Flywheel fixing bolt 88
Oil pressure alarm torque 14~16
Oil filter connecting nut 20
Oil pump mounting bolt 11

1. Technical specifications (2.0L)
Engine model LF483Q
Total displacement 1988mL
Idle speed 750±50
Rated power 98
Maximum torque 185 N·m
Fuel consumption under comprehensive working condition 7.8L/100km
Standard cylinder pressure 1.2MPa

Cylinder pressure Minimum cylinder pressure 1.0MPa

difference
Idle speed 80~300kPa

Oil pressure
Calibrated speed 330~430kPa
Minimum diameter of exhaust cam timing sprocket 97.3mm
Minimum diameter of crankshaft timing sprocket 51.6mm
Maximum thickness of timing chain movable rail 1.0mm

11
Cylinder head flatness Intake side 0.10mm
Exhaust side 0.10mm
Maximum radial runout of camshaft 0.03mm
Intake camshaft 44.168~44.268mm

Intake and exhaust camshaft
maximum lift Exhaust camshaft 43.705~43.805mm

Cylinder head flatness
Intake side 0.08mm
Camshaft radial run-out 0.04mm
Intake camshaft 8.353mm

Intake and exhaust camshaft
maximum lift Exhaust camshaft 7.55mm
1# exhaust 34.449~34.465mm
Camshaft journal
Other 22.949~22.965mm
Standard axial clearance 0.085mm

Camshaft axial clearance
Maximum axial clearance 0.12mm
Free length 44.7~45.7mm
Camshaft axial clearance Installation force 153~169N•m (33.88mm)
Max. working force 335.3~370.7N•m (24.252mm)

Max. deviation 1.0mm

Air valve spring verticality
Maximum deviation angle 2°
Standard thickness Intake 1.25mm, exhaust 1.39mm

Valve edge thickness
Minimum thickness 1.05mm

Intake valve
Minimum length 88.35mm
Valve length
Exhaust valve
Minimum length 88.39mm
Exhaust valve 5.465~5.480mm
Intake valve seat width 1.0~1.4mm

Valve seat contact width
Exhaust valve seat width 1.0~1.4mm
Air valve duct inner diameter 5.510~5.530mm
Mechanical tappet top thickness 5.055~6.005

Intake valve
Va l v e o i l
clearance Standard oil clearance 0.030~0.065mm
Exhaust valve
Valve guide mounting hole inside diameter 10.285~10.306mm
Valve guide designated pressing-in amount 8.7~9.1mm

Air valve clearance (cold
status) Exhaust valve 0.30~0.35mm
Piston diameter standard value 82.442~82.458mm

Piston oil clearance
Piston pin mounting hole diameter 20.006~20.015mm
Piston pin top circle diameter 20.004~20.013mm

Piston oil clearance (Piston pin
mounting hole) Maximum oil clearance 0.011mm
Connecting rod oil clearance 20.012~20.021mm

Piston pin oil clearance
(Connecting rod small end) Maximum oil clearance 0.017mm
First ring groove 0.035~0.075mm
Piston ring groove gap
Second ring groove 0.03~0.075mm
Top ring 0.30~0.45mm

Standard Second ring 0.40~0.60mm
opening gap
Piston Film ring 0.25~0.55mm
ring notch
clearance Top ring 1.00mm
Maximum Second ring 1.10mm
opening gap
Film ring 1.10mm
Connecting rod maximum distortion degree 0.05mm/100mm
Maximum decollimation of link rod 0.05mm/100mm
Nominal diameter 7.30~7.40mm

Connecting rod bolt diameter
Crankshaft maximum radial run-out 0.03mm
Crankshaft main journal diameter 47.982~48.000mm
Main bearing journal maximum taper and out-of-roundness 0.02mm
Crankshaft connecting rod neck diameter 43.984~44.000mm
Crankshaft link rod neck taper and out-of-roundness 0.02mm

Crankshaft oil clearance
8.80~9.00mm
11
Cylinder block main bearing
cap fixing bolt diameter 8.70mm
Cylinder block top surface warpage (maximum warpage) 0.05mm
Cylinder block cylinder hole diameter 82.5~82.015mm
Item N•m
Oil pan draining bolt 42~46
Left engine mounting fixing bolt 85~90
Right engine mounting fixing bolt 85~90
Front engine mounting fixing bolt 85~90
Rear engine mounting fixing bolt 85~90
Power steering pump fastening bolt 45
A/C compressor fastening bolt 25
Electronic throttle body fixing bolt and nut 10~12
Intake manifold fixing bolt 30
Exhaust manifold fixing bolt 37
Exhaust manifold upper thermal shroud fixing bolt 18
Exhaust camshaft timing sprocket fixing bolt 54
Intake camshaft timing sprocket fixing bolt 60
Timing slide rail fixing bolt 19
Timing fixed rail fixing bolt 13

Front enclosure mounting bolts 23
Tensioner fixing nut 11
Crankshaft pulley fixing bolt 138
Water pump mounting bolt 11
Engine front suspension bracket mounting bolts 52
Fixing bolt and nut of the belt tension pulley Bolt: 69 Nut: 29
Generator fixing bolts Short bolt: 25 Long bolt: 54
Cylinder head cover mounting bolt 11
Ignition coil fixing bolt 11
Spark plugs 40
1# camshaft cover
Vehicle speed sensor 23
mounting bolt
mounting bolt
Other bolts 13
Cylinder head fixing bolt (tightened twice) 49(the first time); 90(the second time)
Fuel rail retaining bolt 11

Connecting rod cap fixing bolt 50
Cylinder block drain bolt 23
Oil filter 25~30
Oil filter fixing bolt 25
Oil pan fixing bolt 10
Crankshaft main bearing cover fixing bolt (tightened
The first time 40, the second time 60
twice)
Upper and lower cylinder block fixing bolt 18
Flywheel fixing bolt 88
Oil pressure alarm torque 14~16
Cooling jet fixing bolt 33
Precautions
1. Allow the engine to cool down before discharging the engine coolant.
2. When disconnecting the fuel lines, keep away from the source of ignition and kids as
much as possible.
3. After removing the oil pipes, seal all the oil pipe joints to prevent the piple plugging
or fuel leak.
4. Take special care when removing the engine and do not damage the fitting face and
slipping face.
5. When removing the engine, seal the engine openings with the tape or equivalent
materials to prevent the foreign matters entering the engine.
6. During the removal, identify and arrange all the disassembled parts to facilitate the
troubleshooting and reassembly.
7. Clean and check all the parts thoroughly before the repair or replacement.
8. For the assembly of engine, the basic principles for tightening bolts and nuts are
to tighten the middle bolt or nut first and then those on the diagonal position to the
same torque in several steps. Follow the designated sequence if any.
9. Replace the new gasket, oil seal and seal ring during the assembly of engine.
10. Apply the sealant uniform and install the bonding components in the specified time
after the sealant application.
11. During the assembly of engine, carefully check the engine oil lines and vacuum lines
for clogging.
12. When connecting the sensor connectors, ensure to hear a silvery click before
stopping the installation.
13. After repairing and assembling the engine, start the engine and increase the engine
speed to check the engine coolant, fuel, engine oil and exhaust gas for leak.
Note:
Observe the special requirements if specified in this manual.
XUANLANG 1.8L and 2.0L engine systems are the same except the fuel guide rail.
General inspection
System inspection
1. Check the system components
(a). Check the system for evident mechanical or electrical damage and repair them if
required.
(b). Inspect the system for obvious collision deformation sign; if any, repair it.
(c). Check the system fasteners (such as bolts or nuts) for loosening; if any, retighten it.
(d). Inspect accessory belt for cracks, breakage, loosening and etc.; if any, replace it 11
timely.
2. Inspect the cooling system (See Section 13 - Cooling system - General
inspection)
3. Inspect the lubrication system (See Section 17 - Lubrication system - General
inspection)
4. Inspect intake/exhaust system (See Section 15- Inlet/exhaust system - General
inspection)
Inspect the cylinder pressure
1. Inspect the cylinder pressure

(a). After the engine is warmed up, place
the transmission shift lever in “Neutral”
position,
Note:
After the engine is warmed up, place the
transmission shift lever in “Neutral” position
and apply the parking brake.
(b). Disconnect the ignition coil connectors and
fuel injector connectors
LFWX-6470-11003
(c). Remove all ignition coil mounting bolts,

and remove 4 ignition coils orderly.
(d). Remove all spark plugs with the spark plug
removal tool.
Note:
• Do not damage the insulation portion of the
ignition coil.
• During removal, mark the ignition coil for
each cylinder for subsequent installation.
LFWX-6440-11003
LFWX-6470-11002
(e). Install the pressure gauge into the spark

plug mounting hole.
(f). Start the engine and read the value on the
pressure gauge.
Standard cylinder pressure: 1.2MPa
Minimum cylinder pressure: 1.0MPa
Maximum cylinder pressure: 1.3MPa
Tips:
Before starting, check whether the battery is in full
charge status; otherwise change or replace the
battery.
(g). Measure the other cylinder pressures
LFWX-6470-11004
with the same method and calculate the
maximum pressure difference among all
cylinder pressures.
Maximum cylinder pressure difference:
0.1MPa
Note:
All tests should be completed within a short
time (about 15 s), in order to avoid damage to
the starter.
Fault diagnosis
Fault phenomenon table
Below table helps locating the fault causes. Check all the components in turn and repair or
replace the component as needed.
Phenomena Questionable part Recommended Measures
Battery voltage <8V Charge the battery or replace the battery
Clean and tighten the battery wiring; apply the
Battery wiring corrosion or looseness
thin coat of vaseline oil to the terminals
Start motor malfunction Check the starter and replace it if necessary
No fuel in the fuel supply system Fill fuel
Air in the fuel supply system Bleed the fuel supply system
Clean the fuel supply system and replace the
Fuel supply system contamination
fuel filter
Reverse connection of fuel supply
Connect the pipes correct
system inlet pipe and outlet pipe
Restore the fuel pump harness and connect the
Fuel pump line open circuit
oil pump connectors again
Engine start Minor cylinder flooding: operate the starter with
fails full throttle
Cylinder flooding Severe cylinder flooding: remove the spark plug,
start the starter and repair after the cylinder and
spark plug residual oil drying 11
Fuel supply system injector clogging Replace the injector
Ignition coil connector loose
Connect the ignition coil connectors correctly
connection or wrong connection
Improper spark plug gap Adjust the spark plug gap again
Spark plug damage Replace the spark plug
Ignition coil damage Replace the ignition coil
Engine timing error Adjust the timing
Too high engine oil viscosity Replace the engine oil
Fuel supply system inlet pipe
Build up the fuel supply system pressure
pressure <350kPa
Low fuel tank level Fill fuel
Fuel filter clogging Replace the fuel filter
Engine inlet pipe oil leak Replace the engine oil inlet pipe
Engine ignition
succeeds while Fuel supply system pressure
Replace the fuel pressure regulator
start fails regulator damage
Insufficient fuel pump pressure Replace the fuel pump
Clean the intake passage and replace the air
The air filter clogging
filter element
Front muffler with purifier clogging or
Replace the front muffler with purifier
damage
The engine's Spark plug led connection failure Connect the connectors
idle speed is
unstable Inconsistent spark plug gap Adjust the spark plug gap again

The engine's idle
Individual injector clogging Clean or replace the injector
speed is unstable
Low fuel tank level Fill fuel
Sudden stalling of Engine inlet pipe oil leak Replace the oil inlet pipe
engine during normal Air in the fuel supply system Bleed the fuel supply system
operation Fuel filter or fuel line clogging Replace the fuel filter or clean the fuel line
Fuel bearing water Replace the fuel
Intake not smooth
filter element
Intake pressure temperature Clean the intake pressure temperature sensor
sensor hole clogging try hole and replace the sensor if necessary
Adjust the throttle limit screw and maintain full
Throttle cannot open fully
throttle
Injector clogging Clean or replace the injector
Powerless or slow Spark plug dirty or improper gap Clean the spark plug and adjust the gap
engine acceleration Fuel supply system Clean the fuel supply system and replace the
contamination fuel filter
Fuel pump malfunction Replace the fuel pump
Cylinder gasket sealing failure Replace the cylinder pad
Valve erosion, deformation or
Replace the valve
dent
Check the exhaust system and front muffler
Exhaust system not clear
with purifier
Intake system not clear
filter element
Adjust the throttle limit screw and maintain full
Throttle cannot open fully
throttle
Check the exhaust system and front muffler
Exhaust system not clear
with purifier
Insufficient engine
power
Excessive resistance of power Check the parts related to the power
transmission system parts transmission system
Overheated engine Repair the engine cooling system

Connect all the connectors again and replace
Ignition coil creepage
Unsteady driving the damaged components
Dithering upon Connect all the connectors again and replace
Ignition coil creepage
acceleration the damaged components
Fuel unqualified Replace the fuel
Knocking
Overheated engine Repair the engine cooling system
Restore the ignition of absent cylinder
Post-combustion immediately. If impossible, disconnect the
Ignition system cylinder absence
(too high exhaust injector connector of this cylinder to protect
temperature) the front muffler with purifier
Engine exhaust valve fault Repair the engine
Emission over-
standard testing by Abnormal engine state Check the engine
working conditions

Abnormal control of electronic
Check the electronic injection system
injection system
Exhaust manifold or front muffler Tighten the related bolts and replace the
with purifier joint air leak gaskets if necessary
Air leak of oxygen sensor
Tighten the oxygen sensor
threads
Oil pressure regulator damage Replace the fuel pressure regulator
Emission over-
Overlong term use of front Replace the front muffler with purifier and
standard testing by
muffler with purifier and oxygen oxygen sensor (the service life is not more
working conditions
sensor than 80000km under standard conditions)
Front muffler with purifier and
Replace the front muffler with purifier and
oxygen sensor heavy metal
oxygen sensor
poisoning or overheating
ECM or electronic injection
Improve the system earth wire position
system imperfect earth
ECM housing earthed Insulate ECM housing
Emission over-
standard testing
Engine not fully warmed up Warm up the engine
by simple working
conditions
CO and HC
11
concentration high Engine not fully warmed up Warm up the engine and test high idling first
upon idling
Incorrect metering means Employ the reliable metering means
Complete vehicle state Check the vehicle
Engine status Check the engine
Thermostat damage Replace the thermostat
Coolant temperature sensor
Abnormal consumption Replace the coolant temperature sensor
damage
of fuel
Injector oil leak Replace the injector
Fuel supply system pressure
Replace the fuel pressure regulator
regulator damage
Oxygen sensor damage Replace the rear oxygen sensor
ECM damage Replace ECM
Irregular ON/OFF of
Ignition system connector Check all the wiring terminals and connect
MIL during vehicle
connection failure the connectors of the ignition system
running
Fault diagnosis
1. The diagnostic tester cannot communicate with ECM
Steps Check contents Inspection result

0 Initial inspection Normal Faulty Instruction
The engine is started

Start the engine and difficultly (the engine
Diagnosis is
inspect the engine can not be started; the Go to Step 1
finished
operation engine can be cranked
but not be started)
Diagnostics with the

1 Normal Faulty Instruction
diagnostic tool
Perform troubleshooting
No fault based on the fault code
Read the fault code
code, go to Faulty prompt (see Section 12
with
Step 2 - Engine control system
- Fault diagnosis)
2 Confirm the ambient Normal Faulty Instruction
The ambient
Confirm the ambient temperature The ambient temperature T h e a m b i e n t
operation is normal; is too low temperature is too low
go to Step 3
3 Check battery Normal Faulty Instruction
Inspect the battery

operation (See Charge or replace the
Section 18 - The storage battery's battery (see Section
Go to Step 4
General inspection voltage is too low. 18 - Battery – Battery -
of battery – Battery Replacement)
inspection)
4 Inspect the starter Normal Faulty Instruction
Inspect the starter

operation (see
• The starter is operated Replacement (see
Section 18 -
poorly Section 18 - Starter/
General inspection Go to Step 5
• The starter can not be generator – Starter -
o f s t a r t e r /
operated Replacement)
generator – Starter
inspection)
5 Inspect the fuel Normal Faulty Instruction
Inspect the oil usage

(See Section 15 – • There is no fuel in fuel
• Filling
General inspection Go to Step 6 tank
• Change
of fuel system – • Use any inferior fuel
system inspection)
Inspection by
replacement

Inspect the oil usage
(See Section 16 – Replacement (See
General inspection Section 16 – Lubricating
Go to Step 7 The oil grade is incorrect
of lubricating system – Oil -
system - Engine oil Replacement)
inspection)
Inspect the intake

system
I n s p e c t t h e
• Clean or replace the
operation conditions
air filter cartridge (See
of the intake system
• The air filter clogging Section 14- Intake/
(See Section 14
Go to Step 8 • The air intake tube is exhaust system air filter
– Intake/exhaust
blocked - replacement)
system - General
• Clean and clear the air
inspection -System
intake tube
inspection)
Inspect the water
temperature sensor
I n s p e c t t h e
operation of the Replacement (See
water temperature Section
sensor (See Section The water temperature 15 - Cooling system -
Go to Step 9
12 - Engine control ensor is damaged ater temperature sensor
system - Engine - eplacement) 11
control system -
General inspection)
Inspect the throttle

osition sensor
I n s p e c t t h e
of the throttle Replace the throttle
position sensor (See body (See Section
Go to Step The throttle position
Section 12 – Engine 14 – Intake/ exhaust
10 sensor is damaged
control system system – Throttle -
- Engine control Replacement)
system – General
inspection)

body
I n s p e c t t h e
of the crankshaft Replacement (See
position sensor (See Section 11 - Engine
Go to Step The crankshaft position
Section 12 - Engine mechanical system –
12 sensor is damaged
control system Wiring harness and
- Engine control sensor - Replacement)
system - General
inspection)
I n s p e c t t h e
11 crankshaft position Normal Faulty Instruction
sensor
I n s p e c t t h e
operation
conditions of the
Replacement (See
crankshaft position
Section 11 - Engine
sensor (See Section Go to Step The crankshaft position
mechanical system –
12 - Engine control 12 sensor is damaged
Wiring harness and
system - Engine
sensor - Replacement)
control system -
General inspection)
Check the camshaft

position sensor
I n s p e c t t h e
of the camshaft Replacement (See
position sensor (See Section 11 - Engine
Go to Step Camshaft position sensor
Section 12 – Engine mechanical system –
13 is damaged
control system Wiring harness and
– Engine control sensor - Replacement)
system – General
inspection)
Fuel system
pressure inspection
Inspect fuel
pressure conditions
See Section 13 – Fuel
of the fuel system
system – Diagnostics -
(See Section 13 Go to Step The fuel system pressure
Troubleshooting (3. The
- Fuel system – 14 is too low
fuel system pressure is
General inspection
too low)
- Fuel system
pressure inspection)
Inspect the fuel

injector
Inspect the injector

operation (See
Replacement (See
Section 12 – Engine Individual or multiple
Go to Step Section 13 – Fuel
control system injectors are operated
15 system – Fuel injector -
– Engine control poorly
Replacement)
system – General
inspection)
Inspect the ignition

coil

coil operation (See Replacement (See
Section 17 - Ignition Go to Step Section 17 - Ignition
Ignition coil damage
system - General 16 system - Ignition coil -
inspection - Ignition Replacement)
coil inspection)
Check the spark

plug
Inspect the spark

Clean or replace
plug operation (See • There is oil dirt or
the spark plug (See
Section 17 - Ignition Go to Step carbon deposition on
Section 17 - Ignition
system - General 17 spark plug
system - Spark plug -
inspection - Spark • Spark plug damage
Replacement)
plug inspection)
Inspect the air valve
clearance
Inspect the air valve Adjust the valve

clearance (See clearance
Go to Step The air valve clearance
Section 11 - Engine ( s e e S e c t i o n 11 -
18 is incorrect
mechanical system Mechanical system –
– Air valve - Repair) Air valve - Repair)
Inspect the cylinder

pressure
11
• Inspect and adjust the
air valve clearance (see
Section 11 – Mechanical
system – Air valve -
I n s p e c t t h e
Repair)
• Inspect the piston,
of the cylinder
piston rings and air
pressure (See
Go to Step The cylinder pressure is cylinder (see Section 11
Section 11 - Engine
19 too low – Mechanical system -
mechanical system
Piston and connecting
– General inspection
rod - Repair)
– Cylinder pressure
• Replace the cylinder
inspection)
head gasket (see
Section 11 - Mechanical
system - Cylinder head
- Repair)
Inspection by
replacement
Replace the engine

ECM with the same
Diagnosis is Locate the causes from
type and inspect The fault still exists
finished other fault phenomenon
whether the fault is
eliminated
2. The engine idle speed is instable

Start the engine and The engine idle

Diagnosis is
inspect the engine speed is instable Go to Step 1
finished
operation (too high or too low)

diagnostic tool
No fault
Read the fault code solve the fault depending on
code, go to If it has fault code
with the fault code.
Step 2
Inspect the intake

system
• Reinstall the upper and

lower air filter covers
(See Section 14 – Intake/
exhaust system - Air filter -
Replacement)
• The upper and • Replace the upper or
lower covers of air lower cover of air filter
filter are not tightly (See Section 14- Intake/
Inspect the operation fastened The upper exhaust system air filter -
conditions of the or lower cover of air replacement)
intake system filter is damaged •Clean or replace the air
(See Section 14 • The air filter filter (See Section14 – Inlet/
Go to Step 3
– Intake/exhaust clogging exhaust system - Air filter -
system - General • The intake Replacement)
inspection - System manifold connection • Reinstall the intake
inspection) is not fastened manifold (See Section 14
The intake manifold – Inlet/exhaust system
is - Engine intake tube -
damaged Replacement)
• Replace the damaged
intake manifold (See Section
15- Inlet/exhaust system
- Engine Intake tube -
Replacement)
Inspect the water

temperature sensor
Inspect the operation

of the water
temperature sensor Replacement (See Section
T h e w a t e r
(See Section 12 15 - Cooling system -
Go to Step 4 temperature sensor
- Engine control Water temperature sensor -
is damaged
system - Engine Replacement)
control system -
General inspection)

I n s p e c t t h e
4 intake pressure Normal Faulty Instruction
temperature sensor

of intake pressure
and temperature Replacement (See Section
sensor (See The inlet pressure 14- Inlet/exhaust system
Section 12 – Go to Step 5 and temperature - Intake pressure and
Engine control sensor is damaged temperature sensor -
system – Engine Replacement)
control system –
General inspection)

position sensor

conditions of the
throttle position
Replace the throttle body
sensor (See
The throttle position (See Section 14 – Intake/
Section 12 – Go to Step 6
sensor is damaged exhaust system – Throttle -
Engine control
Replacement)
system – Engine
control system –
General inspection)
Inspect the throttle 11

body
conditions of the Clean or replace the throttle
throttle body (See The throttle body body (See Section 14 –
Section 14- Inlet/ Go to Step 7 is blocked or Intake/exhaust system –
exhaust system - damaged Throttle - Replacement)
General inspection -
System inspection)
Check the fuel

pressure
Inspect fuel pressure

conditions of the fuel
See Section 13 – Fuel
system (See Section
The fuel system system – Diagnostics -
13 - Fuel system – Go to Step 8
pressure is too low Troubleshooting (3. The fuel
General inspection
system pressure is too low)
- Fuel system
Inspect the fuel

injector

operation (See
Section 12 – Engine Individual or Replacement (see Section
control system Go to Step 9 multiple injectors 13 - Fuel system – Fuel
– Engine control are operated poorly injector - Replacement)
system – General
inspection)

coil

coil operation (See
Replacement (See Section
Section 18 - Ignition Go to Step The ignition coil is
17 - Ignition system - Ignition
system - General 10 damaged
coil - Replacement)
inspection - Ignition
coil inspection)
10 Check the spark plug Normal Faulty Instruction
Inspect the spark • There is oil dirt

plug operation (See and carbon deposits Clean or replace the spark
Section 17 - Ignition Go to Step on the spark plug plug (See Section 17 -
system - General 12 • The spark plug is Ignition system - Spark plug
inspection - Spark damaged - Replacement)
plug inspection)

pressure
• Inspect and adjust the

air valve clearance (See
Inspect the operation Section 11 – Mechanical
conditions of the system – Air valve - Repair)
cylinder pressure • Inspect piston, piston rings
(See Section 11 - Go to Step The cylinder and cylinder (See Section 11
Engine mechanical 12 pressure is too low - Mechanical system - Piston
system – General and connecting rod - Repair)
inspection – Cylinder • Replace the cylinder
pressure inspection) g a s k e t ( S e e S e c t i o n 11
- Mechanical system –
cylinder head - repair)
Inspection by
replacement
Replace the engine

ECM with the same
eliminated
3. The engine acceleration is instable

The engine acceleration

is instable (during
Start the engine and acceleration process,
Diagnosis is
inspect the engine there is black smoke, Go to Step 1
finished
operation acceleration ignition,
acceleration jitter, knock
or etc.)

diagnostic tool
No fault If it has fault code, solve Perform troubleshooting

Read the fault code
code, go to the fault depending on based on the fault code
with
Step 2 the fault code. prompt
Inspect the fuel

quality
Inspect the fuel The fuel with poor

Go to Step 3 Replace the fuel
quality quality is used
Inspect the intake

system
• Reinstall the upper

and lower air filter
covers (See Section
14 – Intake/ exhaust
system - Air filter -
11
Replacement)
• Replace the upper and
lower air filter covers
(See Section14 – Inlet/
Inspect the operation • The upper or lower exhaust system - Air
conditions of the cover of air filter is filter - Replacement)
intake system damaged • Clean or replace the
(See Section 14 • The air filter clogging air filter (See Section14
Go to Step 3
– Intake/exhaust • The intake manifold – Inlet/exhaust system –
system - General connection is not Air filter - Replacement)
inspection - System fastened The intake • Reinstall the intake
inspection) manifold is damaged manifold (See Section
14 – Inlet/exhaust
system - Engine intake
tube - Replacement)
• Replace the damaged
intake manifold (See
Section 14- Inlet/
exhaust system -
Engine Intake tube -
Replacement)
Inspect the water

temperature sensor

of the water
Replacement (See
temperature sensor
Section 16 – Cooling
(See Section 12 The water temperature
Go to Step 5 system – Water
- Engine control sensor is damaged
temperature sensor -
system - Engine
Replacement)
control system -
General inspection)
I n s p e c t t h e
temperature sensor

of intake pressure
Replacement (See
and temperature
Section 14- Inlet/
sensor (See The inlet pressure and
exhaust system -
Section 12 – Go to Step 6 temperature sensor is
Intake pressure and
Engine control damaged
system – Engine
Replacement)
control system –
General inspection)
position sensor

conditions of the
Replace the throttle
throttle position
body (See Section
sensor (See Section The throttle position
Go to Step 7 14 – Intake/ exhaust
12 – Engine control sensor is damaged
system – Throttle -
system – Engine
Replacement)
control system –
General inspection)
Check the knock

sensor

conditions of the
Replacement (See
Knock sensor (See
Section 11 – Engine
Section 12- Engine
Go to Step 8 Knock sensor damage mechanical system –
control system
Wiring harness and
- Engine control
sensor - Replacement))
system - General
inspection)
Check the fuel

pressure

conditions of the fuel See Section 13 - Fuel
system (See Section system – Diagnostics -
The fuel system
13 - Fuel system - Go to Step 9 Troubleshooting (3. The
pressure is too low
General inspection fuel system pressure is
- Fuel system too low)

Inspect the fuel
injector

operation (See
Replacement (See
Replacement)
system – General
inspection)

coil

Section 17 - Ignition Go to Step The ignition coil is Section 17 - Ignition
system - General 11 damaged system - Ignition coil -
coil inspection)

Inspect the spark
Inspect the spark plug
plug operation (See
•There is oil dirt and operation (See Section
Section 17 - Ignition Go to Step
carbon deposits on the 17 - Ignition system -
system - General 12
spark plug General inspection -
inspection - Spark
Spark plug inspection) 11
plug inspection)
Inspect the exhaust
recycling system

conditions of the
carbon canister Replacement (See
solenoid valve (See The carbon canister Section 17 - Exhaust
Go to Step
17 - Exhaust control solenoid valve is control system - Carbon
13
system - General damaged canister solenoid valve
inspection – Carbon - Replacement)
cylinder solenoid
valve inspection)

pressure

conditions of the
•Inspect and adjust the
cylinder pressure
(See Section 11 - Go to Step The cylinder pressure is
Engine mechanical 14 too low
system - General
Repair)
inspection - Cylinder
Inspect the catalytic

converter

of the catalytic Replacement (see
converters (see Section 14 - Intake/
Go to Step The catalytic converter
Section 19 - Exhaust exhaust system -
15 is blocked
control - General Catalytic converter -
inspection - Catalytic Replacement)
converter inspection)
Inspection by
replacement
Replace the engine

ECM with the same
Locate the causes from
type and inspect Diagnosis is finished
other fault phenomenon
eliminated
4. The engine power is power

Start the engine and

measure the engine Diagnosis is Insufficient power of
Go to Step 1
power on the test finished engine
bench

diagnostic tool
No fault If it has fault code, solve (See Section 12 -

Read the fault code
code, go to the fault depending on Engine control system -
with
Step 2 the fault code. Fault diagnosis)
2 Inspect the fuel Normal Faulty Instruction
Inspect the fuel The fuel with poor

Go to Step 3 Replace the fuel
quality quality is used
Inspect the intake

system
Inspect the operation air filter element (See
• The air filter clogging
conditions of the Section 14 - Intake and
•The air intake tube is
intake system exhaust system - Air
blocked
(See Section 14 filter - Replacement)
Go to Step 4 •Too long air inlet caused
– Intake/exhaust •Clean and clear the air
by any unreasonable
system - General intake tube
modification
inspection - System •Inlet manifold
inspection) arrangement when
factory restoring
Inspect the exhaust

system

• Replace the catalytic
converter (See Section
•The catalytic converter
14-Inlet/exhaust system
is blocked
- Catalytic converter -
•The connecting tube
Inspect the exhaust Replacement)
and bellows is blocked
system for clogging •Clean and unplug the
•The front muffler is
conditions (See connecting tube and
blocked
Section 14-Inlet/ Go to Step 5 bellows
• T h e r e a r m u ff l e r i s
exhaust system - •Clean and clear the
blocked
General inspection - front muffler
• The exhaust
System inspection) •Clean and clear the
manifold is too long
rear muffler
due to unreasonable
• Restore the factory
modifications
layout of exhaust
manifold
Inspect the water

temperature sensor

of the water
Replacement (See
temperature sensor
Section 15 - Cooling
(See Section 12A The water temperature
Go to Step 6 system - Water
- Engine control sensor is damaged
system - Engine
Replacement)
control system -
General inspection)
11
position sensor

conditions of the
throttle position Replace the throttle
sensor (See Section The throttle position body (See Section 14 –
Go to Step 7
12A – Engine control sensor is damaged Intake/exhaust system –
system - Engine Throttle - Replacement)
control system –
General inspection)

body

conditions of the Clean or replace the
throttle body (See throttle body (See
The throttle body is
Section 14- Inlet/ Go to Step 8 Section 14 – Intake/
blocked or damaged
exhaust system - exhaust system –
General inspection - Throttle - Replacement)
System inspection)
I n s p e c t t h e
temperature sensor

of intake pressure Replacement (See
and temperature Section 14- Inlet/
The inlet pressure and
sensor (See Section exhaust system -
Go to Step 9 temperature sensor is
12 - Engine control Intake pressure and
damaged
system - Engine temperature sensor -
control system - Replacement)
General inspection)
Check the fuel

pressure

conditions of the fuel See Section 13 - Fuel
system (See Section system diagnostics -
Go to Step The fuel system
13 - Fuel system - Troubleshooting (3. The
10 pressure is too low
General inspection fuel system pressure is
- Fuel system too low)
Inspect the fuel

injector

of the fuel injector See Section 13 - Fuel
(See Section 12 system – Diagnostics -
Go to Step The fuel system
– Engine control Troubleshooting (3. The
11 pressure is too low
system – Engine fuel system pressure is
control system – too low)
General inspection)
coil

Section 17 - Ignition Go to Step The ignition coil is Section 17 - Ignition
system - General 12 damaged system - Ignition coil -
coil inspection)
Inspect the spark

Inspect the spark plug
plug operation (See
•There is oil dirt and operation (See Section
Section 17 - Ignition Go to Step
carbon deposits on the 17 - Ignition system -
system - General 13
spark plug General inspection -
inspection - Spark
Spark plug inspection)
plug inspection)
Inspect the exhaust

recycling system

conditions of the
carbon canister Replacement (See
solenoid valve (See The carbon canister Section 14 - Exhaust
Go to Step
17 - Exhaust control solenoid valve is control system - Carbon
14
system - General damaged canister solenoid valve
inspection – Carbon - Replacement)
cylinder solenoid
valve inspection)

pressure

Repair)
conditions of the
•Inspect piston, piston
cylinder pressure
rings and cylinder (See
system - Piston and
system - General
connecting rod - Repair)
inspection - Cylinder
•Replace the cylinder
gasket (See Section 11
11
Inspection by
replacement
Replace the engine

ECM with the same
type and inspect Diagnosis is finished
eliminated
5. The exhaust smoke color is abnormal (black smoke)

Start the engine, hold

it at idle speed and Diagnosis is
Black exhaust Go to Step 1
inspect the exhaust finished
color
Inspect the intake

system

•Clean or replace the
Inspect the operation air filter cartridge (See
conditions of the
• The air filter clogging Section 14- Intake/
intake system (See
Go to Step •The air intake tube is
Section 14 – Intake/ exhaust system air filter
2 blocked
exhaust system - - replacement)
System inspection) •Clean and clear the air
intake tube
Inspect the exhaust

system
•• Replace the catalytic
converter (See Section
14-Inlet/exhaust system
- Catalytic converter -
•The catalytic converter
Inspect the exhaust Replacement)
is blocked
system for clogging
•The connecting tube •Clean and unplug the
conditions (See
Go to Step and bellows is blocked
Section 15-Inlet/ connecting tube and
3 •The front muffler is
exhaust system - bellows
blocked
• T h e r e a r m u ff l e r i s •Clean and clear the
System inspection)
blocked
front muffler
•Clean and clear the
rear muffler
Inspect the water

temperature sensor
•Clean or replace the

air filter cartridge (See
Inspect the operation Section 14- Intake/
• The air filter clogging
of the water
exhaust system air filter
temperature sensor
•The air intake tube is - replacement)
(See Section 12A Go to Step
blocked
- Engine control 4 •Clean and clear the air
•Too long air inlet caused
system - Engine
by any unreasonable intake tube
control system -
modification •Inlet manifold
General inspection)
arrangement when
factory restoring

position sensor

conditions of the
throttle position Replace the throttle
sensor (See body (See Section 14 –
Go to Step The throttle position
Section 12 –
5 sensor is damaged Intake/exhaust system –
Engine control
system - Engine Throttle - Replacement)
control system –
General inspection)
I n s p e c t t h e
temperature sensor

of intake pressure Replacement (See
and temperature Section 14- Inlet/
sensor (See The inlet pressure and exhaust system -
Go to Step
Section 12 - Engine temperature sensor is
6 Intake pressure and
control system damaged
- Engine control temperature sensor -
system - General Replacement)
inspection)
Inspect the oxygen

sensor
Inspect the operation Replacement (See 11

of oxygen sensor
(See Section 19 Section 19 - Exhaust
Go to Step
- Exhaust control Oxygen sensor damage control system - Front/
7
system - General rear oxygen sensor -
inspection, Oxygen
sensor inspection) Replacement)

clearance
Inspect the air valve Adjustment (see Section

clearance (See 11 - Engine mechanical
Go to Step The air valve clearance
Section 11 - Engine
8 is too big system – Air valve -
Air valve - Repair) Repair)
Inspect the fuel

injector
Inspect the injector Replacement (See

operation (See Section 14- Inlet/
Section 12 – Engine Single or multiple exhaust system -
Go to Step
9 Intake pressure and
– Engine control abnormally
system – General temperature sensor -
inspection) Replacement)

pressure

Repair)
conditions of the •Inspect piston, piston
cylinder pressure rings and cylinder (See
system - General system - Piston and
inspection - Cylinder connecting rod - Repair)
•Replace the cylinder
gasket (See Section 11
Inspection by
replacement
Replace the engine

ECM with the same Locate the causes from
Diagnosis is
eliminated
6. The exhaust smoke color is abnormal (white smoke))


measure the engine Diagnosis is
White exhaust Go to Step 1
power on the test finished
bench
1 Confirm the ambient Normal Faulty Instruction
The ambient
Confirm the ambient T h e a m b i e n t
temperature Go to Step 2
operation temperature is normal
is too low
Inspect the fuel

2 Normal Faulty
quality
Inspect the fuel Go to Step

Use low quality fuel Replace the fuel
grade 3

liner

Inspect cylinder liner
condition (See
Section 11 - Engine Go to Step The cylinder line is Replace the cylinder
mechanical system 4 cracked liner
- Cylinder block -
Repair)
4 Verify the repair Normal Faulty Instruction
Install the system,

inspect whether the The fault still exists
fault is eliminated
7. The exhaust smoke color is abnormal (blue smoke)

Start the engine, hold

it at idle speed and Diagnosis is
Blue exhaust Go to Step 1
inspect the exhaust finished
color
1 Inspect the oil grade Normal Faulty Instruction 11

Inspect the oil grade
for correctness R e p l a c e t h e
(See Section 16- recommended oil
Go to Step
Lubricating system - The oil grade is incorrect (See Section 16 -
2
General inspection Lubrication system – Oil
- Engine oil - Replacement)
inspection)

2 Normal Faulty 障
assembly
• Replace the valve
seal (See Section 11
Inspect installation
- Engine mechanical
of air valve, valve • The air valve seal is
system - Air valve,
guide, or valve seal aged and damaged
Go to Step Repair)
(See Section 11 - • The clearance between
3 •Replace the air valve or
Engine mechanical air valve and valve guide
the air valve guide (See
system – Air valve - is too big
Section 11 - Engine
Repair)
Air valve - Repair)
Inspect the piston or

piston rings

•Replace the piston
rings (See Section 11
- Engine mechanical
system - Piston and
• The clearance between
Inspect installation connecting rod - Repair)
piston ring and piston
of piston or piston • Replace the piston
ring groove are not
rings (See Section and piston rings (See
proper
11 - Engine Go to Step Section 11 - Engine
• The piston or piston
mechanical system 4 mechanical system -
ring is worn severely
- Piston and Piston and connecting
• The elasticity of the
connecting rod - rod - Repair)
piston ring does not
Repair) •Replace the piston
meet the requirements
- Engine mechanical
system - Piston and
4 Verify and check Normal Faulty Instruction
Install the system,

Diagnosis Locate the causes from
end other fault phenomenon
fault is eliminated
8. The engine oil pressure is too low (natural step-down mode)


hold it at idle speed,
Diagnosis is The oil pressure warning
and inspect the oil Go to Step 1
finished indicator is turned on
pressure warning
indicator
Inspect the oil

pressure alarm

of the oil pressure
alarm (See Section Replacement (See
16 - Lubricating Go to Step The oil pressure alarm is Section 16 - Lubricating
system - General 2 damaged system - Oil pressure
Inspection - Oil alarm - Replacement)
pressure alarm
inspection)
Inspect the engine

2 Normal Faulty 障
oil pressure

Inspect the engine
oil pressure with the
oil pressure gauge
(See Section 16 - Diagnosis is The oil pressure is too
Go to Step 3
Lubricating system - finished low
General inspection
- Oil pressure
inspection)
3 Inspect the oil Normal Faulty Instruction
Inspect the oil

conditions (See • Fill the oil
Section 16 - • Replace the oil
Go to Step • The oil is shortage
Lubricating (See Section 16 -
4 • The oil is deteriorated
system - General Lubricating system – Oil
inspection - Engine - Replacement)
oil inspection)
Inspect that the oil

filter
of the oil filter Replacement (See
(See Section 16 - Go to Step Section 16 - Lubrication
The oil filter is clogged
Lubricating system - 5 system - Oil filter -
General inspection- Replacement)
System inspection) 11
Inspect the oil
strainer

of the oil strainer
(See Section
Go to Step The oil strainer is
16 - Lubricating Clean the oil strainer
6 blocked
system - General
inspection - System
inspection)
6 Inspect the oil pump Normal Faulty Instruction

conditions of the oil •Oil pump pressure relief Replace the oil pump
pump (See Section Go to Step valve fault (See Section 16 -
16 - Lubrication 7 •Oil pump pressure relief Lubrication system - Oil
system - Oil pump - valve fault pump - Replacement)
Repair)
Inspect the main

7 shaft tiles and Normal Faulty Instruction
connecting rod tiles

Inspect the wear of
Replace the main shaft
the main shaft tiles
tiles or connecting rod
and connecting rod
tiles (See Section 11
(See Section 11A - The main shaft tile or
Go to Step - Engine mechanical
Engine mechanical connecting rod tile is
8 system - Piston and
system - Piston worn severely
connecting rod/
and connecting
crankshaft and flywheel
rod/crankshaft and
– Repair)
flywheel - Repair)
Inspect the engine

life cycle record
Inspect the engine

life cycle record,
and confirm the
Go to Step The engine needs an
engine for overhaul Overhaul the engine
9 Repair.
according to the
maintenance
requirements
Install the system,

fault is eliminated
9. The engine oil pressure is too low (sudden step-down mode)


hold it at idle speed,
Diagnosis is The oil pressure warning
and inspect the oil Go to Step 1
finished indicator is turned on
pressure warning
indicator
Inspection by
replacement
Replace the oil

pressure alarm with
Diagnosis is
the same type and The fault still exists Go to Step 2
finished
inspect the fault for
elimination
2 Inspect the oil pump Normal Faulty

conditions of the oil •Oil pump pressure relief Replace the oil pump
pump (See Section Go to Step valve fault (See Section 16 -
16 - Lubrication 3 • Oil pump mechanical Lubrication system - Oil
system - Oil pump - fault pump - Replacement)
Repair)


Install the system,
fault is eliminated
10. The engine temperature is too high

Start the engine,

operate the engine
at idling speed and Diagnosis is The oil pressure warning
Go to Step 1
inspect the water finished indicator is turned on
temperature alarm
indicator
Inspect the water

temperature sensor

of the water
temperature sensor
(See Section 12 Diagnosis is
The fault still exists Go to Step 2
- Engine control finished
system - Engine
control system - 11
General inspection)
2 Inspect the cooling Normal Faulty Instruction
I n s p e c t t h e
remaining coolant Fill the coolant (See
volume (See Section Go to Step Section 15 - Cooling
Insufficient coolant
15 - Cooling system 3 system – Coolant -
- General inspection Filling)
– Coolant inspection)
Check the heat
radiator.
Inspect the radiator

Clean or replace the
operation (See The radiator is blocked
Go to Step radiator (See Section
Section 15 - Cooling or the radiator element
4 15 - Cooling system –
system – Radiator - is damaged
Radiator - Repair)
Repair)
Check the cooling

fan

of the cooling fan
See Section 15 -
(See Section 15 -
Go to Step Cooling system
Cooling system - Failure of cooling fan
5 – Diagnostics -
General inspection
Troubleshooting
- Cooling fan
inspection)

I n s p e c t t h e
thermostat
I n s p e c t t h e
t h e r m o s t a t
Replacement (See
operation (See 15 The thermostat is faulty
Go to Step Section 15 - Cooling
- Cooling system - and can not be turned
5 system – Thermostat -
General inspection on completely
Replacement)
– Thermostat
inspection)
Check the water

pump.
Inspect the water

pump operations Replacement (See
(See Section 15 Go to Step Section 15 - Cooling
Damages of water pump
- Cooling system 7 system - Water pump -
- Water pump - Repair)
Repair)
7 Inspect the piston Normal Faulty Instruction
Inspect the piston

for carbon deposits
The carbon deposits on
(See Section 11 - Go to Step
the top of the piston is Clean the piston
Engine mechanical 8
too much
system - Piston and
connecting rod)
Inspection by
replacement
Replace the engine

ECM with the same
eliminated
11. The engine has an abnormal sound (natural progressive abnormal sound)


Diagnosis is
listen to the engine Abnormal engine sound Go to Step 1
finished
operation sound
Inspect the exhaust

system
Inspect the exhaust

system operations • The exhaust manifold
• Retighten the fixing
(See Section 14 fixing bolt is loosened
Go to Step bolt
– Intake/exhaust • The exhaust manifold
2 • Replace damaged part
system - General suspension or hoop is
inspection - System loosened or damaged
inspection)

assembly
• Adjust the air valve
clearance (See Section
11 - Engine mechanical
Repair)
air valve tappet (See
Section 11 - Engine
Air valve - Repair)
• The air valve clearance
• Replace the valve
is too small
spring (See Section 11
• The air valve tappet is
- Engine mechanical
dirty, blocked or worn
• The valve spring
Repair)
Inspect the air is broken or loss of
• Replace the air valve
valve assembly elasticity
( S e e S e c t i o n 11 -
operations (See Go to Step • The air valve is stuck
Engine mechanical
Section 11 - Engine 3 • The clearance between
mechanical system air valve and valve guide
Repair)
– Air valve - Repair) is too big
•Replace the air valve or
• The air valve seal is
the air valve guide (See
not tightly sealed
Section 11A - Engine
• The camshaft flange is
mechanical system – 11
damaged
Air valve - Repair)
• Grind the air valve
( S e e S e c t i o n 11 -
Engine mechanical
Repair)
• Replace the camshaft
( S e e S e c t i o n 11 -
Engine mechanical
system – Camshaft –
Repair)
3 Inspect the camshaft Normal Faulty Instruction
Inspect the camshaft

Adjust the camshaft
operations
axial clearance (See
(See Section 11 - Go to Step The camshaft axial
Section 11 - Engine
Engine mechanical 4 clearance is too big
system – Camshaft
Camshaft - Repair)
- Repair)
Inspect the main Inspect the main shaft

4 shaft tiles and Normal Faulty tiles and connecting rod
connecting rod tiles tiles

I n s p e c t t h e
operations of Inspect the operations
main shaft tile and of main shaft tile and
connecting rod tile connecting rod tile (See
The main shaft tile or
(See Section 11 – Go to Step Section 11 – Engine
connecting rod tile is
Engine mechanical 5 mechanical system –
worn or dislocated
system – Piston Piston and connecting
and connecting rod/crankshaft and
rod/crankshaft and flywheel - Repair)
flywheel - Repair)
5 Inspect the piston Normal Faulty Instruction
• Clean the carbon

deposits on top of the
piston
• Replace the piston
pin (See Section 11
- Engine mechanical
• There are excessive
system - Piston and
Inspect the piston carbon deposits on top
operations (See of the piston
Section 11 - Engine • The piston pin is worn
Go to Step or cylinder liner (See
mechanical system • The clearance between
5 Section 11 - Engine
- Piston and the piston and the
mechanical system -
connecting rod - cylinder liner is too big
Piston and connecting
Repair) • The piston rings are
rod - Repair)
worn or damaged
- Engine mechanical
system - Piston and
6 Check crankshaft Normal Faulty Instruction
Adjust the crankshaft

Inspect crankshaft axial clearance (See
operations (See Go to Step The crankshaft axial Section 11 - Engine
Section 11 - Engine 7 clearance is too big mechanical system -
mechanical system) Crankshaft and flywheel
- Repair)
7 Inspect the flywheel Normal Faulty Instruction
Inspect the flywheel

Replace the flywheel
operations (See
bolt (See Section 11
Section 11 - Engine Go to Step The flywheel bolt is
- Engine mechanical
mechanical system 8 loosened or broken
system - Crankshaft
- Crankshaft and
and flywheel - Repair)
flywheel - Repair)
Install the system,

fault is eliminated
12. The engine has an abnormal sound (sudden abnormal sound)


Diagnosis is
listen to the engine Abnormal engine sound Go to Step 1
finished
operation sound
Inspect the fuel

injector

operation (See
Replacement (See
Replacement)
system – General
inspection)
2 Inspect the piston Normal Faulty
Inspect the piston

operations (See Replace the piston and
Section 11 - Engine the cylinder liner (See
Go to Step The piston is scratched
mechanical system 11 - Engine mechanical
3 with the cylinder liner
- Piston and system - Piston and
connecting rod - connecting rod - Repair)
Repair)
11
Install the system,

fault is eliminated
Engine assembly
Change
1. Remove the engine with the transmission assembly
(a). Keep the power in “OFF” state.
Warning: do not perform the following operation items unless the engine cools
down.
(b). Remove the engine trim cover.
(c). Drain the engine oil. (See Section 16 - Lubrication system – Oil - replacement)
(d). Remove the engine oil inlet pipe as well

as carbon tank solenoid valve connecting
hose.
LFWX-6470-11008
(e). Remove the batteries. (See Section 18 -

Batteries - Replacement)
LFWX-6470-18002
(f). Disconnect the connecting hose of air

filer and engine, and remove the air filter
assembly. (See 14 – Air Filter of Air Intake/
Exhaust System, Replacement)
(g). Disconnect the connection of water inlet

and outlet pipe of radiator and engine.
△ Tips:
The radiator outlet pipe is connected at the right
lower corner of the radiator.
11
(h). Disconnect the connection of warm water

inlet and outlet pipes and engine.
(i). Remove gear selecting and shifting flexible
shaft of transmission. (See 21 – Manual
Transmission, Transmission Operating
Mechanism, Replacement).
(j). Remove the clutch slave cylinder (See Section 22 – Clutch - Clutch slave cylinder -
Replacement)
(k). Remove the front wheel (See Section 33 - Wheels and tires - Wheel assembly -
Replacement)
(l). Remove the drive shaft. (See Section 41 – Drive shaft - Dive shaft - Replacement)
(m). Remove the connecting pipe of air
condition compressor and engine. (See
71 Air Conditioning System Compressor,
Replacement).
(n). Remove emission purifying device. (See
14- Front Muffler and Purifier Assembly of
Air Intake/Exhaust System, Replacement)
LFWX-6470-11144
(o). Remove steering gear oil inlet and outlet

pipe connected with engine and oil inlet
and outlet pipe of steering oil can. (See
61 – Power Steering Pump of Hydraulic
Steering System, Replacement).
LFWX-6470-11145
(p). Disconnect the engine ECM.

The engine ECM is mounted on
the instrument panel tube, and
you can see it after removing the
glove box on the right side of the
instrument panel.
Note:
When disconnecting the
connector, do not pull the
wiring harness to prevent it
from breakage.
LFWX-6470-11006
(q). Disconnect the engine harness from the electrical box.

(r). Lift the vehicle.
(s). Remove the steering column. (Refer to 61 - hydraulic steering system, steering
shaft, Replacement)
(t). Remove the auxiliary frame and front

beam. (See 31 front suspension)
LFWX-6470-11012
(u). Use special tools to lift the engine.

(v). Remove the bolts/nuts that connect the left
suspension bracket/right suspension with
the engine.
Mounting torque: 75 ~ 85 N.m
(x). Slowly lower the special tool to remove the
engine with transmission assembly.
Note: 11
• Bef ore lowering t he engine, ch eck
whether all the connectors, ground wires,
oil pipes, vacuum pipes and water pipes
LFWX-6470-11013 are completely disconnected.
• Check the parts around the engine while
lowering it to avoid the engine damage due
to the squeezing.
• Ensure to support the engine firmly. When
lowering the engine, prevent it touching
the vehicle and ensure the personal safety
around.
2. Mount the engine with transmission assembly
Install them back in the sequence reverse to the removal sequence of the engine
transmission assembly.
Note:
• Prevent the engine touching the bodywork and parts around while lifting the
engine and protect the persons.
• Check whether all the connectors, ground wires, oil pipes, vacuum pipes and water
pipes are completely disconnected.
• To prevent the oil tubing, vacuum tubing, air conditioning tubing and water tubing
components from extrusion and damage.

Change
To engine ECU To front section harness assembly
To ignition coil D To coolant temperature sensor
To injector D To carbon canister solenoid valve
To ignition coil C To power ground
To injector & To CPS sensor
To ignition coil B To gear sensor
To injector %
To ignition coil B
To front oxygen sensor $
To injector $
To intake VVT valve
To knock sensor
To temperature sensor
To alternator governor
To A/C solenoid switch To reverse lamp switch
To oil pressure sensor To electronic control throttle valve body
To start switch To intake CAM sensor
LFWX-6470-11001
1. Remove the engine wiring harness and sensor

(a). Disconnect the ignition coil and injector connector.
(b). Disconnect the carbon canister solenoid valve connector.
(c) Disconnect the throttle position sensor connector.
(d). Disconnect the camshaft position sensor connector and remove the camshaft
position sensor.
(e) Disconnect the water temperature sensor connector and remove the water
temperature sensor.
(f) Disconnect VVT control valve connector and remove VVT control valve.
(g). Disconnect the intake pressure and temperature sensor connector and remove the
intake pressure and temperature sensor.
Tips:
The inlet pressure and temperature sensor is located on the back of the intake manifold.
(h). Disconnect the knock sensor connector and remove the knock sensor.
Tips:
The knock sensor is located on the cylinder below the intake manifold.
(i). Disconnect the crankshaft position sensor connector and remove the crankshaft
position sensor.
Tips:
The crankshaft position sensor is located on the transmission housing.
(j). Disconnect the reverse switch connector.
Tips:
The reverse switch is located on the transmission housing.
(k). Disconnect the front oxygen sensor connector.
Tips:
The front oxygen sensor connector is located on the exhaust manifold.
(l). Disconnect air conditioning compressor electronic clutch connector.
(m). Remove the generator power output wire and disconnect the generator connector.
(n). Disconnect the oil pressure alarm connector, and remove the oil pressure alarm.
Tips:
The oil pressure alarm is located on the oil filter.
(o). Remove the starter power wire and disconnect the starter connector.
(p). Remove the grounding wire on the transmission housing.
(q). Remove the negative grounding fixing screw on the transmission and disconnect the
negative grounding wiring harness.
2. Install the engine wiring harness and sensor 11
Tips:
Follow the reverse order of disassembly
Connect the connector; a "click" sound issued indicates that it is connected in place.
Note:
Ensure that each harness connector is securely connected and free of loosening.
Intake manifold
Component drawing
LFWX-6470-11014
Hexagon head bolt and plain washer

1 Rubber seal ring 3
assembly
2 Intake manifold assembly 4 Hexagon flange nut

Repair
1. Remove the intake manifold.

(a). Remove the water tank upper beam trim
panel. (See Section 81 – Inner and outer
trims – Water tank upper beam trim panel -
Replacement)
(b). Disconnect the intake pressure and
temperature sensor connector ① .
(c). Disconnect the throttle position sensor
connector ② .
LFWX-6470-11015
(d) Remove the vacuum booster hose.
11
LFWX-6470-11016
(e). Disconnect air filter hose ④ and engine.

Note:
Block the throttle air inlet with a clean plastic
strap or equivalent, to prevent foreign matter
1
from entering.
2 (f) Removing PCV valve hose ① fastening
3
4 clamp and disconnect the hose connection.
(g) Remove the carbon canister control valve
hose ② .
(h) Remove the engine ventilation hose ④ .
LFWX-6470-11017
(i) Remove the intake manifold mounting bolt

and nut, and remove the intake manifold
and throttle body assembly.
(j) Remove the throttle body mounting bolt
and remove the throttle body assembly.
LFWX-6470-11018
2. Inspect intake manifold and throttle

(a). Check the intake manifold for crack or other damage and replace it if any.
(b). Check the intake manifold fitting face for deformation and replace it if any.
(c) Inspect the intake manifold rubber seal ring for damage; if damaged, replace it.
(d). Check the throttle body for dirt and clean it if any.
3. Install the intake manifold

(a). Install the throttle body assembly onto the
intake manifold, and install the mounting
bolts and tighten them.
Torque: 10 ~ 12 N•m
(b). Install the intake manifold and throttle body
assembly onto the cylinder head, and
install the mounting bolts and nuts and
tighten them.
Torque: 30 N•m
LFWX-6470-11018
(c) Install the air filter hose and the clamp onto
the throttle body and fasten the clamp ③ .
(d) Install PCV valve hose (1) and the clamp
1 onto the mounting position, and fasten the
clamp.
2 3 (e) Install the carbon canister control valve
4 hose ② .
(f) Install the engine breather hose (4) onto
the mounting position.
Note:
Ensure that all tubes are connected securely
LFWX-6470-11017 and reliably
(g) Install the vacuum booster hose.
LFWX-6470-11016
(h). Install the inlet pressure and temperature

sensor connector ① .
(i) Install the throttle position sensor connector
②.
11
LFWX-6470-11015
Timing sprocket
Component drawing
1 Hexagon flange nut 13 Exhaust timing sprocket
2 Shock absorber 14 Exhaust timing sprocket bolt
3 Timing cover 15 Phaser bolt
4 Hexagon flange nut 16 Timing chain movable rail assembly
5 Timing chain tensioner 17 Slide rail positioning bolt
6 Tensioner bolt 18 Hexagon flange bolt
7 Tensioner assembly 19 Hexagon flange bolt

8 20 Hexagon flange bolt
assembly
9 Timing chain 21 Hexagon flange nut
Orbit determination components of
timing chain
11 Crankshaft timing sprocket 23 Crankshaft front oil seal
12 Air intake phaser assembly

Repair
1. Remove the timing sprocket mechanism

assembly.
(a) Remove the spark plug. (See Section
19 - Ignition system - Spark plug -
Replacement)
(b) Remove PCV valve hose ① fastening
clamp and disconnect the hose.
(c). Remove the ventilation hose ② .
LFWX-6470-11020
(d). Remove the cylinder head cover fixing bolt

and take out the cover.
11
LFWX-6470-11021
(e). Remove the generator assembly mounting

bolts and remove the generator assembly.
LFWX-6470-11022
(f). Remove the tensioner assembly.
LFWX-6470-11023
(g). Remove the right engine mounting bracket.
LFWX-6470-11024
(h) Remove the water pump fixing bolt, and

remove the water pump and seal ring.
Note:
The removed water pump seal should not be
used again, and must be replaced with a new
one, to avoid cooling pump leakage.
LFWX-6470-11025
(i). Remove the crankshaft pulley fixing bolts.

Tips:
When removing the crankshaft pulley fixing bolt, fix
the flywheel in advance to prevent the crankshaft
rotating.
(j). Take the crankshaft pulley out with the
puller.
Note:
Do not damage the crankshaft pulley whe
using the puller.
LFWX-6470-11026
(k) Remove the timing chain tensioner

mounting nut and remove the timing chain
tensioner.
11
LFWX-6470-11027
(l). Remove timing cover erection bolt and take

down the timing cover.
Tips:
When removing the timing cover, tap it with the
rubber hammer gently since the sealant may
impair the removal.
Note:
Do not use the hammer or hard tool.
LFWX-6470-11028
(m) Remove the timing chain movable rail

assembly ① and the fixed rail assembly ② .
Note:
In removal of the timing parts, to prevent that
the piston is blocked by the valve tappet or
other parts due to camshaft or crankshaft
rotation, before removal, must rotate the
crankshaft to allow that all pistons are not on
TDC or bottom dead positions.
(n). Take out the timing chain.
LFWX-6470-11029
(o) Remove crankshaft timing sprocket

retainer.
(p) Remove the crankshaft timing sprocket
and the semicircle key.
Tips:
The semicircular key embedded in the pin
slot is not easy to remove, and can not be
removed. If it is required for removal, it must
not be omitted in the installation.
LFWX-6470-11030
(q) Remove the exhaust timing sprocket ①

mounting bolt, and remove the exhaust
timing sprocket ① .
(r). Remove the phaser bolt and remove the
intake phaser assembly ② .
LFWX-6470-11031
Note:
To prevent the camshaft rotating during the
removal, apply the reverse acting force to the
camshaft with the wrench (as shown in the left
figure).
LFWX-6470-11032
2. Inspect the timing chain tensioner

(a) Lift the tensioner shaft locking plate (1) and
inspect the tensioner shaft (2) for extension
and retraction movement; if not, replace
the tensioner.
11
LFWX-6470-11033
(b) Make the locking plate ① to lock the l

tensioner shaft and inspect the tensioner
shaft ② for extension and retraction
movement; If so, replace the tensioner.
Note:
At this point, the tensioner shaft shall only be
retracted and not be extended.
LFWX-6470-11034
3. Check the timing chain

(a). Check the timing chain for damage and
replace it if any.
(b) As shown, apply a force of 140N onto the
timing chain with a spring pressure gauge
and measure the chain length with a
vernier caliper; if the maximum elongation
of the chain is exceeded, replace the chain.
Maximum elongation of the chain: 122.6mm
Tips:
Randomly select 3 or more points to inspect the
LFWX-6470-11035 chain length with the method as shown on the
left.
4. Inspect the exhaust timing sprocket

(a). Install the chain on the exhaust timing
sprocket.
(b). Measure the exhaust timing sprocket
diameter with timing chain with a vernier
caliper. If it is less than the specified value,
replace the exhaust sprocket.
` Minimum diameter: 97.3mm
Minimum diameter: 97.3mm
Note:
LFWX-6470-11036 the vernier caliper must be contacted with the
chain roller.
5. Inspect crankshaft timing sprocket

(a). As shown in the figure, install the chain on
the crankshaft timing sprocket.
(b). Measure the crankshaft timing sprocket
diameter with timing chain with a vernier
caliper. If it is less than the specified value,
replace the crankshaft sprocket.
Minimum diameter: 51.6mm
Note:
LFWX-6470-11037 chain roller.
6. Inspect the timing chain movable rail

assembly
(a). Measure the timing chain movable rail
thickness with a vernier caliper. If the rail
thickness is greater than the maximum
thickness, replace the timing chain
movable rail assembly.
Maximum thickness: 1.0mm
LFWX-6470-11038
7. Install the timing sprocket mechanism

assembly
(a). Install the exhaust timing sprocket ①
onto the mounting position, a d install the
mounting bolts and tighten them.
Torque: 54 N•m
(b). Install the intake phaser assembly ② onto 11
the installation position, and install the
phaser bolts and tighten them.
Torque: 60 N•m
LFWX-6470-11031
Note:
To prevent the camshaft rotating during the
installation,apply the reverse acting force to
the camshaft with the wrench (as shown in
the left figure)
LFWX-6470-11032
(c). Install crankshaft timing sprocket.

(d). Install the crankshaft timing sprocket
retainer ring.
LFWX-6470-11030
(e). Install the timing chain.

Note:
As shown in the figure, in installation of the
timing chain, the marks must be aligned.
LFWX-6470-11039
(f). Install the timing chain movable rail

assembly ① and the fixed rail assembly
② .
Torque: 23 N • m for movable rail
mounting bolt)
11 N • m (for fixed rail mounting bolt)
LFWX-6470-11029
(g). Apply the sealant to the timing cover fitting

face.
Note:
Ensure to clear the old sealant away before
applying the new sealant.
LFWX-6470-11040
(h). Install the timing cover onto the engine,

and install the mounting bolts and tighten
them.
Torque: 23 N•m
11
LFWX-6470-11041
(i). Install the timing chain tensioner onto the

mounting position, and install the mounting
nuts and tighten them.
Torque: 11 N•m
Tips:
When installing the timing chain tensioner, it is
necessary to lock the tensioner plunger with the
locking piece in advance. When the tensioner
fixing bolt is installed, rotate the crankshaft
counterclockwise to release the locking piece
from the buckle.
LFWX-6470-11027 (j). Rotate the crankshaft clockwise and
inspect the timing chain tensioner for
correct installation.
(k). Install the crankshaft pulley onto the

mounting position, and install the bolt
assemblies and tighten them.
Torque: 138 N•m
Tips:
When installing the crankshaft pulley bolt
assembly, fix the flywheel in advance to prevent
the crankshaft rotating.
LFWX-6470-11026
(l). Install the water pump and the seal onto

the mounting position, and install the
mounting boltw and tighten them.
Torque: 11 N•m
LFWX-6470-11025
(m). Install the right engine mounting bracket

onto the mounting position, and install the
fixing bolts and tighten them.
Torque: 52 N•m
LFWX-6470-11024
(n). Install the tensioner assembly onto the

Torque: 69 N • m (bolt); 29 N • m (nut)
LFWX-6470-11023
(o). Install the generator assembly onto the

mounting position, and install the fixing
Torque: 25 N • m (short bolt); 54 N • m
(longbolt)
11
LFWX-6470-11022
(p). Install the cylinder head cover onto the

Torque: 11 N•m
LFWX-6470-11042
(q). Install PCV valve hose ① and the clamp

onto the mounting position, and tighten the
clamp.
(r). Install the ventilation hose ② .
(s). Install the spark plug. (See Section
19 – Ignition system - Spark plug -
Replacement)
LFWX-6470-11020
Camshaft
Component drawing
LFWX-6470-11043
1 Intake camshaft 2 Exhaust camshaft

Repair
1. Remove the camshaft assembly

(a). Remove the timing sprocket mechanism
assembly. (See Section 11 – Engine
mechanical system - Timing chain sprocket
- Repair)
(b). Remove the camshaft cover bolts and
remove all camshaft covers.
Note:
• Remove the camshaft cover bolts in pairs.
• Place the removed camshaft covers orderly,
and distinguish the intake and exhaust
LFWX-6470-11044 camshaft covers.
(c). Ta k e d o w n t h e i n t a k e a n d e x h a u s t
camshaft assembly.
Note:
Distinguish the intake and exhaust camshaft.
1: exhaust camshaft; 2: intake camshaft.
11
LFWX-6470-11043
2. Check the camshaft radial run-out

(a). Place the camshaft on the V-block and
measure the radial run-out around the
center journal with the dial indicator. If the
rocker runout is greater than the maximum
value, must replace the camshaft.
Max.: 0.03mm
LFWX-6470-11045
3. Check the intake and exhaust camshaft

maximum lift
(a). As shown in the figure, measure the
maximum lift of the intake and exhaust
camshaft with the screw thread micrometer
and replace the camshaft if required.
Intake: 44.168~44.268 mm
Exhaust: 43.705~43.805 mm
LFWX-6470-11046
4. Check the camshaft journal

(a). Check the camshaft journal and bearing
cap for rust, abrasion or other damage and
replace them if any or replace the cylinder
head if necessary.
LFWX-6470-11047
(b). Measure the camshaft journal with the

screw thread micrometer and check the oil
clearance if the journal does not meet the
specification.
1#: 24.949~24.965mm
Other: 22.949~22.965mm
LFWX-6470-11048
5. Inspect the axial clearance of the

camshaft
(a). Install the intake and exhaust camshafts
onto the cylinder head.
(b). Move the camshaft reciprocately, and
inspect the axial clearance of the camshafts
with a dial indicator; if the measured value
can not meet the requirements, replace the
camshaft; if necessary, replace the cylinder
head.
Standard axial play: 0.040mm~0.095mm
LFWX-6470-11049 Maximum axial play: 0.10mm
6. Install the camshaft assembly

(a). Install the intake and exhaust camshaft to
the cylinder head.
Note:
• Apply an appropriate amount of clean oil
evenly on various contact surfaces of the
camshaft.
• Separate the intake and exhaust camshafts. 11
(b). Install the camshaft covers onto the
mounting positions, and install the
mounting bolts and tighten them.
LFWX-6470-11044 1# camshaft cover mounting bolt
torque: 23 N•m;
Other torque: 13 N•m
Note:
• As shown in the figure, distinct the intake and
exhaust camshafts and bearing covers in the
order can not mix them. 1 indicates the inlet
side (with marking letter I), and 2 indicates the
exhaust side (with the marking letter E).
• Tighten the camshaft bearing cover fixing
bolts in pairs.
• After tightening the camshaft bearing cap
bolts, rotate the camshaft to ensure the
rotation is flexible without seizing.
LFWX-6470-11050 (c). Install the timing sprocket mechanism
assembly. (See Section 11B – Engine
mechanical system - Timing chain sprocket
- Repair)
Cylinder Head
Component drawing
LFWX-6470-11051
1 Intake camshaft 5 Bolt, cylinder head
2 1# camshaft bearing cover 6 Gasket, cylinder head
3 Intake camshaft cover 7 Water outlet pipe
4 Exhaust camshaft 8 Cylinder head assembly
Repair
1. Remove the cylinder head
(a). Remove the carbon canister solenoid valve. (See Section 19 - Exhaust control
system - Carbon canister solenoid valve - Replacement)
(b). Remove the fuel injector. (See Section 13 - Fuel system – Fuel injector -
Replacement)
(c). Remove the intake manifold. (See Section 11 - Engine mechanical system - Intake
manifold - Repair)
(d). Remove the catalytic converter. (See Section 19 - Exhaust control system –
Catalytic converter - Replacement)
(e). Remove the camshaft. (See Section 11 - Engine mechanical system – Camshaft -
Repair)
(f). Remove the cylinder head bolt and remove

the cylinder head and cylinder gasket.
LFWX-6470-11052
Note:
When removing the cylinder head bolt, loosen
the cylinder head bolts in the sequence shown
in the figure and then remove them. 11
(g). Remove the valve assembly. (See Section
11 - Engine mechanical system – Air valve
-Repair)
2. Inspect the cylinder head assembly

(a). Clean the sealant and the oil on the cylinder head.
(b). Clean the carbon deposition in the combustion chamber of the cylinder head.
Note:
Do not use any sharp tool to scrape the carbon deposition; during removing the
carbon deposition,do not scratch or damage the metal surface.
(c). Use a high pressure water jet to clean the cylinder head.
Tips:
Especially, the water duct and the oil duct.
(d). Dry the cylinder head with the high pressure air.
Note:
When using compressed air, it is suggested to wear goggles and protective mask, to
avoid any injury from flying debris or dirt.
(e). Check the cylinder head bolt for damages. If any, replace it.
(f). Use a ruler and thickness gauge to check

the flatness at cylinder head joint surface
and intake/exhaust sides; if the flatness is
more than the maximum value, replace the
cylinder head.
Cylinder block junction plane: 0.05mm
Intake side: 0.10mm
Exhaust side: 0.10mm
LFWX-6470-11054
3. Install the cylinder head

(a). Install the air valve assembly. (See Section
11 - Engine mechanical system – Air valve
- Repair)
(b). Install the cylinder head gasket on the
cylinder block.
Note:
Must replace the new cylinder head gasket,
and notice its positive and negative installation
surfaces, to ensure proper installation.
(c). Install the cylinder head to the cylinder
LFWX-6470-11052 block, and install the cylinder head bolts
and tighten them.
First torque: 60 N•m
Second torque: 90 N•m
Note:
• Apply an appropriate amount of clean oil onto
the threaded portion of the cylinder head bolts.
• When tightening the cylinder head bolts,
tighten them twice in the order shown in the
figure.
(d). Install the camshaft. (See Section 11 –
Engine mechanical system – Camshaft -
Repair)
(e). Install the catalytic converter. (See Section
19 - Exhaust control system - Catalytic
converter - Replacement)
(f). Install the intake manifold. (See Section
11 -Engine mechanical system - Intake
manifold -Repair)
(g). Install the fuel injector (See Section 13 – Fuel system – Fuel injector - Replacement)
(h). Install the carbon canister solenoid valve. (See Section 19 - Exhaust control system
– Carbon canister solenoid valve - Replacement)
Valve
Component drawing
11
LFWX-6470-11055
1 Tappet 6 "Guide, valve"
2 Valve collet 7 Valve spring
3 "Seat, spring, valve" 8 Exhaust valve
4 Exhaust valve oil seal 9 Intake valve
5 Intake valve oil seal

Adjustment
1. Inspect and adjust the air valve clearance
(a) Adjust 1# cylinder piston to the TDC position.
Tips:
Rotate the crankshaft pulley and align the timing
mark on the crankshaft pulley with “5” mark on the
pulley cover.
(b) Determine 1# cylinder or 4# cylinder on TDC
position of the compression stroke.
• Remove the cylinder head cover. (See Section
11A -Engine mechanical system - Timing chain
sprocket -Repair)
• Observe the exhaust camshaft positions of 1#
LFWX-6470-11056
cylinder or 4# cylinder. If 1# exhaust camshaft
position is downward (i.e., the exhaust valve is about to open), 4# cylinder piston will be on
the compression stroke TDC; if 4# cylinder exhaust camshaft position is downward (i.e.,
the exhaust valve is about to open), 1# cylinder piston will be on compression stroke TDC.
(c). Inspect the air valve clearance.

1 •When 1# cylinder piston is located at the
5 2 compression stroke top dead center, measure the
valve clearances of 8 valves on 1#, 3#, 5#, and 6#
cylinders with the thickness gauge and record the
6 3
4
7 measurement results.
•Rotate the crankshaft 360°, measure the valve
8
clearances of the remaining 8 air valves with the
thickness gauge and record the measurement
results.
Standard intake valve clearance (cold status):
LFWX-6470-11057 0.20 ~ 0.25mm
Standard exhaust valve clearance (cold
status): 0.30~0.35mm
Tips:
If the valve clearance is not consistence with the standard value, replace the tappet on
corresponding valve top, to ensure that the clearance is consistence with the standard
value.
• When 4# cylinder piston is located at the compression stroke top dead center, measure
the valve clearances of 8 valves on 2#, 4#, 7#, and 8# cylinders with the thickness gauge
and record the measurement results.
•Rotate the crankshaft 360°, measure the valve clearances of the remaining 8 air valves
with the thickness gauge and record the measurement results.
(d) Adjust the valve clearance.

• Remove the camshaft. (See Section 11A –
Engine mechanical system – Camshaft - Repair)
• Remove the mechanical tappet that needs to be
replaced.
• Measure the tip thickness of the tappet with a
spiral micrometer.
• Calculate the tip thickness of the new tappet.
Calculation method:
New mechanical tappet top thickness = Measured
clearance value - Standard clearance value +
Replaced tappet top thickness value
(e) Reassemble the engine.
Repair
1. Remove the valve assembly

(a). Remove the cylinder head (See Section
11 - Engine mechanical system - Cylinder
head - Repair)
(b) Remove all mechanical tappets in
sequence. 11
Note:
Place the removed mechanical tappets orderly
corresponding to the installation locations for
subsequent installation.
LFWX-6470-11059
(e). Heat the cylinder head to 80 ~ 100℃ .
LFWX-6470-11060
(f). Place the cylinder head on the wood plate

and take the valve guide out of the cylinder
head with the special tool.
Note:
• The valve guide shall not be reused onced
removed.
• Since the valve guide and cylinder head
adopt the interference fit, the new valve guide
must be oversized.
LFWX-6470-11061
2. Check the valve assembly

(a). Check the air valve locking piece for cracks
or damage, if necessary, replace it.
(b). Use a vernier caliper to measure the valve
spring length under the free status, if it is
beyond the scope, replace it.
LFWX-6470-11062
(c). Use a spring dynamometer to measure

the spring force under the standard
compression length of elasticity; if it can
not meet the requirements, replace it.
Installation spring force:
153~169N(33.88mm)
Maximum working force:
335.3~370.7N(24.1mm)
LFWX-6470-11063
(d). Use a ruler and tablet to check the spring

verticality based on the clearance between
the air valve spring end and the ruler; if it is
beyond the specified value, replace it.
Maximum deviation value: 1.6mm
Maximum deviation angle: 2°
(e). Remove all carbon deposition on the air
valve,check the working surface of the
valve and the air valve stem for wear,
ablation or deformation;if any, repair it; if
necessary, replace the air valve.
LFWX-6470-11064
(f). Use a square angle ruler to measure the

air valve edge thickness; if the measured
value is less than the minimum value,
replace the air valve.
Standard thickness: 1.0mm
Minimum thickness: 0.7mm
11
LFWX-6470-11065
(g). Use a vernier caliper to measure the

air valve length, if it can not meet the
Standard length:
Intake valve: 88.65mm
Exhaust valve: 88.69mm
Minimum length:
LFWX-6470-11066
(h). Use a spiral micrometer to measure the

air valve stem diameter, if it can not the
Intake valve: 5.470mm~5.485mm
Exhaust valve: 5.465mm~5.480mm
LFWX-6470-11067
(i). Check the air valve seat contact width.

Tips:
• Coat a layer of the marking membrane on the
air valve seat, and then install the air valve on the
cylinder head.
• Use the air valve grinding tool to rotate the air
valve 1/4 turns several times, and then remove the
air valve.
LFWX-6470-11068
Note:
• The marking produced on the air valve mating
surface must be a continuous closed trace,
and its width must be within the prescribed
scope.
If the marking is uneven, or the mark width is
beyond the specified scope, must grind and
fine grind and polish the air valve seat.
Intake valve holder width: 1.0 ~ 1.4mm
LFWX-6470-11069
• Intake valve seat: use a air valve seat reamer

to repair it two times. Must use two reamers to
repair it: the first reamer has an angle of 15°,
and the second reamer has an angle of 45°. In
the second repair, must achieve the required
air valve seat width.
Intake valve holder width: 1.0mm~1.4mm
• Exhaust valve seat: the repair procedure is

the same as one for the intake valve.
Exhaust valve seat width: 1.0mm~1.4mm
70
11
(j). Grind the air valve.

Tips:
First coat a layer of coarse grinding paste on the
surface of the valve seat, and use the grinding tool
to grind the air valve; and then coat a layer of fine
grinding paste to grind it, until a perfect fit between
the air valve and the air valve seat is obtained.
(k). After grinding, thoroughly clean the air
valve, air valve seat.
LFWX-6470-11072
(l). Use an inside diameter micrometer to

measure the air valve duct inner diameter.
Air valve duct inner diameter:
5.510mm~5.530mm
(m). Deduce the air valve stem diameter from
the air valve duct, to obtain the air valve
guide duct clearance. If the oil clearance
value is greater than the maximum value,
replace the air valve and the air valve duct.
Standard oil clearance:
Intake valve: 0.025~0.060mm
LFWX-6470-11073 Exhaust valve: 0.030~0.065mm
Maximum oil clearance
(n). Use the inside micrometer to measure the

air valve installation hole diameter.
Inside diameter: 10.285 ~ 10.306mm
Tips:
If the internal diameter of the guide mounting
hole is greater than the maximum value, it
should be machined to 10.335 ~ 10.350 mm, to
accommodate the valve guide with larger size (see
below).
Valve guide diameter Valve Valve guide diameter Valve
guide hole inner guide hole inner
LFWX-6470-11074 STDI 0.285~10.306
O/S0.05 10.335~10.356
(o). Measure the tip thickness of the

mechanical tappet; if necessary, replace it.
Standard value: 5.055mm ~ 6.005mm
LFWX-6470-11075
3. Install the air valve components

(a). Heat the cylinder head to 80℃ ~100℃ .
(b). Take out the cylinder head and place it on
the wood plate.
LFWX-6470-11060
(c). Before installing the valve guide in the

cylinder head, ream the guide hole with
the special tool (10mm reamer) to clear the
burrs.
(d). Press the new valve guide in the valve
guide hole by the designated pressing
in amount with the special tool until the 11
special tool contacts the cylinder head.
Specified press – in amount: 8.7 ~ 9.1mm
(e). Use the special tool (5.5 mm reamer), to
ream the air valve duct hole to achieve the
LFWX-6470-11076 standard oil clearance.
Standard oil clearance:
Intake valve: 0.025~0.060mm
Exhaust valve: 0.030~0.065mm
(f). Install valve, valve spring, valve oil seal
and valve spring retainer in turn.
(g). Use special tools to install valve keys.
Note:
The intake valve oil seal is grey while the
exhaust valve oil seal is black.
The oil seal shall not be reused once removed.
Ensure to use the new oil seal during the
installation.
During the installation, do not tap or beat the
special tool with the hammer or other items;
LFWX-6470-11059 otherwise it will damage the oil seal. To install
the oil seal to the guide tube, just push the
special tool by hand.
(h). Install the mechanical tappet into the

cylinder head.
(i). Install the cylinder head. (See Section 11 -
Engine mechanical system - Cylinder head
- Repair)
LFWX-6470-11077
Control system
Overview�� 1 Structure and installation location
Introduction�� 1 ��12
1.4T engine technical Part Location Drawing��12
characteristics�� 1 Fault diagnosis and inspection 14
1.5T engine basic parameters 1 Inspection and confirmation�14
Type and structure parameters 1 Visual inspection table��14
Performance parameter �� 2 List of fault symptoms��14
Structure and installation location DTC list��17
�� 2 DTC diagnosis��22
Engine number�� 2 Removal and Installation��87
Safety measure�� 3 Crankshaft position sensor��87
Clean rules�� 3 Disassembly��87
Injection device/fuel device�� 3 Installation��88
Control system�� 4 Phaser control valve��88
Technical specifications�� 4 Disassembly��88
Torque specifications �� 4 Inspection��89
Operating principle�� 4 Installation��89
System Overview�� 4 Electronic throttle body��89
Fuel injection control�� 5 Disassembly��89
Air-fuel ratio feedback Inspection��90
compensation (closed-loop Installation��90 21
system)�� 6 Inta
Idle speed control�� 6 ke pressure and temperature
Fuel pump control�� 7 sensor��91
Ignition timing control�� 7 Disassembly��91
Air conditioning compressor Inspection��92
control�� 7 Disassembly ��92
Oil gas emission control�� 8 Inspection��92
Part instructions�� 8 Installation��93
Intake pressure and temperature Camshaft position sensor��93
sensor�� 8 Disassembly��93
Water temperature sensor�� 8 Inspection��93
Electronic throttle body�� 9 Installation��94
Knock sensor�� 9 Water temperature sensor��94
Phaser control valve��10 Disassembly��94
Camshaft position sensor��10 Inspection��95
Crankshaft position sensor��10 Installation��95
Fuel injector��10 Knock sensor��96
Ignition coil assembly�� 11 Disassembly��96
Front oxygen sensor�� 11 Inspection��96
Installation��96
Front oxygen sensor��97
Disassembly��97
��98
Disassembly��98
Electronic control module (ECM)
�� 101
Part sketch�� 101
Change�� 101
Engine control system -Engine control system (1.5T)
21-1
Overview
Introduction
Lifan Xuanlang multipurpose car is equipped with 1.4T in-line 4-cylinder turbocharged
engine, overhead double camshaft structure, and 4 air valves per cylinder; the air valve is
equipped with the hydraulic clearance regulator, and the valve clearance is not required for
adjustment.
Lifan engine is cooled with the closed water cooling system. The cooling water flow rate
circulated in the engine cooling system can be automatically controlled by the opening
level of the double thermostats.
It is a new engine completely independently researched and developed by Lifan engine
company, reflecting the current domestic advanced technology level. This new 1.5T engine
shows the following characteristics in its design:
1. High performance: Adopt direct injection (GDI), intake VVT and other advanced
technologies.
2. Low emissions: meet the requirements of National V & VI emission regulations.
3. High quality: Adopt the chain transmission mechanism, with the same service life as the
engine.
4. Small displacement: Meet the requirements of small displacement and low fuel
consumption, and increase the power and torque; especially, the low speed torque is
carefully matched, very suitable for urban road conditions.
Warning:
Before any electrical device is removed or installed, if any tool or device may
contact with any exposed electrical terminal, be sure to disconnect the battery
negative cable firstly, to prevent any injury or damage. Unless otherwise specified,
the ignition switch must be turned to LOCK position.
21
Note:
When the air filter is removed in every time, its air inlet must be clogged, to prevent
any foreign body. When staring, any foreign body may damage the supercharger
and even the engine.
1.4T engine technical characteristics
1. Exhaust gas turbocharged
2. Direct injection (GDI)
3. Air - water inter-cooler, hydraulic tappets, overhead combination double-camshaft,
double-thermostat cooling system, expansion connecting rod, etc.
4. Bosch spark plugs
5. Air intake VVT
6. Forced circulation cooling system
1.5T engine basic parameters
Type and structure parameters
Engine model LF477ZLQ
Direct injection GDI, exhaust gas turbocharged,
Engine type
intake VVT
Car model Lifan Xuanlang
Number of air valves 4 air valves/cylinder
21-2 Engine control system -Engine control system (1.5T)
Cooling mode Forced circulation cooling liquid

Lubrication mode Pressure & splash
Firing order 1-3-4-2
Cylinder bore x stroke mm 76.5×79
Emission volume mL 1452
Spark plug type F6HI332
Timing driving mode Chain
I/II piston ring notch clearance mm 0.3~0.45/0.4~0.6
Performance parameter
Compression ratio 10
Gasoline brand = research octane number (RON) 92# petrol (National V)
Idle speed 750±50 rpm
Maximum torque 234N•m
Rated power / rated speed 104 kW/4850 rpm
Maximum net torque/rotational speed 230N•m/1750 ~ 3500 rpm
Maximum net power 100 kW
Intake temperature after inter-cooler ≤50°C
Coolant outlet temperature°C Performance test: 88+5°C; Reliability test: 88~110°C
80~200kPa/750rpm,200~320kPa/2500rpm,280~350
Oil pressure kPa/ rpm
kPa/4850rpm
Minimum fuel consumption rate 265g/(kw•h)

Engine number
The engine number (“Engine Identifier” & “Serial
Number”), as shown in Arrow direction, is located
in the junction between the engine and the
transmission.
The engine identifier consists of 8 characters
(letters and numbers), such as LF476ZLQ; its first
part (the first two letters LF) represents “Lifan”,
the second part (the middle three numbers)
represents that the number of cylinders is 4, and
the cylinder diameter is 76mm, and the third part
(the last three letters) represent the gasoline
engine adopted with the turbocharger and direct
injection technologies.
LFWX-6470-11001
The serial number is composed of 9 numbers,
such as: 150100001, the first part (the first
4 numbers 1501) represents January 2015,
the second part (the last 5 numbers 00001)
represents that the first engine produced in that
21-3
month.
The engine identifier is also listed in the car data
nameplate.
Safety measure
During operations on the fuel system, please pay attention to the following notes:
Note:
Before the fuel system is opened, please place a clean cloth around the connector
and loosen carefully the connector to release the pressure.
In order to avoid injuries and/or damage to the fuel injection device and the ignition
device, must pay attention to the following notes:
● Only after the ignition switch is turned off, the wires connected to the injection
device and the ignition device (and tester wire) can be connected or disconnected.
● In some tests, the engine control unit can identify and storage some faults. So,
after all inspection and repair works are completed, please query fault memory,
perform the troubleshooting and remove the fault records.
● Only after the ignition device is turned off, the engine can be cleaned.
Warning:
Please pay attention to the measures when the battery is disconnected.
Warning:
Only when the ignition switch is turned off, the batteries can be connected or
disconnected; otherwise it may damage ECU.
During operations on the cooling system, please pay attention to the following
notes:
Note:
21
● When the engine is under the operating temperature, the cooling system will be
under overpressure condition. Please cover the cooling liquid expansion tank cap
with a cloth and carefully open it, to relief the overvoltage.
● When the expansion tank cap is opened, the hot steam may overflow. Must wear
protective glasses and protective clothing, to avoid burns and other injuries.
If a tester is required for commissioning, must pay attention to the following notes:
Note:
The tester must always be fixed on the rear seat and operated by another repair
person.
Note:
If the tester is operated on the front passenger seat, in case of an accident, the front
passenger seat airbag may be trigged, resulting in injury there.
Clean rules
Injection device/fuel device
Only a small stain may damage the injection device. So, before any operation on the fuel
supply device or the injection device, the following cleaning provisions must be strictly
followed:
● Before any connector is loosened, must use the engine cleaner to thoroughly clean the
connector and the surrounding, and thoroughly dry the cleaning location.
● Plug immediately the opened pipes and connectors with a suitable plug.
● Place the removed parts on a clean cushion and cover them. Do not use a fiber cloth.
Only allow to install the clean parts; any part can be take out form the package only
before installation. Do not use any part without package (such as, parts placed in
the toolbox).
● Any opened device cannot be operated with the compressed air. Do not move the car as
far as possible.
● Anti-fouling and moisture-proof measures must be taken for the disconnected electrical
connectors. They can be connected only in dry condition.
Turbocharger assembly
During operation on the exhaust gas turbocharger, must pay careful attention to the
following “Five Rules” about cleaning:
● Before the connector is loosened, must thoroughly clean the connector and the
surrounding area.
● Place the removed parts on a clean cushion and cover them; do not use a fiber cloth!
● If any fault can not be repaired immediately, must carefully cover or seal the opened
parts.
● Only allow to install the clean parts; remove the parts from the package only before
installation; do not use any part without package (such as, parts placed in the toolbox).
● The opened device can not be operated with the compressed air; do not move the car as
far as possible.
Control system
Name Nm Lb -ft Lb-in
Crankshaft position sensor fixing bolt 11 8 -
Phaser control valve fixing bolt 7 - 64

Electronic throttle body fixing bolt 10 7 -
Intake pressure and temperature

11 8 -
sensor fixing bolt
Camshaft position sensor fixing bolt 11 8 -
Knock sensor fixing bolt 23 17 -
Front oxygen sensor 40 30 -
Operating principle
System Overview
The electronic control system consists of the following parts:
1. Various sensors to determine the engine status and its operation conditions.
2. ECU to control various controllers of the electric injection system based on various
sensor signals.
3. Various electronic controller actuators.
Based on the performances, the electronic control system can be divided into the
following subsystems:
21-5
● Fuel injection control system

● Idle speed control system
● Fuel pump control system
● Ignition timing control system
● Radiator fan control system
● Oil gas emission control system
● A/C control system
The main ECU sensor input signals in the system include:
● Electronic accelerator pedal signal
● Intake pressure and temperature signal
● Throttle angle signal
● Coolant temperature signal
● Engine speed signal
● Phase signal
● Knock sensor signal
● Oxygen sensor signal
● Speed signal
● Air conditioning pressure signal
After the above information is transmitted into ECU, they will be processed to
produce the desired actuator control signals, the signals will be amplified in the
output drive circuit and transmitted to the corresponding actuators, these control
signals will include:
● Electronic throttle body motor
● Fuel injection timing and injection duration
● Fuel pump relay
● Canister control valve opening degree
● Closed angle and ignition advance angle of the ignition coil assembly 21
● Air conditioning compressor relay
● Cooling fan relay
● Oil control valve
Fuel injection control

Based on all kinds of sensor signals, ECU can control the fuel injection time and the fuel
injection timing from the injector to the cylinder head intake port, to
provide appropriate mixed gas under different driving conditions. There are two forms of
injection timing. One is the synchronous injection that is performed at the same crankshaft
angle; the other is asynchronous injection, that is controlled based on the signals from the
intake pressure and temperature sensor and other sensors.
1. Synchronous injection
When the engine is started, the air in the intake manifold is stationary, and the pressure
inside the intake manifold is displayed as the environmental pressure. When it is started,
the electronic throttle body will be opened at certain angle, and the opening size is a
fixing parameter based on the starting temperature. 4 injectors will be performed for one
synchronous injection in each rotation of the engine. The fuel injection rate will vary with
the different engine temperatures. When the engine reaches a certain speed, the mixed
gas will be increased. Once the engine is started for operation, the system will immediately
decrease the mixed gas rate; when the starting is completed (600 ~ 700 rpm), the
increased mixed gas will be decreased.
After the engine is started, when a cylinder is in the exhaust stroke, the fuel injection will
be performed only at the cylinder injector. ECU can detect compression stroke of NO. 1
cylinder via the camshaft position sensor, and on this basis, control the fuel injection in
order of 1st, 3rd, 4th and 2nd cylinders. When the camshaft position sensor has a fault,
the engine will automatically enter into the synchronous injection conditions to maintain the
engine operation.
2. Asynchronous injection
After the engine is started and under the following two conditions, all fuel injectors will not
be controlled by
● The fuel injection system begin the fuel injection under the fuel cutting status.
● When the throttle opening rate is greater than the specified value (the throttle is opened
too fast).
3. Fuel injection time
The determination of the injection time is mainly based on the basic injection time value
calculated with the engine speed, the pressure and temperature in the intake manifold (the
intake volume), and the compensation value identified with the various sensor signals to
monitor the engine and its operating conditions.
4. Fuel cutting
When the speed is decreased (for example, when the throttle is at idle speed position and
the engine is operated at high speed) the fuel injection will be cut (by stopping the injector
action), toensure that the unburned gas can not be exhausted and the engine can be re-
started in above different conditions.
Air-fuel ratio feedback compensation (closed-loop system)

Must make sure that the air-fuel ratio is close to the theoretical value (14.7), to ensure that
the three-way catalytic conversion process can be performed fully and CO, HC and NOx
high purification rates in the exhaust can be achieved.
λ closed loop control system can action only when the oxygen sensor is equipped. The
oxygen sensor is located at side of the three-way catalyst and used to monitor the oxygen
content in the exhaust. The thin mixture (λ >1) produces about 100 mV sensor voltage
and the thick mixture (λ< 1) produces about 800 mV sensor voltage. When λ =1, the
sensor voltage will be a step. λ closed-loop control can respond the input signal (if λ≥ 1,
the mixture is too thin; if λ≤1, the mixture is too thick) to modify control variables, and the
resulted the correction factor is used as a multiplier to correct the injection duration. When
any of the following conditions is met, ECU will exit from the closed loop control.
● When the engine is started and the fuel injection rate is increased after starting.
● When the engine coolant temperature is too low.
● When the load is too high and the fuel injection rate is increased.
● When the fuel is cut.
● When the oxygen sensor is cooled.
Idle speed control

The control system can use ECU to control electronic throttle body, to maintain the basic
stability of the engine idle speed, but the engine idle speed will change due to the following
causes.
● A load is added onto the engine (for example, an electrical load is added, A/C switch is
turned on, etc.).
● The engine changes over the time.
● The starting performance of engine is improved.
● The air-fuel ratio is adjusted during deceleration (slow cushion role).
21-7
● The operation performance of engine is improved during heating process.

Operations:
The idle speed control is operated on basis of the effective information output from ECU;
ECU detects the operating status of engine via the signals from various sensors and
switches and controls the throttle
opening and the air flow via the electronic throttle body motor, so as to control the target
idle speed.
When the vehicle is in a stop status, the throttle is at idle speed position and the engine is
under operating status, the engine speed will be kept at the specified idle speed.
Fuel pump control

ECU controls the opening/closing actions of the fuel pump; in any of cases as follows, it
can use the fuel pump relay to connect the fuel pump.
● After the ignition switch is turned on and operated for 1.5s.
● When the engine is started (transmit the engine start signal to ECU).
● The camshaft position sensor signal is input to ECU.
Ignition timing control

The single-cylinder direct ignition without power distributor is equipped on the system; it
can control connection and disconnection of the ignition coil assembly primary winding
circuit via the connection and disconnection of the internal big-power transistor, to allow
the ignition coil assembly to produce the high voltage (the internal structures of various
engine igniters are not same; some engines are not configured with the igniters and the big
power transistor is located directly in ECU of the electronic controller; some igniters only
cover single Darlington transistors, to play the switching role, and other electronic control
components are integrated with the electronic controller into an whole; in addition to the 21
switching role, some igniters also have constant current control, closed angle control,
cylinder discriminant, ignition monitoring and other functions).
The control unit includes the following three different forms:
● Ignition time when the engine is started (initial ignition time).
● Control after the engine is started.
● Time control of the charging current.
When the throttle is in idle speed position, the ignition time is obtained with the initial
ignition time added with the basic ignition advance angle determined by the engine speed
and the engine cooling compensation and the related idle speed stability compensation
advance angle.
When the throttle opening is greater than the idle position, it is also obtained with the initial
ignition time added with basic ignition advance angle determined with the engine speed,
intake pressure, cooling compensation and the acceleration compensation advance angle.
Air conditioning compressor control
The air conditioning request signal is sent to ECU.ECU controls the connection of the air
conditioning and electrical appliances, and at the same time sends the speed increase
signal to the electronic throttle body and turn on the electric fan.
In order to ensure the power output and protect the engine, the system may disconnect the
operation of the air conditioning under certain conditions.
Air conditioning operation conditions:
● When the water temperature rises to 108°C, the air conditioning will stop the operation;
● When the water temperature is restored to 105°C, the air conditioning will return the
operation.
When the air conditioning and the regulator is started, the engine target idle speed will be
increased to 150 rpm.
Oil gas emission control

The oil gas emission control system is used to prevent fuel steam ventilation. The oil gas
produced in the engine operation or stop will be sent into the gas carbon canister via the
fuel tank pressure control valve and is absorbed or stored by the carbon canister, and the
carbon canister drain valve is controlled by ECU via all kinds of sensor signals.
Only when the following conditions are met, ECU canopen the vacuum channel of the
carbon canister drain valve:
● When the engine is at normal operating temperature.
● When the engine speed is higher than the specified value.
● When the throttle opening is greater than the idle position (at closed throttle position).
● When the engine is operated under the specified load.
As a result, the carbon canister is purified by the air flowed through the bottom of
the carbon canister filter.
The fuel tank pressure control valve is used to maintain a constant pressure in the fuel
tank. When the pressure in the fuel tank is high and reaches the specified value, the valve
will be opened to allow the oil gas to flow into the carbon canister. On the contrary, when
the pressure in the fuel tank is negative and reaches the specified value, the valve will be
opened to allow the air to flow into the fuel tank.
Part instructions
Intake pressure and temperature sensor
The sensor is installed on the intake manifold
and intake pipe respectively, and the sensor
is integrated with both sensors of the intake
manifold absolute pressure sensor and the intake
temperature sensor. The intake pressure sensor
is used to measure the intake manifold pressure
changes due to the changes of engine load and
speed. It can convert the changes into the voltage
output.
The intake temperature sensor is a resistance
LFWX-6470-11002
with negative temperature coefficient (NTC),like
the water temperature sensor, the resistance is
reduced with the increase of intake temperature;
the engine ECU can monitor the changes of
intake temperature via the internal comparison
circuit (equivalent to a series circuit)
Water temperature sensor
The engine water temperature (ECT) sensor is a
thermistor, and its resistance changes with
temperature changes. It is installed on the
thermostat. When the engine coolant temperature
is lower, the resistance value is higher; at - 20°C (4°F), the resistance is 15100 Ω. When
the engine coolant temperature is higher, the resistance is lower; at 130°C (266°F), the
resistance is 19.4 Ω. The engine control module can provide a reference voltage of 5V for
the sensor, when the engine is cold, the voltage will be increased; when the engine is
heated, the voltage will be decreased. By measuring the voltage changes, the engine
control module can determine the engine coolant temperature. For the engine control
system, the sensor is very important to correct the ignition timing and fuel injection rate.
The signal is also sent to the instrument (IP) via CAN network, to display the current
engine operating temperature.
Electronic throttle body
The electronic throttle body assembly is integrated
with the motor and two throttle position sensors,
the electronic throttle valve body is driven by the
drive motor via a reducer mechanism and the
throttle position sensors are used for real-time
monitoring of the motor position. The electronic
throttle body can adjust the engine load via
the electronic pedal signal, and can control the
throttle opening from idle speed to full load via a
DC motor. The throttle opening feedback signal
LFWX-6470-11004 is supplied by two potentiometers integrated in
the throttle valve body. The power supply and
grounding are common and provided by the engine module.
The throttle position sensor is composed of a carbon film resistor and a sliding pointer,
and it is an angle sensor with a linear output, consisting of two circular sliding contact
resistances and two sliding contact arms. The sliding contact arm shaft and the throttle
shaft are connected on the same shaft. The both ends of the sliding contact resistance are
applied with a 5V voltage.
The throttle drive motor is a miniature motor and the motor drives a special gear reducer
mechanism and a two-way spring; when the system is powered off, the mechanism can
guarantee that the throttle valve opening is more than the idle position and no more than
the safety position, to ensure that the vehicle can be driven continuously; if the engine
electronic control system is entered into the fault mode, and the accelerator pedal is
depressed, the valve plate of electronic throttle body will no longer action.
Knock sensor
The knock sensor is installed directly on the
engine body and is located below the intake
manifold. The knock sensor is used to record the
vibrations increased when the combustion noise
in the engine body is increased. ECU can adjust
the ignition and fuel supply characteristics via
the knock sensor signal, in order to avoid fuel
precombustion.
LFWX-6470-11005
Phaser control valve
The oil control valve is controlled by ECU duty
ratio signal, the change of oil channel in VVT
mechanism can change the camshaft phase of
VVT mechanism and the valve timing.
LFWX-6470-11006
Camshaft position sensor

The camshaft position sensor is a Hall sensor
located at the camshaft housing, and is used
to collect No. 1 cylinder intake camshaft raised
signal. The camshaft position sensor can not be
adjusted and can not be set in the installation.
LFWX-6470-11007
Crankshaft position sensor

The crankshaft position sensor is installed on the
transmission, it is used to sense the engine speed
and the crankshaft position, it can not be adjusted
and can not be set in the installation.
LFWX-6470-11008
Fuel injector
The fuel injector is installed on the cylinder head,
it can inject the fuel in the time prescribed in
the instruction of ECU, ECU can control the fuel
injector grounding signal. The fuel injector is
electromagnetic control type fuel injector, and the
fuel injection rate depends on the needle valve
LFWX-6470-11009
opening time, namely the opening width of the electrical impulse
Ignition coil assembly
The ignition coil assembly converses the low-
voltage in the primary winding into the high voltage
in the secondary winding, and produces the
sparks via the spark discharge, to ignite the fuel
and air mixture in the cylinder. ECU can control
the primary coil grounding line of the ignition coil
LFWX-6470-11010 assembly.
Front oxygen sensor

The front oxygen sensor is located on the front
catalyst assembly; it is a zirconia oxygen sensor.
The front oxygen sensor is used to monitor
LFWX-6470-11011 the oxygen content in the exhaust after air-fuel
mixture combustion in the combustion chamber.
The signal from the front oxygen sensor is
received by ECU and is used to adjust the fuel
injection pulse width.
2 3 4
9 8 7
LFWX-6470-11012
1 Crankshaft position sensor 6 Knock sensor
2 Camshaft position sensor 7 Electronic water pump
3 Ignition coil assembly 8 Electronic throttle body
4 Phaser control valve 9 Boost pressure sensor

5
sensor
1
LFWX-6470-11013
1 Water temperature sensor 2 Front oxygen sensor


Inspection and confirmation
1. Confirm the problem of the customer.
2. Visually check whether there is any obvious mechanical or electrical damage sign.
3. If the causes about the fault observed or proposed have been found, the causes must
be processed before entering into the next step.
4. If the problem is hard to identify obviously, then confirm the fault and use the diagnostic
tester to examine the system.
Visual inspection table

Electric
• Fuse
• Harness
• Wiring harness plug
• Relay
• Sensor
• Switch
• Engine control unit (ECU)

If there is a fault on the vehicle, ECU can not detect the fault code and any obvious fault
position is not found in the visual inspection and general inspection, the fault should be
processed with the following diagnosis principle and procedure.
Symptom Possible Cause Recommended Measures

•Air intake system
• Spark plug
Normal starting but Reference: the diagnosis
• Electronic throttle body assembly
unstable idle speed at process for normal starting but
• Ignition timing
any time unstable idle speed at any time.
• The engine's mechanical system
• Engine control module circuit
• Water temperature sensor

• Spark plug
• Fuel pump Reference: Diagnosis procedure
Hard to cold start • Fuel injector for engine being hard to clod
• Electronic throttle body assembly start.
• The engine's mechanical system

Reference: Diagnosis procedure
• Ignition coil assembly
Hard to hot start for engine being hard to hot
• Fuel pump
start.
21-15

• Crankshaft position sensor
• Fuel pump Reference: the diagnosis
The engine cannot be
• Ignition coil assembly process for failure to start the
started at the normal
• ECU engine at the normal starting
starting speed.
• The engine's mechanical system speed.
• Anti-theft system

about idle instability or shutdown
Unstable idle speed or • Air conditioning system
under conditions of normal
stall in case of normal • Electronic throttle body assembly
starting and partial load (for
start and a certain load • Fuel injector
example, the air conditioning is
operated).

• Electronic throttle body assembly
Excessive idle speed in • Vacuum tube
for excessive idle speed in case
case of normal start • Ignition timing
of normal start.
• Control module circuit
Speed increase failure • Air intake system

or stall in case of • Intake pressure and temperature sensor
acceleration • Electronic throttle body assembly
Difficult acceleration • Fuel injector
Slow acceleration • Spark plug
for acceleration fault.
response • Ignition timing
21
Poor acceleration, bad • Fuel
performance • Exhaust blocking
•Control module circuit
• A/C switch
• Refrigerant pressure switch Reference: Diagnosis procedure
The air conditioning can
• Air conditioning relay about insufficient air conditioning
not be controlled properly
• Electromagnetic clutch refrigerating capacity.
• ECU
• Oxygen sensor
• Fuel injector
• Spark plug
• Ignition timing Reference: Diagnosis procedure
Engine running unstably
• Fuel pressure for engine running unstably.
• Fixing bolt loosening or engine
suspension part damage

• Fuel injector
• Spark plug Reference: Diagnosis procedure
Tendency to stall during
• Ignition timing for tendency to stall during
starting
• Fuel pressure starting.
• A/C compressor
• MAP sensor, APP sensor

• Improper A/C system operation
• Unstable or no signals from CMP sensor
• Air leakage on the intake system parts
• Purge solenoid valve fault
• Unstable signal from CKP sensor
• Vacuum leakage
• Poor fuel quality
• Intermittent fault of main relay and fuel
Vehicle jitter during pump relay Reference: Diagnosis procedure
running • Electronic throttle body assembly valve for vehicle jitter during running.
fault
• Engine overheat
• Spark plug fault
• Ignition timing
• Exhaust system limitations
• Insufficient fuel pressure
• Mechanical fault of fuel pump
• Fuel injector
• Unstable signal from APP sensor
• Vacuum leakage
• Air intake system leaks
• Improper control of air/fuel mixture ratio
• Engine electronic control system fault
during fuel evaporation emission
• Fault of APP sensor or relevant lines
Stall during neutral- • Fault of MAP sensor or relevant lines
for stall during neutral-position
position running • Incorrect operation of A/C
running
electromagnetic clutch
• Fuel injector
• Spark plug
• Ignition timing
• Fuel
• Exhaust blocking
21-17
DTC list
DTC Code meaning
P000A Intake VVT running unreasonable
P000B Exhaust VVT running unreasonable
P0011 Intake camshaft position advanced
P0012 Intake camshaft position delayed
P0014 Exhaust camshaft position advanced
P0015 Exhaust camshaft position delayed
P0016 Intake camshaft position run-out
P0017 Exhaust camshaft position run-out
P0026 Intake camshaft locking position running unreasonable
P0027 Exhaust camshaft locking position running unreasonable
P0030 Upstream oxygen sensor heating control circuit open circuit
P0031 Upstream oxygen sensor heating control circuit short to ground
P0032 Upstream oxygen sensor heating control circuit short to power
P0036 Downstream oxygen sensor heating control circuit open circuit
P0037 Downstream oxygen sensor heating control circuit short to ground
P0038 Downstream oxygen sensor heating control circuit short to power
P0053 Upstream oxygen sensor heating circuit internal resistance unreasonable 21

P0054 Downstream oxygen sensor heating circuit internal resistance unreasonable
P006D Environmental pressure sensor circuit voltage unreasonable
P0076 Intake VVT circuit short to ground or open circuit
P0077 Intake VVT circuit short to power supply
P0079 Exhaust VVT circuit short to ground or open circuit
P0080 Exhaust VVT circuit short to power supply
P0101 Flow passing air flow meter too low or too high
P0102 Air flow meter circuit voltage too low
P0103 Air flow meter circuit voltage too high
P0105 Intake pressure sensor signal no fluctuation
P0106 Intake pressure sensor unreasonable
P0107 Intake pressure sensor signal circuit voltage low
P0108 Intake pressure sensor signal circuit voltage high
P0111 Intake temperature sensor signal unreasonable
P0112 Intake temperature sensor circuit voltage low
P0113 Intake temperature sensor circuit voltage high

DTC Code meaning

P0116 Engine coolant temperature sensor signal unreasonable
P0117 Engine coolant temperature sensor circuit voltage low
P0118 Engine coolant temperature sensor circuit voltage high
P0122 Electronic throttle position sensor 1 signal circuit voltage low
P0123 Electronic throttle position sensor 1 signal circuit voltage high
P0130 Upstream oxygen sensor circuit signal fault
P0131 Upstream oxygen sensor signal circuit voltage low
P0132 Upstream oxygen sensor signal circuit voltage high
P0133 Upstream oxygen sensor aging
P0134 Upstream oxygen sensor aging - continuous signal lean or rich
P0136 Downstream oxygen sensor circuit signal fault
P0137 Downstream oxygen sensor signal circuit voltage low
P0138 Downstream oxygen sensor signal circuit voltage high
P0139 Downstream oxygen sensor aging
P0171 Air fuel ratio closed-loop control self-learning value exceeding upper limit
P0172 Air fuel ratio closed-loop control self-learning value exceeding lower limit
P0197 Engine oil temperature exceeding lower limit
P0198 Engine oil temperature exceeding upper limit
P0201 Cylinder 1 injector control circuit open circuit
P0219 Engine overspeeding
P0222 Electronic throttle position sensor 2 signal circuit voltage low
P0223 Electronic throttle position sensor 2 signal circuit voltage high
P025C Oil pump relay control circuit short to ground or open circuit
P025D Oil pump relay control circuit short to power supply
P0261 Cylinder 1 injector control circuit short to ground
P0262 Cylinder 1 injector control circuit short to power

21-19
DTC Code meaning

P0300 Multi-cylinder misfire
P0301 Cylinder 1 misfire
P0313 Misfire caused by fuel level low
P0318 Bad road testing acceleration sensor signal fault
P0321 Gear absence correction frequency too high
P0322 Speed signal not found
P0323 Rotary speed signal frequent loss
P0325 Knock sensor signal circuit voltage low or high
P0335 Gear absence signal frequent loss
P0336 Gear absence signal unreasonable
P0340 Intake camshaft phase sensor short to ground or power supply or open circuit
P0341 Intake camshaft phase sensor signal unreasonable
P0365 Exhaust camshaft phase sensor short to ground or power supply or open circuit
P0366 Exhaust camshaft phase sensor signal unreasonable

21
P0420 Three-way catalyst oxygen reservoir capacity aging
P0444 Canister control valve control circuit open circuit
P0458 Canister control valve control circuit voltage low
P0459 Canister control valve control circuit voltage high
P0500 Vehicle speed sensor signal fault
P0504 Brake switch signal circuit fault or stop lamp switch relativity out-of-sync
P0506 Idle speed control speed below target
P0507 Idle speed control speed above target
P0532 A/C pressure sensor circuit voltage low
P0533 A/C pressure sensor circuit voltage high
P0557 Brake assistance vacuum chamber pressure sensor voltage low
P0558 Brake assistance vacuum chamber pressure sensor voltage high
P0560 System battery voltage signal unreasonable
P0562 System battery voltage low
P0563 System battery voltage high
P0567 Cruise fault

DTC Code meaning

P0601 ECU control module fault
P0604 EEPROM fault
P0605 ECU ROM fault
P0606 ECU RAM fault
P0615 Starter control relay circuit open circuit
P0616 Starter control relay circuit short to ground
P0617 Starter control relay circuit short to power
Second layer safety monitoring fault (speed sensor/electronic throttle pedal/safety fuel cut-
P061F
off)
P062C ASL fault
P0646 A/C compressor relay control circuit short to ground or open circuit
P0647 A/C compressor relay control circuit short to power supply
P0660 Variable intake valve control circuit fault
P0661 Variable intake valve control circuit short to ground
P0662 Variable intake valve control circuit voltage high
P0689 Main relay output voltage signal fault
P0690 Main relay output voltage unreasonable
P0691 Cooling fan relay control circuit short to ground (low speed)
P0692 Cooling fan relay control circuit short to power (low speed)
P0693 Cooling fan relay control circuit short to ground (high speed)
P0694 Cooling fan relay control circuit short to power (high speed)
P0700 TCU request MIL on
P0805 Clutch stroke sensor circuit fault
P0806 Clutch stroke sensor signal unreasonable or PT system fault
P081D Neutral gear switch fault
P0830 Clutch pedal switch signal incorrect
P1427 Brake booster pump control circuit short to power supply
P1428 Brake booster pump control circuit short to ground
P1479 Brake assistance vacuum chamber pressure unreasonable
P1500 LIN bus parity error
P1501 LIN bus frame error
P1502 LIN bus acknowledge overtime
P1503 LIN bus read-back error
P1511 EBSLIN communication load rate high (non-hardware fault)
P1512 EBS or battery fault

21-21
DTC Code meaning

P1513 Battery category changed and unsigned
P1514 HFM heating relay circuit short to power supply
P1515 HFM heating relay circuit short to ground
P1530 Generator LIN bus communication frame error
P1531 Generator LIN bus communication parity error
P1532 Generator LIN bus communication response overtime
P1533 Generator LIN bus communication read-back error
P1541 Generator LIN communication fault
P1542 Generator mechanical fault
P1543 Generator electronic fault
P1545 Electronic throttle actual position deviation from target exceeding limit
P1559 Electronic throttle self-learning process fault
P1564 System voltage not meeting electronic throttle self-learning condition
P1579 Electronic throttle not meeting self-learning condition
P1600 Start-stop main switch bonding
P1604 Electronic throttle gain control self-learning fault
P1610 ECM not matching immobilizer
P1613 Not receiving immobilizer authentication reply; immobilizer verification fail

21
P1614 Immobilizer authentication reply incorrect, immobilizer authentication fail
P2088 VVT intake control valve circuit voltage low
P2089 VVT intake control valve circuit voltage high
P2101 Electronic throttle mechanical BDC self-learning/spring check/position deviation fault
P2106 Electronic throttle drive stage fault
P2127 Electronic throttle pedal position sensor 1 signal voltage lower
P2128 Electronic throttle pedal position sensor 1 signal voltage high
P2132 Electronic throttle pedal position sensor 2 signal voltage lower
P2133 Electronic throttle pedal position sensor 2 signal voltage high
P2135 Electronic throttle position sensor 1 signal unreasonable
Electronic throttle pedal position sensor signal unreasonable (idle speed vicinity pedal
P2138
displacement detection)
P2140 Electronic throttle pedal position sensor signal unreasonable
Air fuel ratio closed-loop control self-learning value exceeding upper limit (medium load
P2177
zone)
Air fuel ratio closed-loop control self-learning value exceeding lower limit (medium load
P2178
zone)
DTC Code meaning

P2187 Air fuel ratio closed-loop control self-learning value exceeding upper limit (low load zone)
P2188 Air fuel ratio closed-loop control self-learning value exceeding lower limit (low load zone)
P2A00 Upstream oxygen sensor signal unreasonable
P2A01 Downstream oxygen sensor signal unreasonable
P300B lectronic throttle safety monitoring torque restriction
U0001 CAN communication related diagnosis
U0101 ECU and TCU control module communication fault
U0121 ECU and ABS control module communication loss
U0123 ECU and ESP (electronic stabilizer program) control module communication loss
U0126 ECU and SAS control module communication loss
U0129 ECU and brake system control module communication fault
U0140 ECU and BCM control module communication loss
DTC diagnosis
1. Intake VVT solenoid valve fault
P0010-VVT intake control valve circuit open circuit
P2088- VVT intake control valve circuit voltage low
P2089-VVT intake control valve circuit voltage high
DTC description:
1. The intake VVT valve is earthed inside by the terminal 71 of ECM harness connector
E01 controlling the solenoid valve.
2. ECM inside has one feedback circuit.The engine ECM determines whether there is open
circuit, short to ground or to power supply in the control circuit by monitoring the feedback
signal.

Check whether the

battery voltage is The detected voltage is Charge the battery
the normal working Go to Step 1 out of the reasonable or replace the
voltage range battery
Voltage: 11V~14V
1 Read DTC Normal Faulty Instruction

21-23

•Connect the vehicle
d i a g n o s t i c t e s t e r,
read and clear DTC,
The intake system has Repair the intake
read and clear DTC It is incidental fault
fault system
•Read DTC again to
check whether DTC
can be read
Check the intake

VVT solenoid valve
•With the ignition

switch in OFF
position, unplug the
VVT solenoid valve
connector
•Measure the
VVT solenoid valve
resistance between
resistance unreasonable, Replace the VVT
both terminals of VVT Go to Step 3
VVT filter screen solenoid valve
solenoid valve.
damaged or clogged
R e s i s t a n c e :
9.4Ω~10.6Ω(20℃ )
•Remove the intake
VVT solenoid valve
and check whether
intake VVT is normal
Check the VVT

3 solenoid valve power Normal Faulty Instruction
circuit
21
•Disconnect intake
VVT valve connector
E13
•Measure whether
there is short circuit
The circuit has short Repair the fault
or open circuit Go to Step 4
circuit or open circuit harness
between the engine
compartment central
control box fuse
FS03 and terminal 1
of E13
Check the VVT

solenoid valve circuit
Disconnect intake
VVT valve connector
E13 and engine
control unit connector
E2
•Measure whether Go to Step 5
or open circuit
between the terminal
2 of E13 and terminal
71 of E2

Inspection by
replacement
•Replace the engine

control module and
carry out road test.
•Perform the Locate the causes
Replace ECM The fault still exists
diagnosis again to from other symptom
read DTC and check
whether DTC and
symptom exist
2. Intake VVT fault
P000A-Intake VVT slow response
P0012- Intake VVT not in default position when starting
P0016- Camshaft and crankshaft relative installation position unreasonable
DTC description:
1. The engine control module monitors the relativity between the crankshaft and camshaft
position through the pulse signal of the crankshaft position sensor and camshaft position
sensor (intake side). The crankshaft variable-reluctance type rotor has 60 teeth, two
of which are absent and used as the reference gap. The teeth interval is 6° except the
reference gap which is 12°.
2. The camshaft signal panel has 4 teeth, 2 narrow and 2 wide. The 4 trailing edge of each
tooth has an interval of 90°.
3. The intake camshaft position (CMP) actuator is connected to the intake camshaft and
operates in a hydraulic way. The hydraulic pressure is supplied by the oil pump to change
the angle of intake camshaft in relation to the crankshaft position (CKP).
4. The intake VVT solenoid valve is powered by the main relay and ECM controls ground
through the pulse-width modulation signal. In this way, the engine oil flow to the camshaft
position actuator is controlled.
5. The engine oil pressure makes one of the safety slide valve inside the camshaft position
actuator mechanism fixed to the camshaft front act. When the safety slide valve acts, the
engine oil is introduced to the camshaft position actuator to make the camshaft rotate.
6. The intake camshaft position actuator can change the cam angle up to 40°±5°(crankshaft
angle).
7. The engine control module will continuously monitor the camshaft timing position and
check the relative position of camshaft and crankshaft. If the relative position out-of-
position exceeds 1 gear teeth, this DTC will occur. The fault causes include the camshaft
position sensor fault or circuit fault, crankshaft position sensor fault or circuit fault, engine
oil contamination and timing belt.

检查蓄电池电压是否
是正常工作电压进行第 1 步检测电压不在合理范围蓄电池充电或更换
电压：11V~14V

21-25

The fault is
incidental. Check the
ECM connectors,
crankshaft position
s e n s o r, c a m s h a f t
read and clear DTC There is DTC; go to Step
It is incidental fault position sensor
•Read DTC again to 2
connectors for
check whether DTC
looseness and
can be read
damage; check the
harness terminals
for corrosion
Check the intake VVT

solenoid valve
•Check whether the

engine oil viscosity
and cleaning degree
are normal
Replace the
The engine oil is engine oil and oil
engine oil level is
unqualified or the filter element and
within the working Go to Step 3
lubrication system has clean the engine
range
fault lubrication system if
necessary
engine oil is changed
in time or contains
additive or the oil
viscosity is incorrect
3 Check the timing belt Normal Faulty Instruction

21
Check the timing
belt for looseness, Timing belt assembly Replace the new
Go to Step 4
gear skip, gear off or fault timing belt
damage
Check the valve

timing
Check the whether

Timing belt assembly Install the valve
the valve timing is Go to Step 5
fault timing belt again
correct
Check the camshaft

position sensor
•Check whether
the intake camshaft
position sensor O-ring damage, Replace the O-ring
Go to Step 6
O-ring is normal and deformation and clean the sensor
the sensor is installed
in position
Check the camshaft

6 position sensor signal Normal Faulty Instruction
wheel

Check whether the
Replace the intake
intake side camshaft Camshaft position
Go to Step 7 side camshaft
position sensor signal sensor signal fault
assembly
wheel is normal
Inspection by
r e p l a c e m e n t
(camshaft position
sensor)
•Replace the intake

camshaft position
sensor and carry out
Replace the intake
road test Intake camshaft position
Go to Step 8 camshaft position
•Read DTC through sensor fault
sensor
diagnosis again to
check whether DTC
and symptom exist
Check the crankshaft

position sensor
Check whether the
crankshaft position
sensor O-ring is O-ring damage, Replace the O-ring
Go to Step 9
normal and the deformation and clean the sensor
sensor is installed in
position
wheel
Check whether the

crankshaft flywheel
Replace the
gear ring is deformed Crankshaft flywheel gear
Go to Step 10 crankshaft flywheel
or damaged and the ring fault
gear ring
gear ring grease is
too thick

position sensor
With the ignition

switch in OFF
position, disconnect
the crankshaft
position sensor
connector E24 and
Replace the
check whether the Crankshaft position
Go to Step 11 crankshaft position
resistance between sensor fault
sensor
crankshaft position
sensor pin E24
terminal 1 and E24
terminal 2 is normal
860Ω±130Ω
21-27

Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
3. Front oxygen sensor heating circuit fault
P0030- Upstream oxygen sensor heating control circuit open circuit (Bank 1)
P0031- Upstream oxygen sensor heating control circuit short to ground (Bank 1)
P0032- Upstream oxygen sensor heating control circuit short to power (Bank 1)
P0053- Upstream oxygen sensor heating circuit internal resistance unreasonable
(Bank 1)
DTC description:
1. The upstream heating type oxygen sensor is the front oxygen sensor. It is designed
to correct the fuel control and compare the ambient air oxygen content and exhaust flow
oxygen content. Each sensor inside is provided with the heating element to heat the
sensor.
2. The engine control module controls the heating type oxygen sensor heating control
circuit to make the system enter the closed loop mode earlier and sensor calculate air fuel
ratio in advance. The engine control module commands the heating element to switch on
or off and maintain the sensor in the specified operating temperature range.
3. The engine control module determines the temperature by measuring the heater current. 21
If the oxygen sensor cannot reach the desired temperature within the set time or the
engine control module cannot maintain the set temperature, this DTC will occur.

Check whether the

Voltage: 11V~14V
The fault is
•Connect the vehicle incidental. Check
d i a g n o s t i c t e s t e r, the front oxygen
read and clear DTC There is DTC; go to Step sensor connector
It is incidental fault
•Read DTC again to 2 for looseness or
check whether DTC damage; check the
can be read harness terminals
for corrosion.
Check the front

2 oxygen sensor power Normal Faulty Instruction
circuit

Disconnect the
front oxygen sensor
connector E23, with
the ignition switch in
The voltage is out of the
ON position, check Go to Step 4 Go to Step 3
reasonable range
the voltage between
terminal 4 of E23 and
the ground
Voltage: 9V~13V
Check the front

oxygen sensor circuit
With the ignition

switch in OFF
front oxygen sensor
connector
•Disconnect the
engine control unit
connector E1, E2 and
front oxygen sensor
connector E23
•Measure whether
there is short circuit The circuit has short Repair the fault
Go to Step 4
or open circuit circuit or open circuit. harness
3 of E23
•Measure whether
or open circuit
4 of E23 and the
engine compartment
central control box
fuse FS03
Check the front

4 Normal Instruction
oxygen sensor

switch in OFF
front oxygen sensor
connector
•At the room
temperature,
Front oxygen sensor Replace the front
measure whether the Go to Step 5
fault oxygen sensor
resistance between
the front oxygen
sensor connector
(component side)
E23 pin 3 and E23
pin 4 is normal
Resistance: 7Ω~11Ω
21-29

Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
4. Rear oxygen sensor heating circuit fault
P0030- Upstream oxygen sensor heating control circuit open circuit (Bank 1)
P0031- Upstream oxygen sensor heating control circuit short to ground (Bank 1)
P0032- Upstream oxygen sensor heating control circuit short to power (Bank 1)
P0053- Upstream oxygen sensor heating circuit internal resistance unreasonable
(Bank 1)
DTC description:
1. The upstream heating type oxygen sensor is the front oxygen sensor. It is designed
to correct the fuel control and compare the ambient air oxygen content and exhaust flow
oxygen content. Each sensor inside is provided with the heating element to heat the
sensor.
circuit to make the system enter the closed loop mode earlier and sensor calculate air fuel
ratio in advance. The engine control module commands the heating element to switch on
or off and maintain the sensor in the specified operating temperature range. 21
3. The engine control module determines the temperature by measuring the heater current.
If the oxygen sensor cannot reach the desired temperature within the set time or the
engine control module cannot maintain the set temperature, this DTC will occur.

Check whether the

Voltage: 11V~14V
The fault is
d i a g n o s t i c t e s t e r, the rear oxygen
for corrosion
Check the rear

2 oxygen sensor power Normal Faulty Instruction
circuit
Disconnect the
rear oxygen sensor
connector E25, with
The voltage is out of the
ON position, check Go to Step 4 Go to Step 3
reasonable range
the voltage between
the ground
Voltage: 9V~13V
Check the rear

With the ignition

switch in OFF
front oxygen sensor
connector
• Disconnect the
engine control unit
front oxygen sensor
connector E25
• Measure whether
there is short circuit Short circuit or open Repair the fault
Go to Step 4
or open circuit circuit harness
3 of E25
• Measure whether
or open circuit
4 of E25 and the
engine compartment
central control box
fuse FS03
Check the rear

oxygen sensor
• With the ignition

switch in OFF
rear oxygen sensor
connector
• At the room
temperature,
Replace the rear
measure whether the Go to Step 5 Rear oxygen sensor fault
oxygen sensor
resistance between
the rear oxygen
sensor connector
(component side)
E25 pin 3 and E25
pin 4 is normal
Resistance: 7Ω~11Ω
21-31

Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
5. Intake pressure sensor fault
P0105- Intake pressure sensor signal no fluctuation
P0106- Intake pressure sensor unreasonable
P0107- Intake pressure sensor signal circuit voltage low
P0108-Intake pressure sensor signal circuit voltage high
DTC description:
1. The intake pressure sensor is designed to measure the pressure inside the intake
manifold.
2. The engine control unit takes the difference of intake manifold pressure and atmosphere
pressure (in linear relationship with the engine load) as the reference to determine the
basic injection volume of the injector so as to help the engine to achieve the optimum air
fuel ratio under different load.
3. If the engine control module detects the intake pressure sensor signal voltage exceeds
the normal range of calibration, this DTC will occur. 21

Check whether the
Voltage: 11V~14V
The fault is
incidental.
Check the intake
pressure sensor
It is incidental fault connector for
looseness or
check whether DTC
damage; check the
can be read
harness terminals
for corrosion.
Check the intake

pressure sensor

pressure temperature
sensor The intake pressure Clear the dirt on
•Check the intake Go to Step 3 temperature sensor the intake pressure
pressure temperature surface has dirt temperature sensor
sensor surface for oil
stain
Check the intake

pressure sensor

sensor Replace the
Intake pressure
•Check the intake Go to Step 4 intake pressure
temperature sensor fault
pressure temperature temperature sensor
stain
Check the intake

4 pressure sensor Normal Faulty Instruction
circuit
• Disconnect the
intake pressure
temperature sensor
connector E16A and
engine control unit
connector E1 and E2
Measure whether
Go to Step 5
or open circuit circuit or open circuit harness
85 of E2, terminal 3
of E15 and terminal
of E15 and terminal
91 of E2.
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
6. Intake temperature sensor fault
P0112- Intake temperature sensor signal voltage low
P0113- Intake temperature sensor signal voltage high
DTC description:
1. The intake temperature sensor (IATS) is designed to detect the intake temperature,
convert the intake temperature signal into electric signal and feed this signal to the engine
21-33
control module (ECM) to allow the ECM to correct the fuel injection time and ignition time
and maintain the engine in the optimum working state.
2. The intake temperature sensor employs the negative temperature coefficient (NTC)
thermal resistor, resistance of which decreases as the temperature rises.
3. If the engine control module detects the intake temperature sensor signal is below the
minimum value of self-inspection or above the maximum value, this DTC will occur.

Check whether the

Voltage: 11V~14V
The fault is
•Connect the vehicle incidental. Check the
d i a g n o s t i c t e s t e r, intake temperature
for corrosion.
Check the intake

temperature sensor
Remove the intake

21
sensor The intake pressure Clear the dirt on
•Check the intake Go to Step 3 temperature sensor the intake pressure
pressure temperature surface has dirt temperature sensor
stain
Check the front


• Use the electrical
heating dryer to blow
the inlet pressure and
temperature sensor
(the distance should
be not too close),
and observe the
changes of resistance
between 1# and 2#
terminals of E15 on Short circuit or open Repair the fault
Go to Step 4
the intake pressure circuit harness
and temperature
sensor; at this time,
the resistance should
be decreased.
• For the temperature
and corresponding
resistance 20 ℃ /
2416Ω~2583Ω85 ℃ /
273Ω~286Ω
Check the intake air
4 temperature sensor Normal Faulty Instruction
circuit
•Disconnect the
intake pressure
temperature sensor
connector E15and
engine control unit
connector E1 and E2
• Measure whether The circuit has short Repair the fault
Go to Step 5
there is short circuit circuit or open circuit harness
or open circuit
of E15 and terminal
102 of E2.
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
7. Coolant temperature sensor fault

P0116- Engine coolant temperature sensor signal unreasonable
P0117- Engine coolant temperature sensor circuit voltage low
P0118- Engine coolant temperature sensor circuit voltage high
DTC description:
21-35
1. The engine coolant temperature sensor (ECT) is designed to convert the coolant
temperature signal into electric signal and feed this signal to the ECM to allow the ECM
to correct the fuel injection time and ignition time and maintain the engine in the optimum
working state.
2. The coolant temperature sensor employs the negative temperature coefficient (NTC)
3. If the engine control module detects the engine coolant temperature sensor signal is
below or above the self-inspection value, this DTC will occur. The fault causes include the
sensor signal short to the ground, sensor fault and engine control module fault etc.

Check whether the

Voltage: 11V~14V
The fault is
•Connect the vehicle incidental. Check the
d i a g n o s t i c t e s t e r, water temperature
for corrosion
Check the coolant 21

temperature sensor
•Remove the engine

coolant temperature
sensor
•Heat the engine
coolant temperature
sensor to test and
check whether the
resistance change
of sensor pin E21 Intake pressure Replace the coolant
Go to Step 3
terminal 1 and E21 temperature sensor fault temperature sensor
terminal 3 decreases
along with the
temperature increase
• Te m p e r a t u r e a n d
corresponding
resistance
30℃ /2240Ω±56Ω
80℃ /333.8Ω±6.7Ω
Check the intake

pressure sensor

• E1、E2
Disconnect the water
temperature sensor
connector E21 and
engine control unit
connector E1 and E2
• Measure whether Short circuit or open Repair the fault
Go to Step 4
there is short circuit circuit harness
or open circuit
of E21 and terminal
101 of E2.
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
8. Electronic throttle signal fault
P0121- Electronic throttle position sensor 1 signal unreasonable
P0122- Electronic throttle position sensor 1 signal circuit voltage low
P0123- Electronic throttle position sensor 1 signal circuit voltage high
P0221- Electronic throttle position sensor 2 signal unreasonable
P0222- Electronic throttle position sensor 2 signal circuit voltage low
P0223- Electronic throttle position sensor 2 signal circuit voltage high
DTC description:
1. In the electronic throttle control (ETC) system, the function of accelerator pedal position
(APP) sensor is to feed the throttle pedal valve opening to the engine control unit through
the sensor signal.
2. Actual throttle position will be compared with the throttle position determined by the
engine load. The engine control module (ECM) determines the engine load according to
the signal of intake manifold absolute pressure sensor (MAPS). By the farther comparison,
the sensor fault can be determined and the corresponding DTC can be set. The fault
causes include the sensor signal open circuit, sensor ground wire open circuit, sensor fault
and engine control module fault etc.

Check whether the

Voltage: 11V~14V
21-37

The fault is
throttle connector
It is incidental fault for looseness or
damage; check the
check whether DTC
harness terminals
can be read
for corrosion
Check the electronic

throttle circuit

switch in OFF
the electronic throttle
connector E14 and
engine control unit
connector E1 and E2
• Measure whether
or open circuit Short circuit or open Repair the fault
Go to Step 3
between the terminal circuit harness
of E14 and terminal
of E14 and terminal
of E14 and terminal 21
77 of E2.

throttle
•Replace the
electronic throttle and
carry out road test
•Perform the Replace the
Go to Step 4 DTC still exists
diagnosis again to electronic throttle
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
9. Front oxygen sensor signal circuit fault

P0130- Upstream oxygen sensor signal unreasonable
P0131- Upstream oxygen sensor signal circuit voltage low
P0132- Upstream oxygen sensor signal circuit voltage high
P0133- Upstream oxygen sensor aging
P0134- Upstream oxygen sensor circuit signal fault
DTC description:
1. To test the oxygen concentration in the exhaust and release the feedback signal to the
engine control unit which will control the increase and decrease of injection volume and
consequently maintain the air fuel ratio near the theoretical value.
2. After the vehicle start, the control module will work in the open-loop mode, namely,
ignoring the front oxygen
sensor signal voltage when calculating the air fuel ratio. The control module supplies
450mV reference voltage approximately to the upstream oxygen sensor. With the engine
running, the upstream oxygen sensor will heat and generate 0 - 0.1V voltage, which
fluctuates around the reference voltage.
3. Once detecting the upstream oxygen sensor voltage exceeding the set threshold
voltage, the control module will immediately enter the closed loop mode. The control
module determines the air fuel ratio by the upstream oxygen sensor voltage. If the
upstream oxygen sensor voltage rises above the reference voltage (tending to 1V), it
indicates the mixture is too rich. If the upstream oxygen sensor voltages drops below the
reference voltage (tending to 0mV), it indicates the mixture is too lean. If the oxygen sensor
voltage fluctuation response speed is below the system value, it indicates the oxygen
sensor is aged.

Check whether the

Voltage: 11V~14V

The fault is
incidental. Check
read and clear DTC
the front oxygen
•Restart the engine
There is DTC; go to Step sensor connector
and carry out the It is incidental fault
2 for looseness or
road test to run the
damage; check the
engine under various
harness terminals
c o n d i t i o n s . Tr y t o
for corrosion
read DTC
Check the front

oxygen sensor
21-39

switch in OFF
the battery negative
Replace the front
terminal Front oxygen sensor
o x y g e n s e n s o r,
• Remove the front Go to Step 3 severe carbon deposit,
change the fuel and
oxygen sensor and whitening
clean the fuel tank
check the sensor
for carbon deposit,
whitening, browning
or darkening
Check the front

Disconnect the
front oxygen sensor
connector E23 and
engine control unit
connector E1 and E2
• Measure whether
there is short circuit Go to Step 4
or open circuit
of E23 and terminal
104 of E2.
Inspection by
4 replacement (oxygen Normal Faulty Instruction 21
sensor)
•Replace the front

oxygen sensor and
carry out road test
•Perform the Replace the front
DTC still exists Go to Step 5
diagnosis again to oxygen sensor
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
10. Rear oxygen sensor signal circuit fault
P0136-Downstream oxygen sensor signal unreasonable
P0137-Downstream oxygen sensor signal circuit voltage low
P0138-Downstream oxygen sensor signal circuit voltage high
P0140-Downstream oxygen sensor circuit signal fault

DTC description:
1. The downstream oxygen sensor is the rear oxygen sensor which is designed to monitor
the three-way catalytic converter operating state.
2. The sensor compares the ambient air oxygen content with the exhaust flow oxygen
content. Every heating type oxygen sensor is provided with the heating element to heat the
sensor inside. The engine control module controls the heating control circuit of the heating
type oxygen sensor.

Check whether the

Voltage: 11V~14V

The fault is
incidental. Check
read and clear DTC
the rear oxygen
There is DTC; go to Step sensor connector
2 for looseness or
damage; check the
harness terminals
for corrosion
read DTC
Check the three-way
catalyst
Ensure the three-way

Replace the three-
catalytic converter is
Go to Step 3 Three-way catalyst fault way catalytic
replaced within the
converter
specified time limit
Check the rear

oxygen sensor

switch in OFF
Replace the rear
terminal. Rear oxygen sensor
o x y g e n s e n s o r,
•Remove the rear Go to Step 4 severe carbon deposit,
change the fuel and
oxygen sensor and whitening
clean the fuel tank
check the sensor
for carbon deposit,
whitening, browning
or darkening
Check the rear

21-41

• Disconnect the
rear oxygen sensor
connector E25 and
engine control unit
connector E1 and E2
• Measure whether
there is short circuit Go to Step 5
or open circuit
of E25 and terminal
43 of E1.
Inspection by
5 replacement (oxygen Normal Faulty Instruction
sensor)
•Replace the front

oxygen sensor and
carry out road test
•Perform the Replace the front
DTC still exists Go to Step 6
diagnosis again to oxygen sensor
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement
•Replace the engine 21

control module and
read DTC and check
whether DTC and
symptom exist
11. Fuel too rich or too lean
P0170- Off-line testing air fuel ratio closed-loop control self-learning unreasonable
P0171- Off-line testing air fuel ratio closed-loop control self-learning lean
P0172- Off-line testing air fuel ratio closed-loop control self-learning rich
DTC description:
1. The engine control module controls the closed loop air fuel ratio measuring system to
make the control performance, fuel economic performance and emission control reach
the optimum matching. In the closed loop mode, the engine control module monitors the
heating type oxygen sensor signal voltage and regulates the fuel supply according to the
signal voltage.
2. The variance in the fuel supply will change the long term and short term fuel regulation
value.
3. The short term fuel regulation value will respond the signal voltage of heating type
oxygen sensor to change quickly. These changes will regulate the engine fuel supply.
4. The long term fuel regulation value will respond the short term fuel regulation trend and
change. The long term fuel regulation will control the fuel supply in a coarse control way to
return the central value of short term fuel regulation and restore the control over the short
term fuel regulation.
5. The ideal fuel regulating value is 0% approximately. The positive value means the
engine control module is increasing the fuel to compensate the lean gas mixture while the
negative value means the engine control module is decreasing the fuel to compensate the
rich gas mixture.

Check whether the

Voltage: 11V~14V

Refer to the
read and clear DTC
corresponding
chapters according
to carry out road
to the DTC displayed
test and run the There is other sensor or
Go to Step 2 on the diagnostic
engine under various actuator DTC
tester to solve the
conditions. Read
faults and then test
DTC and check
according to this
whether the engine
section
has other sensor or
actuator DTC
2 Check the air filter Normal Faulty Instruction
Check whether the Replace the air filter

Go to Step 3 The air filter clogging
air filter is clogged assembly
Check the intake

system line
Check the intake

Intake system line air Repair the air leak
system line for air Go to Step 4
leak fault line
leak
•Remove the spark

plug
Excessive spark plug Replace the spark
•Check whether the Go to Step 5
gap plug
spark plug gap is
normal
Check the ignition

coil
21-43

•Remove the ignition
coil and install the
new spark plug
•Check whether the Go to Step 6 Ignition coil fault Go to Step 6
ignition coil spark-
over and spark are
normal
Check the exhaust

system line
Check the exhaust

Exhaust system line air Repair the air leak
system line for air Go to Step 7
leak fault line
leak
Check the fuel

system pressure
Check whether the

Repair the fuel
fuel system pressure Go to Step 8 Fuel system fault
system
is normal
8 Check the injector Normal Faulty Instruction
•Remove the injector

and connect the
injector to the tester Replace the faulty
Go to Step 9 The injector fault
•Check whether the injector
injector performance
is normal 21
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
12. The injector fault

P0201-Cylinder 1 injector control circuit open circuit
P0202-Cylinder 2 injector control circuit open circuit
P0261- Cylinder 1 injector control circuit voltage low
P0262- Cylinder 1 injector control circuit voltage high
P0264- Cylinder 2 injector control circuit voltage low
P0265-Cylinder 2 injector control circuit voltage high
P0267-Cylinder 3 injector control circuit voltage low
P0270-Cylinder 4 injector control circuit voltage low
DTC description:
1. The injector working voltage is supplied by the main relay under the control of engine
control module. The battery voltage is fed to all the injector harness connectors through the
main relay and then to the injector.
2. The engine control module controls the injector ground wire to ground inside the engine
control module through the harness connection.
3. The engine control module monitors the state of each injector drive circuit. If the engine
control module detects the voltage corresponding the injector drive circuit command state
is incorrect, it will set the DTC of this cylinder injector control circuit.
Note:
Before the diagnosis, observe the data list of fault diagnostic meter and analyze the
data accuracy, which will help the quick troubleshooting.
Tips:
The testing method of cylinder 1 injector fault is the same as the rest cylinders. Here only
describe the cylinder 1 injector faults.

Check whether the

Voltage: 11V~14V

d i a g n o s t i c t e s t e r, The fault is
read and clear DTC incidental. Check the
•Restart the engine injector connector
There is DTC; go to Step
and carry out the It is incidental fault for looseness or
2
road test to run the damage; check the
engine under various harness terminals
c o n d i t i o n s . Tr y t o for corrosion
read DTC
Check the injector

power circuit
•Disconnect cylinder
1 injector connector
E12
Measure the engine
The voltage is out of the compartment central
switch in ON position, Go to Step 3
reasonable range control box relay
check the voltage
K05 and E18A
between terminal 1 of
E12 and the ground
Voltage: 9V~13V
3 Check the injector Normal Faulty Check the injector

21-45

switch in OFF
terminal
•Disconnect cylinder
1 injector connector
Go to Step 4 The injector fault Replace the injector
E12
•Measure whether the
resistance between
two terminals of
injector is normal
12.0Ω±0.6Ω
Check the injector Is there short circuit

4 Normal Faulty
control circuit or open circuit?
•Disconnect ECM
connector E1 and E2
•Measure whether
there is short The circuit has short Repair the fault
Go to Step 5
circuit or open circuit or open circuit harness
circuit between the
connector E1 terminal
and E12 terminal 2
Check the ignition

coil
21
control module and
read DTC and check
whether DTC and
symptom exist
13. P0219- Engine speed exceeding maximum speed limit
DTC description:
1. The engine control unit detects the engine speed exceeds the maximum limit.
2. The fault causes include the engine running in the wrong gear, the engine running at
high speed in the neutral gear, the wheel slipping in the swamp or snowfield at high speed.

Check whether the

Voltage: 11V~14V


It is incidental fault It is incidental fault
check whether DTC
can be read
Check the vehicle

conditions
Check whether the

engine is running in
the wrong gear, the
engine is running at
high speed in the
Go to Step 3 Wrong operation Clear the fault code
n e u t r a l g e a r, t h e
wheel are slipping
in the swamp or
snowfield at high
speed
Check the throttle
pedal position sensor

electronic throttle
pedal is seized in the
high opening position
and cannot return
•Connect the
depress/reset the Throttle pedal position
Go to Step 4 pedal position
throttle pedal, read sensor damage
sensor
the related throttle
pedal data flow and
check whether the
throttle pedal sensor
related data flow
changes in a normal
way

throttle
•Connect the
diagnostic tester
and read the data
stream under various
working conditions
•In the still state Replace the
Electronic throttle
or the idling state, Go to Step 5 electronic throttle
damage
check whether the body assembly
electronic throttle
opening is high or the
pedal is seizing in the
high opening position
and cannot return
21-47

position sensor
R e m o v e t h e
crankshaft position
sensor and measure
w h e t h e r t h e
Replace the
resistance between Crankshaft position
sensor terminal box sensor fault
sensor
1 and terminal 2 is
normal
860Ω±130Ω
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
14. Multi-cylinder misfire
P0300-Multi-cylinder misfire
DTC description:
1. The cylinder misfire means the gas mixture cannot combust in the cylinder normally due 21
to various reasons.
2. If the engine control module detects the misfire which may damage the catalytic
converter, the MIL will blink. At this point, shut down the engine immediately.
3. With the engine running time >60s and coolant temperature > 70°C, when the system
detects the crankshaft position sensor speed fluctuation above the system setting, the
DTC will be triggered. This DTC indicates more than one cylinder has misfire or the
engine control module cannot determine in which cylinder the misfire occurs. The fault
causes include the cylinder mechanical fault, fuel metering error, fuel pressure high or low,
evaporative emissions system fault, ignition system fault and intake system fault etc.


read and clear DTC
and carry out the It is incidental fault It is incidental fault
1
read DTC


Check whether the
Replace the spark
spark plug gap is Go to Step 2 The spark plug has fault
plug
normal
Check the ignition

coil

new spark plug Replace the ignition
Go to Step 3 Ignition coil fault
•Check whether the coil
spark plug spark-over
and spark are normal
•Check the timing

Go to Step 4
damage
Check the valve

timing
Check the whether

correct
Check the cylinder

pressure
Connect the cylinder

pressure tester and
Repair the cylinder
measure whether the Go to Step 6 Cylinder pressure fault
pressure fault
cylinder pressure is
normal
Check the fuel

system pressure

check whether the Fuel system pressure Repair the fuel
Go to Step 7
engine fuel system fault system
pressure is normal
Remove the injector

and check whether
the injector is normal Go to Step 8 The injector fault Replace the injector
with the injector
tester
Check the intake

system
21-49

The intake system has
check the intake Go to Step 9 Repair the faulty line
air leak fault
system for air leak
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
15. Single cylinder misfire
P0301- Cylinder 1 misfire
P0304-Cylinder 4 misfire
DTC description:
1. The cylinder misfire means the gas mixture cannot combust in the cylinder normally due
to various reasons. If the engine control unit detects the misfire which may damage the
catalytic converter, the MIL will blink. At this point, shut down the engine immediately.
2. With the engine running time exceeding 60s and the coolant temperature > 70℃ , if the
crankshaft speed difference exceeds the calibration limit after the cylinder 1 TDC ignition,
the cylinder 1 misfire DTC will occur. 21

read and clear DTC
and carry out the It is incidental fault It is incidental fault
1
read DTC
Check the intake

system

air leak fault
system for air leak

•Check the timing

Go to Step 4
damage
Check the valve

timing
Check the whether

correct
Check the cylinder

pressure

pressure tester and
Repair the cylinder
pressure fault
normal
Check the fuel

system pressure

Go to Step 7
pressure is normal
Remove the injector

and check whether
with the injector
tester
Check the intake

system

air leak fault
system for air leak
Inspection by
replacement
21-51

control module and
read DTC and check
whether DTC and
symptom exist
16. Crankshaft position sensor signal loss fault
P0322- Speed sensor signal fault
DTC description:
1. The crankshaft position sensor signal is to tell the current crankshaft rotary speed
and position to the engine control module. The crankshaft position sensor generates the
alternating voltage of different amplitude and frequency. The frequency depends on the
crankshaft speed and the output AC voltage depends on the crankshaft position sensor.
The crankshaft position sensor works together with the 58X variable-reluctance type rotor
fixed on the crankshaft.
2. The engine control module can work out the ignition timing, injection timing and knock
ignition control according to the input signal of crankshaft position sensor and camshaft
position sensor. The crankshaft position sensor can also detect the misfire and tachometer
display.

Check whether the 21

Voltage: 11V~14V

read and clear DTC
There is DTC; go to Step The fault is
1 incidental.
read DTC

position sensor

switch in OFF
terminal
•Remove the
Replace the
crankshaft position Crankshaft position
sensor and measure sensor fault
sensor
w h e t h e r t h e
resistance between
sensor terminal 1 and
terminal 2 is normal
860Ω±130Ω

position sensor line
•Disconnect the
engine control unit
crankshaft position
sensor connector
E24
Short circuit or open Repair the fault
circuit harness
or open circuit
between E24 terminal
2 and E2 terminal 97;
E24 terminal 1 and
E2 terminal 96
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
17. Knock sensor fault

P03227- Knock sensor signal circuit voltage low
P03227- Knock sensor signal circuit voltage high
DTC description:
1. The knock sensor is responsible for detecting shock upon the engine speed variation.
The knock sensor indicates the shock in the form of voltage. Where necessary, the
engine control module will delay the ignition to avoid the knock. If this voltage is below
the calibration value, the DTC will occur. The fault causes include the knock sensor circuit
fault, knock sensor looseness and knock sensor fault etc.
21-53

Check whether the

Voltage: 11V~14V

read and clear DTC
1 incidental.
read DTC
Check the knock

sensor
knock sensor fixing
bolt model and torque
are correct
Replace the bolt
•Disconnect the
and tighten the
knock sensor
knock sensor to the
connector E19 and Go to Step 3 The knock sensor fault
required torque or
measure whether the 21
replace the knock
resistance between
sensor
two terminals of the
sensor is normal
4.9MΩ±20%
Check the knock

sensor circuit
•Disconnect the
engine control unit
connector E1, E2
and knock sensor
connector E19
•Measure whether The circuit has short Repair the fault
Go to Step 4
or open circuit
E19 terminal 2 and
E2 terminal 89
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
18. Camshaft position sensor fault
P0341- Phase sensor signal unreasonable
DTC description:
1. The phase sensor is also called the camshaft position sensor. It is designed to transmit
the camshaft position and cylinder 1 TDC position (the valve relative position) to the engine
control unit in the form of voltage signal.
2. If the engine control module detects the camshaft position sensor signal abnormal
during the set time interval, this DTC will occur. The fault causes include the camshaft
position sensor circuit, joint, sensor fault and the engine control module fault etc.

Check whether the

Voltage: 11V~14V

read and clear DTC
2 incidental.
read DTC
Check the timing belt

Timing belt assembly Replace the new
for looseness, gear Go to Step 3
fault timing belt
skip, gear off
Check the valve

timing
Check the whether

correct
Check the camshaft

position sensor
21-55

Check whether the
camshaft position
sensor O-ring is O-ring damage, Replace the O-ring
Go to Step 5
normal and the deformation and clean the sensor
sensor is installed in
position
Check the camshaft

signal wheel
Check whether the

Camshaft signal wheel Replace the
camshaft signal Go to Step 6
damage camshaft assembly
wheel is normal
Check the camshaft

6 position sensor Normal Faulty Instruction
(intake side) line
Disconnect the
engine control unit
camshaft position
sensor connector
E20
•Measure whether
Go to Step 7
or open circuit circuit or open circuit harness
21
of E20 and terminal
of E20 and terminal
93 of E2.
Inspection by
r e p l a c e m e n t
(camshaft position
sensor)
•Replace the
camshaft position
sensor and carry out
road test Replace the
•Perform the camshaft position DTC still exists Go to Step 8
diagnosis again to sensor
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
19. Emission overlimit fault
P0420- Three-way catalyst oxygen reservoir capacity aging (emission exceeding
limit)
DTC description:
1. The engine control module monitors the conversion efficiency of three-way catalytic
converter through the two oxygen sensors (front and rear oxygen sensor) installed to the
three-way catalytic converter front and back.
2. The engine control module executes the closed-loop control over the air fuel ratio and
monitors the oxygen content in the exhaust gas not purified by the three-way catalytic
converter through the front oxygen sensor. The rear oxygen sensor sends the oxygen
content of gas purified by the three-way catalytic converter to the engine control module
through the voltage signal.
3. The engine control module determines whether the three-way catalytic converter
is under the normal operating condition by the signal contrast of front/rear oxygen
sensor.With the engine running time exceeding 60s and coolant temperature more
than 70℃ , if the system detects the rear oxygen sensor signal is below or above the
system value, that is, the three-way catalytic converter conversion efficiency is low,
it will turn on the MIL and set this DTC at the same time.

Check whether the

Voltage: 11V~14V

read and clear DTC
2 incidental.
read DTC
Check the exhaust

line
21-57
Check the exhaust The exhaust line has air Check the exhaust
Go to Step 3
line for air leak leak fault line fault
Check the rear

oxygen sensor
Check whether the

Replace the rear
rear oxygen sensor Go to Step 4 Rear oxygen sensor fault
oxygen sensor
signal is normal
Check the three-way

catalyst

Replace the three-
catalytic converter is
Go to Step 3 Three-way catalyst fault way catalytic
replaced within the
converter
5 Change the fuel Normal Faulty Instruction
Check whether the

Replace the three-
camshaft signal Go to Step 6 Three-way catalyst fault
way catalyst
wheel is normal
Inspection by
replacement

control module and 21
read DTC and check
whether DTC and
symptom exist
20. Canister control valve fault
P0444- Canister control valve control circuit open circuit
P0458- Canister control valve control circuit voltage low
P0459- Canister control valve control circuit voltage high
DTC description:
1. The vapor emission system will introduce the fuel vapor in the fuel tank to the tank
provided with active carbon which can absorb the fuel vapor. The engine sucks the fuel
vapor to the engine chamber through the fresh air.
2. If the engine control unit detects the vapor emission system canister control valve
control circuit presents short circuit or open circuit, this DTC will occur. The fault causes
include the canister control valve controlled power supply circuit open circuit, canister
control valve control circuit open circuit or short to the ground, canister control valve fault
and engine control module fault etc.


Check whether the
Voltage:11~14V

read and clear DTC
2 incidental.
read DTC
Check the canister
control valve

switch in OFF
terminal
•Remove the canister
Canister control valve Replace the canister
control valve and Go to Step 3
fault control valve
measure whether the
resistance between
the solenoid valve
two pins is normal
22Ω~30Ω(20℃ )
Check the canister
control valve
•Disconnect the
Check whether
canister control valve
connector E6, with
or open circuit
The voltage is out of the between the engine
ON position, check Go to Step 4
reasonable range compartment central
the voltage between
control box relay
K05 and E05A
the ground
terminal 1
Voltage:9V~13V
Check the canister

4 control valve control Normal Faulty Instruction
circuit
21-59

•Disconnect the
engine control
module connector
E1, E2 and canister
control valve
connector E6 The circuit has short Repair the fault
Go to Step 5
• Measure whether circuit or open circuit harness
or open circuit
2 of E6
Inspection by
replacement
Replace the engine

control module and
read DTC and check
whether DTC and
symptom exist
21. Cooling fan circuit fault
P0480- Cooling fan relay control circuit open circuit (low speed)
P0481- Cooling fan relay control circuit open circuit (high speed)
P0691- Cooling fan relay control circuit voltage low (low speed)
P0692- Cooling fan relay control circuit voltage high (low speed) 21
P0693- Cooling fan relay control circuit voltage low (high speed)
P0694- Cooling fan relay control circuit voltage high (high speed)
DTC description:
1. The cooling fan high and low speed relay coil is powered by the main relay controlled by
engine control module which controls the relay to work through the harness connector. The
engine control module is provided with one drive circuit inside to control the relay coil to
ground.
2. The drive circuit is provided with a feedback circuit to the engine control module which
determines the control circuit open circuit, short to the ground or short to the voltage by
monitoring the feedback voltage.
3. The low speed fan will start when the coolant temperature exceeds 93℃ and the high
speed fan will start when the coolant temperature exceeds 96℃ .

Check whether the

battery voltage is
the normal working It is incidental fault
2 incidental.
voltage
Voltage: 11V~14V


The fault is
incidental. Check
read and clear DTC
the engine control
There is DTC; go to Step module connector
2 for looseness or
damage; check the
harness terminals
for corrosion
read DTC
2 Check the fan relay Normal Faulty Instruction
Remove the engine

compartment central
control box K18 (fan
speed control), K02 Replace the fault
Go to Step 3 Relay fault
(high speed fan), K03 relay
(low speed fan) relay
and check whether
the relay is normal
Check the cooling fan

control circuit

switch in OFF
terminal
•Unplug the K03
(low speed fan) and
K02 (high speed fan)
relay and disconnect
the engine control The circuit has short Repair the fault
Go to Step 4
module connector E1 circuit or open circuit harness
and E2
•Measure whether
or open circuit
between the engine
compartment central
control box K03 and
E1 terminal 56; K02
and E1 terminal 31

circuit
•Disconnect the
cooling fan connector
U26 and U27
•Check whether
U26 terminal 1 and Go to Step 5
terminal 2 as well
as U27 terminal 1
and terminal 2 are
conducted
21-61

Inspection by
5 Normal Right fault Instruction
replacement

control module and
read DTC and check
whether DTC and
symptom exist
22. Vehicle speed signal fault
P0501- Vehicle speed sensor signal fault
P0317- Bad road testing ABS signal fault
DTC description:
1. After the wheel speed sensor detects the vehicle speed signal and ABS ECU process
the signal, the wheel speed sensor will send this signal to CAN bus. The engine control
module will receive the vehicle speed signal from the CAN bus.
2. If the engine control module cannot receive the vehicle speed signal, this DTC will occur.

Check whether the

battery voltage is
the normal working It is incidental fault
1 incidental.
voltage
Voltage: 11V~14V 21

read and clear DTC
2 incidental.
read DTC
2 Read ABS data flow Normal Faulty Instruction

diagnostic tester to
access ABS system
•Start the engine to Check the ABS
carry out road test ABS ECU or wheel control unit, wheel
Go to Step 3
and check whether speed sensor fault speed sensor and
the vehicle speed harness
display is normal
under various
conditions
Check the ECM CAN

communication line

switch in OFF
position, check
whether the E1
Repair the fault
terminal 1 and U06 Go to Step 4 The circuit has fault
harness
terminal 11 as well as
E1 terminal 17 and
U06 terminal 10 are
conducted
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
23. Idle speed too low or too high fault
P0506 - Idle speed too lower
P0507- Idle speed too high
DTC description:
1. The engine control module works out the current engine speed according to the working
conditions and controls the throttle opening by controlling the electronic throttle flap drive
motor and consequently controls and regulates the target idle speed to adapt various
conditions.
2. If the engine control module detects the engine speed is below or above the setting
value for a long time, this DTC will occur. The fault causes include the electronic throttle
control unit, intake system, fuel system, ignition system and engine control module etc.

Check whether the

battery voltage is The detected voltage is
The fault is
the normal working Go to Step 1 out of the reasonable
incidental.
voltage range
Voltage: 11V~14V

read and clear DTC
2 incidental.
read DTC
21-63

Check whether the

Replace the spark
plug
normal
Check the ignition

coil

Check the timing belt

Timing belt assembly Replace the new
for looseness, gear Go to Step 5
fault timing belt
skip, gear off
Check the valve

timing
Check the whether

correct
Check the cylinder

6 Normal Faulty Instruction 21
pressure

pressure tester and
Repair the cylinder
pressure fault
normal
Check the fuel

system pressure
Check whether the

Repair the fuel
fuel system pressure Go to Step 8 Fuel system fault
system
is normal
Remove the injector

and check for leak or Go to Step 9 The injector has fault Replace the injector
clogging
Check the intake

system

Check the intake
s y s t e m a n d The intake system has
Go to Step 9 Repair the faulty line
connected vacuum fault
pipe for air leak
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
24. System power supply voltage fault
P0562- System voltage low
P0563-System voltage high
DTC description:
1. If the engine control module detects the system voltage is continuously about 16V or
below 9V up to 5s, this DTC will occur. The fault causes include the generator fault, voltage
regulator and engine control module fault etc.
DTC set criteria:
1. With the engine running, if the system voltage is below 11V, DTC P0562 will be set. If
the system voltage is above 16V, DTC P0563 will be set.

Check whether the

Voltage: 11V~14V

Check whether
the engine control
read and clear DTC
module power
• Restart the engine
Go to Step 2 if other supply system
to carry out road test, Other system does not
system presents circuit is normal and
read DTC and check present this DTC
this DTC replace the engine
whether the engine,
control module if
ABS and other
necessary; go to
control units present
Step 4
this DTC
Check the generator

voltage output line
21-65

Check whether the
line connection
b e t w e e n t h e Go to Step 3
generator B+ post
and battery is normal
3 Read the data flow Normal Faulty Instruction
•Clear the DTC and

connect the vehicle
diagnostic tester
•Read the generator
Replace the
data flow and Go to Step 4 Generator fault
generator
check whether the
generator output is
normal under various
working conditions
Check the ECM fuse

and relay
Check where the cab

central control box
fuse FS35, engine
Replace the fuse or
compartment central
Go to Step 5 Fuse or relay fault relay of the same
control box fuse
specification
FS17, main relay
fuse FS03 and main
relay K04 are intact
Check the ECM

21
power wire
•Disconnect ECM
connector E1 and E2
switch in ON position,
check the voltage The circuit has short Repair the fault
between terminal 15, Go to Step 6
16, 20, 35 of E1 and
the ground
Voltage:9V~13V
Check the ECM

ground wire
•Disconnect ECM
connector E1 and E2
• C h e c k t h e
resistance between The circuit has short Repair the fault
Go to Step 7
terminal 63, 64, 111, circuit or open circuit harness
112 of E1, E2 and the
ground
Resistance: <2Ω

Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
25. Stop lamp signal unreasonable fault
P0571- Brake switch signal circuit fault or relativity out-of-sync
DTC description:
1. The engine control module determines where the vehicle is under the deceleration
condition through the brake signal and cuts off the fuel injection to reduce the fuel
consumption and exhaust emission and protect the three-way catalytic converter.
2. If the engine control module detects the brake signal circuit voltage is below or above
the calibration value, this DTC will occur.

Check whether the

Voltage: 11V~14V

read and clear DTC
2 incidental.
read DTC
2 Check the fuse Normal Faulty Instruction
Check whether the

cab central control Replace the fuse of
Go to Step 2 Fuse blown
box fuse FS24 and same specification
FS41 are blown，
Check the brake

switch
Check whether
Brake switch assembly Reinstall the brake
the brake switch is Go to Step 4
fault switch
installed in position
21-67

Check the brake
switch

switch in OFF
terminal Replace the brake
Go to Step 5 Brake switch fault
•Disconnect the brake switch
switch connector U04
and check whether
the brake switch is
normal
Check the brake

switch power wire

switch in OFF
terminal
Repair the short
•Disconnect the brake
circuit or open circuit
switch connector U04 The voltage is out of the
Go to Step 6 between the brake
• With the ignition reasonable range
switch and cab
central control box
check the voltage
between terminal
1, 3 of U04 and the
ground 21
Voltage:9V~13V
Check the brake

switch signal wire
•Disconnect the
engine control
module connector E1,
E2 and brake switch
connector UO4
•Measure whether The circuit has short Repair the fault
Go to Step 7
or open circuit
between E1 terminal
25 and U04 terminal
2; E1 terminal 23 and
U04 terminal 4
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
26. ECM internal fault
P0606 - ECM processor fault
P060A - ECM processor fault
DTC description:
1. Engine control module error The fault causes include the engine control module fault,
module calibration alteration attempt, module programming error etc. If this DTC occurs,
delete and check whether it occurs again. If the DTC quickly occurs, it means the electronic
control module should be replaced in most cases.

Check whether the

Voltage: 11V~14V
Connect the vehicle The fault is

d i a g n o s t i c t e s t e r, incidental. Check
read and clear DTC There is DTC; go to Step whether the engine
•Read DTC again to 2 control module
check whether DTC connector pins get
can be read loose or corroded.
Check the ECM

power circuit
Check whether
the engine control
module ground and Go to Step 3
power circuit are
normal
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
21-69
27. Fuel pump relay circuit fault

P0627- Oil pump relay control circuit open circuit
P0628- Fuel pump relay control circuit voltage low
P0629- Fuel pump relay control circuit voltage high
DTC description:
1. The fuel pump relay coil is powered by the main relay controlled by the engine control
module.
2. The engine control module controls the pump relay pull-in through the harness
connector. The engine control module is provided a drive circuit inside to control the relay
coil to ground and the drive circuit is provided with a feedback circuit to the engine control
module which determines the control circuit open circuit, short to the ground or short to the
voltage by monitoring the feedback voltage.

Check whether the

Voltage: 11V~14V
Connect the vehicle

The fault is
incidental. Check
It is incidental fault the fuel pump relay
for looseness or
check whether DTC
corrosion
can be read 21
Check the fuse and
relay
Check whether the

engine compartment Replace the fuse of
central control box same specification
fuse FS06 is normal
Check the fuel pump

relay
Unplug fuel pump

relay K07 and check Replace the fuel
Go to Step 4 Relay fault
whether the relay is pump relay
normal
Check the fuel pump

relay power circuit

•Disconnect the
battery negative
terminal
•Unplug the fuel
pump relay K07 and Go to Step 5
fuse FS06
•Check whether
FS096 and K07 are
conducted
Check the fuel pump

relay control circuit

switch in OFF
terminal
•Disconnect the
engine control
module connector E1
and E2, unplug the The circuit has short Repair the fault
Go to Step 6
fuel pump relay circuit or open circuit harness
•Measure whether
or open circuit
between the engine
compartment central
control box fuel
pump relay K07 and
terminal 41 of E1
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
28. Compressor electromagnetic clutch fault
P0645- A/C compressor relay control circuit open circuit
P0646- A/C compressor relay control circuit voltage low
P0647- A/C compressor relay control circuit voltage high
DTC description:
1. The A/C pulley is idling when A/C is off. It drives the compressor to run only when the A/
C clutch is engaged (under the function of the solenoid valve). The function of A/C clutch
relay is control the clutch release and engagement.
2. If the engine control module detects the A/C clutch relay control circuit is earthed while
the evident current is detected, or the A/C clutch relay control circuit is not earthed while
the voltage is not detected, this DTC will occur.
21-71

Check whether the

Voltage: 11V~14V
The fault is
d i a g n o s t i c t e s t e r, There is DTC; go to Step the compressor
read and clear DTC 2 relay for looseness
• Read DTC again. and terminals for
corrosion
Check whether the

engine compartment Replace the fuse of
central control box same specification
fuse FS05 is normal
C h e c k t h e
compressor relay
Unplug compressor
relay K06 and
Replace the
check whether the Go to Step 4 Relay fault
compressor relay
compressor relay is
normal 21
C h e c k t h e
4 compressor relay Normal Faulty Instruction
power circuit

switch in OFF
terminal
•Unplug compressor Go to Step 5
relay K06 and fuse
FS05
•Check whether
FS05 and K06 are
conducted
C h e c k t h e
5 compressor relay Normal Faulty Instruction
control circuit

switch in OFF
terminal
•Disconnect the
engine control
module connector E1
and E2, unplug the
compressor relay Go to Step 6
•Measure whether
or open circuit
between the engine
compartment
central control box
compressor relay
K06 and terminal 52
of E1
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
29. Main relay output voltage unreasonable

DTC description:
1. When the ignition switch is turned to ON position, the main relay will close. The main
relay supplies the voltage to each sensor actuator to maintain the engine running normal.
2. If ECM detects the main relay output voltage is unreasonable for a period of time, this
DTC will be triggered.

Check whether the

Voltage: 11V~14V

21-73

The fault is
incidental. Check
read and clear DTC
whether the main
•Restart the engine There is DTC; go to Step
It is incidental fault relay and ECU
to perform the road 2
harness connector
test, read DTC and
are securely
check whether DTC
connected
still exists
Check the generator

voltage output line
Check whether the

line connection
b e t w e e n t h e Go to Step 3
generator B+ terminal
and battery is normal
•Clear the DTC and

connect the vehicle
diagnostic tester
•Start the vehicle to
read the generator Replace the
Go to Step 4 Generator fault
data flow and generator
check whether the
generator output is
normal under various
working conditions
21
Check the ECM fuse
and relay
Check whether the

engine compartment Replace the fuse or
central control box Go to Step 5 Fuse or relay fault relay of the same
fuse SB06, FS03 and specification
relay K04 are intact
Check the main relay

output power wire

•Disconnect ECM
connector E1 and E2
check the voltage
between terminal
15, 16 of E1 and the
ground The circuit has short Repair the fault
Go to Step 6
Voltage:9V~13V circuit or open circuit harness
•Check whether there
is short to ground or
power between E1
terminal 15, 16 and
engine compartment
central control box
fuse FS03
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
30. Clutch switch fault
P0704- Clutch pedal switch signal unreasonable
DTC description:
1. The engine control module detects the TCU communication fault. The fault causes
include the CAN data line communication problem and control module fault.

Check whether the

Voltage: 11V~14V
The fault is
d i a g n o s t i c t e s t e r, the clutch switch
read and clear DTC There is DTC; go to Step connector for
•Read DTC again to 2 looseness or
for corrosion
Check the clutch

switch circuit
21-75

switch in OFF
terminal
•Disconnect the
engine control
module connector E1,
E2 and clutch pedal Go to Step 3
switch connector I03
•Measure whether
or open circuit
between I03 terminal
U05 terminal 2 and
ground
Check the clutch

pedal switch
•Disconnect the
clutch switch
connector U05
•When the clutch
switch is depressed,
the clutch switch Replace the clutch
Go to Step 4 Clutch switch damaged
terminals should be switch
conducted; when
the clutch switch is
not depressed, the
21
terminals should not
be conducted
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
31. Electronic throttle self-learning fault
P0606- Electronic throttle safety monitoring function fault
P1336- Electronic throttle safety monitoring torque restriction
P1545- Electronic throttle actual position deviation from target exceeding limit
P1558- Electronic throttle opening resistance high
P1559- Electronic throttle self-learning process fault
P1564- System voltage not meeting electronic throttle self-learning condition
P1565- Electronic throttle lower limit position initialization self-learning fault
P1568- Electronic throttle return resistance high
P1579- Electronic throttle not meeting self-learning condition
DTC description:
1. In the electronic throttle control (ETC) system, the accelerator pedal position (APP) is
designed to transmit the throttle pedal position to the throttle control module in the form of
electric signal to supply the reference for the throttle actuator to control the throttle valve
opening.
2. The throttle actuator is a step motor which controls the throttle opening according to the
command of throttle control module.
3. Under the steady state working condition, if the desired throttle position and actual
throttle position are different evidently and the throttle cannot return and open to the
required degree, this DTC will be recorded. Beside, it will be accompanied with the difficult
engine start.

Check whether the

Voltage: 11V~14V
The fault is
d i a g n o s t i c t e s t e r, the electronic
read and clear DTC There is DTC; go to Step throttle connector
for corrosion
Check the throttle

body
Check whether
Clean the electronic
the throttle flap is
Electronic throttle throttle body
normal, the rotation
Go to Step 3 controller fault or too or replace the
is smooth and check
much carbon deposit electronic throttle
controller
body for dirt

3 throttle controller Normal Faulty Instruction
circuit
•Disconnect the
electronic throttle
connector E14
and engine control
module connector E1
and E2
or open circuit
between the E14
terminals and
terminal E1 and E2
respectively
21-77

throttle controller
•Replace the
electronic throttle
controller and carry Replace the
out road test electronic throttle
•Perform the Go to Step 5 Electronic throttle fault controller and carry
diagnosis again to out the throttle self-
read DTC and check learning
whether DTC and
symptom exist
Check the intake

5 pressure temperature Normal Faulty Instruction
sensor
•Connect the
diagnostic tester
and read the
"intake pressure/
The intake pressure Replace the
temperature" data
temperature sensor is intake pressure
flow under various
Go to Step 6 damaged or the circuit temperature sensor
working conditions
has short circuit or open or repair the fault
•Compare the
circuit harness
standard data flow
and check whether
the data flow
deviation is high
Inspection by 21
replacement

control module and
read DTC and check
whether DTC and
symptom exist
32. Engine immobilizer fault

P1610- ECM not match immobilizer or EEPROM state error
P1626- Immobilizer authentication communication error or immobilizer not respond
P1631- Password error
P1632- Immobilizer authentication checksum error
DTC description:
1. The immobilizer control module is designed to disable the vehicle start unless the
special key exists and matches the various components. At the idle speed around pm, if
hanging carefully a gear, the vehicle will be mode at a low speed.


Check whether the
Voltage: 11V~14V
The fault is
•Connect the vehicle incidental; check
d i a g n o s t i c t e s t e r, the PEPS ECU or
read and clear DTC There is DTC; go to Step RKE ECU, engine
•Read DTC again to 2 control module for
check whether DTC looseness; check
can be read the terminals for
corrosion
Check the PEPS

(BCM) system

diagnostic tester and
Carry out diagnosis
access PEPS (BCM)
Go to Step 3 There is DTC output according to the
system to check
DTC prompt
whether there is DTC
output
Remote control
matching
Match the remote

control again and Remote control matching
Go to Step 4 Re-fit remote control
check whether DTC fault
and symptom exist
ECM immobilizer
matching
Match the engine

and PEPS (BCM)
Match control unit
again and check Go to Step 5 Matching fault
again
whether the DTC and
symptom exist
C h e c k t h e
5 immobilizer coil (one- Normal Faulty Instruction
touch start switch)
21-79

•Disconnect the
immobilizer coil
connector (or one-
touch start button
connector I16 (for
Replace the ignition
one-touch start
switch assembly
model)) Go to Step 6 Immobilizer coil fault
(or one-touch start
switch assembly)
resistance between
connector terminal
1 and terminal 4 (or
I16 terminal 7 and
terminal 2) is normal
Inspection by
6 replacement (PEPS/ Normal Faulty Instruction
BCM controller)
•Replace the PEPS/

BCM controller and
carry out road test
•Perform the PEPS/BCM controller Replace the PEPS/
Go to Step 7
diagnosis again to fault BCM controller
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement
•Replace the engine 21

control module and
read DTC and check
whether DTC and
symptom exist
33. Electronic throttle drive fault

P2106- Electronic throttle drive stage fault
DTC description:
1. In the electronic throttle control (ETC) system, the accelerator pedal position (APP) is
designed to transmit the throttle pedal position to the engine control module in the form
of electric signal to allow the engine control module to drive the throttle motor and control
the throttle opening and send the signal to the engine control module through the sensor
signal.
2. The fault causes include the sensor signal open circuit, sensor ground wire open circuit,
sensor fault and engine control module fault etc.


Check whether the
Voltage: 11V~14V
The fault is
d i a g n o s t i c t e s t e r, the front oxygen
for corrosion.

throttle circuit

switch in OFF
connector E14
and engine control
module connector E1
and E2 Go to Step 3
•Measure whether
or open circuit
E14 terminal 4 and
E2 terminal 75

throttle
•Replace the
electronic throttle and
carry out road test Replace the
•Perform the electronic throttle
Go to Step 4 DTC still exists
diagnosis again to and carry out the
read DTC and check throttle self-learning
whether DTC and
symptom exist
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
21-81
34. Electronic throttle pedal fault

P2122- Electronic throttle pedal position sensor 1 signal voltage lower
P2123- Electronic throttle pedal position sensor 1 signal voltage high
P2127-Electronic throttle pedal position sensor 2 signal voltage lower
P2128-Electronic throttle pedal position sensor 2 signal voltage high
P2138- Electronic throttle pedal position sensor signal 1 unreasonable
DTC description:
1. In the electronic throttle control system, the electronic throttle pedal position is designed
to transmit the throttle pedal position to the throttle control module in the form of electric
signal to supply the reference for the throttle actuator to control the throttle valve opening.
2. To ensure the system safety, the throttle pedal position sensor adopts the dual sensor
setting which is slip resistor type.
3. The fault causes include the electronic throttle pedal position sensor open circuit or short
to the ground; electronic throttle pedal position sensor fault.

Check whether the

Voltage: 11V~14V
The fault is
incidental. Check
whether the throttle
read and clear DTC
pedal position
21
sensor connector
check whether DTC
pins get loose or
can be read
corroded.
Check the throttle

2 pedal position sensor Normal Faulty Instruction
circuit
•Disconnect the
throttle pedal position
sensor connector E03
and engine control
module connector E1
and E2
or open circuit
between the E03
terminals and
terminal E1 and E2
respectively


read the data flow
•Check the throttle
pedal opening
and electronic
throttle opening
with the throttle Throttle pedal position
Go to Step 4 pedal position
pedal depressed sensor damage
sensor
and not depressed
respectively
Note: the electronic
throttle opening
should increase
along with the throttle
pedal opening.。
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
35. Air fuel ratio unreasonable

P2177- Air fuel ratio closed-loop control self-learning value exceeding upper limit
(medium load zone)
P2178- Air fuel ratio closed-loop control self-learning value exceeding lower limit
(medium load zone)
P2187- Air fuel ratio closed-loop control self-learning value exceeding upper limit (low
load zone)
P2188- Air fuel ratio closed-loop control self-learning value exceeding lower limit (low
load zone)
P2195- Front oxygen sensor lags in response to lean to rich (lean Bank 1)
P2196- Front oxygen sensor lags in response to lean to rich (rich Bank 1)
P2270- Rear oxygen sensor lags in response to rich lean (lean Bank 1)
P2271- Rear oxygen sensor lags in response to rich lean (rich Bank 1)
DTC description:
1. The fuel correction means the engine control module controls the fuel feed by increasing
or decreasing the injector opening time and consequently to make the engine acquire the
optimum air fuel ratio (the air gasoline mass ratio is 14.7:1).
2. The rich air fuel ratio means the fuel delivery volume is high while the lean air fuel ratio
means the fuel delivery volume is low. The system lean means the fuel level (in relation to
the air input) is low.

21-83

Check whether the
Voltage: 11V~14V
Refer to the
Connect the vehicle corresponding
d i a g n o s t i c t e s t e r, chapters according
read and clear DTC to the DTC displayed
•Read DTC and Go to Step 2 on the diagnostic
2
check whether other tester to solve the
engine sensor or faults and then test
actuator has DTC according to this
section
Check whether the Replace the air filter

Go to Step 3 The air filter clogging
air filter is clogged assembly
Check the intake

system

air leak fault
system for air leak
4 Check the spark plug Normal Faulty Instruction 21

Check whether the
Replace the spark
plug
normal
Check the ignition

coil

Check the timing

Go to Step 7
damage
Check the valve

timing
Check the whether

correct

Check the cylinder
pressure

pressure tester and
Repair the cylinder
pressure fault
normal
Check the fuel

system pressure

Go to Step 10
pressure is normal
Remove the injector

and check whether
with the injector
tester
Check the oxygen

sensor for poisoning
or severe carbon
deposit
Check the oxygen

sensor for poisoning Replace the rear
Go to Step 12 Oxygen sensor fault
or severe carbon oxygen sensor
deposit
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
36. CAN communication fault

U0001- CAN communication related diagnosis
U0121- ECU and ABS control module communication module loss
U0140- ECU and FBCM communication loss or signal abnormal
DTC description:
1. The engine control module detects the communication fault with other control modules.
The fault causes include the CAN data line communication problem and control module
fault.
2. The signal sent by FBCM to CAN bus is converted into CAN communication signal
21-85
which can be received by ECM through the gateway module in the instrument cluster. In
addition, the CAN signal sent by the ECM will be converted by the gateway module in the
instrument cluster.

Check whether the

Voltage: 11V~14V
The fault is
incidental. Check
•Connect the vehicle the engine control
d i a g n o s t i c t e s t e r, module, FBCM, ABS
read and clear DTC There is DTC; go to Step ECU and instrument
•Read DTC again to 2 cluster connectors
check whether DTC for looseness and
can be read damage; check the
harness terminals
for corrosion
Check the correlated

control system

diagnostic tester
and access the fault
Carry out diagnosis 21
correlated control
Go to Step 3 There is DTC according to the
system for diagnosis
DTC prompt
•Read DTC to check
whether DTC can be
read
Check the CAN

communication line
3. between ECM and Normal Faulty Instruction
relevant control
module

switch in OFF
terminal
•Disconnect the
engine control
module connector
E1, E2, instrument
cluster connector I05,
BCM connector I25
•Check whether The circuit has short Repair the fault
Go to Step 4
the resistance of circuit or open circuit harness
communication line
between the engine
control module and
instrument cluster as
well as instrument
cluster and BCM is
reasonable
•Check the CAN
communication line
for short the power or
to the ground
Inspection by
replacement
•Replace the fault

related control unit
•Perform the
diagnosis again to Go to Step 5 The fault still exists Go to Step 5
read DTC and check
whether DTC and
symptom exist
Inspection by
replacement

control module and
read DTC and check
whether DTC and
symptom exist
21-87

Crankshaft position sensor
Disassembly
1. Remove the crankshaft position sensor.
(a). Disconnect the battery negative connector.
(b). Disconnect the crankshaft position sensor

wiring harness plug.
LFWX-6470-11014
(b). Disconnect the crankshaft position sensor

21
LFWX-6470-11015
Inspection
(a). Check the crankshaft position sensor plug for
good connection, the terminals for good conditions,
and the wiring harness for any breakage.
(b). Check the resistance between 1# and 2#
terminals on the crankshaft position sensor.
Resistance: 860Ω±130Ω(20°C)
Tips
If the resistance does not meet the requirements,
replace the sensor.
LFWX-6470-11016
Installation
1. Install the crankshaft position sensor.
(a). Install the crankshaft position sensor and

tighten the retaining bolts.
Torque: 11 N•m
LFWX-6470-11015
(b). Connect the crankshaft position sensor wiring

harness plug.
(c). Connect the battery negative connector.
LFWX-6470-11014
Phaser control valve

Disassembly
1. Remove the phaser control valve.

(b). Disconnect the phaser control valve wiring
1 harness plug (1) and remove the phaser control
valve fixing bolt (2).
(c). Remove the phaser control valve.
2
LFWX-6470-11017
21-89
Inspection
(a). Use a digital multimeter to measure the resistance between 1# and 2# terminals on the
phaser control valve.
Standard resistance: 9.4 Ω ~ 10.6 Ω (20°C)
If necessary, replace the phaser control valve assembly.
(b). Check the operation of the control valve. Connect the positive (+) pole on the battery
to 1# terminal, and connect the negative (-) pole to 2# terminal, and check the operation of
the control valve.
Remark:
Verify that the electromagnetic valve can be moved freely and not clogged; if necessary,
replace the phaser control valve.
Suggestion: the accumulation of impurities may cause slight pressure leakage. The
pressure leakage may lead to the camshaft timing advance; thus a DTC should be set.
Installation
1. Install the phaser control valve.
(a). Install the phaser control valve fixing bolt

(2) and connect the phaser control valve wiring
1 harness plug (1). Before installation, replace a
new phaser control valve O-ring and coat it with
the oil.
Torque: 7 N•m
2
Note:
When the phaser control valve is installed,
push firstly the control valve into the mounting
hole on the camshaft cover, until the control 21
valve installation convex is container with the
LFWX-6470-11017 camshaft cover; do not forcedly screw the
installation bolt into the hole in the control
valve.
(b). Connect the battery negative connector.
Electronic throttle body
Disassembly
1. Remove the electronic throttle body assembly.

temperature sensor wiring harness plug (1).
1
(c). Remove the electronic throttle body clamp (2).
LFWX-6470-11018
(d). Remove the two screws, and remove the

intake pipe gland.
(e). Remove the intake pipe.
LFWX-6470-11019
(f). Disconnect the electronic throttle body wiring

1 harness plug (1).
(g). Remove the electronic throttle body fixing bolt
2 2 (2).
(h). Remove the electronic throttle body assembly.
2 2
LFWX-6470-11020
Inspection
(a). In case of no powering on, the valve should be at the mechanical DTC position, and
the valve should be moved manually; if it is stuck, there may be any damage in internal
components. If necessary, replace the electronic throttle body assembly.
Installation
1. Install the electronic throttle body assembly
(a). Install the intake pipe fixing bracket and the

1 electronic throttle body assembly and tighten the
electronic throttle body fixing bolt (2).
2 2 Torque: 10N•m
(b). Connect the electronic throttle body wiring
harness plug (1).
2 2
LFWX-6470-11020
21-91
(c). Install the intake pipe.

(d). Install the intake pipe gland and tighten the
two screws.
LFWX-6470-11019
(e). Install the electronic throttle body clamp (2).

(f). Connect the intake pressure and temperature
1
sensor wiring harness plug (1).
(g). Connect the battery negative pole.
21
LFWX-6470-11018

Disassembly
1. Remove the air intake pressure and temperature sensor.

temperature sensor wiring harness plug (2) and
remove the intake pressure and temperature
1
2 sensor fixing bolt (1).
(c). Remove the intake pressure and temperature
sensor.
LFWX-6470-11021
Inspection
(a). Check the intake pressure and temperature sensor.
Turn the digital multimeter to the ohm position; connect its two pens respectively to 1# and
2# pins on the sensor.
Rated resistance at 20°C: 2.5 kΩ±5 %
Use a hair dryer to simulate the air supply to the sensor (it can not be too close to the
sensor), observe the change of the sensor resistance, and the resistance should be
decreased at this time.
If the test result does not meet the requirement, replace the intake pressure and
temperature sensor.
Installation
1. Install the intake pressure and temperature sensor.
(a). Install the intake pressure and temperature

sensor, tighten its fixing bolt (1) and connect the
intake pressure and temperature sensor wiring
1
2 harness plug (2). Before installation, replace the
new O ring of the intake pressure and temperature
sensor and coat the oil on it.
Torque: 11 N•m
LFWX-6470-11021
Disassembly
1. Remove the boost pressure sensor.
(b). Disconnect the boost pressure sensor wiring

harness plug (1) and remove the boost pressure
sensor fixing bolt (2).
1
(c). Remove the boost pressure sensor.
LFWX-6470-11022
Inspection
(a). Check the boost pressure sensor.
Turn the digital multimeter to the ohm position; connect its two pens respectively to 1# and
2# pins on the sensor.
Rated resistance at 20°C: 2.5 kΩ±5 %
21-93
Use a hair dryer to simulate the air supply to the sensor (it can not be too close to the
sensor), observe the change of the sensor resistance, and the resistance should be
decreased at this time.
If the test result does not meet the requirement, replace the intake pressure and
temperature sensor.
Installation
1. Install the boost pressure sensor.
(a). Install the boost pressure sensor, tighten its

fixing bolt (2) and connect the boost pressure
sensor wiring harness plug (1).
1
Before installation, replace the new O ring of the
boost pressure sensor and coat the oil on it.
2 Torque: 11 N•m
LFWX-6470-11022
Camshaft position sensor

Disassembly
1. Remove the camshaft position sensor.
21
(b). Disconnect the camshaft position sensor
wiring harness plug (1) and remove the camshaft
position sensor fixing bolt (2).
(c). Remove the camshaft position sensor.
2
1
LFWX-6470-11023
Inspection
(a). When the power supply is in “ON” position, use a digital multimeter to measure the
voltage between the camshaft position sensor 3# pin and the grounding wire.
Voltage: 5 V
Use a digital multimeter to measure the resistance between the camshaft position sensor
1# pin and the grounding wire.
Resistance: 0Ω
If the measurement can not meet the requirement, it indicates that the camshaft position
sensor is damaged, and needs for replacement.
Installation
1. Install the camshaft position sensor.
(a). Install the camshaft position sensor, tighten

the fixing bolt (2), and connect the camshaft
position sensor wiring harness plug (1). Before the
installation, replace the camshaft position sensor
O-ring and coat it with the oil.
Torque: 11 N•m
2 (b). Connect the battery negative connector.
1
LFWX-6470-11023

Disassembly
1. Remove the water temperature sensor.
(b). Disconnect the water temperature sensor

LFWX-6470-11024
(c). Remove the water temperature sensor limit

clamp and remove the water temperature sensor.
LFWX-6470-11025
21-95
Inspection
(a). Use a ohmmeter to measure the resistance between the two terminals.
Standard resistance
Specified
Conditions
conditions
20 ℃ （ 68°F） 2.32 to 2.59 kΩ
80 ℃ （ 176°F） 0.310 to 0.326 kΩ

If the result does not conform to the requirement, replace the sensor.
Remark:
If the water temperature sensor is checked in the water, don't allow the water to enter into
the terminals. After check, dry the sensor.
Installation
1. Install the water temperature sensor.
(a). Install the water temperature sensor and

the temperature sensor limit clamp; before the
installation, replace a new temperature sensor
O-ring and coat it with the oil.
21
LFWX-6470-11025
(b). Connect the water temperature sensor wiring

harness plug.
LFWX-6470-11024
Knock sensor
Disassembly
1. Remove the knock sensor.
(b). Disconnect the knock sensor wiring harness

plug (1).
(c). Remove the knock sensor fixing bolt (2) and
2 1
remove the knock sensor.
LFWX-6470-11026
Inspection
(a). Use a ohmmeter to measure the resistance
between the two terminals.
Resistance: ﹥ 1 MΩ
If the resistance does not meet the requirements,
replace the sensor.
LFWX-6470-11027
Installation
1. Install the knock sensor.
(a). Install the knock sensor and tighten the fixing

bolt (2).
Torque: 23 N•m
2 1
(b). Connect the knock sensor wiring harness plug
(1).
LFWX-6470-11026
21-97
Front oxygen sensor

Disassembly
1. Remove the front oxygen sensor.
(b). Disconnect the front oxygen sensor plug.
LFWX-6470-11028
(c). Use 22# torque wrench to remove the front

oxygen sensor.
21
LFWX-6470-11029
Installation
1. Install the front oxygen sensor.
(a). Use 22# torque wrench to install the front

oxygen sensor.
Torque: 40 N•m
LFWX-6470-11029
(b). Connect the front oxygen sensor plug.

LFWX-6470-11030

Disassembly
1. Engine wiring harness
(b). Disconnect the wiring harness grounding wire terminal and clamp.
Tips:
The knock sensor is on the cylinder block below the intake manifold, and integrated
together with the electronic water pump and fuel injection nozzle wiring harness as a
whole. Install it in the order opposite to the removal sequence. When the plug is connected,
a “Click” sound indicates that the plug is connected in place. Make sure that all the wiring
harness plug plugs are connected firmly and no loosening phenomenon.
21-99
1 2 3 4 5 6 7 8 9
10
11
21
15 14 13 12
LFWX-6470-11031
Disconnect the water temperature

1 Disconnect phaser control valve plug 9
sensor plug
Disconnect the ignition coil assembly Disconnect the tuborcharger bypass

2 10
plug solenoid valve plug
Disconnect the ignition coil assembly Disconnect the crankshaft position

3 11
plug sensor plug
Disconnect the ignition coil assembly Disconnect the electronic water pump
4 12
plug plug
Disconnect the tuborcharger relief Disconnect the compressor wiring

5 13
valve plug harness plug
Disconnect the ignition coil assembly

6 14 Disconnect the knock sensor plug
plug
Disconnect the camshaft position

7 15 Disconnect the fuel pressure sensor plug
sensor plug
Disconnect the intake pressure and

8
temperature sensor plug
1 2 3 4 5
LFWX-6470-11032
Disconnect the fuel injection nozzle Disconnect the intake pressure and
1 4
wiring harness joint temperature sensor plug
Disconnect the boost pressure Disconnect the high pressure fuel pump
2 5
sensor plug plug
Disconnect the electronic throttle

3
body assembly plug
Tips:
The crankshaft position sensor is on the transmission housing.
(a). Disconnect the front oxygen sensor plug.
Tips:
The front oxygen sensor plug is on the from catalyst assembly.
(a). Remove the starter power wire, and disconnect the starter plug.
(b). Remove the grounding wire of the transmission housing.
(c). Remove the negative grounding wire fixing bolt from the transmission and disconnect
the negative grounding wire.
21-101
Maintenance Tools
General tool
1 Multimeter Measure all sensors

Part sketch
21
Change
Note:
After replacing the engine ECU (ECM), connect the diagnostic tester and write the
vehicle VIN code consistent with the vehicle under repair to the engine ECU through
the diagnostic tester.
(a). Turn the ignition switch to OFF gear.
(b). Disconnect the battery negative cable
Note:
Turn off the ignition switch and light switch before disconnecting and connecting
the battery negative cable. Completely loosen the fixing nut of the battery negative
terminal. Do not pry the cable terminal when doing this.
(c). Remove the glove box.
(d). Disconnect ECM connector.
Note:
After disconnecting the connector, ensure the connector joining part will not contact
the dirt, water and other impurity.

(e). Remove the 4 fixing bolts of ECM with bracket assembly.
(f). Remove ECM with bracket assembly.
Note:
After removing ECM, protect it against water and do not soak in the water. Handle
the ECM carefully when removing it.
(g). Install ECM in the sequence reverse to the removal.
Torque: 10±2N•m
Note:
Pay attention to static electricity protection during installation.
Engine control system - Engine control system
12-a
Engine control system

Engine control system�� 1
Preparations�� 1
Precautions�� 4 12
System description�� 5
LFB479Q component layout 20
Circuit diagram�� 22
Terminal definition�� 24
Basic examination�� 29
Diagnosis�� 30
Fault diagnosis and analysis 34
Read or clear DTC�� 35
Read data flow�� 37
Input/output control function unit
�� 38
Fault phenomenon diagnosis 39
DTC list�� 57
DTC diagnosis�� 65
12-b Engine control system - Engine control system
12-1
Engine control system

Preparations
1. Special tools

12
Read engine control system DTC

1 Diagnosis tester
and data flow etc.
2. Recommended tools
Measure the voltage and

1 Digital universal meter
resistance
2 Circuit group Testing circuit

12-2 Engine control system - Engine control system
Maintenance data
1. Technical specifications
Intake VVT valve operating voltage 11 ～ 14V
Intake VVT valve resistance 9.4 ～ 10.6Ω
Intake temperature/pressure sensor operating voltage 5V±0.1V
Intake temperature/pressure sensor operating current 12mA (maximum)
Intake pressure testing range 10kPa ～ 110 kPa

Intake temperature testing range -40 ～ 125℃
Canister control valve working voltage 8 ～ 16V
Canister control valve minimum start voltage 7V
Operating temperature of canister control valve -30 ～ 120℃
Operating voltage limit of canister control valve 25V（＜ 60 s)
Canister control valve coil inductance 12 ～ 15mH
Canister control valve impedance 19 ～ 22Ω
Oxygen sensor exhaust end working temperature 200 ～ 850℃
Operating temperature of oxygen sensor mounting seat <600℃
Operating temperature of oxygen sensor cable and metal
≤ 250℃
snap ring joint
Oxygen sensor storage temperature -40 ～ 100℃
Oxygen sensor heater resistance 9.6±1.5Ω
Crankshaft position sensor working gap 0.25 ～ 1.75 mm
Crankshaft position sensor coil resistance 560Ω
Crankshaft position sensor working temperature -40 ～ 150℃
Working voltage of coolant temperature sensor 5V
Coolant temperature sensor operating temperature limit -40 ～ 135℃
Coolant temperature sensor temperature response time 17 ～ 27 s
Coolant temperature sensor resistance at 20℃ 2.3 ～ 2.5kΩ
Coolant temperature sensor effective sealing pressure 145 kPa
Camshaft position sensor working temperature -40 ～ 150℃
Camshaft position sensor working voltage 4.5 ～ 13 V
Peak voltage of camshaft position sensor 24 V（1h）
Working gap of camshaft position sensor 0.3 ～ 2mm
Camshaft position sensor low leve output 0 ～ 700mV
Camshaft position sensor high level output 3.2 ～ 5 V
Electronic control throttle valve body operating conditions -40 ～ 120℃
Electronic control throttle valve body valve orifice diameter Φ57mm

Maximum air flow at full throttle (under standard atmosphere
67g/s
pressure)
12-3
Minimum by-pass air flow with throttle fully closed 1.7g/s
Throttle position sensor opening range 7% ～ 93%
Throttle position sensor working voltage 5±0.1V
Throttle position sensor resistance 1.6 ～ 2.4 kΩ
Knock sensor operating temperature –40 ～ 150 ℃
Resistance of knock sensor >1MΩ（ 25℃） 12

Knock sensor capacitance 1480 ～ 2220pF@25℃ @1000Hz
Knock sensor frequency response 3 ～ 18kHz
New knock sensor sensitivity to 5kHz signal 17 ～ 37mV/g
Fuel pump output pressure 400kPa
Fuel pump output flow ≥85 L/H
Fuel pump pressure relief 500 ～ 650 kPa
Fuel pump pressure holding ≥250 kPa
Fuel pump operating voltage 13.5V
Fuel pump overvoltage protection 13.5 ～ 26（<60 s）
Fuel pump dry running <60s
Oil level sensor resistance 40 ～ 250Ω
Maximum operating current of oil level sensor <130mA
Electric fuel pump operating temperature range –40 ～ 75℃
Electric fuel pump operating voltage range 8 ～ 14V
Electric fuel pump fuel level sensor rated current 1 ～ 80 mA
Electric fuel pump pressure range 390 ～ 410kPa
Operating temperature of fuel rail -30 ～ 115℃
Oil pressure regulator no return oil system pressure setting 400kPa
Rated resistance of injector at 20℃ 12.0±0.4Ω
Items N•m
ECM fixing bolt 20
Intake temperature/pressure sensor fixing bolt 21 ～ 25
Coolant temperature sensor fixing bolt 20
Crankshaft position sensor fixing bolt 6 ～ 10
Crankshaft position sensor fixing bolt 6 ～ 10
Oxygen sensor 40 ～ 60
Detonation sensor 15 ～ 25
VVT valve fixing bolt 6 ～ 10

Precautions
1. Irrespective of engine running not, no 12V electrical working device can be
disconnected so long as the power supply is in ON position. Otherwise, the coil self-
inductance of such device will generate the very high instantaneous voltage and
damage the ECM and sensor seriously.
2. Do not unplug any sensor conductor plug (connector) with the engine running;
otherwise ECM will present the factitious DTC (false DTC) and impair the correct
judgment and troubleshooting.
3. If the battery ground wire should be removed, turn the power supply to OFF position,
shut down each electrical load, remove the negative ground wire and wait for 60s
before repairing any electric appliance.
4. The reliability of electronic injection system parts is high. In the case of complete
vehicle or engine malfunction, check the related mechanical parts. System connector
and harness, ground wire and spark plug wire connector first.
5. Before installation, clear the foreign body on the mounting face with the sealant
scraper or steel brush and ensure the sealing face is level and smooth without any oil
stain. Do not forget to remove the sealant on the assembly hole, threaded hole and
threads.
6. Tighten the fixing bolt to the required torque when installing the sensor and actuator
etc.
7. Install and handle the sensors carefully to protect them against damage. Any impact
or fall of the sensor will impair the performance greatly.
8. Do not check the system electric signal by piercing the harness with the fine pin.
9. Do not allow the oxygen sensor to contact the water or other fluid when removing or
replacing the sensor.
10. Do not allow the fuel pump to run without gasoline for a long time. Besides, the pump
should not run with the gasoline bearing air.
11. Most electronic injection parts cannot be repaired. In general, the parts should be
replaced if damaged.
12. The system should use anti-interference type spark plug and ignition coil. The non
- impedance type spark plug and ignition coil will not only release the interference
wave but also generate adverse effect on the ignition coil driver module in ECM.
13. Do not disassemble ECM.
14. Do not check the electronic control system sensors and ECM control unit (including
the wiring terminal) by the test lamp.
15. Unless otherwise specified in the test program, do not check the electronic control
system resistance with the pointer type universal meter. Instead, check the resistance
with the high impedance digital multimeter (above 10MΩ) or the special testing
instrument for the electronic control system.
16. For the vehicle equipped with electronic control system, do not check the electrical
circuit by the striking through grounding or scratch the wire in any case.
17. Where the jump start is required for the vehicle equipped with electronic control
engine, shut down the ignition switch and all electrical loads of the electronic control
vehicle before removing and installing the jumper wire.
18. In the case of arc welding on the vehicle equipped with electronic control system,
disconnect the ECM electric power supply wire to prevent the high voltage damaging
the ECM.
19. When repairing the body near ECM or sensor, take special care to avoid damaging
these electronic components.
12-5
20. To remove the wire joints of the electronic control system, shut down the power
supply (OFF) first and remove the battery negative ground wire. Only shut down the
power supply (OFF) is required if checking the electronic control system only.
21. Remember the electronic control vehicle adopts negative ground power supply
system. Do not connect the positive and negative terminal wrong when installing the
battery.
22. When installing or removing ECM, the operator should ground himself first to prevent
the human body static electricity damaging ECM circuit. 12
23. Release the fuel system pressure first before removing any section of the oil line.
Keep far from the naked flame when repairing the fuel line system.
24. The loose contact may be caused by the connector terminal rust, outside dirt entering
the terminal or the low contact pressure between the connector plug and socket.
Unplug the connector and insert it again. This may change the connecting condition
and restore the normal contact. If the harness and connector are normal during the
fault diagnosis and the fault disappears after the inspection, it indicates the wiring or
connector has fault.
25. Prevent the water splashing onto ECM and circuit when cleaning the engine or repair
in a raining day.
26. The electronic control system fault mainly involves in the harness and connector fault
such as the harness fracture, connector loose contact, connector terminal unplugged
or not inserted in position or the part ground.
27. It is very unusual that the harness is broken in the middle. In most cases, it breaks at
the connector. Therefore, check the harness of the sensor and connector carefully.
28. Before connecting the diagnostic tester, shut down the power supply (OFF); turn on
the power supply (ON) after connecting the tester.
29. In the case of system fault, if the system fault is not solved after clearing the DTC by
the diagnostic tester, the DTC will exist in the DTC reading process until the fault is
solved.
System description
1. Engine control system description
LIFAN XUANLANG LF6470 is equipped with LFB479Q engine, which employs Delphi
MT22.3 electronic control fuel injection system. This system is based on the torque
and electronic throttle control and featured with computer closed-loop control, multi-
point fuel sequential injection without distributor block sequential ignition and three-
way catalyst post treatment.
(a). System diagram
Diagnosis Diagnosis
Sensor Actuator
Signal acquisition Control command
Engine
LFWX-6470-12001
(b). The engine control system generally consists of the sensor, electronic control module
(ECM) and actuator. In addition, it controls the air intake volume, injection volume and
ignition advance angle with the engine running.
(c). In the engine electronic control system, as the input part, the sensor is designed
to measure various physical signals (such as the temperature and pressure) and
convert them into the corresponding electric signal. ECM is designed to receive the
sensor input signal, process the signal according to the set program to generate
the corresponding control signal and send to the power drive circuit which drives
the engine to run according to the set control strategy by driving every actuator to
execute different actions; in addition, the fault diagnosis system of ECM will monitor
the system components or control functions and store DTC once detecting and
confirming the fault and call the "limp home" function. When the fault is detected
solved, the normal running will resume.
(d). The sensors mainly include the intake pressure/temperature sensor, crankshaft
position sensor, camshaft position sensor, throttle position sensor (integrated in the
electronic throttle), coolant temperature sensor, knock sensor, throttle pedal position
sensor and oxygen sensor etc.
(e). The actuators mainly include the injector, ignition coil, throttle motor (integrated in the
electronic throttle), phaser control valve and canister solenoid valve etc.
2. Engine control system function
(a). Basing on the torque control strategy, all the inside demands and outside demands
of the engine are defined by the engine torque or efficiency requirement. The engine
demands are converted into the torque or efficiency controlled variables, which are
processed by ECM and converted into the engine control parameters such as the fuel
injection time and ignition timing.
Efficiency requirement
Engine start
Catalytic heating
Idling control
External torque demand:

Vehicle speed limit
Complete vehicle dynamic control Fuel injection time
(headlamp on, A/C on......)
Driving performance (brake,
steering etc.)
Fuel cut-off cylinder

by cylinder
Internal torque demand:

Engine start control
Idling control Ignition timing
Engine speed limit
Engine protection
LFWX-6470-12002
12-7
(b). System main functions:
S/N Functions S/N Functions

Gaseous thermodynamic model air
1 8 Variable valve timing (VVT) control
flow calculation for the engine
ECM built-in ignition drive module,

2 Engine torque output control mode 9 without distributor-type sequence 12
ignition
Entire vehicle main power supply relay

3 10 Knock control
control
Closed-loop control multi-point fuel

4 11 Electronic throttle control
sequential injection
5 Control of oil supply without oil return 12 Cooling fan relay control
6 Fuel pump operation control 13 System self-diagnosis
7 Control of canister control valve 14 Overvoltage protection
3. System function description

(a). Start control
During the start, control the charge volume, fuel injection and ignition timing by the
special calculation method. At the start stage of this process, the air inside the intake
manifold is still and the internal pressure is the environmental atmosphere pressure.
The throttle valve is closed. For the idle adjuster, the one is specified as a fixed
parameter depending on the starting temperature. Before the engine is started, as
soon as the ignition switch is turned on, the ECM works out the percentage of the total
air flow through calculation by collecting the relevant parameters, and then works out
the relative number of steps of the step motor by conversion through the relationship
between the idle air flow percentage and the position of the step motor. The general
trend is that the lower the engine starting temperature, the greater the opening
degree of the idle valve. When the calculated value of the idle air flow percentage
exceeds 100%, the idle valve will remain fully open. Idle air flow is changed to
improve idle speed stability, by the corresponding adjustment of the position of the
step motor according to the actual operating conditions of the engine after the start is
over. The fuel delivery varies depending on the temperature of the engine to promote
the formation of the oil film on the intake manifold and cylinder walls. Thus, the
mixture should be enriched before the engine reaches a certain rotational speed. In
the starting conditions, the ignition angle is also constantly adjusted. Change with the
engine temperature, intake temperature and engine speed.
(b) Idle speed control system
The electronic-controlled throttle valve is used in the system to achieve high precision
idling speed control, so that the actual speed coincides with the target idling speed.
For electrical load compensation, when there is an electrical load working or cut
off, a sudden increase or decrease in the engine load causes a certain range of
fluctuations in the engine speed. The electronic-controlled throttle system allows the
engine to adjust the intake air volume and/or the ignition advance angle accordingly
so that the idling speed is stable in the optimum condition when the load is increased
or decreased on the engine. Common electrical load compensation includes: A/C

compressor compensation, engine cooling fan compensation, blower compensation,
battery voltage compensation, power steering compensation, and charcoal canister
solenoid valve compensation. Whether the above compensation works depends on
the system configuration and functional requirements.
(c). λ closed-loop control
Oxygen content Control
λ closed-loop control: Voltage signal command
Oxygen sensor Fuel injection time
Engine
λ open-loop control: Engine

Fuel injection time
LFWX-6470-12003
The system adopts closed-loop control over the engine fuel supply to make the engine
run under the perfect working condition (the air fuel ratio does not deviates from
the theoretical value too much) all the time. Adopt the open-loop control when the
engine just starts or the higher rotary speed is required. The advantages of closed-
loop control include the low emission and high dynamic performance and economic
performance. λ is the air fuel ratio of gas mixture. The theoretical ratio is 14.7:1 with λ
=1.
The λ closed-loop control is active only when the front oxygen sensor is provided.
The front oxygen sensor detects the oxygen content in the exhaust gas near the
three-way catalyst side. The lean mixture (λ>1) can generate 100mV sensor
voltage approximately; the rich mixture (λ <1) can generate 900mV sensor voltage
approximately. The sensor voltage will jump when the λ = 1. In such a case, theλ
closed-loop control will respond to the input signal (λ>1, the oxygen sensor voltage
is below 100mV; λ <1, the oxygen sensor voltage is above 900mV) to modify the
controlled variable and generate the correction factor as the multiplier to correct the
fuel injection duration.
The three-way catalyst exhaust post treatment is the efficient way to reduce the
concentration of the hazardous substances in the exhaust gas.
The three-way catalyst can reduce the hydrocarbon (HC), carbon monoxide (CO) and
nitrogen oxides (NOx) by 98% or more and convert them into water (H2O), carbon
dioxide (CO2) and nitrogen (N2).…However, such high efficiency can only be achieved
in a very narrow range with the engine excess air coefficient λ =1. The λ closed-
loop control is designed to maintain the mixture concentration within this range.
(d) Gaseous thermodynamic model air flow calculation for the engine
ECM calculates the air flow into the cylinder, through the intake air temperature
pressure sensor, and makes the air-fuel ratio meet the requirements of each
condition, by controlling the fuel supply.
(e) Torque control mode
12-9
The system estimates the output torque based on the accelerator pedal position
sensor signal and controls the output power of the engine.
(f) Crankshaft position reference and speed measurement
The system determines the crankshaft position and measures the engine speed
according to the crankshaft position sensor signal, and precisely controls the engine
ignition and fuel injection timing.
(g) Judgment of the working sequence of each cylinder of the engine
The camshaft position sensor cooperates with the gear mounted on the camshaft, 12
and passes the information of the top dead center of one cylinder of the engine to
the ECM, whereby the ECM determines the working sequence of the cylinders of the
engine.
(h) Fuel control
There are two main modes of fuel control: closed-loop fuel control and open-loop fuel
control.
• Closed-loop fuel control provides precise control of the air-fuel ratio of the engine,
thus effectively controlling emissions. Closed-loop control has such an advantage that
the system has the ability to eliminate the difference caused by the manufacture and
wear in use for the system and the related mechanical parts, and improve the overall
consistency of the vehicle and cut vehicle emissions.
• Open-loop fuel control is mainly used for working conditions in which it is not uitable
to use closed-loop fuel control, such as engine start-up and oxygen sensor failure.
(i) Ignition angle control
• Sequential ignition is used for ignition control. That is, cylinders are subjected to
ignition in the order of 1-3-4-2.…The necessary condition for sequential ignition control
is that the engine has determined the cylinder sequence. Otherwise, the matter will
work in the packet ignition mode until the cylinder sequence is determined.
• In idling mode, for the ignition angle, closed-loop control will be made to stably
control the rotational speed.
(j) Fuel injection system without fuel return
Return-less multi-point sequential injection is used in the system. For each engine
cycle, accurate fuel supply is implemented through the main pulse width and trimmed
pulse width, with closed-loop control and self-learning function.
(k) Ignition energy control
The system supports sequential ignition; "Magnetization and discharge" logic is used
in the system, and the magnetizing time and discharging time of the ignition coil are
precisely controlled.
(l) Principle of knock
• The system detects the characteristic vibration present when the knock is
generated, through the knock sensor mounted at the appropriate position of the
engine, and converts it into an electronic signal which is transmitted to the ECM and
processed.
• When the knock sensor detects a knock, the system will calculate the ignition
advance angle that needs to be retarded based on the current conditions, knock
strength, etc., and retards the ignition angle to the corresponding ignition angle to
avoid or reduce knocking.
• The knock control system can independently control the ignition timing of each
cylinder of the engine.
(m) Evaporative emission pollution control

The system controls the cleaning rate of the charcoal canister according to the engine
operating conditions.
(n) Variable valve timing (VVT) control
The VVT actuator is used in the variable valve timing control system to change the
relative position between the intake side camshaft and the crankshaft. The engine
management system calculates the current optimum valve timing based on the
engine operating conditions and controls the intake VVT valve actuation so that the
flow and direction of the oil pressure entering the VVT actuator changes, eventually
driving the camshaft to the desired position.
(o) Overvoltage protection
In the case of voltage high due to the charge system malfunction, the system will
enable the guard mode and limit the engine speed to prevent ECM damage.
(p). A/C system pressure, compressor control
When the A/C switch is turned on, the system will receive a signal called A/C request,
make preparations according to the current working conditions of the engine, and
then turns on the A/C compressor; the system will control the A/C on or off according
to the A/C's own protection needs. In order to ensure the power output and protect
the engine, the system may disconnect the operation of the air conditioning under
certain conditions.
(q) Three-way catalytic converter
The function of the three-way catalytic converter is to convert the harmful gases from
the engine after burning into harmless gas to be discharged into the atmosphere. The
internal structure of the three-way catalytic converter is a honeycomb pipe design.
The honeycomb wall has a coating of noble metal elements such as palladium,
rhodium and platinum as the catalytic reaction medium. The three-way catalytic
converter is to make the engine power loss from 3% to 5%.
(r) Three-way catalytic converter system overheat protection function
The system predicts the tendency of engine exhaust temperature rise according to
the actual working condition of the engine, and reduces the combustion temperature
of the engine by controlling the mixture ratio of fuel to air in time, and protects the
three-way catalytic converter.
(s) Cooling fan relay control
The vehicle is provided with the electric double speed engine cooling fan.
Electric fan control function: ECM determines to turn on each fan or not according to
the engine coolant temperature and A/C switching on condition to reduce the engine
power consumption.
(t) System self-diagnosis
• Self-diagnosis of system failure is an essential function of the engine control
system; when one or several parts of the system are working abnormally, the system
will prompt the vehicle user to carry out the necessary inspection and maintenance
through the MIL on; in the event of failure, the system can also control the engine
work by using the temporary emergency program to ensure that users can go to
repair by driving the vehicle.
• When a sensor and actuator are detected to be abnormal, the engine fault check
light is on to alert the driver.
• When a sensor and actuator are detected to be abnormal, the trouble code
12-11
corresponding to the fault condition is output.

• The RAM data associated with the sensors and actuators in the ECM can be read
by equipment for diagnosing faults. In addition, under certain conditions, the actuator
can be forcedly driven.
4. Principle of start control
(a). After the ignition switch is turned on, the fuel pump will run for 2s approximately and
then stop.
(b). After the engine starts running and ECM detects 2 effective 58X signals, the fuel 12
pump will run.
(c). After the rotary speed signal loses (the analog signal is susceptible to disturbance)
0.8s, the fuel pump will stop.
(d). Pre-injection:
The pre-injection is made once in the normal start process only (if the fuel is absorbed
by the carbon deposit, the gas mixture will become lean and make the start difficult).
The conditions for starting the pilot injection are as follows:
(1) The engine starts to rotate (the ECM detects at least a valid 58-teeth signal);
(2) The pump relay is engaged.
(3) The pump running time exceeds the accumulating delay time.
(4) Start pilot injection has not been carried out.
(5) Once the above conditions are met, starting pilot injection is carried out
simultaneously at all cylinders.
(e). Start early stage:
The intake manifold internal pressure is shown as the environmental atmosphere
pressure. The throttle closes and ECM designates a fixed parameter according to the
start temperature (the coolant temperature).
(f). During start:
The fuel injection volume varies from the engine coolant temperature and the ignition
angle varies from the engine coolant temperature, intake temperature and engine
speed.
(g). Start end:
The start process ends when the engine speed exceeds 800r/min.
5. Principle of fuel injection control
(a). ECM controls the driving time and injection timing of fuel injector to enable the engine
to achieve gas mixture of optimum air fuel ratio under various working conditions.
(b). In the fuel rail, the fuel pressure regulator maintains the fuel injection pressure stable
and the injector directly injects the fuel in the air passage of each cylinder. In each
working cycle of engine (every time the crankshaft rotates two circles), each cylinder
injects fuel once (the injection sequence is 1-3-4-2), which is called sequence
injection.
(c). Where the engine is running under cold state or under high load, ECM will perform
open-loop control to maintain good performance and supply rich gas mixture; where
the engine is running under normal operating conditions (moderate or low load), ECM
will perform closed-loop control through the feedback signal of oxygen sensor to
obtain optimal air fuel ratio and achieve the best purification efficiency of three-way
catalytic converter.
(d). Fuel injection pulse width control
Input signal. ECM Control output

Correction of air fuel ratio
Correct closed-loop feedback
Intake manifold pressure
Inflation temperature
Inflation efficiency
Charge efficiency compensation of valve

timing
Self-leaning correction Calculate injection volume Fuel injection pulse width

Correct power voltage
Exhaust gas recirculation
Acceleration Enrichment
Leaning upon deceleration
Deceleration Fuel Cut Off
Protective fuel cutoff
Injector parameters
(e). Control signal description
Correction item Contents
● Start air fuel ratio

● Air fuel ratio during engine running
● Air fuel ratio at low engine coolant temperature
Air fuel ratio including ● Air fuel ratio at normal engine coolant temperature
● Theoretical air fuel ratio
● Rich air fuel ratio
● Overheating protection air fuel ratio
● Control the actual air fuel ratio near the theoretical air fuel ratio through
Correct closed-loop feedback
the feedback signal of oxygen sensor
Intake manifold pressure ● Read through MAP installed on the intake manifold
● Changes in the gas phase will affect the engine’s charging efficiency.
The basic charging efficiency table is calibrated when the phase control
Charge efficiency system is not activated and the relative positions of the camshaft and
compensation of valve timing crankshaft are in the initial position. When the phase control system
is activated, the system will compensate the corresponding charging
efficiency to ensure that the intake air volume is accurate.
● Correct the slow change of the engine due to the inside mechanical
Self-learning
wear over long time running
● When the battery voltage changes, the voltage correction can

Power voltage
guarantee the correct fuel injection volume
12-13
● When ECM detects the intake manifold pressure and throttle opening
Acceleration Enrichment greatly increases, it will the increase the injection volume to enhance the
engine power and avoid the gas mixture becoming lean shortly.
● When ECM detects the intake manifold pressure and throttle opening
greatly decreases, it will decrease the injection volume to enhance the
Leaning upon deceleration
emission and driving performance and avoid the gas mixture becoming
rich shortly.
● When the system detects the vehicle deceleration, it will cut off the fuel 12
to reduce the emission and fuel consumption.
Deceleration Fuel Cut Off ● When the engine speed is higher than the setting value, the fuel will be
cut off.
● When the ignition system has fault, the fuel will be cut off.
The system will stop the fuel injection if any of the following conditions is
met:
• Oil supply will be cut off when the engine speed is higher than 6200r/
min; oil supply will be resumed when when the speed is below 6000r/
min;
Protective fuel cutoff
• Oil supply will be cut off when the system detects an ignition system
failure;
• When the system voltage is greater than 18V, it will enter the electronic
throttle body function limiting mode (forced idling mode).
• Deceleration Fuel Cut Off
Fuel injection parameters ● Provide the relationship between the engine and injection volume
(f). Correction of engine gas mixture
● Under the normal working temperature of the engine, part of the load is under the
closed-loop fuel control. At this point, the system will carry out the real time correction
on the injection volume through ECM according to the voltage signal feedback from
the oxygen sensor to maintain the mixture density near the theoretical air fuel ratio
and consequently ensure the three-way catalytic converter can reach the optimum
noxious gas conversion efficiency in addition to ensuring the proper fuel economic
performance.
● Under the normal working temperature of the engine, the open-loop fuel control
is active under the full load running. At this point, to guarantee the optimum power
output of the engine, the system will control the injection volume with the rich air fuel
ratio and increase the ignition advance angle with the premise of no engine knocking.
The system also controls the exhaust temperature through the exhaust temperature
mathematic model established during the calibration to protect the engine and three-
way catalytic converter.
● The system determines whether the engine is under full load by the signal supplied
by the throttle position sensor. In general, the system will determine the engine is
under full load when the throttle opening reaches 80% ~ 90% or higher. When the
driver depresses the accelerator pedal, the system will increase the injection volume
as appropriate to guarantee the engine power demand upon the acceleration. The
additional injection volume is proportional to the throttle opening change rate. During
the acceleration, ECM will put off ignition advance angle first as appropriate and then
restore gradually to avoid the impact to the power train due to the fast increase of
torque during the sharp acceleration.
● When the acceleration condition is near the engine full load, the system will
temporarily shut down the A/C system to guarantee the engine power output upon the
acceleration. In any case, if the engine speed exceeds the maximum speed set by
the system, the fuel supply will be cut off to restrain the speed increase to protect the
engine and prevent racing; when the rotary speed falls below the maximum speed
restriction, the system will immediately resume the fuel supply.
6. Principle of ignition control
(a). Start
When the engine starts, it adopts a fixed ignition advance angle to ignite the gas
inside the cylinder and supply positive torque. When the engine speed increases to
a certain value, ECM will calculate the ignition advance angle according to the input
signal.
(b). Control of ignition advance angle
Correct signal ECM Control output

Correct coolant temperature
Correct intake temperature
Correct idle speed
Main ignition angle Calculate ignition advance

Ignition advance angle
Correct DFCO angle
Correct acceleration
Power thickening correction
Correct A/C
(c). Main ignition advance angle

After the engine temperature reaches the normal value, the main ignition angle upon
the throttle opening is the minimum ignition angle at the optimum torque point. When
the throttle is closed, the ignition angle should be decreased to maintain the idle
speed stable.
(d). Correction of ignition advance angle
● Acceleration correction: when the vehicle is accelerating, the ECM will detect the
knock signal and correct the ignition angle until no knock is detected. Also it can
relieve the engine speed fluctuation caused by the transmission system shock.
● Power enriching correction: near the external characteristic point, to obtain the
better power and torque, the system will enrich the air fuel ratio to the optimum torque
and most lean air fuel ratio.
● Deceleration fuel cut-off correction: when quiting the deceleration fuel cut-off,
correct the ignition advance angle to make the transition smooth.
● A/C control correction: shut down A/C upon the engine idling to correct the ignition
advance angle and make the engine speed transition smooth.
(e). Acceleration correction
The ignition advance angle acceleration correction is used to reduce the engine
speed fluctuation caused by the torsional vibration of the transmission system; it is
12-15
also possible to eliminate the possibility of knocking during the acceleration process
so that the acceleration process is smooth.
(f). The dynamic enrichment correction
Near the external characteristic point, and in order to obtain better power and torque,
the air-fuel ratio will be enriched to the Lean Best Torque (LBT), whereby the ignition
angle correction can be performed to obtain the MBT point.
(g). Ignition angle compensation of valve timing control 12
When the valve timing control mechanism is activated, the engine inlet-exhaust
overlap angle changes, which will affect the internal exhaust gas recirculation rate
and the cylinder temperature. For different valve timing, the ignition advance angle
correction is required to ensure that the actual operating advance angle of ignition is
best under the current valve timing.
(h). Deceleration fuel cut-off correction
When exiting deceleration fuel cutoff, the correction of the ignition angle can be made
so that the transition is smooth during throttle closure/exit.
(i). A/C control correction
When the engine is driven at idling speed and after the air conditioning is turned off,
the ignition advance angle can be corrected, to achieve the smooth transition of the
engine speeds.
7. Principle of idle speed control
(a). Idle speed control
It controls the by-pass air volume of throttle according to the idling condition and engine
load variance during idling to maintain the idle speed at the optimal value. ECM
drives the idle speed step motor according to the engine coolant temperature and A/
C load to make the engine run at the preset target idle speed.In addition, during the
engine idling, if A/C switch is turned on or off, the idle speed step motor will adjust
the by-pass air volume according to the engine load conditions to avoid instable idle
speed.
(b). Calculate target idle speed
Input signal. ECM Control output

Basic target idle speed
Voltage compensation
Speed compensation
Headlamp compensation Calculate target idle speed Target idle speed
Fan compensation
A/C compensation
Deceleration adjustment
● Voltage compensation: when the voltage is below 12V, the system will automatically
increase the target idling to increase the generator output.
In idling mode, when the voltage fluctuates the moment the system is subjected to the
impact of external power load, the system will automatically compensate the intake
air volume to inhibit the engine speed transition fluctuations.

● A/C compensation: when A/C is turned on with the vehicle idling, the target
idle speed will be increased to 100r/min to compensate the compressor power
consumption.
● Headlamp compensation: when the headlamp is on, the target idle speed will
increase by 50r/min approximately to compensate the power consumption.
● Fan compensation: when the coolant temperature increases, the fan will run. To
compensate the fan power consumption, the target idle speed will increase by 50r/
min.
(c). Idle speed control parameters:
● Air volume upon idling control.
● Fuel injection volume control.
Ignition timing control.
(d). Idle speed design control timing:
● Calibration of idle speed stability.
● Calibration of acceleration condition.
● Calibration of deceleration condition.
● Fuel cut-off upon deceleration.
● Calibration of fuel supply upon transient condition of engine.
● Calibration of uniform speed running.
● Calibration of mechanical and electrical load increase/decrease.
(e). Target idle speed determinative factors:
● If the engine coolant temperature is low, the system will release the higher target
idle speed to accelerate the warm-up.
● If the external load (such as the headlamp, A/C, cooling fan and other electrical
load) is on, the system will increase the idle speed to compensate the additional load
and maintain the idle speed stable.
8. Principle of knock control
(a). Description of knock sensor:
The knock sensor is a vibration acceleration sensor mounted on the engine cylinder
block. Generally it is mounted between the cylinders 2 and 3, which is conducive to
the knock balance of the engine. Using the vibration frequency signal output from the
sensor and by means of ECM internal filtering, ECM further determines whether there
is a knock for the engine. When the knock signal is detected, the ECM corrects the
ignition angle until no knock occurs.
(b). Knock control start conditions
• …The vehicle is equipped with a knock sensor with the knock control function started;
• …The engine is running and running time is more than 2s; and
• …The engine water temperature is higher than 70°C.
•The engine speed is more than 600r/min.
(c). Knock control mode
• Steady state knock control: When the engine is running normally, the ECM collects
and analyzes the sound present during the combustion of the engine, through the
knock sensor, and detects knocking after filtration. Once the knock strength exceeds
12-17
the allowable limit, the system will quickly retard the ignition advance angle of the
cylinder subjected to knock. The knock is eliminated in the subsequent combustion
cycle. The ignition advance angle will gradually return to normal angle.
• Transient knock control: When there is a rapid acceleration or the engine speed
changes rapidly, the knock is easy to occur. After the system predicts the possibility
of knocking, it will automatically retard the ignition advance angle to avoid overrun
(strong) knocking occurs. After the system detects the knock, according to the 12
different engine speed, it quickly retards the ignition advance angle by 3-5°, and
makes the control back to normal control in the subsequent 2-3s.
• Adaptive adjustment of the ignition angle: There is a difference between the engines
due to manufacturing errors and wear after long term use. After the system and
engine are initially used or the ECM is re-powered, the engine may be subjected to
knock in work and the system will record it. After a period of running-in, the system
will automatically generate an adaptive ignition adjustment correction value (self-
learning value).…When the engine becomes in the same conditions, the system will
automatically adjust the ignition advance angle in an adaptive manner to prevent the
occurrence of strong knock. System adaptive learning is such that it is continually
updated during engine operation.
9. Principle of canister control valve control
(a). It is used to control the flow of charcoal canister cleaning airflow. The charcoal
canister solenoid valve is controlled by the ECM sending the duration and frequency
of the electrical pulse (i.e., the duty ratio) after a comprehensive calculation according
to a series of signals including engine load, engine coolant temperature, and speed.
Gasoline steam in the charcoal canister will, after being excessively accumulated,
lead to leakage of gasoline, causing environmental pollution. Thus, the charcoal
canister solenoid valve has the function of opening in the appropriate time so that
excess gasoline steam in the charcoal canister enters the inlet pipe, after being fully
mixed with the air in the charcoal canister, and is involved in burning.
The charcoal canister solenoid valve further controls the amount and time of fuel
steam into the cylinder by controlling the switching time and timing of the passage
between the charcoal canister and the inlet pipe, thus minimizing the evaporative
emissions from vehicles. At the same time, the impact on engine performance is
minimized.
(b). Working condition of the charcoal canister solenoid valve
To r0educe the impact of fuel steam into the cylinder on the normal combustion
and doing work of the engine, the charcoal canister solenoid valve must meet the
following conditions before opening:
• System voltage is less than 18V but greater than 8V;
• The engine water temperature is higher than 0°C;
• The engine intake air temperature is higher than 0°C; and
• There is no related system failure.
• No relevant system failure (failure listed as follows):
Fuel system fault
Oil pump fault
Idle speed high/low fault

Intake pressure sensor fault
Engine misfire fault
Front oxygen sensor heating fault
Front oxygen sensor signal fault
System voltage low/high fault
Crankshaft position sensor fault
Ignition coil fault
Injection nozzle fault
Canister control valve output fault
(c). Working mode of the charcoal canister solenoid valve
The opening of the charcoal canister solenoid valve is determined by the duty ratio
(PWM) signal determined by the ECM according to the engine state. In non-idling
mode, the maximum charcoal canister solenoid valve opening is determined by the
closed-loop air flow, with a maximum of 100%.
The charcoal canister will not participate in the work in the following cases:
● The engine has run for a period of time after the cold start.
●The engine cooling water temperature is relatively low.
● The engine is idling.
● The engine is under high load.
● The important system sensor has fault.
10. Electronic-controlled throttle control
(a). Forced engine-off mode
When the ECM reports a failure, or the intake system or the throttle valve body has a
problem in controlling the intake air volume, the control strategy is to close the fuel,
ignition and throttle, so that the engine goes out and no longer output power.
(b). Forced idling power management mode
When the engine idles, the ETC system cannot reliably control the engine power by
using the throttle. At this point, ETC cancels the control of the throttle. Its opening
returns to the mechanical default state. The engine power is controlled only by
switching the injection of a cylinder and retarding the angle of ignition.
(c). Forced idling mode
When the driver's intentions cannot be reliably obtained, for example all pedal signals
fail, the engine only works in idling mode to maintain the car environment’s cooling,
heating, power supply, lighting and other functions. When the accelerator pedal is
depressed, the engine does not respond. Therefore, in this mode the car will not be
driving.
(d). Restricted power management mode
The ETC system cannot normally control the engine power by using the throttle valve.
In this mode, the system determines whether the idle speed or acceleration is present
according to the pedal signal. The engine controls the engine power output by closing
or opening a cylinder fuel injection and retarding the ignition angle. Therefore, the
engine output fluctuations are obvious and prolonged work in this mode will be
harmful to the engine and the emission system. The model ensures that the car can
12-19
barely drive, but it is difficult to control driving in the normal traffic flow or climbing
steep slopes.
(e). When the reliability of determining the driving intention is reduced or the high power
cannot be output:
for example when the two pedals have signal input but the difference is too large, the
output torque of the engine is limited and the engine's response to the pedal changes
is also much slow. The driver will obviously feel that the engine output becomes 12
weak, but normal driving is still possible.
(f). Normal mode: The vehicle can travel exactly as the driver intends.
11. Variable valve timing control principle
(a). Variable valve timing control mechanism actuating conditions
The variable valve timing control mechanism can act according to the requirements of
the engine management system to control the relative position between the camshaft
and crankshaft, so as to cause the engine to obtain the best economic, dynamic and
emission performance when the following conditions are met:
• The system voltage must not exceed 16V or less than 10.5V;
• The engine water temperature should not exceed the specified limit of 115°C.
• Engine speed shall not be higher than 7000r/min, nor less than 900r/min; and
• There is no fault associated with the variable valve timing control system. (See the
detailed failure codes for the list of failures)
(b). In the operation of the variable valve timing control system, when the above
conditions are met, the appropriate valve timing is determined according to the
current operating conditions (speed, and load) of the engine. When the valve timing
changes, the engine's charge efficiency and the best ignition angle will change: the
charge efficiency compensation is automatically calculated by the formula.
12. Fan control logic
The system controls the cooling fan of the engine and A/C. ECM decides whether to
turn on the various fans according to the engine coolant temperature and to whether
the conditions are in line with A/C ON conditions etc.
(a). Fan working modes and working conditions
• When A/C is off:
When the temperature of the coolant is less than 91°C, the engine fan is off.
When the temperature of the coolant is greater than 94°C, the engine fan runs at low
speed.
When the temperature of the coolant is greater than 94°C, the engine fan runs at high
speed.
After the coolant temperature falls to below 201.20 ℉ , the engine fan will run at low
speed again.
After the coolant temperature drops below 89°C, the engine fan is off.
• When the air conditioner is turned on, start the low speed fan.
LFB479Q component layout
1
2 3
4 5
12
13
6
9 7
10
11
LFWX-6470-12004
1 Engine ECU mounting bracket 8 Canister control valve

2 Engine ECU 9 Camshaft position sensor
3 Hexagon flange bolt 10 Electronic throttle body assembly
4 Ignition coil assembly 11 Knock sensor
5 Fuel guide rail assembly 12 Intake pressure temperature sensor
6 Oxygen sensor 13 Coolant temperature sensor
7 Crankshaft position sensor
Tips:
The sensors and actuators are detailed as follows:
S/N Component Qty. Functions

Based on the sensor signal, optimize the
1 ECU 1 control system, to operate the engine
under various conditions
12-21
S/N Component Qty. Functions

2 Fuel pump 1 Transport fuel
3 Ignition coil 4 Ignite the mixture gas
Check the oxygen concentration in the

4 Front oxygen sensor 1
exhaust gas
12
5 Fuel injector 4 Inject the fuel according to the ECM signal
Camshaft position Supply crankshaft and camshaft position

6 1
sensor information to ECM
Control the emission according to the

7 Canister controller 1
ECM digital pulse square wave
Check the oxygen concentration in the

8 Rear oxygen sensor 1
exhaust gas
Crankshaft position Test the engine crankshaft rotation

9 1
sensor position and rotary speed
Electronically controlled
10 1 Control the air input
throttle valve body
Coolant temperature
11 1 Detect the engine coolant temperature
sensor
12 Knock sensor 1 Check the engine for knocking
Check the engine intake temperature,

Intake temperature/
13 1 intake volume and determine the
pressure sensor
compression TDC
Control the engine oil flow to the camshaft

14 Intake VVT valve 1
position actuator
Engine management system
Engine compartment central electrical control box
Cab circuit central control box
IG1 B B
FS35
10A
FS03
25A
FS11
0.85 BlR
0.85 BlR
10A
0.50 BlR
0.75 BlR
Heating type front oxygen sensor
Variable camshaft timing (intake)

1 main relay
Heating type rear oxygen sensor

5 1D 1 3
1 E29 4 E29 1 I46 4 I46 1 E04 1 E22
5 I1D
0.50 BrB
Canister control valve

2 5
0.85 R
41 IU1
41 UI1
2.50 BlR
0.50 R
42 IU1
0.50 BrB
0.50 Y
42 UI1 2 E29 3 E29 2 I46 3 I46
0.50 RG
0.50 RB
To instrument 1 E09 2 E04 2 E22
10 UE1
0.50 RW
cluster
0.85 R
3 UE1 24 UE1 39 UI1 10 EU1

42 IU1 40 IU1
3 EU1 24 EU1 39 IU1
0.50 VB
42 UI1 40 UI1
3 E09
Generator
2.00 BlR
7 UE1 1 UE1
0.50 RG
0.50 RB
7 EU1 1 EU1
0.85 BW
2 E09
16 UE1 26 UE1
0.75 WG
0.50 YW
0.50 VW
1.50 BlR
1.50 BlR
0.50 OY
0.50 VB
0.75 BW
16 EU1 26 EU1
0.50 R
0.50 Y
0.50 RG
0.50 RB
68 E01 67 E01 44 E01 5 E01 5 E01 24 E01 47 E01 73 E01 48 E01 23 E01 43 E01 64 E01
+39
66 E01 54 E01 76 E01 71 E01 42 E01 74 E01 41 E01 70 E01 77 E01 49 E01 20 E01 21 E01 52 E01 27 E01
0.50 RW
0.50 RB
0.50 PB
0.50 YB
0.50 YG
0.50 WB
28 EU1 27 EU1 29 EU1 18 EU1 25 EU1 17 EU1
0.50 LgW
0.50 RGr
0.50 RB
0.50 RB
0.50 YB
0.50 W
0.50 W
0.50 W
28 UE1 27 UE1 29 UE1 18 UE1 25 UE1 17 UE1
0.50 P
050 V
0.50 WB
0.50 RW
050 ?
0.50 Bl
0.50 P
0.50 RBr
0.50 YW
0.50 YBl
0.50 PB
0.50 YR
0.50 YG
Circuit diagram
8 E20 5 E20 2 E20 4 E20 3 E20 1 E20

3 E06 4 E06 1 E06 2 E06 5 U27 6 U27 1 U27 3 U27 4 U27 2 U27 2 E19 3 E19 1 E19 1 E21 3 E21
3
Intake temperature/pressure sensor Throttle pedal sensor Phase sensor 1 (intake) Coolant Electronic throttle body
temperature sensor
12-22

12
Engine management system II

12-23
Cab central electrical control box
B+ IG+ B+ B+
Engine compartment central

Injector Injector Injector Injector
electrical control box

FS35
FS06
7.5A
FS24
FS04
2 E18
E13
25A
2 E12 2 E14 2 E16
15A
15A
Ignition coil
Ignition coil
Ignition coil
Ignition coil
2 2 2 2
1 Fuel pump relay

1 3 1 3
1 Main relay

1 1E 5 1D 3 1 3 1 3 1 3 1
1 E11 2 E11 1 E13 2 E13 1 E15 2 E15 1 E17 2 E17 3 E12 1 E12 3 E14 1 E14 3 E16 1 E16 3 E18 1 E18
1 I1E 5 I1D
2 5 2 5
0.85 BlR
0.85 BlR
0.85 BlR
0.85 BlR
0.85 BlR
0.85 BlR
0.85 BlR
0.85 BlR
0.50 R
0.85 R
0.50 Y
0.50 WY
1 I06 3 I06 2.50 BlR
24 UE1
24 EU1
Brake switch
4 UE1
1.25 W
1.50 B
3 UE1
4 EU1
2 I06 4 I06 3 EU1
1.25 GO
0.75 OB
1.25 PG
0.75 GY
0.75 PY
0.75 YR
0.50 WY
1.25 Bl
1.25 V
26 IU1 27 IU1
0.50 Y
1 UI1
26 UI1 27 UI1 1 IU1
0.50 Br
0.50 GO
19 UE1 20 UE1
19 EU1 20 EU1
1.25 W
33 E01 69 E01 6 E01 8 E01 7 E01 25 E01 4 E01 81 E01 1 E01 62 E01 44 E01 9 E01
+39 PCANH PCANL
17 E01 65 E01 10 E01 35 E01 40 + 79 + 60 E01 2 E01 3 E01 36 E01 37 E01 17 E01 1 E01 6 IB1
0.50 BlG
0.50 GW
0.50 G
2.00 B
2.00 B
6 BI1
0.50 YB
0.50 OBL
0.50 BlO
0.50 BlY
To fuel signal
0.50 Y
32 EU1 9 EU1 13 EU1
0.50 W
1.25 W
050 =
050 B
32 UE1 9 UE1 13 UE1
To diagnostic interface
Instrument
0.30 GR
0.50 BlG
1 B02
0.50 GW
0.50 G
To stop To fan high To fan low To AC signal To high/low
lamp speed signal speed signal To compressor beam system
2 B02
relay
13 UI1
Fuel pump
1 U09 2 U09 1 E05 2 E05
13 IU1
M
3-state switch
3 B02
0.50 BlG
3.00 B
0.30 BBl
Clutch pedal bottom switch
4 B02
3 U09 2 U09 1 I03
Angle sensor
Self-adapting
head lamp
system
ACU
EPS
Knock sensor To fuel signal GND
1.25 B
0.50 RY
0.50 B
Optional Optional
2 I03
0.50 B
To AC switch signal
G14 G24 G01 G27 G02
Terminal definition
E01 Connect to the engine ECU
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
1 2
62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
3
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25
4 5
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6
Terminal Wire size/ Terminal Wire size/

Fuction Fuction
No. color No. color
1 0.75/lgW Ignition coil B 42 0.5/Gr Throttle pedal sensor 2
2 2.0/B Ground 43 0.5/YW Intake VVT valve
3 2.0/B Ground 44 0.5/Y Main relay
4 0.75/LgR Ignition coil A 45 NC
5 0.75/GBl Solenoid valve power protection 46 NC
6 0.75/OB Injector A 47 0.5/OY The front oxygen sensor signal is high
7 0.75/PY Injector B 48 0.5/Gr The rear oxygen sensor signal is high
8 0.75/YR Injector D 49 0.5/YB Water temperature sensor
9 0.5/BO Fuel pump relay 50 NC
10 0.5/W A/C clutch relay 51 NC
11 0.5/GrBl Crankshaft position sensor signal high 52 0.5/BlW Throttle position sensor 1
12 NC 53 NC
13 NC 54 0.5/P Intake pressure sensor
14 NC 55 NC
15 NC 56 0.5/VO Neutral gear switch
16 NC 57 NC
17 0.5/OBl High speed fan 58 NC
18 NC 59 NC
19 NC 60 0.5/BlG Clutch top switch
20 0.75/V Electronic control throttle high 61 NC
21 0.75/Y Electronic control throttle low 62 0.75/Br Ignition coil C
22 NC 63 NC
23 0.75/G Heating type rear oxygen sensor 64 0.75/WG Canister solenoid valve
24 0.75/VW Heating type front oxygen sensor 65 0.5/BlY Low speed fan
25 0.75/GY Injector C Throttle pedal sensor 2, intake

66 0.5/RW
26 NC temperature/pressure sensor 5V power
67 0.5/R ECU power

12-25
Terminal Wire size/

Fuction
No. color
Terminal Wire size/ Throttle pedal sensor 1, intake
Fuction
No. color camshaft position sensor, coolant
70 0.5/RB
temperature sensor electronic control
27 0.5/P Throttle position sensor 2 throttle valve body 5V power
28 NC 71 0.5/Bl Intake temperature sensor
29 NC 72 0.5/GBr Reverse switch

12
30 0.5/GrG Crankshaft position sensor signal low 73 0.5/VB Oxygen sensor 5V power
31 NC Throttle pedal sensor 1, intake

camshaft position sensor, coolant
32 NC 74 0.5/W
temperature sensor electronic control
33 0.5/BlR Brake lamp throttle valve body common ground
34 0.5/BlBr Power assisted steering switch 75 NC
35 0.5/BlO Head lamp load Throttle pedal sensor 2, intake

76 0.5/WB temperature/pressure sensor common
36 0.5/W The knock sensor signal is high ground
37 0.5/B The knock sensor signal is low 77 0.5/LgW Air intake camshaft position sensor
38 0.5/BlW PCAN high 78 NC
39 0.5BlB PCAN low 79 0.5/RG A/C request switch
40 0.5/VR A/C medium pressure 80 NC
41 0.5/RY Throttle pedal sensor 1 81 0.75/PG Ignition coil D
E12 Connect to the ignition coil A E05 Connect to the oil injector 1
1 2 3
Terminal Wire size/

Fuction Terminal Wire size/
No. color Fuction
No. color
1 0.85/BIR Main relay power supply 1 0.85/BIR Injector A
2 0.85/B Grounding 2 0.75/OB Main relay power supply
3 0.75/LgR Ignition coil a
E14 Connect to the ignition coil B E13 Connect to the oil injector B
2
1 2 3

Fuction Fuction
No. color No. color
1 0.85/BW Main relay power supply 1 0.85/BIR Injector B
2 0.85/B Grounding 2 0.85/YR Main relay power supply
3 0.75/PG Ignition coil B
E16 Connect to the ignition coil C E15 Connect to the oil injector C
1 2 3

Fuction Fuction
No. color No. color
1 0.85/BW Main relay power supply 1 0.85/BIR Injector C
2 0.85/B Grounding 2 0.75/PY Main relay power supply
3 0.75/LgW Ignition coil C
E18 Connect to the ignition coil D E17 Connect to the oil injector D
1 2 3

Fuction Fuction
No. color No. color
1 0.85/BW Main relay power supply 1 0.85/BIR Injector D
2 0.85/B Grounding 2 0.75/GY Main relay power supply
3 0.75/Br Ignition coil D
E20 Connect to the electronic throttle E09 Connect to the motor regulator
4 3 2 1
3 2 1
8 7 6 5
12-27
Terminal Wire size/

No. color Fuction
No. color
1 0.5/W Sensor ground
1 0.5/R Battery power
2 0.5/BlW Throttle position sensor 1
2 0.85/BW Igition power
3 0.5/P Throttle position sensor 2
3 0.5/V Charge indicator
4 0.5/RB Sensor 5V power
5 0.75/Y Electronic control throttle low 12

6 Electronic control throttle high
7 NC
8 0.75/V Electronic control throttle high
E5 Connect to the knock senso E22 Connect to the carbon canister solenoid valve
1 2 1 2

Fuction Fuction
No. color No. color
1 0.5/W The knock sensor signal is high 1 0.75/WG Canister solenoid valve
2 0.5/B The knock sensor signal is low 2 0.85/BlR Main relay power supply
E06 Connect to the air intake pressure and temperature sensor E04 Connect to the variable inlet end
4 2
2 1
3 1
Terminal Wire size/

Fuction
No. color Terminal Wire size/
Fuction
No. color
1 0.5/WB Sensor ground
1 0.85/BlR Main relay power supply
2 0.5/Bl Intake temperature sensor
2 0.5/YW Intake VVT valve
3 0.5/RW 5VPower supply
4 0.5/P Intake pressure sensor
E24 Connect to the air intake camshaft position sensor E21 Connect to the water temperature sensor
3 2 1
C 3 2 1 A

Fuction Fuction
No. color No. color
1 0.5/GrG Crankshaft position sensor signal low 1 0.5/YB Water temperature sensor
2 0.5/GrBl Crankshaft position sensor signal high 2 NC
3 0.5/B Engine ground 3 0.5/W Sensor ground
E29 Connect to the front oxygen sensor I46 Connect to the oxygen
sensor
1 2 3 4
4 3 2 1

Fuction Fuction
No. color No. color
1 1.25/BIR Main relay power supply 1 0.5/BrB Rear oxygen sensor ground
2 0.75/VW Heating type front oxygen sensor 2 0.5/RG Rear oxygen sensor
3 0.5/OY The front oxygen sensor signal is high 3 0.75/RB Rear oxygen sensor heating
4 0.5/VB Oxygen sensor 5V power 4 0.75/BlR Main relay power supply
E24 Connect to the crankshaft position sensor
Terminal Wire size/

Fuction
No. color
1 0.5/GrG Crankshaft position sensor signal low
2 0.5/GrBl Crankshaft position sensor signal high
3 0.5/B Engine ground

12-29
Basic examination
Tips:
If there is no determined DTC during the DTC inspection, regard all the possible circuits
as the fault causes to analyze them and solve the fault. In most cases, carry out the basic
engine inspection according to below diagram to quickly and efficiently locate the fault part.
Steps Check contents Recommended Measures

12
Yes Go to Step 2
Check the battery voltage
1 •The battery voltage should be ≥9.6V
Inspect whether the result is normal? No Charge or replace the battery.
Check whether the engine starts Yes Go to Step 3

2 •Start the engine
Inspect whether the result is normal? No Go to Step 6
Check the air filter Yes Go to Step 4

•Take out the air filter
3 • Check the air filter for excessive
contamination or oil stain. No Clean or replace air filter
Inspect whether the result is normal?
Check the idling speed Yes Go to Step 5

•Start the engine. Refer to Chapter 12 Engine control
4
•Bring the engine to idling state. No system - fault diagnosis, list of fault
Inspect whether the result is normal? phenomenon
Check the ignition timing Yes Go to Step 6

•Use the timing test lamp test method
5 or ignition timing tester Refer to Chapter 12 Engine control
Check the ignition timing No system - fault diagnosis, list of fault
Check the fuel pressure Yes Go to Step 7

•Check the fuel pressure with the fuel Refer to Chapter 12 Engine control
6
pressure gauge No system - fault diagnosis, list of fault
Check the spark plug Yes The basic inspection is finished

•Remove spark plugs one by one.•
7
•Test the spark of the spark plugs.
No Replace the spark plug
Inspect whether the result is normal?
Diagnosis
System description
1. System overview
The engine electronic injection diagnostic system means the emission control on-
board diagnosis (OBD) system. It allows the function to identify the possible fault
zones and store the information in the electronic control module memory in the form
of DTC.
2. Information storage
(a). After the fault occurs and the system confirms, each fault will be stored in the
electronic control module (ECM) in the form of individual status code.
(b). In addition to the information, it stores the engine status parameters while the fault
occurs, including the load value, engine speed, fuelpressure and correction, vehicle
speed and coolant temperature etc.
3. Information reading
(a). Connect the diagnostic tester or PC to vehicle through the diagnostic interface to
read DTC and the engine status parameters when the fault occurs.
(b). Diagnostic interface:

16-pin interface, at the left lower corner of
I01
the instrument desk.
16 15 14 13 12 11 10 9
8 7 6 5 4 3 2 1
LFWX-6470-12007
(c). Diagnostic interface description:
Terminal No. Wire size/color Functions

1 NC
2 NC
3 0.3/W BCAN-H
4 0.5/B Diagnostic interface ground wire
5 0.5/B Diagnostic interface ground wire
6 0.3/Y PCAN-H
8 0.3/RY B+
12-31
9 NC
10 NC
11 0.3/WB BCAN-L
12 NC
13 NC
12
14 0.3/YB PCAN-L
15 NC
16 0.3/R IG1+
4. MIL
(a). Position and symbol
The dashboard includes two malfunction
indicator lamps which are the engine
malfunction indicator lamp “MIL” (B) and
4 OBD malfunction indicator lamp SVS
(A). Both lamps are calibrated and
4
4
2
1
120
0
！
controlled by ECM. The difference is that
OBD SVS is mandatory according to the
national regulations. This lamp means
the electronic control system presents the
LFWX-6470-12005
fault which may deteriorate the complete
vehicle emission; while MIL lamp indicates
the electronic control system presents
other faults. With the engine under normal
running, if any fault occurs, both lamps will
be on according to the respective rule
5. MIL lighting mode
Tips:
• Before starting the car, turn and hold the ignition switch/one-key start switch in ON
position for about 2s. Observe whether the instrument indicator has self-test. Start the car
at least 5s after turning off the ignition switch.
•The SVS and MIL lamps on the instrument are designed to remind the driver of the
electronic control system fault. The lamp is controlled on by the ECM internal rating data.
(a). If the system has no fault.
•When the ignition switch is turned to ON gear, the MIL will be on all the time while
SVS lamp will turn on after completing the self-inspection.
•Both MIL and SVS lamp will turn off after the vehicle starting;
•Both MIL and SVS lamp will immediately turn off after the engine stalling.
(b). If the system has fault.
• When the power is ON, the MIL light will be on or flash, and the SVS light will go off
and on after self-test.
• If the MIL in the failure class is defined as on mode, the MIL light will go off and on
after start if the condition for MIL light to go on is met. If the SVS light in the failure
class is defined as on mode, the SVS light will be on continuously if the condition for
SVS light to go on is met.
• When the ignition switch is turned OFF after flameout, all goes off after the
AFTERRUN process (up to 90s).
6. Classification of engine electronic control system faults
(a). Turn on OBD fault indicating lamp; when OBD fault indicating lamp of instrument is
turned on, according to related requirements of national regulations, users should
immediately invite professionals from Lifan authorized maintenance station for
treatment.
(b). SVS fault light should be turned on, the fault will not influence drainage, but it also
represents electrical control system works abnormally, and users should inspect in
Lifan authorized maintenance station at the right moment.
Tips:
Both faults will require the customer immediately to go to the authorized maintenance
center of LIFAN to check the vehicle by the fault diagnostic tester or the equivalent special
equipment.
12-33
Fault diagnosis procedure
Send the vehicle to the repair shop
Inquire the customer about the fault occurring

conditions, time and symptom and ask whether
vehicle is repaired 12
Check whether the system has fault with the

diagnostic tester
No
Whether there is DTC output
Yes Visual check:

Check whether the wiring of
system elements is correct and
Record the DTC and clear it; check whether there is DTC output. firm; whether the surface of
harness and elements has
damage.
No
Basic inspection:
Is relevant fault listed? Check the battery voltage, fuel
level, cylinder pressure, ignition
timing and idle speed etc.
Intermittent fault:
Verify the fault with the fault
Yes
symptom analogy method
DTC list
Does the fault occur? Is relevant fault listed?
No
Yes
Overall analysis and inspection

Repair the corresponding circuit and replace the corresponding fault Sensor inspection
No parts Data flow analysis
Actuator inspection
Confirm the fault is solved or not
End
LFWX-6470-12006
Fault diagnosis and analysis

△ Tips:
The typical faults of the electronic control engine include the difficult start, immediate
stalling after start, unsteady idle speed, too high idle speed, powerless driving, poor
acceleration, back fire blasting, tremble and surge, smoking and high fuel consumption etc.
The fault causes are quite complex. It is necessary to analyze the fault carefully.
1. Analyze and determine whether there is engine fault

The general method to determine the engine fault is:
•If the engine cannot start or it cannot work normally after starting, or the exhaust pipe
blasting, intake pipe back fire and the evident knock sound occur while the engine
running, it can be determined the engine has fault;
•Whether the engine MIL of engine electronic control system is on. If so, it indicates
the engine electronic control system has fault;
•If the engine performance changes a lot in a short time, it can be determined the
engine has certain fault such as the evident engine power drop, fuel consumption
increase etc.;
•If the engine performance change is not evident, test as follows: run the engine
under various simulated conditions and check the exhaust pipe and intake pipe for
abnormal sound with the engine running; feel the engine vibration and check for
evident dithering, metal knock sound and engine speed variation etc.
Note:
•Slowly depress the accelerator pedal to increase the engine speed gradually and
check whether the above phenomena exist.
•If so, it indicates the engine may have fault. Repeat the test to supply the reference
for the correct fault determination;
•Depress the accelerator pedal abruptly and observe whether the above phenomena
occur and the engine speed increase rate is perfect. If the abnormal circumstance
occurs or the engine speed increase rate is too low, it indicates the engine has fault;
•If no abnormal occurrence is detected during the engine running under the above
two cases, release the accelerator pedal and observe the engine idling conditions:
observe whether the idle speed is too high, unsteady or the engine dithering is
severe.
△ Tips:
If no abnormity is detected during the above operation, it indicates the engine operation is
normal. To carefully check the engine dynamic performance, economic performance and
emission conditions, use the testing line or special test instruments for the troubleshooting
and diagnosis.
2. Analyze and determine the fault nature
In the case electronic control engine fault, check the conditions of the electronic
control system self-diagnostic MIL. If this lamp is on with the engine running, it
indicates the electronic control engine has fault which can be monitored by the self-
diagnosable system. In general, the fault relates to the electronic control system.
At this point, recall the DTCs stored in PC memory and find out the fault causes
12-35
according to the DTCs. If the engine has fault while the engine MIL on the dashboard
is not on with the engine running, it indicates the engine malfunction cannot be
identified by the electronic control module self-diagnosable system. In such a case,
arrive at the tentative diagnosis result according to the fault phenomenon, analyze
the possible fault causes and carry out the deep diagnosis in the principle of outside
to inside and simple to complex. Remember do not remove or disassemble the
electronic control system at will in such a case. First confirm the fault occurs in the 12
electronic control system and then check this system; otherwise check the rest part.
3. Analyze the system where the failure is identified
To reduce the troubleshooting workload, use the 1/2 deduction method in the case
of engine abnormal reaction to narrow the doubtful objects by 1/2.Therefore, first
confirm the oil circuit has fault or the electric circuit has fault. Most engine faults are
caused by the oil circuit or electric circuit fault. In the event of engine malfunction,
if you are certain about the fault occurring in the oil circuit or electric circuit, the
troubleshooting workload can be reduced by half. In such a case, operate as follows:
(a). Judge whether oil line or electric circuit has faults.
Since the electric circuit fault diagnosis is simple and visual, check the electric circuit
for fault first. Carry out the spark over test over the cylinder block. If no high voltage
spark is detected or the spark is too weak, it indicates the ignition system has fault. If
the above inspection result is normal and each cylinder spark is normal, it indicates
the fault occurs in the oil circuit.
(b). Judge whether individual or all air cylinders work bad or not.
The improper engine operation can be caused by the failure of individual cylinder or
all cylinders. In the case of individual cylinder out of operation or failure, start with
the faulty cylinder. If every cylinder is working while the fault is not evident, start with
the cause for cylinder operation failure. In this way, the diagnosis workload can be
cut off by 1/2.…In such a case, operate as follows: start the engine, run it idling until
the temperature is normal and then shut down the distributor cylinder by cylinder to
observe the engine running conditions. If the engine running does not change upon
the cylinder flame out and on, it indicates this cylinder does not work well. Therefore,
locate the cause for the operation failure of this cylinder. If the engine running does
not change during the above test for each cylinder, it indicates the working conditions
of all the cylinders are the same. In such a case, start from the cause for the
abnormal cylinder operation.
Read or clear DTC

1. Description
(a). DTC is the vehicle PC self-diagnostic trouble code. It is the information stored in the
vehicle PC in the form of code after the vehicle PC testing the performance of each
component and detecting the fault before the vehicle start and during the vehicle
running. For example, in the case of coolant temperature sensor open circuit, the PC
will detect the jump of sensor interface signals or deviation from the allowable normal
value. At this point, the PC will memorize this state. Reading DTC is to read the DTC
information from the vehicle PC and interpret it in a correct way.

(b). In general, both the DTC meaning and instrument DTC meaning include the fault
location and fault nature. For example, in DTC P0107, intake pressure sensor means
the fault location while voltage low or open circuit means the fault nature. In some
models, the DTC defines the fault nature in details, including short to the ground,
short to the power, open circuit, loose contact, high signal, low signal, fast variation
and slow variation etc. In this way, the maintenance staff can easily distinguish them.
Note:
•In most cases, the probable fault causes and location can be identified by the
DTC interpretation. Sometimes, the determination mistake may occur, causing
the misleading.
•In fact, the DTC is merely a conclusion of Yes or No and cannot indicate the
specific fault causes; to determine the fault location, it requires the further
analysis and inspection according to the engine fault symptom.
• Some sensor failures may not be shown in the self-diagnostic system. When
detecting the sensor signals, ECM can only receive abnormal signals beyond
its built-in range (sensor), so as to determine whether the sensor has failed.
In general, after the DTC interpretation, check the relevant sensors, line
connectors and circuits, find out the fault points of open circuit or short circuit
and then the fault can be solved. However, if the sensor sensitivity drops due
to some reasons (the sensor response is slow and the output characteristic
offsets though it is in ECM setting scope), the self-diagnosable system will not
detect the fault.
•Though the engine has fault, the self-diagnosable system yields the normal
code which means no fault in the engine. At this point, carry out the analytical
judgment according to the engine fault symptom, test the sensor individually
and solve the sensor fault. For example, if the engine idling is unsteady
and the engine running disturbance occurs while the system does not yield
the DTC, consider the fault of intake manifold pressure/temperature sensor
first. Since the performance of these two sensors has direct influence on the
basic fuel injection volume, it is necessary to check them though there is no
corresponding DTC
• The self-diagnostic system may display incorrect wrong failure codes. This
is due to working condition signal failure. For example, the failure code shows
the failure of “coolant temperature sensor short circuit or open circuit”; but the
engine failure phenomenon is: it cannot be started properly whether in cold or
hot conditions, accompanied by tempering, idle instability and constantly lower
engine speed. It is clear that these failures are not closely related to the coolant
temperature sensor (no failure after checking the coolant temperature sensor).
• It is recommended that, when the failure code appears, it should be compared
with the actual failure phenomenon of the engine to obtain a reasonable
judgment; the failure code should not be regarded as the only basis.
•The improper repair may cause the incorrect DTC. For example, if any
sensor plug is unplugged with the engine running, ECM will memorize one
12-37
corresponding sensor DTC.

•If the old DTC is not cleared due to the improper operation after the last time
engine repair, the survival DTC will be repeated when the DTC is read, which
will make the maintenance work confused and difficult.
•Before the reproduction reading of system fault, execute the DTC clear
operation first.
•In the case of system fault, if the system fault is not solved after clearing the 12
DTC by the diagnostic tester, the DTC will exist in the DTC reading process
until the fault is solved.
2. Read the steps

△ Tips:
The DTC of XUANLANG engine electronic control system should be read through
the professional diagnostic meter submitted by LIFAN; the reading of DTC with other
diagnostic meters will be unreliable
(a). Connect diagnostic tester to the diagnostic

interface.
(b). Select "fault diagnosis", "6.4 version
or above", "power assembly", "engine
management system" and "Delphi" in turn.
(c). Read or clear DTC.
LFWX-6470-72006
Read data flow

1. Description
The so called "data flow" means the electric signal sent by the vehicle PC
continuously in the form of system working parameters and working state. There are
many items in the data flow. The typical data flow of the engine system includes:
Ignition advance angle
•Throttle opening
•Fuel injection pulse width
•Coolant temperature
•Intake temperature
I ntake manifold pressure
•Atmosphere pressure
•Fuel injection initial angle
•Battery voltage
Note:
The data values including the switch, sensor and actuator parameters can be checked
by reading the data sheet shown on the diagnostic tester without removal. To shorten the
diagnosis time, read the data sheet as the first step for troubleshooting.
Input/output control function unit

1. Description
The action test is the self-learning process of the assembly and includes the test
and special operation learning of the relay and actuator. It need not remove any
component.
2. Test contents
S/N Name Test mode NOTE

Engine malfunction indicator Open / Close switch Test whether the operation of engine
1
lamp (MIL) on/off MIL is normal
Start the engine and test whether

2 Carbon canister purification 0 ～ 100 (%) the operation of the canister control
valve is normal
Open / Close switch Test whether the operation of fuel

3 Fuel pump relay
on/off pump relay is normal
Open / Close switch Test whether the operation of low

4 Fan low-speed
on/off speed fan is normal
Open / Close switch Test whether the operation of high

5 Fan high-speed
on/off speed fan is normal
Open / Close switch Test whether the operation of A/C

6 A/C clutch
on/off relay is normal
Start the engine, and enter the

Control the idling air control
7 0 ～ 255（Steps） value. Turn off the ignition switch to
valve step by step
restore the original settings

Install the speed control 0 ～ 255(RPM
8 value. Turn off the ignition switch to
idling air control valve =13.7*N+1000)
restore the original settings
The engine does not start; click the

Idling air control valve
9 button to reset the idling air control
resetting
valve

10 Ignition advance/retardation 0 ～ 255
value. Turn off the ignition switch
Start the engine. "ON" is to carry out

Crankshaft position sensor Open / Close switch crankshaft position sensor target
11
target gear error learning on/off gear error learning. "OFF" is to
cancel the operation
12-39
S/N Name Test mode NOTE

Start the engine, and it is possible to
12 Injector on/off
control the work of the injector
Start the engine. 'ON' is to carry

Open / Close switch
13 Fuel unit BLM Learn out fuel unit BLM Learn. "OFF" is to
on/off
12
Open / Close switch Start the engine and select "ON/
14 Fuel ON cycle
on/off OFF" fuel ON cycle
The engine does not start. Click: run

15 Fuel unit reset BLM Rest
directly
Start the engine. 'ON' is to start the

Open / Close switch
16 Catalyst offline diagnosis catalyst offline diagnosis. 'OFF' is to
on/off
Start the engine. 'ON' is for oxygen

Oxygen sensor offline Open / Close switch
17 sensor offline diagnosis. 'OFF' is to
diagnosis on/off
Fault phenomenon diagnosis
1. The diagnostic tester cannot communicate with ECM

Connect the diagnostic

The diagnostic tester
tester and check whether Diagnosis is
cannot communicate Go to Step 1
the engine management finished
with ECM
system can be accessed
Check whether diagnostic

Replace the fuse of
interface fuse FS20 and Go to Step 2 Fuse blown
same specification
FS37 are blown
Check diagnostic interface

power and ground circuit

•When the power supply
at ON position, check the
voltage between terminal
8 and 16 of diagnostic
interface connector I01 and
Repair corresponding
the ground Harness or connector
Go to Step 3 harness, connector
Vo l t a g e : C o n n e c t t h e presents open circuit
or terminal
diagnostic tester
•Check the resistance
between I01 terminal 4,
terminal 5 and the ground
Resistance: <2Ω
Check ECM power and

ground circuit
•Disconnect ECM connector

E01
at ON position, check
the voltage between
terminal 69, 68 and 33
Repair corresponding
of E01connector and the Harness or connector
Go to Step 4 harness, connector
ground presents open circuit
or terminal
Vo l t a g e : C o n n e c t t h e
diagnostic tester
•Check the resistance
between terminal 60, 40
and 2/3 and the ground
Resistance: <2Ω
Check the ECM diagnosis

communication line
When the power supply

at ON position, check the
voltage between terminal
D i a g n o s i s
6 and 14 of diagnostic
Go to Step 6 communication line Go to Step 5
interface connector I01 and
presents fault
the ground
Voltage: <2.5
Check the ECM diagnosis

communication line
12-41

• Disconnect ECM
connector E01 Repair the open
•Check whether the Harness or connector circuit between
Go to Step 6
terminal 38 and 39 of E01 presents open circuit diagnostic interface
are connected to terminal 6 and ECM connector
and 14 of I01 12
6 Inspection by replacement Normal Faulty Instruction
Replace the same model

Locate the causes
ECM and check whether
Replace ECM The fault still exists from other fault
DTC can be read with the
phenomenon
diagnostic tester
2. Engine does not rotate or rotate slowly when starts.

With the engine starting,

measure the voltage The detected
of two battery terminal voltage is out of Replace the
Go to Step 1
posts with the universal the reasonable battery
meter range
Voltage: 9~13V
Check the start motor

voltage
Keep ignition switch in

starting position and
The detected
check voltage of starting
voltage is out of Repair or replace
motor positive terminal Go to Step 2
the reasonable the fault harness
with universal meter
range
V o l t a g e : 9 V
approximately
2 Check the start motor Normal Faulty Instruction
Remove the start motor

and check the start
The start motor Repair or replace
motor for short circuit or Go to Step 3
has fault start motor
check for seizing due to
lubricant starvation
3 Check the lubricating oil Normal Faulty Instruction


The lubricating
If the fault occurs in oil does not meet
w i n t e r o n l y, c h e c k the specification Replace the
whether the engine Go to Step 4 and causes lubricating oil of
lubricating oil and gear the excessive appropriate grade
oil are proper resistance of start
motor
Check the engine inside

mechanical resistance
Check whether
the engine internal Engine inside
Locate the causes
mechanical resistance mechanical Check the engine
from other fault
is excessive and causes resistance is internal resistance
phenomenon
start motor cannot rotate excessive
or rotate slowly
3. Engine can rotate but cannot start successfully when starts

Connect the fuel pressure The detected

Check the fuel
gauge, start the engine and Go to Step 1 voltage is out of the
supply system
check the fuel pressure reasonable range
1 Check the speed signal Normal Faulty Instruction
Connect the diagnostic tester

and observe the data item
R e p a i r t h e
in "engine speed"; start the Crankshaft position
engine and check whether sensor line fault
sensor line
there is rotary speed signal
output
2 Check the ignition system Normal Faulty Instruction
Unplug the ignition coil of one

cylinder, connect the spark
plug, bring the spark plug
The ignition system Repair the ignition
to contact the engine block Go to Step 3
has fault system
and start the engine to check
whether there is blue-white
high pressure fire
3 Check the lubricating oil Normal Faulty Instruction
The lubricating oil

If the fault occurs in winter does not meet the
Replace the
o n l y, c h e c k w h e t h e r t h e specification and
Go to Step 4 lubricating oil of
engine lubricating oil and gear causes the excessive
appropriate grade
oil are proper resistance of start
motor
12-43
4 Check the cylinder pressure Normal Faulty Instruction
Check the pressure of each

cylinder and observe whether The cylinder pressure Eliminate engine
Go to Step 5
the cylinder pressure is is insufficient mechanical fault
insufficient 12
Check the engine control

module
Disconnect the engine control

module connector, turn on the
Check whether the
ignition switch and check the Locate the
voltage is out of
voltage between terminal 44, causes from Repair the fault
reasonable range or
66, 68, 70 and the ground other fault circuit
the ground circuit has
Voltage: 9~13V phenomenon
fault
Check whether terminal 74, 76
and the ground are conducted
4. Hot start is difficult

Connect the fuel pressure

The detected voltage is
gauge, start the engine and Check the fuel
Go to Step 1 out of the reasonable
check the fuel pressure supply system
range
Pressure: 400kPa
Unplug the ignition coil of

one cylinder, connect the
spark plug, bring the spark
plug to contact the engine The ignition system Repair the ignition
Go to Step 2
block and start the engine has fault system
to check whether there is
blue-white high pressure
fire
Check the coolant

temperature sensor
Unplug the coolant Repair the circuit

temperature sensor joint, Coolant temperature or replace the
Go to Step 3
start the engine and check sensor fault temperature
whether the engine starts sensor
Check the fuel pressure

regulator vacuum pipe

The vacuum pipe has Repair or replace
regulator vacuum pipe for Go to Step 4
fault the vacuum pipe
looseness or air leak
4 Check the fuel Normal Faulty Instruction
Check the fuel condition

The fuel does not meet Replace the
and check whether fault is Go to Step 5
the specification standard fuel
caused by filling fuel

module
Disconnect the engine

control module connector,
turn on the ignition switch
Check whether the
and check the voltage Locate the
voltage is out of
between terminal 44, 66, causes from Repair the fault
reasonable range or
68, 70 and the ground other fault circuit
fault
Check whether terminal
74, 76 and the ground are
conducted
5. Difficult cold start


The detected
Go to Step 1 voltage is out of the
reasonable range
Pressure: 400kPa
Unplug the ignition coil of one

cylinder, connect the spark
plug, bring the spark plug
The ignition system Repair the ignition
to contact the engine block Go to Step 2
has fault system
and start the engine to check
whether there is blue-white
high pressure fire
Check the coolant

temperature sensor
Unplug the coolant Repair the circuit

temperature sensor joint, Coolant temperature or replace the
Go to Step 3
start the engine and check sensor fault temperature
whether the engine starts sensor
12-45

Check the engine start
conditions
Depress the throttle slightly The throttle and idling Clean the throttle
and observe whether the Go to Step 4 air passage ambient and idling air
start is easy are dirty passage 12
Remove the injector and Repair or replace

Go to Step 5 The injector has fault
check for leak or clogging the injector
5 Check the fuel conditions Normal Faulty Instruction
Check the fuel condition and

The fuel does not Replace the
check whether fault is caused Go to Step 6
meet the specification standard fuel
by filling fuel
Check the pressure of each

cylinder and observe whether The cylinder pressure Eliminate engine
Go to Step 7
the cylinder pressure is is insufficient mechanical fault
insufficient

module
Disconnect the engine control

module connector, turn on
the ignition switch and check Check whether the
Locate the
the voltage between terminal voltage is out of
causes from Repair the fault
44, 66, 68, 70 and the ground reasonable range or
other fault circuit
Voltage: 9~13V the ground circuit has
phenomenon
Check whether terminal fault
conducted
6. The start is normal while the idling is unsteady during engine warming up

Check the air filter for

The intake system Repair the intake
clogging and intake Go to Step 1
has fault system
passage for air leak

Check each cylinder spark

plug and confirm the The spark plug has Adjust or replace
Go to Step 2
model and gap meet the fault the spark plug
specification
2 Check the throttle Normal Faulty Instruction
Check the throttle body for To o m u c h t h r o t t l e Clean relevant

Go to Step 3
carbon deposit carbon deposit parts
Check the coolant

temperature sensor
Unplug the coolant

temperature sensor joint,
T h e c o o l a n t Repair the circuit
start the engine and check
Go to Step 4 temperature sensor or replace the
whether the engine idling
has fault sensor
is unsteady during the
warming up
Remove the injector and Repair or replace

check for leak or clogging the injector


Check the pressure of
each cylinder and observe Eliminate engine
Go to Step 7 The cylinder has fault
whether the cylinder mechanical fault
pressure difference is large

module

Check whether the
voltage is out of
reasonable range or
fault
conducted
12-47
7. The rotary speed is normal while the engine start is difficult at any time


has fault system
12
1
gauge

gauge, start the engine The detected
Check the fuel
and check the fuel Go to Step 2 pressure is out of the
supply system
pressure reasonable range
Pressure: 400kPa
Unplug the ignition coil of

one cylinder, connect the
spark plug, bring the spark
plug to contact the engine The ignition system Repair the ignition
Go to Step 3
block and start the engine has fault system
to check whether there is
blue-white high pressure
fire

Go to Step 4
specification
Check the coolant

temperature sensor
Unplug the coolant

The coolant Repair the circuit
temperature sensor joint,
Go to Step 5 temperature sensor or replace the
start the engine and check
has fault sensor
whether the engine starts
5 Normal Faulty Instruction Instruction
Depress the throttle The throttle and Clean the throttle

slightly and observe Go to Step 6 idling air passage and idling air
whether the start is easy ambient are dirty passage
Remove the injector and Replace the

check for leak or clogging injector
Check the fuel condition The fuel does

Replace the
and check whether fault is Go to Step 8 not meet the
standard fuel
caused by filling fuel specification

Check the cylinder
pressure

The cylinder
Go to Step 9 p r e s s u r e i s
insufficient
pressure is insufficient
Check the ignition

9 sequence and ignition Normal Faulty Instruction
timing
Check whether the engine The ignition

ignition sequence and sequence or ignition Adjust the ignition
Go to Step 10
ignition timing meet the timing does not meet timing
specification the specification
module

turn on the ignition
Check whether the
switch and check the Locate the
voltage is out of
voltage between terminal causes from Repair the fault
reasonable range
44, 66, 68, 70 and the other fault circuit
or the ground circuit
groundVoltage: 9~13V phenomenon
has fault
conducted
8. The start is normal while idling is unsteady at any time


has fault system

throttle
Check the electronic The electronic Clean or replace the

Go to Step 2
throttle body for seizing throttle has fault electronic throttle
Check each cylinder

spark plug and confirm The spark plug has Adjust or replace
Go to Step 3
the model and gap meet fault the spark plug
the specification

12-49
Clear the throttle

Check the throttle body Too much throttle
Go to Step 4 body carbon
for carbon deposit carbon deposit
deposit
Remove the injector and 12

The injector has
check it for leak, clogging Go to Step 5 Replace the injector
fault
or flow out-of-tolerance

Replace the
and check whether fault Go to Step 6 not meet the
standard fuel
is caused by filling fuel specification
Check the cylinder

pressure
Check the pressure

of each cylinder and
The cylinder has Eliminate engine
observe whether the Go to Step 7
fault mechanical fault
cylinder pressure
difference is large
Check the ignition

timing
The ignition
Check whether the
sequence or
engine ignition sequence Adjust the ignition
Go to Step 8 ignition timing
and ignition timing meet timing
does not meet the
the specification
specification
module
Disconnect the
engine control module
connector, turn on the
ignition switch and check Check whether the
Locate the
the voltage between voltage is out of
terminal 44, 66, 68, 70 reasonable range
other fault circuit
and the ground. or the ground
phenomenon
Voltage: 9~13V circuit has fault
76, 74 and the ground
are conducted
9. The start is normal while idling is unsteady after engine warming up


clogging and intake passage Go to Step 1
has fault system
for air leak

Go to Step 2
specification
Clear the throttle

Check the throttle body for To o m u c h t h r o t t l e
Go to Step 3 body carbon
carbon deposit carbon deposit
deposit
Check the coolant

temperature sensor
Unplug the coolant

temperature sensor joint, Repair the circuit
start the engine and check Coolant temperature or replace the
Go to Step 4
whether the engine idling is sensor fault temperature
unsteady during the warming sensor
up
Remove the injector and

Replace the
check it for leak, clogging or Go to Step 5 The injector has fault
injector
flow out-of-tolerance


Go to Step 7 The cylinder has fault
pressure is insufficient

module
12-51

and check the voltage Check whether the
Locate the
between terminal 44, 66, 68, voltage is out of
reasonable range or
70 and the groundVoltage: other fault circuit
9~13V phenomenon
fault 12
conducted
10. The start is normal while engine idling is unsteady or stalls under partial load


has fault system
1 Check the engine power Normal Faulty Instruction

tester, observe the ignition
advance angle, fuel
The detected value is
injection pulse width and air
Go to Step 2 out of the reasonable Go to Step 3
input variance and check
range
whether the engine power
increases when A/C is
switched on
2 Check the ECM circuit Normal Faulty Instruction
Disconnect ECM harness

Repair the
connector E1 and check The detected level
harness between
whether the terminal 14 of Go to Step 3 signal is out of the
E C M a n d
E1 is high level signal when reasonable range
headlamp
the headlamp is turned on
3 Check A/C system Normal Faulty Instruction
Check whether A/C system

pressure, compressor The A/C system has Repair the A/C
Go to Step 4
electromagnetic clutch and fault system
A/C compressor are normal

Replace the
check it for leak, clogging or Go to Step 5 The injector has fault
injector
flow out-of-tolerance

module

Check whether the
voltage is out of
reasonable range or
68, 70 and the ground]. other fault circuit
fault
conducted
11. The start is normal while idle speed is too high

Check the electronic The electronic throttle Adjust the

Go to Step 1
throttle for seizing has fault electronic throttle
1 Check the intake system Normal Faulty Instruction
Check the intake system

and connected vacuum Go to Step 2
has fault system
pipe for air leak
2 Check the throttle body Normal Faulty Instruction
Check the throttle body for The throttle body has Clean the related
Go to Step 3
carbon deposit fault parts
Check the coolant

temperature sensor
Unplug the coolant

temperature sensor joint, T h e c o o l a n t Repair the circuit
start the engine and check Go to Step 4 temperature sensor or replace the
whether the engine idle has fault sensor
speed is too high
Check the engine ignition

timing
Check whether the engine The engine ignition

Adjust the ignition
ignition timing meets the Go to Step 5 timing does not meet
timing

module
12-53

Check whether the
voltage is out of
reasonable range or
Voltage: 9~13V phenomenon 12
fault
conducted
12. The engine speed cannot increase or stalls upon acceleration

Check whether the air The intake system Repair the intake
Go to Step 1
filter is clogged has fault system

gauge

gauge, start the engine The detected
Check the fuel
and check the fuel Go to Step 2 pressure is out of the
supply
pressure reasonable range
Pressure: 400kPa
Check each cylinder

Go to Step 3
the specification
Check the throttle body To o m u c h t h r o t t l e Clean relevant

Go to Step 4
for carbon deposit carbon deposit parts
Check the intake pressure

sensor
Check the whether the Repair the circuit

The intake pressure
intake pressure sensor Go to Step 5 or replace the
sensor has fault
and circuit are normal sensor



Check the ignition
timing
Check whether the engine The ignition

ignition sequence and sequence or ignition Adjust the ignition
Go to Step 8
ignition timing meet the timing does not meet timing
8 Check the exhaust pipe Normal Faulty Instruction
Check whether the Exhaust pipe has Repair or replace

Go to Step 9
exhaust is clear fault the exhaust pipe

module

Check whether the
voltage is out of
reasonable range or
fault
conducted
13. Slow response upon acceleration

has fault system

gauge

The detected
gauge, start the engine
pressure is out of Check the fuel
and check the fuel Go to Step 2
the reasonable supply system
pressure
range
Pressure: 400kPa
Check each cylinder

Go to Step 3
the specification

12-55

Check the throttle body Too much throttle
Go to Step 4 Clean relevant parts
for carbon deposit carbon deposit

sensor
Check the whether the

intake pressure sensor Go to Step 5
The intake pressure Repair the circuit or 12
sensor has fault replace the sensor
and circuit are normal
Remove the injector and The injector has

Go to Step 6 Replace the injector
check for leak or clogging fault

Replace the
and check whether fault is Go to Step 7 not meet the
standard fuel
caused by filling fuel specification
Check the ignition

timing
The ignition
Check whether the engine
sequence or
ignition sequence and Adjust the ignition
Go to Step 8 ignition timing
ignition timing meet the timing
does not meet the
specification
specification
8 Check the exhaust pipe Normal Faulty Instruction
Check whether the The exhaust pipe Repair or replace

Go to Step 9
exhaust is clear has fault the exhaust pipe

module

Check whether the
voltage is out of
reasonable range
or the ground circuit
has fault
conducted
14. Powerless acceleration and poor performance


Check whether there are
faults of clutch slip, low tire Repair and solve
There is mechanical
pressure, stagnant braking, Go to Step 1 the mechanical
fault
incorrect tire size, incorrect fault
four-wheel alignment

clogging and intake passage Go to Step 2
has fault system
for air leak

gauge

The detected
Go to Step 3 pressure is out of the
reasonable range
Pressure: 400kPa
Check the high pressure fire
intensity
Unplug the wheel cylinder

wire of one cylinder, connect
the spark plug, maintain
the spark plug electrode
The intensity is out of Repair the ignition
5mm from the engine block Go to Step 4
reasonable range system
approximately, start the
engine and check whether
the high pressure fire
intensity is normal

Go to Step 5
specification
Check the throttle body for To o m u c h t h r o t t l e Clean relevant

Go to Step 6
carbon deposit carbon deposit parts

sensor
Check the whether the Repair the circuit

The intake pressure
intake pressure sensor and Go to Step 7 or replace the
sensor has fault
circuit are normal sensor


12-57

Check the ignition sequence

and ignition timing
12
Check whether the engine The ignition sequence
ignition sequence and or ignition timing Adjust the ignition
Go to Step 10
ignition timing meet the does not meet the timing
specification specification

module

Check whether the
voltage is out of
between terminal 44, 66, 68, causes from Repair the fault
reasonable range or
70 and the ground other fault circuit
fault
conducted
DTC list
DTC Code meaning Questionable part
• VVT actuator assembly
• ECM
P0011 Air intake VCP phase response lag • VVT solenoid valve
• Solenoid valve filter element
• Valve timing
• Intake VVT valve

P0012 Intake VCP camshaft phase error high •• Intake VVT valve harness
• ECM
• Valve timing
• VVT solenoid valve
P0016 Intake VCP cam gear learning deviation off-limit • VVT actuator assembly
• ECM
• Solenoid valve filter element
• Valve timing
P0026 Intake VCP hydraulic control valve clamped • Solenoid valve filter element
• VVT actuator assembly
• ECM

• Front oxygen sensor
P0031 Front oxygen sensor heater short to low voltage • Front oxygen sensor harness
• ECM

P0032 Front oxygen sensor heater short to high voltage • Front oxygen sensor harness
• ECM
• Rear oxygen sensor

P0037 Rear oxygen sensor heater short to low voltage • Rear oxygen sensor harness
• ECM

P0038 Rear oxygen sensor heater short to high voltage • Rear oxygen sensor harness
• ECM

Intake VCP hydraulic control valve coil voltage
P0076 • ECM
low or open circuit
• VVT solenoid valve harness

Intake VCP hydraulic control valve coil voltage
P0077 • ECM
high
• VVT solenoid valve harness
• Intake pressure/temperature sensor

harness
P0105 No intake air pressure sensor signal
• ECM
•Intake pressure temperature sensor
• Intake pressure temperature sensor

harness
P0106 Intake pressure/throttle position rationality fault
• ECM

The intake air temperature sensor circuit has too harness
P0107
low voltage or is broken • ECM

The voltage of the intake air temperature sensor harness
P0108
circuit is high • ECM

The voltage of the intake air temperature sensor harness
P0112
circuit is low • ECM
12-59

The intake air temperature sensor circuit has too harness
P0113
high voltage or is broken • ECM
• Coolant temperature sensor harness

12
P0117 Coolant temperature sensor circuit voltage low • ECM
• Coolant temperature sensor harness

Coolant temperature sensor circuit voltage high
P0118 • ECM
or open circuit
• Throttle position sensor

Electronic throttle position sensor circuit lower
P0122 • Throttle position sensor harness
voltage
• ECM

Electronic throttle position sensor circuit high
voltage
• ECM

P0131 Front oxygen sensor signal short to low voltage • Front oxygen sensor harness
•ECM
P0132 Front oxygen sensor short to high voltage • Front oxygen sensor harness
•ECM

P0133 Too slow front oxygen sensor response • Front oxygen sensor harness
•ECM

P0134 Front oxygen sensor circuit short • Front oxygen sensor harness
•ECM

P0137 Rear oxygen sensor heater short to low voltage • Front oxygen sensor harness
•ECM

Rear oxygen sensor short-circuited to low
P0138 • Front oxygen sensor harness
voltage
•ECM

P0140 Rear oxygen sensor circuit broken • Front oxygen sensor harness
•ECM

•Injector
• Canister solenoid valve
P0171 Too dilute fuel in non-idle speed condition •Intake pressure temperature sensor
•Injector
P0172 Too concentrated fuel in non-idle speed condition •Intake pressure temperature sensor

Electronic throttle position sensor 2 signal circuit
voltage low
• ECM

Electronic throttle position sensor 2 signal circuit
voltage high
• ECM
•Fuel pump relay

P0230 Fuel pump relay fault • Pump relay harness
• ECM
• Cylinder 1 injector
P0261 1# Cylinder nozzle circuit lower voltage fault • Injector harness
• ECM
P0262 1# Cylinder nozzle circuit high voltage fault • Injector harness
• ECM
• ECM
• ECM
• ECM
• ECM
• ECM
12-61

• ECM
• Engine harness
•Injector
12
• Ignition system
•Fuel pressure
A single cylinder or multiple cylinders misfire
• Compression pressure
(catalyst damage type misfire) a single cylinder
P0300 • Valve mechanism timing
or multiple cylinders misfire (emission damage
• Valve lash
type misfire)
• Cylinder head
• Ventilation valve line
• Intake system
• Vacuum hose
• ECM
• Knock sensor
P0324 Faulty detonation control system • Knock sensor harness
• ECM
• Knock sensor
P0325 Knock control sensor fault • Knock sensor harness
• ECM

• Sensor signal disc
P0335 Crankshaft position sensor circuit no signal
• Crankshaft position sensor harness
• ECM

Crankshaft position sensor circuit signal • Sensor signal disc
P0336
interference • Crankshaft position sensor harness
•ECM
• ECM
Intake VCP camshaft position sensor state • Camshaft position sensor
P0340
diagnosis • Camshaft position sensor harness
• Camshaft signal wheel
• ECM
• Camshaft position sensor
P0341 Intake VCP target wheel diagnosis fault
• Camshaft position sensor harness
• Camshaft signal wheel

• ECM
P0351 Ignition coil 1# output fault • Ignition coils
• Ignition coil harness
• ECM
P0352 Ignition coil 2lb output fault • Ignition coils
• ECM
• ECM
• ECM
• Three-way catalytic converter
P0420 Low catalytic converter efficiency • Front oxygen sensor
• Exhaust gas leaks
• ECM
Canister solenoid valve output short to low
P0458 • Canister solenoid valve
voltage or short circuit
• Canister solenoid valve harness
• ECM
Canister solenoid valve output short to high
P0459 • Canister solenoid valve
voltage
• Canister solenoid valve harness
• ECM
• Low speed fan relay
P0480 Low speed fan fault
• Low speed fan relay harness
• Cooling fan
• ECM
• High speed fan relay
P0481 High speed fan fault
•High-speed fan relay harness
• Cooling fan
• Speed sensor
P0502 Vehicle speed sensor no signal • Speed sensor harness
• ECM
• Brake switch
P0504 Braking switch relevance fault • Brake switch harness
• ECM
12-63

• ETC throttle valve block assembly
• Intake system
P0506 Idle speed low
• ECM
• Exhaust system
• ETC throttle valve block assembly

12
• Intake system
P0507 Idle speed high
• ECM
• Exhaust system
• Power steering switch

Power steering switch line voltage range/
P0551 • Power steering switch harness
performance fault
• ECM
• ECM
P0562 System voltage low • Battery
• Engine harness
• ECM
P0563 System voltage high • Battery
• Engine harness
P0602 ECM processing fault •ECM
P0604 RAM error •ECM
P0606 ECM processing fault •ECM
P060A ECM program error •ECM
• Ignition key
• Ignition key excitation coil
P0633 Non-learning fault of immobiliser
• Chip anti-theft module
• ECM
•Injector
Rather rich during deceleration/fuel cutoff for the
P1167 •Intake pressure temperature sensor
front oxygen sensor
Front oxygen sensor
•Injector
Rather lean during acceleration/enrichment for
P1171 •Intake pressure temperature sensor
the rear oxygen sensor
Front oxygen sensor

• Replace or adjust ECM or crankshaft
gear ring.
After matching the relative position of
gear ring and 58X, carry out the gear
message learning again
P1336 58-tooth gear error not learned
• The crankshaft position sensor
connector is in poor contact and the
sensor harness is open or short-
circuited.
• ECM
Electronic-controlled throttle steady state

P1516 • ECM
diagnosis error
Electronic-controlled throttle drive second-order

P2101 • ECM
diagnostic error
• Electronic-controlled throttle body:

dirty
P2119 Throttle restores default position fault
• Electronic-controlled throttle body:
mechanical failure
• Throttle pedal position sensor

Electronic throttle pedal position sensor 1# circuit harness
P2122
voltage low • ECM

P2123
voltage high • ECM

P2127
voltage low • ECM

P2128
voltage high • ECM
• Accelerator pedal assembly

Electronic throttle pedal position sensor 1# and • Electronic accelerator pedal position
P2135
2# relevance fault sensor harness
• ECM
12-65

• Accelerator pedal assembly
Electronic throttle pedal position sensor 1# and • Electronic accelerator pedal position
P2138
2# relevance fault sensor harness
• ECM
•Injector
12
P2187 Idling working condition fuel system overlean • Canister solenoid valve
•Injector
P2188 Idling working condition fuel system overrich • Canister solenoid valve
DTC diagnosis
1. Intake VVT fault

P0011- Intake VCP phase response hysteresis
P0012- Intake VCP camshaft phase error high
P0016- Intake VCP cam gear learning deviation off-limit
P0026- Intake VCP hydraulic control valve clamped
DTC description:
1. The engine control module monitors the relativity between the crankshaft and
camshaft position through the pulse signal of the crankshaft position sensor and
camshaft position sensor (intake side). The crankshaft variable-reluctance type
rotor has 60 teeth, two of which are absent and used as the reference gap. The teeth
interval is 6° except the reference gap which is 12°.
2. The camshaft signal panel has 4 teeth, 2 narrow and 2 wide. The 4 trailing edge of
each tooth has an interval of 90°.
3. The intake camshaft position (CMP) actuator is connected to the intake camshaft and
operates in a hydraulic way. The hydraulic pressure is supplied by the oil pump to
change the angle of intake camshaft in relation to the crankshaft position (CKP).
4. The intake VVT solenoid valve is powered by the main relay and ECM controls
ground through the pulse-width modulation signal. In this way, the engine oil flow to
the camshaft position actuator is controlled.
5. The engine oil pressure makes one of the safety slide valve inside the camshaft
position actuator mechanism fixed to the camshaft front act. When the safety slide
valve acts, the engine oil is introduced to the camshaft position actuator to make the
camshaft rotate.
6. The intake camshaft position actuator can change the cam angle up to 50°.
7. The engine control module will continuously monitor the camshaft timing position and
check the relative position of camshaft and crankshaft. If the relative position out-
of-position exceeds 1 gear teeth, this DTC will occur. The fault causes include the
camshaft position sensor fault or circuit fault, crankshaft position sensor fault or circuit
fault, engine oil contamination and timing belt.
DTC set criteria:
1. With the engine running, if the system has no VVT component fault, crankshaft
position sensor fault, system voltage fault and current VVT opening change rate is
less than 15°/s, when ECM monitors the VVT phase error exceeds 15° or the VVT
actual opening exceeds 5° and <50°, DTC P0012 will be set.
2. If the VVT system finishes the gear deviation learning, the system has no VVT
component fault, crankshaft position sensor fault, system voltage fault and the engine
is running, when ECM monitors the VVT cam gear learning deviation is less than 0.2
or more than 0.35, DTC P0016 will be set.
3. With the engine running, if the system has no VVT component fault, crankshaft
position sensor fault, system voltage fault and OCV valve cleaning function is not
active, when ECM monitors the VVT actual phase >50°while the phase error <-20°
or the VVT actual phase <10°and phase error >20°, DTC P0026 will be set.
4. If DTC P0012 or P0016 occurs, the intake VCP will work in default mode and the
engine oil control valve will not act any more.

The fault is
•Connect the vehicle ECM connectors,
diagnostic tester, read and camshaft position
There is DTC; go
clear DTC It is incidental fault sensor connectors
to Step 2
•Read DTC again to check for looseness and
whether DTC can be read damage; check the
harness terminals
for corrosion
1 Check the engine oil Normal Faulty Instruction
•Check whether the engine

oil viscosity and cleaning
degree are normal Replace the
•Check whether the engine The engine oil is engine oil and oil
oil level is within the unqualified or the filter element and
Go to Step 2
working range lubrication system clean the engine
•Check whether the engine has fault lubrication system if
oil is changed in time or necessary
contains additive or the oil
viscosity is incorrect
2 Check the timing belt Go to Step 4 Faulty Instruction
Check the timing belt for

Timing belt Replace the new
looseness, gear skip, gear Go to Step 3
assembly fault timing belt
off or damage
3. Check the valve timing Normal Right fault Instruction

12-67
Check the whether the Timing belt Install the valve

Go to Step 4
valve timing is correct assembly fault timing belt again
4 Check the intake VVT valve Normal Faulty Instruction
Check whether the intake

VVT valve installation is 12
correct; remove the valve
Go to Step 5
and check the filter screen
for damage or foreign
matter
Check the camshaft

position sensor

camshaft position sensor Replace the O-ring
O-ring damage,
O-ring is normal and Go to Step 6 and clean the
deformation
the sensor is installed in sensor
position
Check the camshaft position

sensor signal wheel

Replace the intake
side camshaft position Camshaft position
Go to Step 7 side camshaft
sensor signal wheel is sensor signal fault
assembly
normal
Inspection by replacement
(camshaft position sensor)
•Replace the intake

camshaft position sensor
and carry out road test Intake camshaft Replace the intake
•Perform the diagnosis Go to Step 8 position sensor camshaft position
again to read DTC and fault sensor
check whether DTC and
symptom exist

position sensor
Check whether the

crankshaft position sensor Replace the O-ring
O-ring damage,
O-ring is normal and Go to Step 9 and clean the
deformation
the sensor is installed in sensor
position

wheel
Check whether the

crankshaft flywheel Replace the
Crankshaft flywheel
gear ring is deformed or Go to Step 10 crankshaft flywheel
gear ring fault
damaged and the gear ring gear ring
grease is too thick
•Replace the engine control

module and carry out road
test.
Locate the causes
•Perform the diagnosis Replace ECM The fault still exists
from other symptom
again to read DTC and
symptom exist
2. Intake VVT solenoid valve circuit fault

P0076- Intake VCP hydraulic control valve coil voltage low or open circuit
P0077- Intake VCP hydraulic control valve coil voltage high
DTC description:
1. The intake VVT solenoid valve is powered by the main relay and ECM controls
ground through the pulse-width modulation signal. In this way, the engine oil flow to
the camshaft position actuator is controlled.
2. The intake VVT valve is earthed inside by the terminal 43 of ECM harness connector
E01B controlling the solenoid valve.
3. ECM inside has one feedback circuit. The engine ECM determines whether there is
open circuit, short to ground or to power supply in the control circuit by monitoring the
feedback signal.
4. If the engine ECM detects the control circuit voltage is in the preset range when the
control circuit is disconnected by command, this DTC will occur.
DTC set criteria:
1. With the engine running time >0.5s, system voltage > 11V but < 16V, if the ECM
monitors intake VCP hydraulic control valve coil voltage low or open circuit, DTC
P0076 will be set.
monitors intake VCP hydraulic control valve coil and 12V power have short circuit,
DTC P0077 will be set.
3. When DTC P0076 and P0077 occur, the intake VCP will work in default mode and
the engine oil control valve will not act any more.

The fault is
There is DTC; go
to Step 2
harness terminals for
corrosion
12-69

Check the intake VVT
solenoid valve
•With the ignition switch

in OFF position, unplug
the VVT solenoid valve
connector
•Measure the resistance
VVT solenoid 12
valve resistance
between both terminals of
unreasonable, Replace the VVT
VVT solenoid valve. Go to Step 2
VVT filter screen solenoid valve
Resistance: 6.9Ω~7.9Ω
damaged or
(20°C)
clogged
•Remove the intake VVT
solenoid valve and check
whether intake VVT is
normal
Check the VVT solenoid

2 Go to Step 4 Instruction
valve power circuit

Replace the new
timing belt
off or damage
Replace the VVT

3. Check the valve timing Normal Instruction
solenoid valve
• Disconnect intake VVT

valve connector E04
• Measure whether there
The circuit has
is short circuit or open Repair the fault
Go to Step 4 short circuit or
circuit between the engine harness
open circuit
compartment central control
box fuse FS03 and terminal
1 of E04

test.
Locate the causes
from other symptom
symptom exist
3. Front oxygen sensor heating circuit fault

P0031- Front oxygen sensor heater short to low voltage
P0032- Front oxygen sensor heater short to high voltage
P0134- Front oxygen sensor open circuit
DTC description:
1. Front oxygen sensor is designed to correct the fuel control and compare the ambient
air oxygen content and exhaust flow oxygen content. Each sensor inside is provided
with the heating element to heat the sensor.
circuit to make the system enter the closed loop mode earlier and sensor calculate air
fuel ratio in advance. The engine control module commands the heating element to
switch on or off and maintain the sensor in the specified operating temperature range.
3. The engine control module determines the temperature by measuring the heater
current. If the oxygen sensor cannot reach the desired temperature within the set
time or the engine control module cannot maintain the set temperature, this DTC will
occur.
DTC set criteria:
monitors the front oxygen sensor heating line is short the ground, DTC P0031 will be
set.
monitors the front oxygen sensor heating line is short the 12 V power , DTC P0032
will be set.
3. When there are no P0106, MAP sensor, CTS sensor, TPS sensor, P0171, P0172,
injector, misfire, crankshaft position sensor, ignition system, idling control system,
canister cleaning circuit related DTC, the coolant temperature is above 70°C, the
system voltage is above 11V and the engine running time is more than 60s, if the
ECM monitors the oxygen sensor signal voltage is less than 1.3V but less than 3.8V,
the DTC P0134 will be set.
4. If DTC P0031 or P0032 occurs, the system will force the fuel control work in the
open-loop mode, forbid the fuel correcting the pulse width and not update the self-
learning value any more. If DTC P0134 occurs, the system will stop the close-loop
control over the fuel.

T h e f a u l t i s
There is DTC; go
to Step 1
corrosion
Check the front oxygen

sensor power circuit
Disconnect the front oxygen

sensor connector E29, with
the power supply at ON The voltage is out
position, check the voltage Go to Step 3 of the reasonable Go to Step 2
between terminal 1 of E29 range
and the ground
Voltage: 9V~13V
12-71

sensor circuit

at OFF position, unplug
the front oxygen sensor
connector E29 12
• Disconnect the ECM
connector E01 and front
oxygen sensor connector
E29
• Measure whether there is
short circuit or open circuit
The circuit has
between the terminal 24 Repair the fault
of E01 and terminal 2 of harness
open circuit
E29, the terminal 47 of
E01 and terminal 3 of E29,
the terminal 73 of E01 and
terminal 4 of E29,
is short circuit or open
circuit between the terminal
1 of E29 and the engine
box fuse FS03
3. Check the valve timing Normal Faulty Instruction
• When the power supply

the front oxygen sensor
connector
• At the room temperature,
measure whether the Front oxygen Replace the front
Go to Step 4
resistance between the rear sensor fault oxygen sensor
(component side) E27 pin 3
and E27 pin 4 is normal, pin
1 and pin 2
Voltage: 9.6Ω±1.5Ω

test.
The fault still Locate the causes
•Perform the diagnosis Replace ECM
exists from other symptom
symptom exist
4. Rear oxygen sensor heating circuit fault

P0037- Rear oxygen sensor heater short to low voltage
P0038- Rear oxygen sensor heater short to high voltage
P0140- Rear oxygen sensor open circuit
DTC description:
1. The downstream oxygen sensor is the rear oxygen sensor which is designed to
monitor the three-way catalytic converter operating state. The sensor compares the
ambient air oxygen content with the exhaust flow oxygen content. Every heating type
oxygen sensor is provided with the heating element to heat the sensor inside.
2. The engine control module controls the heating control circuit of the heating type
oxygen sensor. This makes the system enter the closed-loop mode earlier and control
module to calculate the air fuel ratio earlier.
3. The engine control module commands the heating element to switch on or off and
maintain the sensor in the specified operating temperature range.The engine control
module determines the temperature by measuring the heater current.
DTC set criteria:
monitors the front oxygen sensor heating line is short the ground, DTC P0037 will be
set.
monitors the front oxygen sensor heating line is short the 12 V power , DTC P0038
will be set.
3. When there are no P0106, MAP sensor, CTS sensor, TPS sensor, P0171, injector,
misfire, crankshaft position sensor, ignition system, idling control system, canister
cleaning circuit, rear oxygen sensor heater related DTC, the coolant temperature is
above 70°C, the system voltage is above 11V and the engine running time is more
than 600s, if the ECM monitors the oxygen sensor signal voltage is more than 1.3V
but less than 3.8V, the DTC P0140 will be set.
4. If DTC P0037 or occurs, the system will force the fuel control work in the open-loop
mode, forbid the fuel correcting the pulse width and not update the self-learning
value any more. If DTC P0140 occurs, the system will disable the rear oxygen sensor
signal.

T h e f a u l t i s
There is DTC; go
to Step 1
corrosion
Check the rear oxygen

sensor power circuit
12-73

Disconnect the rear oxygen
sensor connector I46,
when the power supply The voltage is out
at ON position, check the Go to Step 3 of the reasonable Go to Step 2
voltage between terminal 4 range
of I46 and the ground
Voltage: 9V~13V 12
sensor circuit

connector
• Disconnect the engine
control unit connector E01
and front oxygen sensor
connector I46
The circuit has
short circuit or open circuit Repair the fault
between the terminal 23 of harness
open circuit
E01 and terminal 1 of I46,
the terminal 48 of E01 and
terminal 2 of I46
between the terminal 1
of I46 and the engine
compartment central
control box fuse FS03

3. Normal Faulty Instruction
sensor

connector
• At the room temperature,
The circuit has
measure whether the Repair the fault
resistance between harness
open circuit
connector (component
side) I46 pin 3 and I46 pin
4 is normal, pin 3 and pin 2
Voltage: 9.6Ω±1.5Ω

control module and carry
out road test.
Locate the causes
from other symptom
symptom exist
5. Intake pressure sensor circuit fault

P0105- Intake pressure sensor signal clamping
P0106- Intake pressure/throttle position rationality fault
P0107- The voltage of the intake air temperature sensor circuit is low.
P0108- The voltage of the intake air temperature sensor circuit is high.
DTC description:
1. The intake pressure sensor is designed to measure the pressure inside the intake
manifold.
2. The engine control unit takes the difference of intake manifold pressure and
atmosphere pressure (in linear relationship with the engine load) as the reference
to determine the basic injection volume of the injector so as to help the engine to
achieve the optimum air fuel ratio under different load.
3. If the engine control module detects the intake pressure sensor signal voltage
exceeds the normal range of calibration, this DTC will occur.
DTC set criteria:
1. After the engine starting, if the intake manifold intake pressure does not change
within a certain time, the DTC P0105 will be set.
2. If the system has no DTC related to the manifold absolute pressure senor, throttle
position sensor and coolant temperature sensor while the elevation intake pressure
value exceeds the limit set by the control system according to the engine speed and
throttle opening, the DTC P0106 will be set.
3. If the system has no throttle position sensor fault, the battery voltage is above 11.5V,
the engine speed is not more than 1000rpm and the throttle opening exceeds 0% or
the engine speed is above 1000rpm and the throttle opening exceeds 10%, when
ECM monitors the MAP sensor signal value is less than 6.5%, the DTC P0107 will be
set.
4. If the system has no throttle position sensor fault, the engine is running, the engine
speed is not more than 2400rpm and the throttle opening is less than 15% or the
engine speed is above 2400rpm and the throttle opening exceeds 35%, when ECM
monitors the MAP sensor signal value exceeds 94.5%, the DTC P0108 will be set.
5. If DTC P0105, P0106, P0107 or P0108 occurs, the system will forbid the fuel
correcting pulse width, not update the self-learning value, prohibit adjusting the target
idle speed, not update the atmosphere pressure and the manifold absolute pressure
will employ the default.

0 Steps Check contents Inspection result 指导
The fault is
There is DTC; go
to Step 1
harness terminals
for corrosion
12-75

sensor
•Remove the intake pressure The intake

temperature sensor p r e s s u r e Clear the dirt on
•Check the intake pressure Go to Step 2 temperature the intake pressure
temperature sensor surface sensor surface temperature sensor
for oil stain has dirt
12
•Connect the diagnostic

t e s t e r, r e a d t h e i n t a k e
pressure sensor data flow
and check whether the data
flow is normal
•Intake pressure/output Intake pressure Replace the
voltage Go to Step 3 temperature intake pressure
Reference 1: 20KPa/0.8V sensor fault temperature sensor
Reference 2:40KPa/1.61V

sensor circuit
• Disconnect the intake

and engine control unit
connector E01
The circuit has
between the terminal 4 harness
open circuit
of E06 and terminal 54 of
E01, terminal 2 of E06 and
terminal 71 of E01, terminal
1 of E06 and terminal 76 of
terminal 3 of E06.

test.
Locate the causes
•Perform the diagnosis again Replace ECM The fault still exists
from other symptom
to read DTC and check
whether DTC and symptom
exist
6. Intake temperature sensor fault

P0112- The voltage of the intake air temperature sensor is low.
P0113- The intake air temperature sensor circuit has too high voltage or is
broken.
DTC description:
1. The intake temperature sensor (IATS) is designed to detect the intake temperature,
convert the intake temperature signal into electric signal and feed this signal to the
engine control module (ECM) to allow the ECM to correct the fuel injection time and
ignition time and maintain the engine in the optimum working state.
2. The intake temperature sensor employs the negative temperature coefficient (NTC)
3. If the engine control module detects the intake temperature sensor signal is below the
minimum value of self-inspection or above the maximum value, this DTC will occur.
DTC set criteria:
1. If the system has no vehicle speed signal fault, the vehicle speed exceeds 50km/
h and the engine running time exceeds 120s, when ECM monitors IAT intake
temperature sensor signal value is less than 2.0%, the DTC P0112 will be set.
2. If the system has no vehicle speed signal fault, coolant temperature sensor fault,
the vehicle speed is below 25km/h, the coolant temperature exceeds 50°C and the
engine running time exceed 120s, when ECM monitors IAT sensor signal value
exceeds 98%, the DTC P0113 will be set.
3. When DTC P0112 or P0113 occurs, the system will adopt the default intake
temperature set by the system.

The fault is
incidental. Check
diagnostic tester, read and
the rear oxygen
clear DTC
There is DTC; go sensor connector
•Restart the engine and It is incidental fault
to Step 1 for looseness or
carry out the road test to run
damage; check the
the engine under various
harness terminals
conditions. Try to read DTC
for corrosion
Check the three-way

catalyst

Replace the three-
catalytic converter is Three-way catalyst
Go to Step 2 way catalytic
replaced within the specified fault
converter
time limit

sensor
12-77

•With the ignition switch in
OFF position, disconnect
Rear oxygen Replace the rear
terminal.
sensor severe o x y g e n s e n s o r,
•Remove the rear oxygen Go to Step 3
carbon deposit, change the fuel and
sensor and check the
whitening clean the fuel tank
sensor for carbon deposit, 12
whitening, browning or
darkening

sensor circuit
• Disconnect the rear

I46 and engine control unit
connector E01
The circuit has
• Measure whether there is Repair the fault
short circuit or open circuit harness
open circuit
between the terminal 2 of
I46 and terminal 8 of E01,
terminal 13 of I46 and
terminal 23 of E01.
(oxygen sensor)
• Replace the rear oxygen

sensor and carry out road
test.
Replace the rear
•Perform the diagnosis The fault still exists Go to Step 5
oxygen sensor
symptom exist
(ECM)

test.
Locate the causes
from other symptom
symptom exist
7. Coolant temperature sensor fault

P0117- Coolant temperature sensor circuit voltage low
P0118- Coolant temperature sensor circuit voltage high or open circuit
DTC description:
1. The engine coolant temperature sensor (ECT) is designed to convert the coolant
temperature signal into electric signal and feed this signal to the ECM to allow the
ECM to correct the fuel injection time and ignition time and maintain the engine in the
optimum working state.
2. The coolant temperature sensor employs the negative temperature coefficient (NTC)
3. If the engine control module detects the engine coolant temperature sensor signal is
below or above the self-inspection value, this DTC will occur. The fault causes include
the sensor signal short to the ground, sensor fault and engine control module fault
etc.
DTC set criteria:
1. If the engine running time exceeds 120s, when ECM monitors CTS sensor signal
value is less than 2.0%, the DTC P0117 will be set.
2. If the engine running time exceeds 120s, when ECM monitors CTS sensor signal
value is more than 97.5%, the DTC P0118 will be set.
3. If DTC P0112 or P0113 occurs, the system will estimate the coolant temperature
sensor according to the default formula basing on the engine running time and intake
temperature. The maximum value should not exceed 90.75°C. After the DTC is set,
the high speed fan will run after 0.5s delay

The fault is incidental.

Check the coolant
t e m p e r a t u r e
clear DTC It is incidental fault
•Read DTC again to check
damage; check the
whether DTC can be read
corrosion
Check the coolant

temperature sensor
•Remove the engine coolant

temperature sensor
• Heat the engine coolant
temperature sensor to
test and check whether
the resistance change of
C o o l a n t
sensor E21 pin 1 and pin Replace the coolant
Go to Step 2 temperature
3 decreases along with the temperature sensor
sensor fault
temperature increase
•For the temperature and
corresponding resistance,
refer to in-vehicle inspection
- inspection of coolant
temperature sensor
Check the coolant
temperature sensor circuit
12-79

• Disconnect the water
temperature sensor
connector E21 and engine
The circuit has
open circuit
between the terminal 3 12
terminal 49 of E01.

test.
symptom exist
8. Electronic throttle position sensor fault

P0122- Electronic throttle position sensor 1 (TPS1) circuit voltage low
P0123- Electronic throttle position sensor 1 (TPS1) circuit voltage high
P0222- Electronic throttle position sensor 2 (TPS1) circuit voltage low
P0223-Electronic throttle position sensor 2 (TPS1) circuit voltage high
P2135- Electronic throttle position sensor 1# and 2# circuit relativity fault
DTC description:
1. In the electronic throttle control (ETC) system, the accelerator pedal position (APP)
is designed to transmit the throttle pedal position to the engine control module in the
form of electric signal to allow the engine control module to drive the throttle motor
and control the throttle opening and send the signal to the engine control module
through the sensor signal.
2. Actual throttle position will be compared with the throttle position determined by the
engine load. The engine control module (ECM) determines the engine load according
to the signal of intake manifold absolute pressure sensor (MAPS). By the farther
comparison, the sensor fault can be determined and the corresponding DTC can be
set. The fault causes include the sensor signal open circuit, sensor ground wire open
circuit, sensor fault and engine control module fault etc.
DTC set criteria:
1. With the engine running, when ECM monitors TPS sensor signal 1 value is less than
3.5%, the DTC P0122 will be set.
2. With the engine running, when ECM monitors TPS sensor signal 1 value is more than
3. With the engine running, when ECM monitors TPS sensor signal 2 value is less than
4. With the engine running, when ECM monitors TPS sensor signal 2 value exceeds
5. If DTC P0122, P0123, P0222 or P0223 occurs, the system will estimate the throttle
opening according to the engine speed.


throttle control
There is DTC; go modu le co nnecto r
damage; check the
corrosion

throttle circuit

at OFF position, disconnect
connector E20 and engine
The circuit has
open circuit
terminal 70 of E01

throttle
•Replace the electronic

throttle and carry out road
test
R e p l a c e t h e
•Perform the diagnosis Go to Step 3 DTC still exists
electronic throttle
symptom exist

test.
Locate the causes
from other symptom
symptom exist
12-81
9. Front oxygen sensor signal circuit fault

P0131- Front oxygen sensor signal short to low voltage
P0132- Front oxygen sensor short to high voltage
P0133- Too slow front oxygen sensor response
P0134- Front oxygen sensor open circuit
DTC description:
1. The front oxygen sensor is to test the oxygen concentration in the exhaust and 12
release the feedback signal to the engine control unit which will control the increase
and decrease of injection volume and consequently maintain the air fuel ratio near
the theoretical value.
2. After the vehicle start, the control module will work in the open-loop mode, namely,
ignoring the front oxygen sensor signal voltage when calculating the air fuel ratio.
3. Once detecting the upstream oxygen sensor voltage exceeding the set threshold
voltage, the control module will immediately enter the closed loop mode. The control
module determines the air fuel ratio by the upstream oxygen sensor voltage. If the
upstream oxygen sensor voltage rises above the reference voltage (tending to 1V),
it indicates the mixture is too rich. If the upstream oxygen sensor voltages drops
below the reference voltage (tending to 0mV), it indicates the mixture is too lean. If
the oxygen sensor voltage fluctuation response speed is below the system value, it
indicates the oxygen sensor is aged.
DTC set criteria:
system voltage is above 11V and the engine running time is more than 60s, if the
ECM monitors the oxygen sensor signal voltage is less than 0.03V but less than 3.8V,
the DTC P0131 will be set. If the oxygen sensor signal voltage is above 3.8V, the
2. If the system monitors the front oxygen sensor output signal lean to rich average time
(LRA) >0.4s or the front oxygen sensor output signal rich to lean average time (RLA)
>0.13s or the raito of LRA to RLA is <0.2 or >8, or the front oxygen sensor output
signal lean to rich frequency <15 or the front oxygen sensor output signal rich to lean
frequency <15, the DTC P0133 will be set.

The fault is
incidental. Check
the front oxygen
clear DTC
damage; check the
harness terminals
for corrosion

sensor

the battery negative terminal Front oxygen Replace the front
• Remove the front oxygen sensor severe o x y g e n s e n s o r,
Go to Step 2
sensor and check the carbon deposit, change the fuel and
sensor for carbon deposit, whitening clean the fuel tank
darkening

sensor circuit
•Disconnect the front

E03 and engine control unit
connector E01
The circuit has
open circuit
terminal 47 of E01
(oxygen sensor)
•Replace the front oxygen

test
Replace the front
•Perform the diagnosis DTC still exists Go to Step 4
oxygen sensor
symptom exist
(ECM)

test.
Locate the causes
from other symptom
symptom exist
10. Rear oxygen sensor signal circuit fault

P0137- Rear oxygen sensor short-circuited to low voltage
P0138- Rear oxygen sensor short to high voltage
P0140- Rear oxygen sensor open circuit
DTC description:
1. The rear oxygen sensor is to monitor the operating state of the three-way catalytic
converter.
2. The sensor compares the ambient air oxygen content with the exhaust flow oxygen
content. Every heating type oxygen sensor is provided with the heating element to
heat the sensor inside. The engine control module controls the heating control circuit
12-83
of the heating type oxygen sensor. This makes the system enter the closed-loop
mode earlier and control module to calculate the air fuel ratio earlier.
DTC set criteria:
system voltage is above 11V and the engine running time is more than 600s, if the 12
ECM monitors the rear oxygen sensor signal voltage is less than 0.03V, the DTC
P0137 will be set. If the rear oxygen sensor signal voltage is above 3.8V, the DTC
P0138 will be set.
2. If DTC P0137 or P0138 occurs, the system will disable the rear oxygen sensor signal.

•Connect the vehicle The fault is

diagnostic tester, read and incidental. Check
clear DTC the rear oxygen
•Restart the engine and There is DTC; go sensor connector
carry out the road test to Step 1 for looseness or
to run the engine under damage; check the
various conditions. Try to harness terminals
read DTC for corrosion
Check the three-way

catalyst

Replace the three-
replaced within the specified fault
converter
time limit
sensor
•With the ignition switch in

Rear oxygen Replace the rear
terminal.
sensor severe o x y g e n s e n s o r,
•Remove the rear oxygen Go to Step 3
carbon deposit, change the fuel and
sensor and check the
whitening clean the fuel tank
sensor for carbon deposit,
darkening

sensor circuit

• E01 Disconnect the rear
I46 and engine control unit
connector E01
The circuit has
open circuit
of I46 and terminal 48 of
E01, terminal 3 of I46 and
terminal 23 of E01.
(oxygen sensor)
• Replace the rear oxygen

test.
Replace the rear
•Perform the diagnosis The fault still exists Go to Step 5
oxygen sensor
symptom exist
(ECM)

test.
Locate the causes
from other symptom
symptom exist
11. Fuel too rich or too lean

P0171-Too dilute fuel in non-idle speed condition
P0172-Too concentrated fuel in non-idle speed condition
DTC description:
1. The engine control module controls the closed loop air fuel ratio measuring system
to make the control performance, fuel economic performance and emission control
reach the optimum matching. In the closed loop mode, the engine control module
monitors the heating type oxygen sensor signal voltage and regulates the fuel supply
according to the signal voltage.
2. The variance in the fuel supply will change the long term and short term fuel
regulation value.
3. The short term fuel regulation value will respond the signal voltage of heating type
oxygen sensor to change quickly. These changes will regulate the engine fuel supply.
4. The long term fuel regulation value will respond the short term fuel regulation trend
and change. The long term fuel regulation will control the fuel supply in a coarse
control way to return the central value of short term fuel regulation and restore the
control over the short term fuel regulation.
5. The ideal fuel regulating value is 0% approximately. The positive value means the
12-85
engine control module is increasing the fuel to compensate the lean gas mixture
while the negative value means the engine control module is decreasing the fuel to
compensate the rich gas mixture.
DTC set criteria:
1. When the system has no P0106, MAP sensor, IAT sensor, CTS sensor, TPS sensor,
oxygen sensor, injector, crankshaft position sensor, camshaft position sensor,
idling control system, misfire, canister cleaning circuit related DTC, the system is 12
under closed-loop control over the fuel, the intake temperature exceeds -7°C, the
atmosphere pressure exceeds 72kPa and he system voltage exceeds 11V, if the
fuel closed-loop learning value exceeds 1.45 and the duration exceeds 5s, the DTC
P0171 will be set. If the fuel closed-loop learning value is less than 0.76 and the
duration exceeds 5s, the DTC P0172 will be set.


Refer to the
corresponding
clear DTC
chapters according
•Restart the engine to
There is other to the DTC displayed
carry out road test and run
Go to Step 1 sensor or actuator on the diagnostic
DTC tester to solve the
conditions. Read DTC and
faults and then test
check whether the engine
according to this
has other sensor or actuator
section
DTC
Check whether the air filter The air filter Replace the air filter
Go to Step 2
is clogged clogging assembly
2 Check the intake system line Normal Faulty Instruction
Check the intake system line Intake system line Repair the air leak
Go to Step 3
for air leak air leak fault line
3. Check the spark plug Normal Faulty Instruction
•Remove the spark plug

Excessive spark Replace the spark
•Check whether the spark Go to Step 4
plug gap plug
plug gap is normal
4 Check the ignition coil Normal Faulty Instruction
•Remove the ignition coil

and install the new spark
plug Replace the ignition
•Check whether the ignition coil
coil spark-over and spark
are normal

Check the exhaust system
line
Check the exhaust system Exhaust system Repair the air leak
Go to Step 6
line for air leak line air leak fault line
Check the fuel system

pressure
Check whether the fuel Repair the fuel

Go to Step 7 Fuel system fault
system pressure is normal system
•Remove the injector and

connect the injector to the
Replace the faulty
tester Go to Step 8 The injector fault
injector
•Check whether the injector
performance is normal
8. Inspection by replacement Normal Faulty Instruction

test.
•Perform the diagnosis again Replace ECM
exist
12. The injector fault

P0261- Cylinder 1 nozzle circuit low voltage fault
P0262- Cylinder 1 nozzle circuit high voltage fault
DTC description:
1. The injector working voltage is supplied by the main relay under the control of engine
control module. The battery voltage is fed to all the injector harness connectors
through the main relay and then to the injector.
2. The engine control module controls the injector ground wire to ground inside the
engine control module through the harness connection.
3. The engine control module monitors the state of each injector drive circuit. If the
engine control module detects the voltage corresponding the injector drive circuit
12-87
command state is incorrect, it will set the DTC of this cylinder injector control circuit.
DTC set criteria:
monitors the cylinder 1 injector circuit is short the ground, DTC P0261 will be set. If
ECM monitors cylinder 2 injector circuit is short to 12V power, the DTC P0262 will be
set.
2. If DTC P0261 or P0262 occurs, the system will disable the nozzle output drive and 12
forbid the closed-loop fuel control.
Note:
Before the diagnosis, observe the data list of fault diagnostic meter and analyze the
data accuracy, which will help the quick troubleshooting.
Tips:
The testing method of cylinder 1 injector fault is the same as the rest cylinders. Here
only describe the cylinder 1 injector faults.

The fault is
incidental. Check
the injector
clear DTC
There is DTC; go connector for
to Step 1 looseness or
damage; check the
harness terminals
for corrosion
Check the injector power

1 Faulty Instruction
circuit
Measure whether
• Disconnect cylinder 1
injector connector E11
or open circuit
• When the power supply The voltage is out
between the engine
at ON position, check the of the reasonable
compartment central
voltage between terminal 1 range
control box relay
of E11 and the ground
fuse FS47 and
Voltage: 9V~13V
terminal 2 of E18B
3. Check the injector Faulty Instruction
• When the power supply at

OFF position, disconnect the
battery negative terminal
• Disconnect cylinder 1
injector connector E11
• Measure whether the
resistance between two
terminals of injector 1, 2 is
normal
Resistance: 12.0Ω±0.6Ω
Check the injector control

circuit

control module connector
E01 The circuit has
Repair the fault
• Measure whether there is Go to Step 6 short circuit or
harness
short circuit or open circuit open circuit
E01 and terminal 2 of E11

test.
Locate the causes
from other symptom
exist
13. Misfire fault

P0300-One or more cylinders misfire
DTC description:
1. The cylinder misfire means the gas mixture cannot combust in the cylinder normally
due to various reasons.
2. If the engine control module detects the misfire which may damage the catalytic
converter, the MIL will blink. At this point, shut down the engine immediately.
3. With the engine running time >60s and coolant temperature > 70°C, when the system
detects the crankshaft position sensor speed fluctuation above the system setting,
the DTC will be triggered. This DTC indicates more than one cylinder has misfire or
the engine control module cannot determine in which cylinder the misfire occurs. The
fault causes include the cylinder mechanical fault, fuel metering error, fuel pressure
high or low, evaporative emissions system fault, ignition system fault and intake
system fault etc.
DTC set criteria:
1. When the system has no MAP sensor, CTS sensor, TPS sensor, crankshaft position
sensor, camshaft position sensor and vehicle speed sensor related DTC, under
the steady working condition, if the ECM monitors the crankshaft speed fluctuation
exceeds the system set threshold, the DTC P0300 will be set.
2. With DTC P0300 occuring, if the misfire degree is low and only influences the exhaust
emission, it will only record DTC, freeze the data flow and illuminate MIL. If the misfire
degree is too high to result in the catalyst overheating, it will force the system to enter
the fuel open-loop control and disable the rear oxygen sensor correction learning.
When the engine speed exceeds 2000r/min or MAP exceeds 50kPa, the MIL will blink
at the frequency of 1Hz to remind the driver of reducing the engine speed and load
and driving to the maintenance center for repair as soon as possible.
12-89


clear DTC
There is DTC; go
•Restart the engine and It is incidental fault It is incidental fault
to Step 1
12
Check whether the spark The spark plug Replace the spark
Go to Step 2
plug gap is normal has fault plug
2. Check the ignition coil Normal Faulty Instruction
•Remove the ignition coil and

install the new spark plug
Replace the ignition
•Check whether the spark Go to Step 3 Ignition coil fault
coil
plug spark-over and spark
are normal

off or damage
Check the whether the valve Timing belt Install the valve
Go to Step 5
timing is correct assembly fault timing belt again
5. Check the cylinder pressure Normal Faulty Instruction

pressure tester and measure Cylinder pressure Repair the cylinder
Go to Step 6
whether the cylinder fault pressure fault
pressure is normal

pressure
Start the engine and check

Fuel system Repair the fuel
whether the engine fuel Go to Step 7
pressure fault system
system pressure is normal
7. Check the injector Normal Faulty Instruction


check whether the injector
is normal with the injector
tester
8. Check the intake system Normal Faulty Instruction
Start the engine and check The intake system Repair the faulty
Go to Step 9
the intake system for air leak has air leak fault line

test.
Locate the causes
from other symptom
exist
14. Knock sensor circuit fault

P0324- Knock sensor system fault
P0325- Knock sensor fault
DTC description:
1. The knock sensor is responsible for detecting shock upon the engine speed variation.
The knock sensor indicates the shock in the form of voltage. Where necessary, the
engine control module will delay the ignition to avoid the knock. If this voltage is
below the calibration value, the DTC will occur. The fault causes include the knock
sensor circuit fault, knock sensor looseness and knock sensor fault etc.
DTC set criteria:
1. If the system has no knock related fault, the engine running time exceeds 5s, the
coolant temperature is above 50°C, the engine speed exceeds 1600rpm and the
indicated mean effective pressure exceeds 600kPa, when the ECM monitors the
average of maximum signal of each cylinder from the knock sensor is below the
minimum threshold set by the system or above the maximum threshold set by the
system, the DTC P0324 will be set.
2. If the engine speed is above 1600rpm, the coolant temperature is above 50°C, the
engine running time exceeds 5s, the indicated mean effective pressure exceeds
600kPa and there is no knock related fault, when ECM monitors the knock sensor
cylinder signal difference is less than the minimum threshold set by the system, the
3. When the P0324 or P0325 DTC occurs, the ignition advance angle will adopt the
system default.
12-91

The detected
Check whether the battery Charge the battery
voltage is out of
voltage is the normal working Go to Step 1 or replace the
the reasonable
voltage battery
range
1 Read DTC Normal Faulty Instruction 12
The fault is
incidental. Check
the knock sensor
clear DTC
damage; check the
harness terminals
for corrosion
2. Check the knock sensor Normal Faulty Instruction
•Check whether the knock

sensor fixing bolt model and
torque are correct Replace the bolt
• Disconnect the knock sensor and tighten the
connector E5 and measure The knock sensor knock sensor to the
Go to Step 3
whether the resistance fault required torque or
between two terminals of the replace the knock
sensor is normal sensor
Resistance:
Resistance: >1MΩ
Check the knock sensor

circuit
• E15 Disconnect the engine

and knock sensor connector
E5 The circuit has
Repair the fault
• Measure whether there is Go to Step 4 short circuit or
harness
short circuit or open circuit open circuit
between E5 terminal 1 and
E01 terminal 36; E5 terminal
2 and E01 terminal 37

test. L o c a t e t h e
The fault still
•Perform the diagnosis again Replace ECM causes from other
exists
to read DTC and check symptom
exist
15. Crankshaft position sensor circuit fault

P0335 - Crankshaft position sensor circuit no signal
P0336- Crankshaft position sensor circuit signal interference
DTC description:
1. The crankshaft position sensor signal is to tell the current crankshaft rotary speed
and position to the engine control module. The crankshaft position sensor generates
the alternating voltage of different amplitude and frequency. The frequency depends
on the crankshaft speed and the output AC voltage depends on the crankshaft
position sensor. The crankshaft position sensor works together with the 58X variable-
reluctance type rotor fixed on the crankshaft.
2. The engine control module can work out the ignition timing, injection timing and
knock ignition control according to the input signal of crankshaft position sensor and
camshaft position sensor. The crankshaft position sensor can also detect the misfire
and tachometer display.
DTC set criteria:
1. If the system has no camshaft position sensor fault and the engine is starting, when
the ECM does not monitor effective engine speed pulse signal within a certain time,
the DTC P0335 will be set.
2. With the engine running, if the sensor monitors the number of cylinders is 4 while the
gear signal deviation is high, the DTC P0336 will be set.

The fault is
incidental. Check
the knock sensor
clear DTC
damage; check the
harness terminals
for corrosion

position sensor
• When the power supply at

OFF position, disconnect the
battery negative terminal
• Remove the crankshaft Crankshaft Replace the
position sensor and measure Go to Step 2 position sensor crankshaft position
whether the resistance fault sensor
between sensor terminal 1
and terminal 2 is normal
Resistance: 1000Ω±100Ω

position sensor shielded wire
12-93

• Disconnect the crankshaft
position sensor connector
The sensor signal Check the harness
E24 and measure whether
shielded wire between the
the resistance between Go to Step 3
opens to the crankshaft position
the E24 terminal 3 and the
ground sensor and ground
ground is normal
Resistance: <2Ω 12
position sensor line
•Disconnect the engine

and crankshaft position
The circuit has
open circuit
between E24 terminal 1
and E01 terminal 30; E24
terminal 2 and E01 terminal
11
••Replace the engine control

test.
Locate the causes
from other symptom
exist
16. Camshaft position sensor circuit fault
P0340- Camshaft position sensor circuit no signal/intake VCP camshaft
position sensor state diagnosis
P0341- Camshaft position sensor circuit rationality fault/intake VCP target
wheel diagnosis fault
DTC description:
1. The camshaft position sensor is designed to transmit the camshaft position and
cylinder 1 TDC position (the valve relative position) to the engine control unit in the
form of voltage signal.
2. If the engine control module detects the camshaft position sensor signal abnormal
during the set time interval, this DTC will occur. The fault causes include the camshaft
position sensor circuit, joint, sensor fault and the engine control module fault etc.
DTC set criteria:
1. If the system has no crankshaft position sensor fault, the engine is running and the
system finishes cylinder 1 signal judgment, when ECM monitors the camshaft status
signal is the same twice continuously, the DTC P0340 will be set.
2. If the system has no crankshaft position sensor fault, the engine is running and there
is no camshaft sensor no sinal fault, when ECM monitors the camshaft rotates by 2
turns and the status signal is the same, the DTC P0341 will be set.

The fault is
• Connect the vehicle
camshaft position
clear DTC
damage; check the
harness terminals
for corrosion

sensor (intake side) line

control unit connector E01,
and camshaft position
The circuit has
open circuit
E01.
sensor
Check whether the camshaft
position sensor O-ring is O-ring damage, Replace the O-ring
Go to Step 3
normal and the sensor is deformation and clean the sensor
(camshaft position sensor)
• Replace the camshaft

position sensor and carry
out road test Replace the
•Perform the diagnosis again camshaft position DTC still exists Go to Step 4
to read DTC and check sensor
exist
Check the camshaft signal

wheel
Check whether the camshaft Camshaft signal Replace the

Go to Step 5
signal wheel is normal wheel damage camshaft assembly
5. Check the timing belt Normal Faulty Instruction

off or damage
12-95
Check the whether the valve Timing belt Install the valve
Go to Step 7
timing is correct assembly fault timing belt again
Inspection by replacement 12
(ECM)

test.
Locate the causes
from other symptom
exist
17. Ignition coil circuit fault

P0351- Cylinder 1 ignition coil fault
DTC set criteria:
1. If the engine running time >0.5s, the system voltage exceeds 11V and below 16V,
when the cylinder 1 ignition circuit is short to the power or ground or open circuit
occurs, the DTC P0351 will be setIf the cylinder 2 ignition circuit is short to the power
or ground or the open circuit occurs, the DTC P0352 will be set. If the cylinder 3
ignition circuit is short to the power or ground or the open circuit occurs, the DTC
P0353 will be set. If the cylinder 4 ignition circuit is short to the power or ground or
the open circuit occurs, the DTC P0354 will be set.
2. If the DTC P0351, P0352, P0353 or P0354 occurs, the system will stop the fuel
injection of corresponding cylinder and disable the closed-loop fuel control to
generate the misfire DTC.
△ Tips:
The testing method of cylinder 1 ignition coil fault is the same as the rest cylinders. Here
only describe the cylinder 1 ignition coil faults.

• Connect the vehicle Check the ignition

diagnostic tester, read and coil and ECM
clear DTC connectors for
There is DTC; go
•Restart the engine and It is incidental fault looseness and
to Step 1
carry out the road test to run damage; check the
the engine under various harness terminals
conditions. Try to read DTC for corrosion


• Disconnect the ignition coil
connector
•Measure the resistance
The resistance
between ignition coil Replace the ignition
Go to Step 2 is out of the
terminals. Primary coil coil
reasonable range
Resistance: 0.71Ω±0.071Ω;
secondary coil Resistance:
8.7kΩ± 0.87kΩ
Check the ignition coil

power
•Disconnect the ignition coil Check the circuit

connector E04 between the
•When the power supply The voltage ignition coil harness
at ON position, check the Go to Step 3 value is out of the connector E22B
voltage between harness reasonable range and engine central
terminal 3 and the ground control box fuse
Voltage: 9V~13V FS46
3. Check the ignition coil circuit Normal Faulty Instruction

E01 and ignition coil
connector E12, E4, E16,
E18
•Measure whether there is
The circuit has
between E12 terminal 1 and harness
open circuit
E01 terminal 4; E14 terminal
1 and E01 terminal 81, E16
terminal 1 and E01 terminal
1, E18 terminal 62 and E01
terminal 1, E12, E14, E16,
E18 terminal 2 and ground
• Replace the engine control

test.
Locate the causes
from other symptom
symptom exist
18. Emission overlimit fault

P0420- Low catalytic converter efficiency
DTC description:
1. The engine control module monitors the conversion efficiency of three-way catalytic
converter through the two oxygen sensors (front and rear oxygen sensor) installed to
12-97
the three-way catalytic converter front and back.

2. The engine control module executes the closed-loop control over the air fuel ratio and
monitors the oxygen content in the exhaust gas not purified by the three-way catalytic
converter through the front oxygen sensor. The rear oxygen sensor sends the oxygen
content of gas purified by the three-way catalytic converter to the engine control
module through the voltage signal.
3. The engine control module determines whether the three-way catalytic converter 12
is under the normal operating condition by the signal contrast of front/rear oxygen
sensor. With the engine running time exceeding 60s and coolant temperature more
than 70℃ , if the system detects the rear oxygen sensor signal is below or above the
system value, that is, the three-way catalytic converter conversion efficiency is low, it
will turn on the MIL and set this DTC at the same time.
DTC set criteria:
1. If the system has no MAP sensor, coolant temperature sensor, TPS sensor, cooling
system, oxygen sensor, fuel correction, vehicle speed sensor, injector, misfire,
crankshaft position sensor, camshaft position sensor, ignition system, idling control
and system voltage related DTC, the coolant temperature is above 70°C, the engine
running time exceeds 440s, the fuel system is under closed-loop control, the vehicle
runs for a certain distance at the uniform speed and then stops for idling, the system
calculates the catalytic converter oxygen reservoir time by comparing the front/rear
oxygen sensor signal, when the weighted oxygen reservoir time is less than the set
threshold, the system will set the DTC P0420.

Check whether the battery

The detected Charge the battery
voltage is the normal
Go to Step 1 voltage is out of the or replace the
working voltage
reasonable range battery
Voltage: 11V~14V
• Connect the vehicle The fault is

clear DTC the rear oxygen
•Restart the engine and There is DTC; go to sensor connector
carry out the road test Step 2 for looseness or
to run the engine under damage; check the
various conditions. Try to harness terminals
read DTC for corrosion
2. Check the exhaust line Normal Faulty Instruction
Check the exhaust line for The exhaust line Check the exhaust
Go to Step 3
air leak has air leak fault line fault

sensor

Check whether the rear
Rear oxygen sensor Replace the rear
oxygen sensor signal is Go to Step 4
fault oxygen sensor
normal
Check the three-way

catalyst

Replace the three-
replaced within the fault
converter
5. Check the fuel Normal Faulty Instruction
Check whether the

unqualified fuel is filled; Three-way catalyst Replace the three-
Go to Step 6
ensure the three-way fault way catalyst
catalyst is not replaced
• •Replace the engine

out road test.
Locate the causes
from other symptom
symptom exist
19. Canister control valve circuit fault

P0458- Canister solenoid valve circuit short to voltage low or open circuit
P0459- Canister solenoid valve output short to high voltage
DTC description:
1. The vapor emission system will introduce the fuel vapor in the fuel tank to the tank
provided with active carbon which can absorb the fuel vapor. The engine sucks the
fuel vapor to the engine chamber through the fresh air.
2. If the engine control unit detects the vapor emission system canister control valve
control circuit presents short circuit or open circuit, this DTC will occur. The fault
causes include the canister control valve controlled power supply circuit open circuit,
canister control valve control circuit open circuit or short to the ground, canister
control valve fault and engine control module fault etc.
DTC set criteria:
monitors the canister solenoid valve circuit is short the 12V high voltage, DTC P0459
will be set. If ECM monitors the canister solenoid valve is short to the ground, the
2. If DTC P0458 or P0459 occurs, the system will disable the canister control valve
circuit function.
12-99

The fault is
incidental. Check
the canister control
clear DTC
There is DTC; go valve connector
damage; check the
12
harness terminals
for corrosion
Check the canister control

valve
• With the ignition switch in

the battery negative terminal
• Remove the canister
control valve and measure
Canister control Replace the canister
whether the resistance Go to Step 2
valve fault control valve
between the solenoid valve
two pins is normal
19Ω~22Ω(20°C)

valve power circuit
• Disconnect the canister Check whether
control valve connector E22 there is short circuit
• When the power supply or open circuit
The voltage is out
at ON position, check the between the engine
Go to Step 3 of the reasonable
voltage between terminal 1 compartment central
range
of E22 and the ground control box relay
Voltage: 9V~13V fuse FS47 and
terminal 2 of E05B

valve control circuit

E101 and canister control
The circuit has
valve connector E22 Repair the fault
• Measure whether there is harness
open circuit
E01 and terminal 2 of E22


test.
symptom exist
20. Cooling fan relay circuit fault

P0480- low speed fan fault
P0481-high speed fan fault
DTC description:
1. The cooling fan high and low speed relay coil is powered by the main relay controlled
by engine control module which controls the relay to work through the harness
connector. The engine control module is provided with one drive circuit inside to
control the relay coil to ground.
2. The drive circuit is provided with a feedback circuit to the engine control module
which determines the control circuit open circuit, short to the ground or short to the
voltage by monitoring the feedback voltage.
3. When the engine running time exceeds 60s and the coolant temperature exceeds
93°C, the low speed fan will start. When the engine running time exceeds 60s and
the coolant temperature exceeds 96°C, the high speed fan will start.
DTC set criteria:
monitors the control circuit is short to the power or ground or open circuit, the DTC
P0480 will be set. If the ECM monitors the circuit is short to the power or ground or
open circuit, the DTC P0481 will be set.
2. If DTC P0480 occurs, the system will start the high speed fan.

The fault is
incidental. Check
the engine control
clear DTC
There is DTC; go module connector
damage; check the
harness terminals
for corrosion
1 Check the fan relay Normal Faulty Instruction

12-101

Remove the engine
box K08 (fan speed control),
Replace the fault
K07 (high speed fan), K10 Go to Step 2 Relay fault
relay
(low speed fan) relay and
check whether the relay is
normal 12
control circuit

the battery negative terminal
• E01 Unplug the K10
(low speed fan) and K09
(high speed fan) relay and
disconnect the engine
The circuit has
control module connector Repair the fault
E01 harness
open circuit
is short circuit or open
circuit between the engine
box K08 and E01 terminal
65; K07 and E01 terminal
17
3. Check the cooling fan circuit Normal Faulty Instruction
• Disconnect the cooling fan

connector U21
•Check whether the cooling There is short
fan appearance is normal circuit or open Repair the fault
•Check whether the Go to Step 4 circuit or the harness or replace
cooling fan U21 terminal 1 cooling fan is the cooling fan
and terminal 3 as well as damaged
terminal 2 and terminal 4
are conducted

test.
Locate the causes
from other symptom
symptom exist
21. Vehicle speed signal fault

P1502- Vehicle speed signal source fault
DTC description:
1. After the wheel speed sensor detects the vehicle speed signal and ABS and
instrument cluster process the signal, the wheel speed sensor will send this signal to
the engine control module.
2. If the engine control module cannot receive the vehicle speed signal, this DTC will
occur.
DTC set criteria:
1. With the engine running, system voltage exceeding 11V but below 16V, coolant
temperature above 60°C, no intake pressure sensor, coolant temperature sensor,
electronic throttle position sensor, injector, ignition coil and misfire related fault:
In deceleration mode: the intake pressure compensation ≤22kPa, engine speed
>1600rpm but <6500rpm, electronic throttle position <0.8%, engine speed fluctuation
<75rpm, vehicle speed less than 5km/h for more than 7.5s.
In acceleration mode: intake pressure compensation >60kPa, engine speed
>1600rpm but <4500rpm, electronic throttle position <70% but >20%, vehicle speed
less than 5km/h for more than 45s. The DTC P1502 will be set.
2. When DTC P1502 occurs, the vehicle speed output will become the default.

The fault is
wheel speed sensor,
ABS control module
clear DTC
There is DTC; go and engine control
to Step 1 module connectors
for looseness and
damage; check the
harness terminals
for corrosion
1 Read ABS data flow Normal Faulty Instruction
Connect the vehicle

diagnostic tester to access
ABS system Check the ABS
•Start the engine to carry out ABS ECU or wheel control unit, wheel
Go to Step 2
road test and check whether speed sensor fault speed sensor and
the vehicle speed display harness
is normal under various
conditions
Check the ECM CAN

communication line
• •With the ignition switch

in OFF position, check The circuit has
Repair the fault
the voltage between E01 Go to Step 3 short circuit or
harness
terminal 38 of terminal 39 open circuit
Resistance: 120Ω

12-103

test.
Locate the causes
from other symptom
exist 12
22. Idle speed too low or too high fault

P0506 - Idle speed too lower
P0507- Idle speed too high
DTC description:
1. The engine control module works out the current engine speed according to the
working conditions and controls the throttle opening by controlling the electronic
throttle flap drive motor and consequently controls and regulates the target idle speed
to adapt various conditions.
2. If the engine control module detects the engine speed is below or above the setting
value for a long time, this DTC will occur. The fault causes include the electronic
throttle control unit, intake system, fuel system, ignition system and engine control
module etc.
DTC set criteria:
crankshaft position sensor, camshaft position sensor and ignition system related DTC,
the canister fuel concentration is less than 100%, the atmosphere pressure exceeds
72kPa, the engine running time exceeds 60s, the intake temperature exceeds -20°C,
the coolant temperature exceeds 60°C, the manifold intake pressure is less than
60kPa, the battery voltage is more than 11V but less than 16V and the engine speed
is below the target idle speed by 100rpm or more, the DTC P0506 will be set.
crankshaft position sensor, camshaft position sensor and ignition system related DTC,
the canister fuel concentration is less than 100%, the atmosphere pressure exceeds
72kPa, the engine running time exceeds 60s, the intake temperature exceeds -20°C,
the coolant temperature exceeds 60°C, the manifold intake pressure is more than
22kPa, the battery voltage is more than 11V but less than 16V and the engine speed
is above the target idle speed by 200rpm or more, the DTC P0507 will be set.


throttle and throttle
clear DTC
pedal position
•Restart the engine and There is DTC; go
It is incidental fault sensor connectors
carry out the road test to Step 1
for looseness and
to run the engine under
damage; check the
various conditions. Try to
read DTC
corrosion
Check whether the spark The spark plug has Replace the spark
Go to Step 2
plug gap is normal fault plug
2. Check the ignition coil Normal Faulty Instruction
• Remove the ignition coil

plug Replace the ignition
•Check whether the spark coil
are normal
3. Check the timing belt Normal Faulty Instruction

off or damage
Check the whether the Timing belt Install the valve

Go to Step 5
valve timing is correct assembly fault timing belt again
Check the cylinder

pressure

pressure tester and Cylinder pressure Repair the cylinder
Go to Step 6
measure whether the fault pressure fault
cylinder pressure is normal

pressure

Fuel system Repair the fuel
whether the engine fuel Go to Step 7
pressure fault system
7. Check the injector Normal Faulty Instruction

12-105

tester

12
The intake system
the intake system for air Go to Step 9 Repair the faulty line
has air leak fault
leak
• Replace the engine

out road test.
Locate the causes
from other symptom
symptom exist
23. System power supply voltage fault

P0562- System voltage low
P0563-System voltage high
DTC description:
1. If the engine control module detects the system voltage is continuously about 16V or
below 9V up to 5s, this DTC will occur. The fault causes include the generator fault,
voltage regulator and engine control module fault etc.
DTC set criteria:
1. With the engine running, if the system voltage is below 11V, DTC P0562 will be set. If
the system voltage is above 16V, DTC P0563 will be set.

Check whether the battery The detected

Charge the battery
voltage is the normal voltage is out of
Go to Step 1 or replace the
working voltage the reasonable
battery
Voltage: 11V~14V range
Check whether
the engine control
module power
clear DTC
Go to Step 2 if Other system does supply system
• Restart the engine to carry
other system not present this circuit is normal and
out road test, read DTC and
presents this DTC DTC replace the engine
check whether the engine,
control module if
ABS and other control units
necessary; go to
present this DTC
Step 4

Check the generator voltage
output line
Check whether the line

The circuit has
connection between the Repair the fault
generator B+ post and harness
open circuit
battery is normal
3. Read the data flow Normal Faulty Instruction
•Clear the DTC and connect

the vehicle diagnostic tester
•Read the generator data
Replace the
flow and check whether the Go to Step 4 Generator fault
generator
generator output is normal
under various working
conditions
Check the ECM fuse and

relay
Check where the cab central

control box fuse FS35,
Replace the fuse or
engine compartment central
Go to Step 5 Fuse or relay fault relay of the same
control box fuse FS11, main
specification
relay fuse FSB04, FS03 and
main relay K04 are intact
5. Check the ECM power wire Normal Faulty Instruction
• Disconnect ECM
connector E01
The circuit has
at ON position, check the Repair the fault
voltage between terminal harness
open circuit
44, 67, 68 of E01 and the
ground
Voltage: 9V~13V
6. Check the ECM ground wire Normal Faulty Instruction
• Disconnect ECM
connector E01
The circuit has
• Check the resistance Repair the fault
between E01 terminal 2, harness
open circuit
terminal 3 and the ground
Resistance: <2Ω

12-107

test.
Locate the causes
from other symptom
symptom exist 12
24. Stop lamp signal unreasonable fault

P0504-Brake switch relativity fault
DTC description:
1. The engine control module determines where the vehicle is under the deceleration
condition through the brake signal and cuts off the fuel injection to reduce the fuel
consumption and exhaust emission and protect the three-way catalytic converter.
2. If the engine control module detects the brake signal circuit voltage is below or
above the calibration value, this DTC will occur.
DTC set criteria:
1. With the vehicle speed more than 20km/h and persisting over 1s, if the system
monitors the vehicle deceleration exceeds 6m/s2, making the vehicle speed below
3km/h and the ECM detects the brake pedal state does not change within a certain
time, the DTC P0504 will be set.

The fault is
incidental. Check
the brake switch
There is DTC; go to connector for
Step 1 looseness or
damage; check the
harness terminals
for corrosion
Check whether the cab

Replace the fuse of
central control box fuse Go to Step 2 Fuse blown
same specification
FS24 and FS35 are blown
2. Check the brake switch Normal Faulty Instruction
When the power supply

at OFF position, check Brake switch Reinstall the brake
Go to Step 3
whether the brake switch is assembly fault switch


Disconnect the brake
switch connector I06,
Replace the brake
remove the brake switch Go to Step 4 Brake switch fault
switch
and check whether the
brake switch is normal
Check the brake switch

power wire

terminal Repair the short
• Disconnect the brake The voltage is out circuit or open circuit
switch connector I06 Go to Step 5 of the reasonable between the brake
• When the power supply range switch and cab
at ON position, check the central control box
voltage between terminal 1,
3 of l06 and the ground
Voltage: 9V~13V
Check the brake switch
signal wire
• I05 Disconnect the

engine control module
connector E01, and brake
switch connector I06
The circuit has
Go to Step 6 short circuit or open
circuit
33 and I06 terminal 2;
E01 terminal 69 and I06
terminal 4

out road test.
Locate the causes
from other symptom
symptom exist
25. ECM internal fault

P0602-ECM ECM processor fault
P0606-ECM ECM processor fault
P060A-ECM programming error
DTC description:
1. Engine control module error The fault causes include the engine control module fault,
module calibration alteration attempt, module programming error etc. If this DTC
occurs, delete and check whether it occurs again. If the DTC quickly occurs, it means
12-109
the electronic control module should be replaced in most cases.

DTC set criteria:
1. With the ignition switch in ON position, if the ECM detects the calibration document
does not match the program document, the DTC P0602 will be set. If the ECM
detects the main processor function module malfunction, the DTC P0606 will be set.
If the ECM detects the safety detection logic malfunction, the DTC P060A will be set.
Steps Check contents Inspection result 12

working voltage
Voltage: 11V~14V
The fault is
incidental. Check
There is DTC; go to whether the engine
Step 2 control module
connector pins get
loose or corroded.
Check the ECM power

circuit
Check whether the engine The circuit has

Repair the fault
control module ground and Go to Step 3 short circuit or open
harness
power circuit are normal circuit

out road test.
Locate the causes
from other symptom
symptom exist
26. Fuel pump relay circuit fault

P0230- Fuel pump relay fault
DTC description:
1. The fuel pump relay coil is powered by the main relay controlled by the engine control
module.
2. The engine control module controls the pump relay pull-in through the harness
connector. The engine control module is provided a drive circuit inside to control the
relay coil to ground and the drive circuit is provided with a feedback circuit to the
engine control module which determines the control circuit open circuit, short to the
ground or short to the voltage by monitoring the feedback voltage.


There is DTC; go to
clear DTC It is incidental fault the fuel pump relay
Step 1
•Read DTC again to check for looseness or
whether DTC can be read corrosion
1 Check the fuse and relay Normal Faulty Instruction

compartment central Replace the fuse of
control box fuse FS06 is same specification
normal
2. Check the fuel pump relay Normal Faulty Instruction
Unplug fuel pump relay

Replace the fuel
K06 and check whether Go to Step 3 Relay fault
pump relay
the relay is normal
Check the fuel pump relay

power circuit
• Disconnect the battery

negative terminal
• Unplug the fuel pump The circuit has short Repair the fault
Go to Step 4
relay K06 and fuse FS06 circuit or open circuit harness
• Check whether FS06
and K06 are conducted
Check the fuel pump relay

control circuit

E01, unplug the fuel pump
relay K06
•Measure whether there
is short circuit or open Go to Step 5
circuit between the engine
compartment central
control box fuel pump
relay K06 and terminal 9
of E01

out road test.
Locate the causes
from other symptom
symptom exist
12-111
27. Main relay output voltage unreasonable

P0685- main relay fault
DTC description:
1. When the power supply at ON position, the main relay will close. The main relay
supplies the voltage to each sensor actuator to maintain the engine running normal.
2. If ECM detects the main relay output voltage is unreasonable for a period of time, this
DTC will be triggered. 12
DTC set criteria:
1. When the power supply at ON position or engine running, the system voltage > 11V
but < 16V, if the ECM monitors the main relay power supply device failure events
exceed a certain number, the DTC P0685 will be set.


clear DTC whether the main
There is DTC; go to
•Restart the engine to It is incidental fault relay and ECU
Step 1
perform the road test, read harness connector
DTC and check whether are securely
DTC still exists connected
Check the generator

voltage output line
Check whether the line

The circuit has
connection between the Repair the fault
generator B+ post and harness
circuit
battery is normal
• Clear the DTC and

connect the vehicle
diagnostic tester
•Start the vehicle to read
Replace the
the generator data flow Go to Step 3 Generator fault
generator
generator output is normal
under various working
conditions
Check the ECM fuse and

relay

compartment central Replace the fuse or
control box fuse FS11, Go to Step 4 Fuse or relay fault relay of the same
FS03 and relay K04 are specification
intact
Check the main relay

output power wire

at ON position, check
the voltage between E01
terminal 5 and and the
The circuit has
ground Repair the fault
Voltage: 9V~13V harness
circuit
• Check whether there is
short to ground or power
between E01 terminal 5
and engine compartment
central control box fuse
FS03

out road test.
Locate the causes
from other symptom
symptom exist
28. Electronic throttle body fault

P0641- ETC reference voltage A# amplitude fault
P0651-ETC reference voltage B# amplitude fault
P1516- ETC drive steady state diagnosis error
P2101- ETC drive second order diagnosis error
P2119- Electronic throttle return fault
DTC description:
1. In the electronic throttle control (ETC) system, the accelerator pedal position (APP)
is designed to transmit the throttle pedal position to the throttle control module in the
form of electric signal to supply the reference for the throttle actuator to control the
throttle valve opening.
2. The throttle actuator is a step motor which controls the throttle opening according to
the command of throttle control module.
3. Under the steady state working condition, if the desired throttle position and actual
throttle position are different evidently and the throttle cannot return and open to the
required degree, this DTC will be recorded. Besides, it will be accompanied with the
difficult engine start.
DTC set criteria:
1. When the power supply at ON position, if the sensor supplied 5V reference voltage B
voltage above 5.5V or below 4.5V more than 500ms, the DTC P0651 will be set.
2. When the power supply at ON position, the throttle opening fluctuation less than
5% and stable for 1s at least, if the actual throttle opening and predicted opening
difference (the absolute value) exceeds a certain value (20%) and this state duration
12-113
exceeds 300ms, the DTC P1516 will be set.

3. When the power supply at ON position, if the actual throttle opening and predicted
opening difference (the absolute value) exceeds a certain value (5%) and this state
duration exceeds 240ms, the DTC P2101 will be set.
4. When the power supply at ON position, if the electronic throttle default position is
between 10% and 34%, the throttle return to default position time exceeds a certain
fixed value (for example, 1s) and this state duration exceeds 240ms, the DTC P2119 12
will be set.
5. If the system presents DTC P0651, P1516, P2101 or P2119 while there is no other
fault, the engine will work under normal state. However, if the throttle opening sensor
fault or MAP sensor fault occurs, the electronic throttle will work under the protected
mode and consequently the engine will work under the limp mode which will limit the
engine output torque.


Charge the battery
voltage is the normal working voltage is out of
voltage the reasonable
battery
The fault is
incidental. Check
the electronic
There is DTC; go throttle connector
damage; check the
harness terminals
for corrosion
2. Check the throttle body Normal Faulty Instruction
Check whether the throttle Clean the electronic

Electronic throttle
flap is normal, the rotation throttle body
controller fault or
is smooth and check the Go to Step 3 or replace the
too much carbon
electronic throttle body for electronic throttle
deposit
dirt controller
Check the electronic throttle

controller
• Replace the transmission

control unit and carry out Replace the
road test. electronic throttle
Electronic throttle
•Perform the diagnosis again Go to Step 4 controller and carry
fault
to read DTC and check out the throttle self-
whether DTC and symptom learning
exist


test.
exist
29. Engine compulsory idling fault

P2104- Engine compulsory idling
DTC set criteria:
1. With the ignition switch in ON position, if two or more following faults are detected,
this fault can be determined:
• Pedal position sensor 1 short circuit or open circuit
• Pedal position sensor 2 short circuit or open circuit
•The displayed position of throttle sensor 1 and pedal position sensor 2 does not
match (relativity check fault of two inputs)
• Throttle sensor 1 short circuit or open circuit
• Throttle sensor 2 short circuit or open circuit
•The displayed position of throttle sensor 1 and pedal position sensor 2 does not
match (relativity check fault of two inputs),the DTC P2104 will be set.
2. If the DTC P2104 occurs, the electronic throttle will work under the protected mode
and consequently the engine will work in the limp mode which will limit the engine
output torque. Then the engine will not respond the throttle pedal signal and can
only work at the idle speed of 800rpm approximately. In such a case, engage a gear
carefully and drive the vehicle slowly.


voltage is the normal voltage is out of Charge the battery or
Go to Step 1
working voltage the reasonable replace the battery

• Connect the vehicle Check the electronic
diagnostic tester, read and throttle pedal and
There is DTC; go
clear DTC It is incidental fault electronic throttle
to Step 2
•Read DTC again to check connectors for
whether DTC can be read looseness; check the
terminals for corrosion
2. Check the data flow Normal Faulty Instruction

12-115

diagnostic tester and read
the throttle pedal position
and electronic throttle data
flow D a t a f l o w
Go to Step 6 Go to Step 3
•Depress the throttle pedal abnormal
and check whether the 12
throttle pedal position and
throttle position data flow
changes
Check the throttle pedal

position sensor and circuit
• Check whether the

sensor is intact
•Disconnect the throttle
connector U03 and ECM
The throttle pedal
connector E01
position sensor is Replace the throttle
damaged or the pedal position sensor
resistance between the Go to Step 4
circuit has short assembly or repair the
circuit or open fault harness
sensor terminals is normal
circuit
•Check whether there is
between the throttle pedal
position sensor harness
connector and ECM
harness connector
Check whether the throttle

Electronic throttle Clean the electronic
flap is normal, the rotation
controller fault or throttle body or replace
is smooth and check the Go to Step 5
too much carbon the electronic throttle
electronic throttle body for
deposit controller
dirt

throttle body
• Replace the electronic

throttle controller and carry
Replace the electronic
out road test
Electronic throttle throttle controller and
•Perform the diagnosis Go to Step 6
fault carry out the throttle
self-learning
symptom exist


out road test.
symptom exist
30. Engine compulsory shutdown fault

P2105- Engine compulsory shutdown
DTC set criteria:
1. When the power supply at ON position, if the following faults are detected, this fault
can be determined:
•MAP sensor fault
•Throttle sensor fault or throttle drive fault, then the DTC P2105 will be set.
2. If the DTC P2105 occurs, the ECM will cut off the fuel injection and ignition, stop the
electronic throttle control and the engine will immediately stall.


working voltage
Voltage: 11V~14V
The fault is
incidental; check
•Connect the vehicle the intake pressure
diagnostic tester, read and temperature sensor
There is DTC; go to
clear DTC It is incidental fault and electronic
Step 2
•Read DTC again to check throttle connectors
whether DTC can be read for looseness; check
the terminals for
corrosion

the intake pressure and
throttle position sensor data
flow Go to Step 6 Data flow abnormal Go to Step 3
• Depress the throttle pedal
changes

3. temperature sensor and Normal Faulty Instruction
circuit
12-117

•Check whether the intake
sensor is intact
•Disconnect the intake
pressure temperature The intake pressure
Replace the
sensor connector E06 and temperature sensor
intake pressure
ECM connector E01 is damaged or the 12
Go to Step 4 temperature sensor
•Check whether there circuit has short
or repair the fault
is short circuit or open circuit or open
harness
circuit between the intake circuit
sensor harness connector
and ECM harness
connector
Check whether the throttle Clean the electronic

Electronic throttle
flap is normal, the rotation throttle body
controller fault or
is smooth and check the Go to Step 5 or replace the
too much carbon
deposit
dirt controller
throttle body

throttle controller and carry Replace the
Electronic throttle
•Perform the diagnosis Go to Step 6 controller and carry
fault
again to read DTC and out the throttle self-
check whether DTC and learning
symptom exist

test.
Locate the causes
from other symptom
symptom exist
31. Engine limp mode fault

P0068- Electronic throttle air flow error
P2106- Engine performance limit
P2110- Engine power management
DTC set criteria:
1. With the engine running time >0.5s, no intake pressure sensor fault (P0105, P0106,
P0107, P0108), intake temperature sensor fault (P0112, P0113), the difference of
air flow calculated by speed - density method and the air flow predicted from the
electronic throttle position >9g/s and the duration >4s, if the ECM detects the front the
oxygen sensor heating line is short to the 12V power, the DTC P0068 will be set.
2. With the ignition switch turned to ON from ACC, if the pedal position sensor 1 short
circuit or open circuit is detected; pedal position sensor 2 short circuit or open circuit
is detected; the pedal position sensor 1 and pedal position sensor 2 displayed
position does not match, the DTC P2106 will be set.
3. With the ignition switch turned to ON from ACC, if the throttle sensor 1 short circuit or
open circuit is detected; throttle sensor 2 short circuit or open circuit is detected; the
4. If the DTC P0068, P2106 or P2110 occurs, the electronic throttle will work under
the protected mode and consequently the engine will work in the limp mode which
will limit the engine output torque. During the idling, the engine output fluctuation is
evident. The mode allows the vehicle to run by constraint while difficul to control in
the normal traffic current or climb a steep slope.


Charge the battery
voltage is the normal working voltage is out of
voltage the reasonable
battery
The fault is
incidental; check
•Connect the vehicle the intake pressure
diagnostic tester, read and temperature sensor
There is DTC; go
clear DTC It is incidental fault and electronic
to Step 2
•Read DTC again to check throttle connectors
whether DTC can be read for looseness;
check the terminals
for corrosion

diagnostic tester and read the
throttle pedal, throttle position
sensor and front oxygen
D a t a f l o w
sensor data flow Go to Step 6 Go to Step 3
abnormal
• Depress the throttle pedal
changes

sensor and circuit
12-119

•Disconnect the front oxygen
sensor connector E29 and
ECM connector E01
resistance between the front The front oxygen
Replace the front
oxygen sensor terminal 3 and sensor is damaged
oxygen sensor
terminal 4, terminal 1 and Go to Step 4 or the circuit has 12
or repair the fault
terminal 2 is normal short circuit or
harness
•Check whether there is open circuit
between the front oxygen
and ECM harness connector

position sensor and circuit
• Check whether the throttle

pedal position sensor is intact
• U27 Disconnect the throttle
connector E01 and ECM
The throttle pedal
connector Replace the throttle
position sensor is
•Check whether the pedal position
damaged or the
resistance between the Go to Step 5 sensor assembly
circuit has short
throttle pedal position sensor or repair the fault
circuit or open
terminals is normal harness
circuit
•Check whether there is short
circuit or open circuit between
the throttle pedal position
and ECM harness connector
Check whether the throttle C l e a n t h e

Electronic throttle
flap is normal, the rotation electronic throttle
controller fault or
is smooth and check the Go to Step 6 body or replace the
too much carbon
deposit
dirt controller
Check the electronic throttle

body

throttle controller and carry Replace the
Electronic
•Perform the diagnosis again Go to Step 7 controller and carry
to read DTC and check throttle fault out the throttle self-
whether DTC and symptom learning
exist


test. L o c a t e t h e
•Perform the diagnosis again Replace ECM The fault still exists causes from other
to read DTC and check symptom
exist
32. Electronic throttle pedal circuit fault

P2122- Electronic throttle pedal position sensor 1# circuit lower voltage
P2123- Electronic throttle pedal position sensor 1# circuit high voltage
P2127- Electronic throttle pedal position sensor 2# circuit lower voltage
P2128- Electronic throttle pedal position sensor 2# circuit high voltage
P2138- Electronic throttle pedal position sensor 1# and 2# relevance fault
DTC description:
1. In the electronic throttle control system, the electronic throttle pedal position is
designed to transmit the throttle pedal position to the throttle control module in the
form of electric signal to supply the reference for the throttle actuator to control the
throttle valve opening.
2. To ensure the system safety, the throttle pedal position sensor adopts the dual sensor
setting which is slip resistor type.
3. The fault causes include the electronic throttle pedal position sensor open circuit
or short to the ground, electronic throttle pedal position sensor fault, engine control
module fault etc.
DTC set criteria:
1. With the engine running, when ECM monitors APS sensor circuit 1 signal value is
less than 3.5%, the DTC P2122 will be set. When ECM monitors APS sensor circuit 1
signal value exceeds 97.5%, the DTC P2123 will be set.
2. With the engine running, when ECM monitors APS sensor circuit 2 signal value is
less than 3.5%, the DTC P2127 will be set. When ECM monitors APS sensor circuit 2
signal value exceeds 97.5%, the DTC P2128 will be set.

The fault is
•Connect the vehicle incidental.Check
diagnostic tester, read and whether the throttle
There is DTC; go
clear DTC It is incidental fault pedal position
to Step 1
•Read DTC again to check sensor connector
whether DTC can be read pins get loose or
corroded.

position sensor circuit
12-121

The fault is
•Disconnect the throttle pedal
incidental; check
position sensor connector
the intake pressure
U27 and engine control
The circuit has temperature sensor
module connector E01
Go to Step 2 short circuit or and electronic
open circuit throttle connectors
for looseness; check 12
between U27 and E01
the terminals for
terminals
corrosion

the data flow
• Check the throttle pedal
opening and electronic
Throttle pedal Replace the throttle
throttle opening with the
Go to Step 3 position sensor pedal position
throttle pedal depressed and
damage sensor
not depressed respectively
Note: the electronic throttle
opening should increase
along with the throttle pedal
opening.

test.
exist
33. Air fuel ratio overlimit or oxygen sensor ageing fault

P1167- Too thick in case of front oxygen deceleration loss
P1171- Too dilute in case of front oxygen acceleration enrichment
P2187- Idling working condition fuel system overlean
P2188- Idling working condition fuel system overrich
P2A01- Rear oxygen sensor deceleration fuel cut-off response slow
DTC description:
1. The fuel correction means the engine control module controls the fuel feed by
increasing or decreasing the injector opening time and consequently to make the
engine acquire the optimum air fuel ratio (the air gasoline mass ratio is 14.7:1).
2. The rich air fuel ratio means the fuel delivery volume is high while the lean air fuel
ratio means the fuel delivery volume is low. The system lean means the fuel level (in
relation to the air input) is low.
DTC set criteria:
engine running time is more than 60s and the engine is in deceleration fuel cut-off
(DFCO) working condition, if the ECM monitors the oxygen sensor signal voltage is
higher than 0.55V, the DTC P1167 will be set. If the engine is in power enrich (PE)
working condition, the air fuel ratio is less than 13.5 and ECM monitors the oxygen
sensor signal voltage is above 0.35V, the DTC P1171 will be set.
2. With the engine idling, atmosphere pressure higher than 72kPa, intake temperature
more than -7°C and battery voltage higher than 11V, if ECM monitors the system fuel
learning value exceeds (1.4), the DTC P2187 will be set. If ECM monitors the system
fuel learning value is less than (0.7), the DTC P2188 will be set.
3. If the DTC P1167, P1171, P2187 or P2188 occurs, the ECM will disable the catalyst
diagnosis.

R e f e r t o t h e
•Connect the vehicle corresponding chapters
diagnostic tester, read and according to the DTC
clear DTC displayed on the
Go to Step 1 There is DTC
•Read DTC and check diagnostic tester to
whether other engine solve the faults and
sensor or actuator has DTC then test according to
this section
Check whether the air filter The air filter Replace the air filter
Go to Step 2
is clogged clogging assembly

The intake system
the intake system for air Go to Step 3 Repair the faulty line
has air leak fault
leak
Check whether the spark The spark plug

Go to Step 4 Replace the spark plug
plug gap is normal has fault
•Remove the ignition coil

plug
Go to Step 5 Ignition coil fault Replace the ignition coil
•Check whether the spark
are normal

12-123

Timing belt Replace the new timing
assembly fault belt
off or damage
6 Check the valve timing Normal Faulty Instruction
Check the whether the valve Timing belt Timing belt assembly
Go to Step 7 12
timing is correct assembly fault fault
Check the ccylinder

pressure

pressure tester and Cylinder pressure Repair the cylinder
Go to Step 8
measure whether the fault pressure fault
cylinder pressure is normal

pressure

Fuel system
whether the engine fuel Go to Step 9 Repair the fuel system
pressure fault

tester

test.
The fault still Locate the causes from
exists other symptom
symptom exist
34. Crankshaft position system deviation not learned

P1336- 58-tooth gear error not learned
Description of DTC
1. When there is no coolant temperature sensor, throttle position sensor, crankshaft
position sensor, vehicle speed sensor, injector and ignition system related DTC, if the
coolant temperature exceeds 60°C, the engine running time exceeds 10s while the
gear message learning flag bit is not set, the DTC P1336 will be set.
2. The gear message learning program should be made after the engine control module
and crankshaft position sensor are replaced.


Check the brake
There is DTC; go switch connector for
to Step 1 looseness or damage;
check the harness
terminals for corrosion
Carry out gear message

learning
•After starting, when

the coolant temperature
reaches 60°C and running
time of vehicle is more than
10s, the other vehicle load
should be inactive
•Send the gear message
learning command through
the diagnostic tester
•Quickly depress the throttle
to the bottom and hold.
Then the ECM should carry
out gear message learning, The fault still Locate the causes from
Replace ECM
the engine speed will exists other symptom
repeat 2~5 cycles changing
within 1300 - 4500 rpm and
oscillate around 4500rpm
in the end and then the
learning ends; (the above is
the typical characteristic of
the engine speed during the
gear message learning. This
can be used to determine
whether the gear message
learning is made and
finished)
35. CAN communication fault

U0001- CAN communication fault
U0073- CAN bus off
U0121- ECU and ABS control module communication loss
U0140- ECU and body control module communication loss
U0151- ECU and airbag control module communication loss
DTC description:
1. If the engine control module detects the bus is off or cannot receive the corresponding
node information, such DTC will be set. The fault causes include the CAN data line
communication problem and control module fault. Change.
12-125


•Connect the vehicle Check the ECM, FBCM,
diagnostic tester, read and ABS ECU connectors
There is DTC;
clear DTC It is incidental fault for looseness and
go to Step 1
•Read DTC again to check damage; check the 12
whether DTC can be read harness terminals for
corrosion
Check the correlated control

system

Carry out diagnosis
access the fault correlated
Go to Step 2 There is DTC according to the DTC
control system for diagnosis
prompt
•Read DTC to check
C h e c k t h e C A N
communication line
between ECM and relevant
control module
•When the power supply at

terminal
E01, instrument cluster
connector I07, FBCM1
connector I09
The circuit has
• Check whether
Go to Step 4 short circuit or Repair the fault harness
the resistance of
open circuit
commnunication line
between the engine
control module and
instrument cluster as well
as instrument cluster and
FBCM is reasonable
•Check the CAN
communication line for short
the power or to the ground


•Replace the fault related
control unit
•Perform the diagnosis Replace the fault The fault still
Go to Step 4
again to read DTC and control units exists
symptom exist

test.
The fault still Locate the causes from
exists other symptom
symptom exist
36. Immobiliser fault of engine

P0633-non-learning fault of immobiliser
U0167-no response of immobiliser (C167)
U0426-no response of immobiliser (C426)
DTC description:
1. The immobilizer control module is designed to disable the vehicle start unless the
special key exists and matches the various components.

• Check whether the battery The detected
Charge the battery
voltage is the normal voltage is out of
working voltage the reasonable
battery
An occasional
• Connect the vehicle fault. Check PEPS
diagnostic tester, read and ECU, RKEECU
There is DTC; go
clear DTC It is incidental fault or engine control
to Step 2
• Read DTC again to check unit for loosening
whether DTC can be read or terminals for
corrosion.
2. Check PEPS(RKE) system. Normal Faulty Instruction

Carry out diagnosis
unit, enter into PEPS(RKE) There is DTC
Go to Step 3 according to the
system, and check the fault output
DTC prompt
codes for output.
12-127

3 Remote control matching Normal Faulty Instruction
Re-match the remote

c o n t r o l l e r, a n d c o n f i r m Remote control Re-matching remote
Go to Step 4
whether the fault codes and matching fault control
symptoms exist.
12
4 ECM immobilizer matching Normal Faulty Instruction
Re-match engine PEPS

(RKE) ECU, and confirm Match control unit
Go to Step 5 Matching fault
whether the fault codes and again
symptoms exist.
Check the anti-theft coils

5 (ignition switch) / one-key Normal Faulty Instruction
ON/OFF.
• Disconnect I49 connector

of anti-theft coils, (ignition
switch connector I48)/
One-key starting switch
connector I23. Replace the ignition
• Check whether the Immobilizer coil switch assembly
Go to Step 6
resistance between the anti- fault (or one-touch start
theft coil terminal (or the switch assembly)
ignition switch terminal) is
normal/check whether one-
key start switch terminal is
normal.
(PEPS/RKE ECU)
• Replace the PEPS/

RKEECU and carry out road
test.
PEPS/RKEECU Replace PEPS/
• Perform the diagnosis Go to Step 7
fault RKEECU
symptom exist
(ECM)

test.
Locate the causes
• Perform the diagnosis Replace ECM The fault still exists
from other symptom
symptom exist

Part sketch
LFWX-6470-12009
Replacement
Note:
After replacing the engine ECU (ECM), connect the diagnostic tester and write the
vehicle VIN code consistent with the vehicle under repair to the engine ECU through
the diagnostic tester.
(a). Power supply is turned to “OFF”.
Note:
Turn off the ignition switch and light switch before disconnecting and connecting
the battery negative cable. Completely loosen the fixing nut of the battery negative
terminal. Do not pry the cable terminal when doing this.
(c). Remove the glove box.
(d). Disconnect ECM connector.
Note:
After disconnecting the connector, ensure the connector joining part will not contact
the dirt, water and other impurity.
(e). Remove the 4 fixing bolts of ECM with bracket assembly.
(f). Remove ECM with bracket assembly.
Note:
After removing ECM, protect it against water and do not soak in the water. Handle
the ECM carefully when removing it.
(g). Install ECM in the sequence reverse to the removal.
Torque: 10±2N•m
Note:
Pay attention to static electricity protection during installation.
Fuel system
Fuel system��1
Technical specifications��1
General specifications�� 1
Torque specifications�� 1
Operating principle�� 1
System Overview�� 1
Part instructions��1
uel pressure regulation
F
solenoid valve�� 1
Fuel pressure sensor�� 2
High pressure fuel pump�� 2
Fuel guide rail�� 2
Fuel injector�� 2
Structure and installation location��3
Part Location Drawing�� 3
Part exploded view�� 4
Fault diagnosis and inspection��5
Safety measure�� 5
Fuel system check�� 5
21
List of fault symptoms�� 5
Diagnosis about that the fuel pressure in
the engine is too low��6
Removal and Installation��7
High pressure fuel pump�� 7
Disassembly�� 7
Fuel injector�� 10
Maintenance Tools��13
Engine fuel system - Engine fuel system (1.5T)
21-1
Fuel system
Name Size
Crankshaft position sensor fixing bolt High pressure Q200bar Low pressure =5.5bar
Name Nm Lb-ft Lb-in
High pressure fuel pump fixing bolt 11 8 -
High pressure fuel pipe component bolt 23 17 -
Fuel rail fixing bolt 23 17 -
Low pressure fuel pipe component bolt 23 17 -
High pressure fuel pipe component

11 8 -
bracket bolt
Operating principle
System Overview
he high pressure fuel pump is installed on the
T
camshaft cover, and the fuel rail is installed on the
cylinder head assembly. The fuel in the fuel tank is 21
delivered by the fuel pump to the high pressure fuel
pump via the fuel filter and low-pressure fuel pipe, the
high pressure fuel pump applies the pressure for the
fuel via high pressure fuel pump tappet driven by the
camshaft, and then the fuel is delivered into the fuel
rail via the high-pressure tubing assembly, and finally
injected into the cylinder by the fuel injector controlled
by the engine ECU.
LFWX-6470-03001
Part instructions
Fuel pressure regulation solenoid valve
The fuel pressure regulation solenoid valve is
integrated on the high pressure fuel pump and is
controlled directly by ECU, to ensure that the fuel
pressure in the fuel rail is consistent with the required
fuel pressure; the fuel pressure regulation solenoid
valve and the fuel pressure sensor together form a
closed loop control system.
LFWX-6470-03002
21-2 Engine fuel system - Engine fuel system (1.5T)
Fuel pressure sensor

he fuel pressure sensor is installed on the fuel rail,
T
and is used to measure the fuel pressure in the fuel
rail; the fuel pressure sensor and the fuel pressure
regulation solenoid valve form a closed loop control
system in a high pressure fuel pipe.
LFWX-6470-03003
High pressure fuel pump

he high pressure fuel pump is installed on the
T
camshaft cover, and is driven in mechanical mode via
the camshaft, to apply the pressure for the fuel in the
low pressure pipe and supply the pressure required in
the fuel rail; the inlet and outlet fuel valves on the high
pressure fuel pump are one-way valves, to prevent the
pressure drop in the fuel rail.
LFWX-6470-03004
Fuel guide rail

he fuel rail is installed on the cylinder cover, and
T
is connected to the high pressure fuel pump via the
high pressure tubing components, to distribute a
certain fuel pressure to the fuel injector and provide an
enough volume to compensate for the fuel pressure
fluctuations; the fuel rail is not only a high pressure
fuel container, is also a fuel injector, as well as the
connection component between the fuel pressure
LFWX-6470-03005 sensor and the high pressure fuel pipe.
Fuel injector
he fuel injector is installed on the engine cylinder
T
cover, its opening/closing operations are controlled by
ECU, to inject the fuel distributed in the fuel rail into
the cylinder and mixed with the air to form a mixture.
LFWX-6470-03006
21-3

3
2
1
4
5
21
LFWX-6470-03007
High-pressure fuel tubing

1 4 Fuel guide rail
components
Low-pressure fuel tubing

2 5 Fuel pressure sensor
components
3 High pressure fuel pump

Part exploded view
9
8
7
4
6
5 LFWX-6470-03008
1 Camshaft cover 6 Fuel rail fixing bolt
2 Cylinder head assembly 7 High pressure fuel pump fixing bolt
3 Fuel injector 8 High-pressure fuel tubing components
4 Fuel guide rail 9 High pressure fuel pump
5 Fuel pressure sensor

21-5

Safety measure
• Pressure relief of high pressure fuel pipe in the fuel system
The operation pressure in the high pressure pipeline is up to 200 Bar; before check, the fuel pressure must
be reduced to 4 ~ 7 Bar, with the steps as follows:
1. Remove the low pressure fuel pump fuse, and disconnect the fuel pressure regulation solenoid valve plug.
2. Start the engine and operate it at the idle speed for 10 s.
3. Turn off the ignition switch.
Note:
After pressure relief, the fuel in the fuel pipe is still full, but is not under the high pressure. When the
fuel system is opened, must wear protective glasses and protective clothing, so as to avoid exposure
and harm to skin. Before the high-pressure fuel pipe joint is opened, place a cloth around the joint, in
order to eliminate the residual pressure in the fuel system.
• Cleaning provisions about the fuel system operation.
In the fuel system operations, the following cleaning provisions must be followed.
1. Before the fuel pipe joint is loosened, use the engine cleaner to thoroughly clean the joint and
surrounding, and dry thoroughly the cleaning location.
2. Use suitable covers to seal the opened pipe and joint immediately.
3. Place the removed components on a clean cushion and cover them; but don't use a fiber cloth.
4. Do not use the compressed air to clean the opened devices and do not move the vehicle as much as
possible.
Fuel system check

• Check the low pressure fuel pipe in the fuel system.
Check whether the low-pressure pipe joint of the high pressure fuel pump is loosened or whether the low
pressure fuel pipe is damaged or leaked.
• Check the high pressure fuel pipe in the fuel system.
Check whether the low-pressure pipe joint of the high pressure fuel pump is loosened or whether the low 21
pressure fuel pipe is damaged or leaked.
• Check the electrical components in the fuel system.
Check whether the circuits of high pressure fuel pressure sensor and the pressure regulation solenoid valve
are normal; measure whether the sensor and solenoid valve data are within the normal range.

• The pressure in the low pressure fuel pipe is
too low • Check whether the low pressure fuel pump is
The engine
• The pressure in the high pressure fuel pump normal, and whether the fuel filter is clogged.
jitters or the
is relieved • Replace the high pressure fuel pump.
acceleration is
• The fuel pressure regulation solenoid valve is • eplace the pressure regulation solenoid valve.
poor damaged • Replace the fuel injector.
• The fuel injector is damaged
• Tighten the low pressure oil pipe joint or
• The low pressure fuel pipe components is
replace the low pressure fuel pipe.
leaked
• Tighten the high pressure oil pipe joint or
The fuel system • The high pressure fuel pipe components is
replace the high pressure fuel pipe.
is leaked leaked
• Tighten the high pressure fuel pump bolts to
• The high pressure fuel pump holder is leaked
the standard torque and replace the seals.
• The fuel injector is leaked
• Replace the leaked fuel injector.
• The fuel solenoid valve is damaged

The fuel pressure • The high pressure fuel pump tappet is Reference: Diagnosis procedure about that
in the engine is damaged the fuel pressure in the engine is too low (fuel
too low • The high pressure fuel pipe is leaked system, fault diagnosis and check).
• The fuel injector is leaked
Diagnosis about that the fuel pressure in the engine is too low
1. Check whether the pressure in the low pressure fuel pipe is too low.
A. Confirm when the pressure in the low pressure fuel pipe is

too low.
→ Yes
Repair the low pressure fuel pump unit.
→ No
To step 2.
2. Check whether the high pressure fuel regulation solenoid valve is damaged.
A. Confirm whether the fuel pressure regulation solenoid

valve is damaged.
→ Yes
Replace the high pressure fuel pump.
→ No
To step 3.
3. Check whether the fuel pressure regulation solenoid valve power supply has a fault.
A. Confirm whether the fuel pressure regulation solenoid

valve power supply has a fault.
→ Yes
Repair the solenoid valve power supply circuit.
→ No
To step 4.
4. Check whether the high pressure fuel pump tappet is damaged.
A. Confirm whether the high pressure fuel pump tappet is

damaged.
→ Yes
Repair or replace the low pressure fuel pipe components.
→ No
To step 5.
5. Check whether the high-pressure fuel pipe assembly is leaked.
A. Confirm whether the high-pressure fuel pipe assembly is

leaked.
→ Yes
Replace the high pressure fuel pipe components.
→ No
To step 6.
6. Check whether the fuel injector is leaked; if necessary, replace the leaked fuel injector.
Confirm that the fault has been ruled out.

Engine fuel system - Engine fuel system
21-7

High pressure fuel pump
Disassembly
1. Remove the high pressure fuel pump.
(a). Disconnect the high pressure fuel pump wiring

harness plug.
Warning:
Before the high pressure components are removed,
such as, high pressure fuel pump, fuel rail, fuel
injector and fuel pipe or fuel pressure sensor, the
fuel pressure within the high pressure range must
be relieved, to eliminate the fuel pressure and
prevent any risk.
(b). Disconnect the battery negative connector.
LFWX-6470-03009
(c). Remove the high pressure fuel pipe component

bracket bolt.
21
LFWX-6470-03010
(d). Remove the high pressure oil pipe component (1)

on the high pressure fuel pump.
(e). Remove the low pressure oil pipe components (2).
2
LFWX-6470-03011
21-8 Engine fuel system - Engine fuel system
(f). Remove the high pressure fuel pump fixing bolts

and remove the high pressure fuel pump.
LFWX-6470-03012
(g). Remove the high pressure fuel pump tappet.
LFWX-6470-03013
Installation
1. Install the high pressure fuel pump.
(a). Coat the oil on the high pressure fuel pump

tappet, and then install the high pressure fuel
pump tappet.
Note:
When the tappet is installed, must pay attention to
the positioning of high-pressure pump tappet and
the camshaft cover.
LFWX-6470-03014
21-9
(b). Install the high pressure fuel pump and tighten

the high pressure fuel pump fixing bolts.
Torque: 11 N•m
LFWX-6470-03015
(c). Install and tighten the lock connectors of high-

pressure fuel pipe component (1) and low
pressure pipe component (2).
2 Torque: 23 N•m
LFWX-6470-03011
(d). Install the high pressure fuel pipe component

bracket bolt. 21
Torque: 11 N•m
LFWX-6470-03017
(e). Connect the high pressure fuel pump wiring

harness plug.
(f). Connect the battery negative connector.
LFWX-6470-03016
Fuel injector
Disassembly
1. Remove the fuel injector.
(a). Remove the intake manifold and the intake pipe

components.
Reference: Removal and installation of the
2 intake components in the intake and exhaust
system.
(b). Remove the high pressure oil pipe component
bracket bolts (1).
1
(c). Remove the high pressure oil pipe component
bolts (2).
2
LFWX-6470-03018
(d). Disconnect the fuel pressure sensor wiring

harness plug (1).
2 2 2 2 1 (e). Disconnect the fuel injector wiring harness plug
(2).
LFWX-6470-03019
(f). Remove the fuel rail fixing bolts and remove the
fuel rail.
LFWX-6470-03020
21-11
(g). Insert the puller into the slot in the fuel injector.
LFWX-6470-03021
(h). Screw the pulling device on the puller and

carefully pull out the fuel injector.
Note:
After the fuel injector is removed, must replace
the spring element and Teflon seal ring in the fuel
injector.
LFWX-6470-03022 21
Installation
1. Install the fuel injector
(a). In the installation, first install the fuel injector on

the fuel rail, align the fuel injector with the fuel
injection hole on cylinder head, gently insert the
entire fuel rail into the installation hole, and then
install the fuel rail assembly on the cylinder head
assembly.
Note:
When the fuel injector is installed, do not coat any
oil or grease on Teflon seal ring in the fuel injector.
LFWX-6470-03023
(b). Align the fuel rail and the fuel injector pin and
install it in place, and then tighten evenly the fuel
rail fixing bolts.
Torque: 23 N•m
LFWX-6470-03024
(c). Connect the fuel pressure sensor wiring harness

plug (1).
2 2 2 2 1 (d). Connect the fuel injector wiring harness plug (2).
LFWX-6470-03019
(e). Install and tighten the high-pressure fuel pipe

component bracket bolts (1).
Torque: 11 N•m
2 (f). Install and tighten high pressure oil pipe
component bolts (2).
Torque: 23 N•m
1 (g). Install the intake manifold and intake pipe
components.
2
LFWX-6470-03018
21-13
Maintenance Tools
General tool
Quick wrench,
1 connecting rod and -
socket
2 Torsion wrench -
3 Puller -
21
4 M-shaped spline -
5 T-shaped spline -
Fuel system - Fuel system 13-a
Fuel system
Fuel system��1
Precautions�� 2
Schematic diagram�� 3
Fuel tank component drawing (1.8L2.0L)�� 4
Fuel tank component drawing (1.5T)�� 5
Fuel vaporization system component
drawing (1.8L2.0L)�� 6
Fuel vaporization system component
drawing (1.5T)�� 7
On-vehicle inspection�� 8
Bleed�� 10
Fault phenomenon table��11
Fuel tank��12
Overhaul�� 12
Fuel pump��15 13
Testing�� 15
Replacement�� 16
Fuel filter��16
Inspection�� 16
Canister��19
Fuel line��21
Inspection�� 21
13-b Fuel system - Fuel system
Fuel system - Fuel system 13-1
Fuel system
Preparations
1. Recommended tool
S/N Tool External view Description
1 Bracket Lift the fuel tank
Measure the pressure of fuel in

2 Oil pressure gauge
the fuel system.
13
Digital universal Measure the current, voltage

3
meter and resistance
13-2 Fuel system - Fuel system
Maintenance data
Capacity of fuel tank 60L
Model of fuel Car unleaded gasoline of 92# or above
Normal pressure of fuel 1.8L/2.0L:400kPa 1.5T:500kPa
Resistance of oil level sensor

40Ω
(the highest value)
Resistance of oil level sensor

250Ω
(the lowest value)
2. Tightening torque list
Items N·m
Torque of fuel tank assembly fixing bolt 65~85
Torque of carbon tube support fixing bolt 6~12

Torque of fuel filter support fixing bolt 20~26
Fuel tank cap 60~70
Precautions
1. Regardless of gasoline engine running, it’s prohibited to connect any element of connecting
system as long as the ignition switch is ON, e.g.: any cable of battery, fuel injector, electric fuel
pump, ignition system conductor, electronic control unit (ECU) line or air conditioner line, etc.
2. No smoking and keep away from open fire during the operation of fuel system. Keep ventilated
and make the corresponding fire extinguishers available on the maintenance site.
3. After the engine stops, a higher residual pressure still keeps in the fuel system. During the
removal of any element of fuel system, be sure to release the pressure of fuel system first, so
as to prevent the fuel from spraying out of the system, and avoid any personal injury or fire
accident.
4. Before disconnecting any fuel pipe, it’s required to clean the pipe and remove the dust or dirt
near to it.
5. After disconnecting the fuel pipe, it’s required to seal the pipe joint to avoid the entry of foreign
substance into it.
6. During the maintenance, replace all the cracked, scratched or damaged nylon fuel pipes, and
don’t attempt to repair each section of nylon fuel pipe.
7. Carry out the emptying work before installing the fuel system.
8. During the installation of any new fuel pipe, don’t hit any fuel pipe bundle clamp directly with a
hammer, otherwise it may damage the nylon pipe, resulting in fuel leakage.
9. During the connection of fuel pipes, be sure to drop some clean oil to the pipe joint to ensure
the correct connection and avoid the fuel leakage (“O” seal ring may expand during the correct
operation. If it isn’t be lubricated, it can’t be correctly reinstalled).
10. Prevent any rubber or leather tool or part from contacting the gasoline.
11. In order to avoid unexpected fire accident or explosion, don’t pour the fuel into the opened
container.
Schematic diagram
Intake manifold
Air filter
Fuel guide rail Engine
Activated carbon canister

solenoid valve
Fuel filter
Canister
Air
Fuel pump
Fuel 13
Fuel tank Fuel steam
LFWX-6470-13001
Fuel tank component drawing (1.8L2.0L)
16
14
17
3
1 13
12
18
19
15
20 10
2
11
3 5 6 10
5
3 9
4
3
8
3
7 3
LFWX-6470-13002
1 Engine inlet pipe assembly 11 Fuel return hose
2 Engine inlet pipe assembly II 12 Fuel tank bracket assembly II
Hexagon head bolt, spring washer

3 13 Fuel tank
and plain washer subassembly
4 Fuel tank bracket assembly 14 Fuel pump assembly
5 Hoop, worm drive hose, type A 15 Rubber ring
6 Filling hose 16 Rubber pad
7 Filler cap assembly 17 Fuel tank output pipe assembly
8 Fuel filler sealing cover 18 Fuel filter subassembly

Hexagon head bolt and taper elastic
9 Filler tube 19
washer assembly
10 Hoop, worm drive hose, type A 20 Fuel tank output pipe assembly
Fuel tank component drawing (1.5T)
13
LFWX-6470-13025
1 Engine inlet pipe assembly 2 Engine inlet pipe assembly II
3 Fuel pump assembly

Fuel vaporization system component drawing (1.8L2.0L)
LFWX-6470-13003
1 Canister assembly 9 Steel band elastic hoop
2 Adsorption tube III 10 Steel band elastic hoop
3 Evaporating pipe 11 Dual pipe clip
4 Canister ventilation tube 12 Dual pipe clip II
5 Canister shield 13 Hexagon flange bolt
6 Adsorption tube II 14 Hexagon flange nut
7 Adsorption tube 15 Canister mounting bracket
8 Steel band elastic hoop

Fuel vaporization system component drawing (1.5T)
2 3
2
13
LFWX-6470-13026
1 Adsorption tube II 2 Steel band elastic hoop
3 Adsorption tube 4 Dual pipe clip

On-vehicle inspection
1. Check the level of fuel.

(a). When the power supply at “ON” position, i.e. the
fuel level of fuel tank indicated in the figure.
Tips:
The oil level meter indicates the approximate level of
fuel in the fuel tank. When the volume of residual fuel in
the fuel tank is about 5L, the fuel alarm lamp goes on.
The volume of residual fuel is about 4L, the fuel alarm
lamp flashes at the intervals of 0.5s and fails to indicate
any segment code, it indicates the insufficiency of fuel,
and it’s required to refill the fuel as soon as possible.
LFWX-6470-13004
2. Check the fuel system for fuel leakage.

(a). Check the fuel pipes and hoses for fuel leakage.
LFWX-6470-13005
(b). Check both ends of fuel filter fuel pipe for

leakage.
LFWX-6470-13006
3. Test the pressure of fuel system.

(a). Relieve the pressure of fuel system.
(b). Ensure that the voltage of battery should be 12V
or so.
Note:
High or low voltage has direct influence on the
supply pressure of fuel pump.
LFWX-6470-13007
(c). Disconnect the fuel inlet pipe of fuel guide rail.

Tips:
After relieving the fuel pressure, a small amount of fuel
may exist in the fuel pipe, so it’s required to wrap the
pipe joint with a clean rag during the disconnection of
all the pipes, so as to avoid the fuel splashing.
Note:
• Don’t bend or torsion any resin pipe. 13
• In the case of fuel spill, wipe it off to prevent
the rubber or leather tools and parts
contacting the gasoline.
LFWX-6470-13008
(d). Connect the special fuel pressure gauge to the

fuel system.
Tips:
• As shown in the figure, press down the hump
of resin pipe joint, and pull out the fuel pipe.
LFWX-6470-13009
• The connection of special fuel pressure gauge is

as shown in the figure (schematic diagram).
(e). Start the engine and keep it running at idle
speed.
Tips:
Before stating the engine, perform the pressure
accumulation test, turn on the ignition switch 10s-15s
to make the sufficient fuel stored in the fuel pipe before
restarting the engine.
Note:
Check the connection for fuel leakage.
(f). Read the reading of pressure gauge. If it’s
unqualified, replace the fuel pump.
Fuel pressure: 400kPa (1.8L/2.0L) 550kPa (1.5T)
LFWX-6470-13010 (g). Turn off the ignition switch.
(h). Relieve the pressure of fuel.
(i). Take down the special fuel pressure gauge, and

reinstall the fuel pipe.
Tips:
Upon hearing a clear cracking sound, it indicates the
proper installation of resin fuel pipe joint.
Note:
Pull off fuel pipe joints slowly from both ends of fuel
pressure gauge, and take out the fuel pressure gauge.
(j). Start the engine after accumulating the fuel
pressure.
LFWX-6470-13008
Bleed
Note:
Perform the emptying work before installing the fuel
system.
1. Empty the fuel system.
(a). Wrap the inlet tube of fuel guide rail with a clean
rag.
(b). Pull off the inlet tube of fuel guide rail slowly (don’t
pull it off) to prevent the fuel from splashing.
(c). Turn on the ignition switch to start the fuel pump.
(d). Observe the inlet tube joint of fuel guide rail until
the fuel goes out of the tube smoothly.
(e). Reinstall the inlet tube of fuel guide rail.
LFWX-6470-13008
Fault diagnosis
Below table helps locating the fault causes. Check all the components in turn and repair or replace
the component as needed.
No fuel in fuel tank. Fill fuel
Check whether the fuse of fuel pump is blown.

Failure of electrical fuel pump
Check the fuel pump, and replace it if necessary.
Drain the fuel mixed with water, and refill the
Water in fuel tank.
clean fuel.
Air in fuel system. Empty the fuel system.

Starting failure of Clean the fuel line and replace the fuel filter if
Fuel line or fuel filter clogging
engine necessary
Reverse connection of fuel
Connect the tube correctly.
outlet tube or return tube
Loose connection of Ensure the firm and reliable connection of

connector connector.
Check whether the injector working condition is 13

Injector damage
normal with the special instrument
Check whether the connection of fuel pump

Poor operation of electrical
connectors is firm and reliable, and replace the
fuel pump
fuel pump if necessary.
Insufficient power of
Clean the fuel line and replace the fuel filter if
engine Fuel line or fuel filter clogging
necessary
Insufficient or unstable Check the pressure of fuel system, operations of

pressure of fuel supply electrical fuel pump and fuel injector circuit.
Check whether the injector working condition is

Shaking of engine Injector damage
normal with the special instrument
Sudden stalling of Low fuel tank level Fill fuel

engine during normal
Blowout of fuel pump fuse Replace the fuel pump fuse.
operation
Fuse blown Check the fuse

Failure of fuel indicator
Failure of line Repair the circuit.
lamp
Failure of fuel sensor Check the sensor.
Fuel tank
Overhaul
1. Remove the fuel tank.

(a). Release the fuel pressure.
(b). Turn off the ignition switch.
Note:
Before the work of fuel system, first turn off the ignition switch.
(c). Lift the vehicle
(d). Disconnect the connection of pipes shown in the

figure.
Tips:
• After relieving the fuel pressure, some fuel
may exist in the fuel pipes, so it’s required to
wrap the fuel pipe joints with clean rags before
disconnecting all the fuel pipe, so as to avoid the
fuel splashing.
• It’s best to mark the corresponding fuel pipe
before disconnecting the fuel pipes, so as to
avoid any mixed installation of pipes.
Note:
In the case of fuel spill, wipe it off to prevent the
rubber or leather tools and parts contacting the
gasoline.
LFWX-6470-13008
(e). Use a hydraulic bracket to haul the fuel tank.

(f). Remove circumferential bands between oil filling
pipe and refueling hose & air return hose, and
take out the refueling hose and air return hose.
(g). Disconnect the connection of desorption pipe III
and carbon tank, plug out the desorption pipe;
remove the circumferential band used to connect
the evaporating pipe and carbon tank, and plug
out the evaporating pipe.
(h). Remove fixing bolt of fuel filter and car body;

disconnect the connection of fuel filter oil outlet
pipe and engine oil inlet pipe; disconnect the
connection of desorption pipe III and desorption
pipe II.
LFWX-6470-13077
(i). Remove 4 fixing bolt components on oil tank

bracket component, and take down the oil tank
bracket component.
13
LFWX-6470-13012
(j). Lower the hydraulic bracket slowly, disconnect

the connector of electrical fuel pump, and take
down the fuel tank assembly.
Note:
While lowering the hydraulic bracket, be sure
to check the fuel tank pipes, so as to avoid the
damages caused by pipe squeezing.
(k). Remove the fuel pump and fuel pipe. (see
Chapter 13 Fuel System-Injection Pump,
Replacement)
LFWX-6470-13013
2. Check and repair the fuel tank.

(a). Clean the fuel tank.
• Adopt a high-pressure water gun to clean the
fuel tank.
• Adopt the compressed air to dry the fuel tank.
(b). Check the fuel tank.
• Check the fuel tank for damages or fuel
leakage. If any, replace the fuel tank.
• Check the fuel tank rubber gasket and fuel tank
cover for damage, and replace it if any.
LFWX-6470-13014
3. Install the fuel tank.

(a). Install the fuel pump and fuel pipe. (see Chapter
13 Fuel System-Fuel Pump, Replacement)
(b). Adopt a hydraulic bracket to hold the fuel tank
slowly up to its installed position, and connect the
connector of electric fuel pump.
LFWX-6470-13013
(c). Connect refueling hose and oil filling pipe and

install a circumferential band between them;
connect oil filling pipe and air return hose, and
install a circumferential band between them.
(d). Connect desorption pipe II and carbon tank;
connect evaporating pipe and carbon tank, and
install circumferential band between them.
LFWX-6470-13011
(e). Install oil tank bracket component on its

installation site, and fasten 4 fixing bolts.
Torque:65~85 N·m
(f). Lower the hydraulic bracket slowly, hold and
move it away.
(h). Lower the vehicle.
(i). Start the engine after accumulating the fuel
pressure.
LFWX-6470-13012
Fuel pump
Testing
1. Check and test the fuel pump.

(a). Apply the battery voltage between #2 and #4
terminals of electrical fuel pump, and check
whether the fuel pump works.
Note: 13
The fuel pump can’t run without fuel for a long
time, and shall not run with fuel in the air, so its
check and test time shall not be too long (≤10s), so
as to avoid the burning of motor.
LFWX-6470-13015
(b). Adopt “Ohms” range of digital multimeter to

measure the resistance of fuel level sensor.
Tips:
Connect #1 or #4 terminal of electrical fuel pump
with a digital multimeter, lift up the fuel float slowly
from its lowest point, and observe the changes of
its resistance.
Lowest point:250Ω
Highest point:40Ω
4 3 2 1
LFWX-6470-13016
Replacement
1. Remove the fuel pump.

(a). Remove the fuel tank. (refer to Chapter 13 Fuel
system - fuel tank, repair)
(b). Disconnect two oil pipes and one evaporating
pipe which are connected with the fuel pump.
(c). After unscrewing fuel tank cover, take out the fuel
pump.
Tips:
When disconnecting the fuel pipe, it’s best to mark
the fuel pipe, so as to avoid any mixed installation.
LFWX-6470-13017
2. Install the fuel pump.

(a). Install the electrical fuel pump in the fuel tank.
Note:
During the installation of electrical fuel pump, first
install the fuel float of fuel sensor inclinedly into
the fuel tank, then install its whole body into the
tank, and be sure to avoid its knock against the
float.
(b). Screw up fuel tank cover.
(c). Install oil pipe and evaporating pipe which are
connected with the fuel pump.
(d). Install the fuel tank. (refer to Chapter 13 Fuel
system - fuel tank, repair)
LFWX-6470-13017
Fuel filter
Inspection
1. Check the fuel filter.

(a). As shown in the figure, ventilate the inlet tube
joint opening with an air tube, and confirm
whether it’s ventilated. If it’s difficult to ventilate or
not ventilated, replace it.
LFWX-6470-13018
(b). Block the fuel outlet of fuel filter, and fill the fuel
into the filter from its fuel inlet.
(c). Block the fuel inlet or outlet of fuel filter, and
shake the fuel filter to left or right.
LFWX-6470-13019
(d). Drain the fuel out of fuel filter. If it has a lot of

sundries or it’s discolored, replace the fuel filter.
Tips:
The common replacement interval of fuel filter is
one year or 20,000km.
13
LFWX-6470-13020
Replacement
1. Remove the fuel filter.
(c). Lift the vehicle
(d). Disconnect the fuel pipes from both ends of fuel

filter.
Tips:
After relieving the fuel pressure, a small amount
of fuel may exist in the fuel pipe, so it’s required
to wrap the pipe joint with a clean rag during the
disconnection of all the pipes, so as to avoid the
fuel splashing.
LFWX-6470-13022
(e). Remove the fixing bolts of fuel filter support, and

take down the fuel filter with support assembly.
LFWX-6470-13021
2. Install the fuel filter.

(a). Install the fuel filter with support assembly to its
installed position, and tighten its fixing bolts.
Torque: 20~26 N·m
LFWX-6470-13021
(b). Connect the fuel pipes on both ends of fuel filter.

(c). Lower the vehicle.
LFWX-6470-13022
Canister
Replacement
1. Remove the carbon canister.

(c). Lift the vehicle 13
(d). Disconnect carbon tank breather pipe,

evaporating pipe and desorption pipe.
LFWX-6470-13024
(b). Install two bolts and nuts of carbon tank shield,

and take down carbon tank shield and carbon
tank.
LFWX-6470-13023
2. Install the carbon canister.

(a). Install the canister on the support, and ensure its
firm installation.
(b). Install the canister support and its fixing bolts,
and tighten them.
Torque: 6~12 N·m
LFWX-6470-13023
(c). Connect carbon tank breather pipe, evaporating

pipe and desorption pipe.
(d). Lower the vehicle.
LFWX-6470-13023
Fuel line
Inspection
1. Inspect the fuel pipeline

(a). Check the fuel pipe for damages and fuel
leakage. If any, replace it.
LFWX-6470-13005
13
Intake/exhaust system
Intake/exhaust system��1
Operating principle��1
Part instructions�� 2
sensor�� 2
Throttle body�� 2
sensor�� 2
Inter-cooler assembly�� 3
Front catalyst assembly�� 3
Air intake system�� 4
Exhaust system�� 5
Air intake system�� 6 21
Exhaust system�� 7
Cleaning throttle control unit�� 8
Diagnosis for powerless
engine acceleration�� 9
Removal and Installation�� 11
Intake manifold��11
Disassembly��11
Exhaust manifold�� 14
Front catalyst assembly�� 16
Engine intake/exhaust system - Intake/exhaust system (1.5T) 21-1
Intake/exhaust system
Apply Size
Vacuum degree of intake manifold under

≥ -60 kPa
idling condition
Exhaust back pressure at engine speed of

≤ 49 kPa
4850 rpm
Name Nm Lb-ft Lb-in
Intake manifold assembly bolt 23 17 -
Exhaust manifold assembly bolt 23 17 -
Bolt for connecting supercharger assembly

23 17 -
and exhaust manifold assembly
Turbocharger shield cover bolt 11 8 -
Front catalyst assembly support bolt 18 13 -
Bolt for connecting front catalyst assembly

23 17 -
and supercharger assembly
Fixing bolt for exhaust manifold heat shield 11 8 -

21
Operating principle
System Overview
The air intake system is mainly comprised by air filter
assembly, compressor inlet manifold, inter-cooler
assembly, electronic throttle body assembly, and
inlet manifold assembly, etc. The air intake system
is designed to filter, compress and cool the air in the
inlet pipe and make the air enter cylinder through inlet
manifold to mix with fuel from injector to form mixed
gas.
LFWX-6470-05001
The exhaust system is mainly comprised by exhaust

manifold assembly, supercharger assembly, front
catalyst and silencer, etc. The exhaust system is
designed to discharge exhaust gas into atmosphere
from burning mixed gas through purification and
silencing treatment.
LFWX-6470-05002
21-2 Engine intake/exhaust system - Intake/exhaust system (1.5T)
Part instructions
It is mounted on main engine intake manifold

to measure air pressure and temperature after
compression by turbocharger.
LFWX-6470-05003
Throttle body
It is mounted on engine intake manifold assembly to

regulate air intake of engine through ECU control.
LFWX-6470-05004
It is mounted on engine intake manifold assembly to

test pressure of intake temperature after supercharging
and cooling by inter-cooler.
LFWX-6470-05005
Inter-cooler assembly
It is mounted on engine intake manifold to cool

compressed air.
LFWX-6470-05006
Front catalyst assembly
It is mounted on exhaust end of turbocharger to purify

hazardous gas in engine exhaust and reduce engine
exhaust pollution.
21
LFWX-6470-05007

Air intake system
3
4
LFWX-6470-05008
1 Intake manifold 4 Electronic throttle body

2 5 Intake pressure and temperature sensor
sensor
3 Intake manifold assembly

Exhaust system
1 2
21
LFWX-6470-05009
1 Turbocharger heat shield cover 4 Front catalyst assembly
2 Turbocharger assembly 5 Exhaust manifold assembly
3 Front oxygen sensor

Part exploded view

Air intake system
4
3 5
2
8
15
16
14
13
12
11
10
LFWX-6470-05010
1 Intake manifold cover 9 Throttle body assembly

Gasket for intake manifold transition
2 Intercooler screw 10
block
3 Intake manifold 11 Intake manifold transition block
4 12 Bolt for intake manifold transition block
sensor
Bolt for intake pressure and
5 13 Intake manifold assembly
temperature sensor
6 Bolt for throttle body 14 Intake pressure and temperature sensor
Bolt for intake pressure and temperature
7 Clamp 15
sensor
8 Intake manifold holder 16 Intake manifold assembly bolt
Engine intake/exhaust system - Intake/exhaust system 21-7
Exhaust system
13
11
12
9
10
4
21
8
7 5
6 LFWX-6470-05011
1 Turbocharger heat shield cover 8 Exhaust manifold heat shield bolt
2 Turbocharger shield cover bolt 9 Exhaust manifold assembly bolt
3 Exhaust manifold gasket 10 Bolt for front catalyst bracket
4 Turbocharger assembly 11 Front oxygen sensor
Exhaust manifold upper pressure

5 12 Front catalyst assembly
plate
Exhaust manifold lower pressure

6 13 Heat resistant nut
plate
7 Exhaust manifold heat shield

21-8 Engine intake/exhaust system - Intake/exhaust system

Cleaning throttle control unit
Note:
Do not scratch throttle housing when cleaning it.
• Remove throttle control unit.
• Manually open throttle and use appropriate tool (such as wooden or plastic wedge) and lock it
at the opening position.
Note:
The throttle cleaning agent is inflammable liquid! Follow appropriate precautions and notices while
working with inflammable liquid. Do not use compressed air to clean throttle. Be sure to wear
protective glasses, gloves and garment to avoid skin contact and personal injury.
• Use throttle cleaning agent and a clean brush to

carefully clean throttle housing, especially around
closed throttle.
LFWX-6470-05012
• Use non-fiber cloth to wipe off throttle housing.

• After cleaning agent is completely evaporate,
mount it into clean throttle control unit.
LFWX-6470-05013

• Clean or replace the air filter.

• The air filter is blocked. • Repair or replace the intake
• The inlet pipe is leaking gas. duct components.
• The throttle has failure. • Repair or replace the throttle.
The engine cannot • The turbocharger has failure. • Repair or replace the
provide enough power • The supercharger pressure and turbocharger.
for acceleration. temperature sensor has failure. • Repair the sensor circuit or
• The inter-cooler cannot dissipate heat replace the sensor.
properly. • Repair or replace the inter-
• The front catalyst is blocked. cooler.
• Replace the front catalyst.
• Repair or replace the intake

piping components.
• The inlet pipe is leaking gas.
• Repair supercharger lubricating
The engine generates • The turbocharger is not properly
components or replace the
much noise during lubricated.
supercharger.
acceleration. • The exhaust manifold is not well sealed.
• Replace exhaust manifold
• The front catalyst is damaged. sealing gasket.
• Replace the front catalyst.
Diagnosis for powerless engine acceleration

Test conditions Results/methods
1. Check if the engine filter is blocked. 21

A. Verify if the air filter is blocked.
→Yes
Clean or replace the air filter.
→No
To step 2.
2. Check if the engine intake pipe is leaking gas.
A. Verify if the engine intake pipe is leaking gas.

→Yes
Repair or replace the intake duct components.
→No
To step 3
3. Check whether the intake pressure and temperature sensor has a fault.
A. Verify if the intake pressure and temperature sensor has

failure.
→Yes
Repair the sensor circuit or replace the sensor.
→No
To step 4.
Test conditions Results/methods
4. Check if the turbocharger has failure.
A. Verify if the turbocharger has failure.

→Yes
Repair or replace the turbocharger.
→No
To step 5.
5. Check if the supercharger pressure limit solenoid has failure.
A. Verify if the supercharger pressure limit solenoid has

failure.
→Yes
→No
To step 6.
6. Check if the throttle has failure.
A. Verify if the throttle has failure.

→Yes
Repair or replace the throttle components.
→No
To step 7.
7. Check if the inter-cooler does not dissipate heat properly.
A. Verify if the inter-cooler does not dissipate heat properly.

→Yes
Clean, lubricate or replace the inter-cooler.
→No
To step 8.
8. Check whether the intake pressure and temperature sensor has a fault.
A. Verify if the intake pressure and temperature sensor has

failure.
→Yes
→No
To step 9.
9. Check if the front catalyst is blocked.
A. Verify if the front catalyst is blocked.

→Yes
Replace the front catalyst.
→No
To step 10.
10. Check the engine cylinder pressure and verify if the engine is leaking gas due to wear inside. Repair
the engine if necessary.
Confirm that troubleshooting is completed.


Intake manifold
Disassembly
1. Remove the intake manifold.
(a). Rotate out two bolts and take down intake

manifold cover.
LFWX-6470-05014
(b). Disconnect the wiring plug for intake pressure

and temperature sensor (1).
(c). Loosen connecting clamp for intake manifold
1
and its cover and pull out lower part of intake
manifold.
(d). Take intake manifold from waste gas
turbocharger.
2 21
LFWX-6470-05015
(e). Disconnect the wiring plug for intake pressure

and temperature sensor.
LFWX-6470-05016
(f). Disconnect throttle wiring plug (1).

(g). Disconnect canister solenoid combined pipe (2).
(h). D i s c o n n e c t t h e b r e a t h e r p i p e f o r o i l / g a s
separation valve (3).
1 (i). Remove the inter-cooler.
Refer to dismantle and mounting of inter-
2 cooler.
(j). Remove electronic throttle assembly.
Refer to dismantle and mounting of electronic
throttle assembly.
3
LFWX-6470-05017
(k). Remove intake manifold fixing bolt and take down

intake manifold.
LFWX-6470-05018
Installation
1. Mount the intake manifold.
(a). Mount the intake manifold and tighten fixing bolt.

Torque: 23 N•m
(b). Mount electronic throttle body assembly.
LFWX-6470-05018
(c). Connect throttle wiring plug (1).

(d). Connect canister solenoid combined pipe (2).
(e). Connect breather pipe for oil/gas separation
valve. (3).
1 (f). Mount inter-cooler.
LFWX-6470-05017
(g). Connect wiring plug for intake pressure and

temperature sensor.
21
LFWX-6470-05019
(h). Connect wiring plug for intake pressure and

temperature sensor (1).
(i). Mount lower part of intake manifold onto intake
1
manifold and fix the clamp.
LFWX-6470-05015
(j). Mount intake manifold onto supercharger

assembly. Mount intake manifold cover and
tighten tapping bolt.
(k). Fill cooling liquid.
LFWX-6470-05014
Exhaust manifold
Disassembly
1. Remove exhaust manifold.
(a). Remove front catalyst assembly.

Refer to dismantle and mounting of front
catalyst.
(b). Remove supercharger assembly with exhaust
manifold assembly.
Refer to dismantle and mounting of
supercharger.
(c). Remove fixing bolt for exhaust manifold and
supercharger and remove exhaust manifold.
LFWX-6470-05020
(d). Remove sealing gasket for exhaust manifold.
LFWX-6470-05021
Installation
1. Mount exhaust manifold.
(a). Mount sealing gasket for exhaust manifold.
LFWX-6470-05021
(b). Mount and tighten the bolt for connecting exhaust

manifold and supercharger.
Torque: 23 N.m
Note:
Before the installation, check the supercharger
guide pin and gasket for damage and replace them
if so.
(c). Mount supercharger assembly with exhaust
manifold assembly.
21
LFWX-6470-05020
Front catalyst assembly

Disassembly
1. Remove front catalyst assembly.
(a). Remove the fixing bolt for supercharger heat

shield and remove heat shield.
LFWX-6470-05022
(b). Remove the fixing bolt for front catalyst and

turbocharger.
LFWX-6470-05023
(c). Disconnect wiring plug for front oxygen sensor(1).

1
(d). Remove bolt for connecting front catalyst and
silencer(2).
(e). Remove front catalyst bracket bolt(3).
(f). Remove front catalyst assembly.
3
2
2
3
LFWX-6470-05024
Installation
1. Mount front catalyst assembly.
(a). Install front catalyst assembly, and fasten the

catalyst support bolt for several circles.
LFWX-6470-05025
(b). Mount bolt for connecting front catalyst and

supercharger.
Torque: 23 N.m
(c). Fasten front catalyst support bolt.
Torque: 18 N.m
21
LFWX-6470-05023
(d). Align muffler pin with front catalyst, and connect

front oxygen sensor wiring harness plug.
LFWX-6470-05026
(e). Mount supercharger heat shield and tighten fixing

bolt.
Torque: 11 N.m
LFWX-6470-05022
(f). Install muffler retaining nut.

Torque: 38 N.m
LFWX-6470-05027
Maintenance Tools
General tool
1 Screwdriver -
2 Pipe wrench -
Quick wrench,
socket
21
4 Torque wrench -
Intake/exhaust system - Intake/exhaust system 14-a
Intake/exhaust system - Intake/exhaust system

Intake and exhaust system�� 1
Precautions�� 1
Component drawing
(intake system 1.8L 2.0L-5MT)�� 2
Component drawing
(intake system 2.0L-CVT)�� 3
Component drawing (intake system 1.5T)�� 4
Component drawing
(exhaust system 1.8L 2.0L)�� 5
Component drawing
(exhaust system 1.5T-5MT)�� 6
Component drawing
(exhaust system 1.5T-8AT)�� 7
Fault diagnosis��9
Fault diagnosis gauge�� 9
Air filter��10
14
Inspection�� 10
Front muffler with purifier assembly�� 14
Rear muffler��16
14-b Intake/exhaust system - Intake/exhaust system
Intake/exhaust system - Intake/exhaust system 14-1
Intake and exhaust system

Maintenance data
Items N·m
Fixing bolts and nuts for connecting exhaust

55~65
manifold and front mufflers.
Fixing bolts and nuts for connecting front and rear

55~65
mufflers
Fixing bolts and nuts for connecting the drain tube

6~12
and vehicle body
Fixing bolt connecting the air filter and bodywork 55~65
Precautions
1. The cartridge of air filter is a paper cartridge, which should be handled with care during the
operation.
2. The temperature of exhaust pipe is high during the operation of engine. During the work of
exhaust system, stop the engine, and restart it after the engine and exhaust system is cooled
down.
14
14-2 Intake/exhaust system - Intake/exhaust system
Component drawing (intake system 1.8L 2.0L-5MT)
LFWX-6470-14001
1 Air filter assembly 4 Steel strip elastic hoop
1-1 Upper cover subassembly of air filter 5 Drain tube assembly
1-2 Filter 6 Hexagon flange bolt
1-3 Lower cover subassembly of air filter 7 Hexagon flange bolt
Hexagon head bolt, spring washer and

2 Hoop, worm drive hose, type A 8
plain washer subassembly

3 Air inlet hose assembly 9
Component drawing (intake system 2.0L-CVT)
4 3
1-1
2
7 5
3
1-2 1
6
9
8 11 1-3
9
10
14
LFWX-6470-14022
1 Air filter assembly 4 Hoop, worm drive hose, type A
1-1 Upper cover subassembly of air filter 5 Air inlet hose assembly
1-2 Filter 6 Crankcase ventilation pipe
1-3 Lower cover subassembly of air filter 7 Steel strip elastic hoop
2 Cross recessed flange bolt 8 Drain tube assembly

10 Hexagon flange bolt 11 Air filter mounting bracket

Component drawing (intake system 1.5T)
7
6
2
4
8
9 7
1-1
3
10 3
3
1-2
1-3
5 1
11
12
4
13
12
LFWX-6470-14024
1 Air filter assembly 6 Pressure relief nozzle
1-1 Upper cover subassembly of air filter 7 Hoop, worm drive hose, type A
1-2 Filter 8 Crankcase ventilation pipe
1-3 Lower cover subassembly of air filter 9 Steel strip elastic hoop
2 Cross recessed flange bolt 10 Steel strip elastic hoop

3 11 Drain tube assembly

4 Hoop, worm drive hose, type A 12
5 Air inlet hose assembly 13 Hexagon flange bolt

Component drawing (exhaust system 1.8L 2.0L)
14
LFWX-6470-14002
Hexagon nut and plain washer

1 Rear muffler assembly 6
subassembly
2 Front muffler with purifier assembly 7 Rubber suspension block
3 Heat shield II 8 All-metal hexagon flange lock nut
4 Heat shield 9 Hexagon flange bolt
5 Small seal gasket

Component drawing (exhaust system 1.5T-5MT)
6
4 5
7
2
3
4
1
4
LFWX-6470-14025
1 Front muffler assembly 5 Connection tube assembly
2 Hexagon flange bolt 6 Small seal gasket
3 Small seal gasket 7 Rubber suspension block
4 All-metal hexagon flange lock nut 8 Rear muffler assembly

Component drawing (exhaust system 1.5T-8AT)
4 6
5
2
4
2
3
14
LFWX-6470-14026
1 Front muffler assembly 5 Connection tube assembly
2 Hexagon flange bolt 6 Small seal gasket
3 Small seal gasket 7 Rubber suspension block
4 All-metal hexagon flange lock nut 8 Rear muffler assembly

1. Check the intake system

(a). As shown in the figure, check the air inlet system
for suction. If no, check and repair the air inlet
system.
 Tips:
It’s required to start the engine during the check,
and be sure to avoid any contact with the engine.
LFWX-6470-14003
2. Inspect the exhaust system

(a). Start the engine, check each subassembly of
exhaust system for leakage, cracking or damage.
If any, repair it, and replace it if necessary.
LFWX-6470-14004
Fault diagnosis
Fault diagnosis gauge
the component as needed
Air leakage and poor intaking Clean the air inlet pipe and replace the air filter
Unstable idling or
of air inlet pipe or air filter cartridge.
weak acceleration of
Intake pressure temperature Clean the intake pressure temperature sensor
engine
sensor hole clogging try hole and replace the sensor if necessary
It’s easy to start the

engine at cold state, Air leakage of air inlet pipe or Repair the housing of inlet pipe or air filter, and
but it’s difficult to start air filter replace if necessary.
at hot state.
Insufficient engine Air vent clog of exhaust

Check and repair the exhaust system.
power system
Crackling or hissing of
Leakage of exhaust system Check and repair the exhaust system.
exhaust system
Too high noise of

Damages of muffler Replace the muffler. 14
exhausting
Cracking or vibration Loosening of muffler rubber

Repair or replace
noises produced by suspension block
the exhaust system Loosening of heat shield Tighten the fixing bolts of heat shield.
Air filter
Inspection
1. Check the subassembly of air filter.
(a). Apply the compressed air to clean the air filter
subassembly.
LFWX-6470-14005
(b). Visually check the air filter cartridge for damages.

If any, replace it.
LFWX-6470-14006
(c). Visually check the air filter housing for damages.

If any, replace it.
LFWX-6470-14008
Replacement
1. Remove the air filter.
(a). Loosen the hoop for connecting the inlet hose
and air filter, and pull out the inlet hose.
LFWX-6470-14009
(b). Remove the fixing bolts of drain tube assembly.
14
LFWX-6470-14010
(c). Remove the upper cover fixing reed of air filter,

and take down the air filter upper cover in upward
direction.
LFWX-6470-14011
(d). Take out the air filter cartridge.
LFWX-6470-14012
(e). Remove 3 fixing bolts on lower cover component

of air filter, and take down the lower cover
component from car body.
2
1
LFWX-6470-14013
2. Install the air filter

(a). Install the lower cover of air filter on the
2 permanent position of car body, and fasten the
1 fixing bolt of lower cover and car body.
Torque: ① 20~26N·m; ② 6~12N·m
LFWX-6470-14013
(b). Install the air filter element.
LFWX-6470-14012
(c). Install the air filter upper cover on air filter lower
cover, and fasten the fixing shrapnel.
LFWX-6470-14011 14
(d). Tighten the fixing bolts of drain tube and vehicle

body.
Torque: 6~12 N·m
LFWX-6470-14010
(e). Install the hoop for connecting the inlet hose and
air filter, and tighten the hoop.
LFWX-6470-14009
Front muffler with purifier assembly

Replacement
1. Remove the front muffler with purifier

assembly.
(a). Lift up the vehicle or park it on the trench.
(b). Disconnect the connector of rear oxygen sensor.
LFWX-6470-14020
(c). Remove the fixing bolts and nuts for connecting

the front muffler with purifier and exhaust
manifold.
(d). Remove rubber mounting blocks of front muffler
with purifier assembly.
LFWX-6470-14014
(e). Remove the fixing bolts and nuts for connecting

the front muffler with purifier and front muffler.
(f). Take down the front muffler with purifier
assembly.
 Tips:
Don’t use any removed sealing gasket any longer.
Replace it with a new gasket. Prevent the front
muffler falling and causing physical injury while
supporting it.
LFWX-6470-14015
2. Install the front muffler with purifier assembly.

(a). Place the front muffler with purifier in its installed
position.
(b). Install rubber mounting blocks of front muffler
with purifier assembly.
14
LFWX-6470-14017
(c). Install fixing bolt for connecting front muffler with

purifier assembly and exhaust manifold and
fasten it (small gasket is installed on the joint of
muffler and manifold).
Torque: 55~65 N·m
LFWX-6470-14018
(d). Install the fixing bolt and nut for connecting front
muffler with purifier assembly and rear muffler
(small gasket is installed on the joint of front
muffler and rear muffler).
Torque: 55~65 N·m
LFWX-6470-14015
(e). Connect rear oxygen sensor.
LFWX-6470-14020
Rear muffler
Replacement
1. Remove rear muffler.
(a). Remove the fixing bolts and nuts for connecting
rear and front mufflers.
(b). Remove 3 front and rear rubber mounting blocks
of rear muffler assembly.
(c). Remove rear muffler assembly.
LFWX-6470-14019
2. Install rear muffler.

(a). Place rear muffler assembly in its installed
position, and install the muffler rubber suspension
blocks.
(b). Install the fixing bolts and nuts for connecting
rear muffler and three-way catalyst.
Torque: 55~65 N·m
LFWX-6470-14019
14
Cooling system - Cooling system 15-a
Cooling system
Cooling system��1
Precautions�� 2
Radiator component drawing
(1.8L 2.0L)�� 3
(1.5T-5MT)�� 4
(1.5T-8AT)�� 5
Inter-cooler assembly component
drawing (1.5T-5MT)�� 6
Inter-cooler assembly component
drawing (1.5T-8AT)�� 7
Oil cooler component drawing
(2.0L-CVT)�� 8
15
Coolant��10
Radiator��12
Inspection�� 12
Water pump��18
Overhaul�� 18
Thermostat��19
Overhaul�� 19
Water temperature sensor��20
15-b Cooling system - Cooling system
Cooling system - Cooling system 15-1
Cooling system
System description
 Tips
XUANLANG series models include LF6470, LF6470B, LF6470C, LF6470G, LF6470H, equipped
with LFB479Q, LF483Q and LF477ZLQ engines and 5MT or CVT or 8AT. Depending on the
installed engine and transmission, the cooling line layout is different while the service method is
almost the same. This section describes the LF6470 model equipped with LFB479Q engine and
5MT.
1. Function
The function of the cooling system: to dissipate some of the heat absorbed by the heated parts
to maintain the engine working under the proper temperature. In addition, the cooling system can
supply the hot air flow inside the vehicle.
2. Composition
The cooling system mainly consists of the coolant, radiator, cooling fan, water pump, electronic
water pump, thermostat and cooling line etc.
3. Schematic
Legend
ECU
Fan Battery Water temperature

gauge
High 15
Water Radiator
tank
Low
Water tank
cover
Heater
Interior water passage

Coolant Cylinder Cylinder Water
Thermostat pump block outlet
head
Water
temperature
sensor
LFWX-6470-15001
15-2 Cooling system - Cooling system
Maintenance data
Opening
temperature of 82ºC
thermostat valve
(1.5T) Glycol type, freezing point according to temperature

Capacity of anti- 7.4±0.2 L
requirements
freeze cooling
fluid (1.8L/2.0L) Glycol type, freezing point according to
6±0.2 L
temperature requirements
Items N·m
Drain plug 3~5
Water pump fixing bolts 25~30
Fan motor fixing nuts 5~6
Fan locking nuts 5~6
Fixing bolts of fan shield with fan assembly 9~12
Fixing bolts of heat radiator left or right mounting support 9~12
Precautions
1. Precautions before repair
(a). No matter the engine is running or no, do not connect any system element so long as the
ignition switch is on, including the battery cable, injector, fuel pump, ignition system conductor
and electronic control unit (ECU) circuit etc.
2. Maintenance precautions
(1). During the work of cooling system, be sure to start the work after the engine is cooled.
(2). During the work, don’t splash the cooling fluid on drive belt.
(3). During the removal of heat radiator, be sure to avoid any scratch or damage of heat exchanger
core.
(4). During the reinstallation of cooling system, please ensure the firm connection of each hose and
proper installation of hose clamps.
Radiator component drawing (1.8L 2.0L)
5-2
11 5-3
5
6
1 11 8
5-4
5-5 5-1 5-5
6
4 9
10
7
8
7
2 3-1
3-2 15
8
3-3
LFWX-6470-15002
1 Radiator assembly 5-3 Water pot gasket
2 Radiator water outlet pipe 5-4 Radiator overfill tube
3 Electronic fan with cowl assembly 5-5 Steel strip elastic clamp
3-1 Fan motor 6 Radiator upper mounting bushing
3-2 Fan blade 7 Radiator lower suspension
3-3 Cowl 8 Steel strip elastic clamp
4 Radiator water inlet pipe 9 Steel strip elastic clamp

5 Water pot with pipe assembly 10
5-1 Water pot body 11 Hexagon flange bolt
5-2 Water pot lid

Radiator component drawing (1.5T-5MT)

13-1
11-2
11 12
17 7
13
18 11-1
15
14
1
13-2
3 16 - 2
7 7
16-1
18
13-3
6 13-4
2
16 7
2 5-1
6
6
5 6
2
5-2
7
5-4 2
4 7 5-3
8
6 6 16-4
10 16-5 16-3
10 2
9
LFWX-6470-15020
1 Radiator assembly 11-2 Expansion tank cover

3 Radiator upper mounting bushing 13 Refill tube assebly
4 Radiator lower suspension 13-1 Refill tube I
5 Radiator water inlet pipe assembly 13-2 Refill tube II
5-1 Radiator water inlet pipe I 13-3 Refill tube III
5-2 Radiator water inlet pipe II 13-4 Water replenishing three-way pipe
5-3 Radiator water inlet pipe III 14 Water replenishing pipe bracket
5-4 Radiator water inlet three-way pipe 15 Hexagon flange bolt
6 Steel strip elastic clamp 16 Electronic fan with cowl assembly
7 Steel strip elastic clamp 16-1 Electronic fan blade (left)

8 Radiator water outlet pipe 16-2 Electronic fan blade (right)
9 Radiator drain pipe 16-3 Electronic fan left motor
10 Steel strip elastic clamp 16-4 Electronic fan right motor
11 Expansion tank assembly 16-5 Electronic fan shield
Radiator upper installation cross member

11-1 Expansion tank body 17
assembly

18
Radiator component drawing (1.5T-8AT)

13-1
11-2
11 12 7
17
13
18 11-1
15
14
1
16-2 13-2
3 7
16-1 7
18
13-3 15
6 13-4
2
16 7
6 8
2 6 5-2
6 2
5-4
5-1 6 7 5-3
4 7
5 6
16-4
10 16-5 16-3
10 9
2
LFWX-6470-15021
1 Radiator assembly 12 Hexagon flange bolt

2 13 Refill tube assebly
3 Radiator upper mounting bushing 13-1 Refill tube I
4 Radiator lower suspension 13-2 Refill tube II
5 Radiator water inlet pipe assembly 13-3 Refill tube III

5-1 Radiator water inlet pipe I 13-4 Water replenishing three-way pipe
5-2 Radiator water inlet pipe II 14 Water replenishing pipe bracket
5-3 Radiator water inlet pipe III 15 Hexagon flange bolt
5-4 Radiator water inlet three-way pipe 16 Electronic fan with cowl assembly
6 Steel strip elastic clamp 16-1 Electronic fan blade (left)
7 Steel strip elastic clamp 16-2 Electronic fan blade (right)
8 Radiator water outlet pipe 16-3 Electronic fan left motor
9 Radiator drain pipe 16-4 Electronic fan right motor
10 Steel strip elastic clamp 16-5 Electronic fan shield
Radiator upper installation cross

11 Expansion tank assembly 17
member assembly

11-1 Expansion tank body 18
11-2 Expansion tank cover
Inter-cooler assembly component drawing (1.5T-5MT)
7-5 8
8 8
7-1
7-2
1 8
7-3
3 8
4-1 3 8
4-4
3 7-5
7-4
5 8
4-3
2 8
4-2
6
LFWX-6470-15022
1 Inter-cooler assembly 2 Inter-cooler water outlet pipe
3 Steel strip elastic clamp 4 Inter-cooler water inlet pipe assembly
4-1 Inter-cooler water inlet pipe I 4-2 Inter-cooler water inlet pipe II
4-3 Inter-cooler water inlet pipe III 4-4 Intercooler water inlet four-way pipe IV
5 Steel strip elastic clamp 6 Steel strip elastic clamp
7 Inter-cooler exhaust tube assembly 7-1 Inter-cooler exhaust tube I
7-2 Inter-cooler exhaust tube II 7-3 Inter-cooler exhaust tubeIII
7-4 Inter-cooler exhaust tube IV 7-5 Intercooler exhaust three-way pipe
8 Steel strip elastic clamp
Inter-cooler assembly component drawing (1.5T-8AT)
7-5 7
7-2
1 8 8
8 7-1
8
3 8
4-1
3 15
4-4
7-5 7-3
8
8
4-2
2 5
3 4-3 8 7-4
4
8
3
LFWX-6470-15023
1 Inter-cooler assembly 2 Inter-cooler water outlet pipe
3 Steel strip elastic clamp 4 Inter-cooler water inlet pipe assembly
4-1 Inter-cooler water inlet pipe I 4-2 Inter-cooler water inlet pipe II
4-3 Inter-cooler water inlet pipe III 4-4 Intercooler water inlet four-way pipe IV
5 Steel strip elastic clamp 6 Steel strip elastic clamp
7 Inter-cooler exhaust tube assembly 7-1 Inter-cooler exhaust tube I
7-2 Inter-cooler exhaust tube II 7-3 Inter-cooler exhaust tubeIII
7-4 Inter-cooler exhaust tube IV 7-5 Intercooler exhaust three-way pipe
8 Steel strip elastic clamp
Oil cooler component drawing (2.0L-CVT)
3-1
1
3
3-2
4 2
3-3
LFWX-6470-15024
1 Oil cooler assembly 2 Hexagon flange bolt
3 Oil cooler inlet/outlet tube assembly 3-1 Oil cooler inlet tube
3-2 Oil cooler outlet tube 3-3 Oil cooler inlet and outlet oil pipe clip
4 Hexagon flange bolt 5 Steel strip elastic clamp

Fault diagnosis
Below table helps locating the fault causes. Check all the components in turn and repair or replace the
component as needed.
Insufficiency of cooling fluid Add in the anti-freeze fluid and empty the air.
Wears or looseness of water pump Check the drive belt, and replace it if
drive belt necessary.
Poor heat Check the thermostat, and replace it if

Thermostat locked in closed position
radiation or failure necessary.
Damages of heat radiator core Replace the core.
Blockage of heat radiator pipe Clean the heat radiator pipe.
Failure or slow rotation of cooling fan Check the electronic fan circuit or fuse.
Loosening of cooling fluid hose Check the cooling fluid pipe, and replace the
clamps or its breakage damaged parts.
Water pumping sealing failure Replace the water pump liner.
Poor sealing of expansion water tank

Coolant leakage Replace the expansion water tank cover. 15
cover
Check and repair the water tank, and replace

Breakage of heat radiator water tank
it if necessary.
Water pot fracture Replace the water pot
1. Check for coolant

(a) Check for coolant leak.
• Fill the coolant. (See Section 15 - Cooling
System - Coolant, Replacement)
• Connect the radiator cap tester, adjust the
pressure to 50 ~ 100kPa and then observe
whether the pressure falls.
 Tips:
• If the pressure falls, check the cooling line,
radiator and water pump for leak.
• If there is no coolant leak trace on the engine
outside, check the radiator core, cylinder block
and cylinder head for leak.
(b) Drain a little coolant to a container.
LFWX-6470-15003
(c) Check the drained coolant for scale, rust, impurity
or color change (the normal coolant is light
green); if so, replace the coolant.
2. Check the cooling line

(a) Check the cooling line for crack or aging; if so,
replace the cooling line.
LFWX-6470-15004
Coolant
Replacement
Note:
• Perform the work after the engine is cooled.
• Cover the filler cap with a piece of thick rag and open the filler cap carefully. First
release the pressure inside the radiator and then completely open it.
1. Drain the coolant

(a) Place a catch pan under the radiator draining
plug.
(b) Remove the radiator draining plug to drain the
coolant in the catch pan.
Tips:
To drain the coolant quickly, open the radiator filler
cap and release the cooling system pressure.
(c) Install the radiator draining switch.
LFWX-6470-15005
(d). Remove the storage liquid pot.(refer to 15 - cooling system storage liquid pot, replacement)
(e) Pour the coolant in the expansion water pot in the catch pan.
(f) Install the expansion water pot. (refer to 15 - cooling system storage liquid pot, replacement)
2. Fill the coolant.

(a) Check whether the cooling system line joints are
firm.
(b) Open the radiator filler cap.
(c) Fill the coolant to the radiator slowly until the
coolant level is flush with the filler port.
LFWX-6470-15004
(d) Open the storage liquid pot cover.

(e) Fill the coolant to the storage liquid pot slowly
until the coolant level is between F and L.
(f) Install the storage liquid pot cover.
(g) Start engine and make it run to operating 15
temperature, pay attention to observe cooling
fluid level of radiator filler port; if liquid level drops
down, make up cooling fluid until all air in cooling
system is exhausted out.
LFWX-6470-15007
(h). Install the radiator filler cap.
LFWX-6470-15008
Radiator
Inspection
1. Clean the radiator

(a). Open the engine hood and secure it to prevent the unexpected falling.
(b). Drain the coolant.
(c). Wipe the dirt on the radiator core with the hairbrush and soap water gently.
Note:
Ensure to clean along with the radiator texture and do not clean in the reverse direction;
otherwise the radiator core will be deformed.
(d). After the cleaning, slowly rinse the radiator with the clean water to clear all the dirt away.
(e). Fill the clean water to the radiator until it is full.
(f). Place a catch pan under the radiator draining plug.
(g). Remove the draining plug to drain the coolant in the catch pan.
(h). Repeat the operation of e to g until the drained water is clean.
2. Check the radiator
(a). Check the radiator filler cap. (Refer to 15 - cooling system, on-board inspection)
(b). Check the radiator filler for fracture or other damage; if so, replace it.
(c). Check the radiator core for flexural deformation; if so, repair or replace the radiator.
Replacement
1. Remove the radiator assembly
Note:
• Perform the work after the engine is cooled.
(a). Open compartment, and remove cross beam decorating plate on water tank. (Refer to 81 -
interior trims and exterior trims, radiator upper cross member, replacement)
(b). Remove the front bumper. (Refer to Section 81 - inside and outside trims, front bumper,
replacement)
(c). Drain the coolant. (See Section 15 - Cooling System - Coolant, Replacement)
(d). Remove clamping stirrup used to connect fluid

reservoir water pipe and radiator, and pull it out
from its installation site.
LFWX-6470-15006
15
(e). Remove two fixing bolts used to connect fluid
reservoir and car body, and take down fluid
reservoir and water pipe assembly.
LFWX-6470-15011
(f). Remove four fixing bolts on the upper cross

beam of water tank, and take down the upper
cross beam of water tank.
LFWX-6470-15010
(g). Remove the clamping stirrups of water inlet and

outlet hoses of radiator, and plug the water inlet
and outlet hoses out of their installation sites.
(h). Take out radiator as well as electronic fan and
cowl assembly.
LFWX-6470-15009
2. Disassemble the radiator and the electronic

fan with the hood assembly
(a). Remove 5 fixing bolts of electric fan and fan
shield assembly, and take down electric fan and
fan shield assembly.
LFWX-6470-15012
(b). Remove the lock nut on the arrow position in

Figure, and take down the electronic fan blade.
LFWX-6470-15077
(c). Respectively remove respective 3 fixing bolts of

each fan motor, and take out motor assembly.
LFWX-6470-15013
3. Assemble the radiator and the electronic fan

with fan guard assembly
(a). Install fan motor assembly on installation site,
and fasten fan motor fixing bolt.
Torque: 5 ~ 6 N•m
15
LFWX-6470-15013
(b). Put the electronic fan blade on its installation site,

and install lock nuts (one left and one right nuts)
on the position indicated by arrow in Figure.
Torque:5 ~ 6 N•m
LFWX-6470-15077
(c). Install the electronic fan with fan guard assembly

onto the heat radiator, and tighten its fixing bolts
Torque:5 ~ 6 N•m
LFWX-6470-15012
4. Install radiator assembly

(a). Put radiator and fan assembly on its installation
site (below radiator and on cross beam), and
suspend and position it by radiator.
LFWX-6470-15014
(b). Install water inlet and outlet hoses of radiator,

and install them in place by special steel band
clamping stirrup.
Note:
Ensure that the hose is firmly and reliably installed.
LFWX-6470-15009
(c). Put upper cross beam of water tank on its

installation site, and install four fixing bolts for
connecting the upper cross beam with the car
body and fasten them.
Torque:8~12 N•m
LFWX-6470-15010
(d). Install and fasten two fixing bolts for connecting

fluid reservoir with car body.
Torque:8 ~ 12 N•m
15
LFWX-6470-15011
(e). Install water pipe connected with fluid reservoir

and radiator, and use special clamping stirrup to
LFWX-6470-15006
(f). Refill the cooling fluid. (See Section 15 - Cooling System - Coolant, Replacement)
(g). Install the front bumper. (Refer to Section 81 - inside and outside trims, front bumper,
replacement)
(h). Install the radiator upper cross member trim board. (Refer to 81 - interior trims and exterior
trims, radiator upper cross member, replacement)
Water pump
Overhaul
 Tips:
LF6470 vehicle is equipped with LF479Q-h engine, which is introduced below as an example of
LFB479Q-h.
1. Remove the water pump assembly. (See 11 - Engine Mechanical System Timing
Sprocket, Overhaul)
2. Repair the pump assembly

(a). Rotate the water pump pulley, check whether
water pump bearing runs smoothly without noise
or not, if it makes noise, repair it or change it
when necessary.
LFWX-6470-15015
(b). Check whether the pump housing has cracks

and damage or not, if yes, repair it and change it
when necessary.
(c). Check whether water pump impeller is damaged
and rusty or not, if yes, repair it and change it
when necessary.
3. Install the water pump assembly. (See 11 - Engine Mechanical System Timing Sprocket,
Overhaul)
Thermostat
Overhaul
1. Remove the thermostat.

(a). Discharge the coolant. (Refer to: 15 - cooling
system, coolant, draining)
(b). Remove engine water inlet hose clamping
stirrup and withdraw the water inlet hose from its
installation site.
(c). Remove the fixing bolt of engine water inlet and
take down the water inlet.
LFWX-6470-15017
(d). Take out thermostat and sealing ring.

Tips:
Do not reuse the removed seal ring. Use the new
seal ring during the installation. 15
LFWX-6470-15018
2. Install the thermostat.

(a). Install the thermostat and seal ring to the engine.
(b). Install engine water inlet on its installation site, and install and fasten the fixing bolt.
Torque: 20N•m ~ 25N•m
(c). Install engine water inlet hose and clamping stirrup on water inlet pipe.
(d). Feed cooling liquid. (See 15 – Cooling System, Cooling Liquid, Filling)

Replacement
1. Remove the water temperature sensor.

(a). Disconnect the battery negative cable.
(b). Discharge the coolant. (See Section 15 - Cooling System - Coolant, Replacement)
(c). Disconnect the water temperature sensor

harness connector.
(d). Remove the water temperature sensor.
LFWX-6470-15019
2. Install the water temperature sensor.

(a). Smear special sealant on screw threads of water temperature sensor.
(b). Install the water temperature sensor in the installing hole.
Torque: 20N•m
(c). Connect the water temperature sensor harness connector.
(d). Connect the battery negative cable.
(e). Fill the coolant. (See Section 15 - Cooling System - Coolant, Replacement)
3. Test
(a). Start engine, check whether there is leakage on the water temperature sensor installation site
or not, if yes, reinstall it.
15
Cooling system
Cooling system��1
Part specifications�� 1
System diagram�� 2
Thermostat test�� 5
Electronic water pump�� 7
Disassembly�� 7
Thermostat assembly�� 9
Disassembly�� 9
21
Water pump assembly��11
Disassembly��11
Oil cooler�� 13
Engine cooling system - Cooling system (1.5T) 21-1
Cooling system
Part specifications
Name Size
Thermostat open temperature Intake 83 / Exhaust 87 (ºC)
Thermostat full open temperature Intake 98 / Exhaust 103 (ºC)
Water pump type Impeller
Name Nm Lb-ft Lb-in
Fixing bolt for thermostat assembly 11 8 -
Fixing bolt for water pump assembly 11 8 -
Water pump pulley bolt 18 13 -
Fixing bolt for oil cooler 11 8 -
Operating principle
System Overview
Note:
• When the engine reaches working temperature, the cooling system will be under pressure.
Release pressure before repair if necessary.
21
• The connecting hose is clamped by spring clip. During repair, use appropriate spring clip to
clamp all connecting hoses.
• Use clamp pliers to mount steel elastic strap.
• Replace sealing ring and gasket.
• During mounting, ensure that cooling hoses have no stress so that they will not be in contact
with other parts.
• The arrow positions on cooling pipes and ends of cooling hoses should be well aligned.
The cooling systems include radiator, cooling expansion tank, hose, water pump, electronic
pump, electronic fan and thermostat. The radiator is of piping type. During cooling of engine,
the normal working temperature is around 95ºC(203ºF). Within this temperature range, all the
engine components can work properly. If the engine cannot reach ideal working temperature for
long period, it will cause wear of body. With low temperature, the mixed gas cannot be burned
completely in the chamber, thus causing serious carbon deposit. Therefore, the engine needs to be
working at low temperature.
Normal working temperature should be reached within short period. Preferably there is little heat
exchange between the engine and outside atmosphere.
At this moment, the cooling liquid inside control chamber of thermostat is circulating only inside
engine body, thus bringing heat generated around cylinder wall to other parts of engine to increase
the temperature quickly. The water pump will circulate cooling liquid inside the cylinder and cooling
liquid will circulate inside water sleeve, throttle assembly and cylinder cover, which is called “minor
circulation”.
When the temperature reaches 88℃ (190.4ºF), the cooling liquid will be extracted by water pump
to water sleeve, cylinder cover and radiator, which is called "great circulation".
21-2 Engine cooling system - Cooling system (1.5T)

System diagram
1 2 3 4 5
7 12 11 10 9 8
1 Expansion kettle 7 Flow-limiting valve
2 Electronic water pump 8 Oil cooler
Intake manifold assembly with inter-

3 9 Radiator
cooler
4 Check valve 10 Auxiliary radiator
5 Heat exchange for heating unit 11 Turbocharger assembly
6 Thermostat assembly 12 Cylinder cover/body

Part exploded view
1 2 3 4 5 6
7
9
23 10
24
8
11
12
13
20 14
19
15
16
22
17 21
21 20 19 18
1 Oil inlet pipe, turbocharger 13 Turbocharger assembly
2 Hexagon socket lobular pan head screw 14 Turbocharger oil return pipe sealing gasket 1I
3 Hexagon socket lobular pan head screw 15 Hexagon socket lobular pan head screw
4 Turbocharger water outlet pipe 16 Oil return pipe, turbocharger
5 Turbocharger bracket 17 Hexagon socket lobular pan head screw
6 Hexagon socket lobular pan head screw 18 Turbocharger oil return pipe sealing gasket 1II
7 O ring for turbocharger inlet pipe 19 Exhaust manifold assembly bolt
8 Heat resistant bolt 20 Upper and lower plate for exhaust manifold
9 Hexagon socket lobular pan head screw 21 Exhaust manifold assembly
10 Hexagon socket lobular pan head screw 22 Exhaust manifold gasket
11 Turbocharger water inlet pipe 23 Turbocharger oil inlet pipe bolt
12 O ring for turbocharger inlet pipe 24 Copper backing

1 2 3 4
7 6 5
1 Water temperature sensor 5 Electronic water pump
2 O ring for water temperature sensor 6 Electronic water pump bracket
Limit card for water temperature

3 7 Water pump inlet pipe
sensor
4 Thermostat assembly 8 Limit card for water pump inlet pipe


Thermostat test
1. Check if the discharge valve of thermostat is clean. If this valve is blocked, it will cause much
heat for engine.
2. Check if there is something unusual in the valve seat. There shall be no unusual object inside;
otherwise, the valve cannot be mounted tightly.
3. Check if the sealing pieces of thermostat are broken, deformed or damaged.
4. Check the wax bead by following the steps below under constant temperature:
• Remove the thermostat.
Reference: Thermostat (cooling system, removal and installation).
• Immerse the thermostat under water that can be heated.
• Put thermometer in water.
• Heat water and observe the state of thermostat.

Check if valve opening temperature is the
same as specified temperature:
Thermostat opening temperature: inlet 83/outlet 87(ºC)
Thermostat full open temperature: inlet 98/outlet 103(ºC)
• If the valve opening temperature is obviously
lower/higher than specified temperature,
change it with new thermostat. Use of
thermostat outside specified temperature will
result in overheat or over-cooling.
List of fault symptoms 21

If there is a fault on the vehicle, ECU can not detect the fault code and any obvious fault position
is not found in the visual inspection and general inspection, the fault should be processed with the
following diagnosis principle and procedure.
• Check if hose is aging and if hose connector is

leaking.
• Check if radiator is leaking.
• Check if water pump and electronic water pump are
leaking. Perform the pressure test for the pressure
• Hose or hose connector components in the cooling system If necessary,
• Radiator install a set of new water pump or the pump gasket.
• Water pump Refer to: water pump (cooling system,
dismantling and mounting)
• Electronic water pump
• Check if thermostat housing is leaking. Perform the
• Thermostat housing
Loss of cooling liquid pressure test for the pressure components in the
• Expansion tank pressure cover cooling system If necessary, install a set of new
of cooling liquid thermostat housing and thermostat housing gasket.
• Coolant expansion tank Reference: Thermostat (cooling system, removal
• Hot-wind water tank and installation).
• Engine • Check if pressure cover of cooling liquid expansion
tank is always locked and damaged. If necessary,
install a set of new coolant expansion tank cap.
• Check if hot-wind water tank is leaking.
• Check engine, cylinder head, cylinder block and
cylinder pad.
• Check the coolant expansion tank for damage. If

necessary, install a set of new coolant expansion
tank.
• Check if water pump or pump washer is damaged.
If necessary, install a set of new coolant expension
tank cap.
Reference: Water pump (cooling system, removal
and installation).
• Check engine, cylinder cover, cylinder body and
cylinder gasket.
• Release air in cooling system.
• Check if cooling liquid expansion tank pressure cover
is locked or damaged. If necessary, install a set of new
coolant expansion tank cap.
• Cooling system cannot sustain • Check the coolant expansion tank for damage. If
pressure necessary, install a set of new coolant expansion
• There is air in the system. tank.
• Cooling liquid expansion tank • Check cooling liquid level. Fill cooling system again
pressure cover or sealing as needed.
• Coolant expansion tank • Check cooling liquid condition. If cooling liquid is
Overheating engine (sign • Cooling liquid level or condition not in good condition, release it and fill new cooling
of boiling cooling liquid) • Cooling liquid contamination liquid.
• Water tank grille • Change cooling liquid.
• Water pump • Check if water tank grille blocks air or is damaged.
• Thermostat Repair or mount new parts as necessary.
• Accessory drive belt • Conduct pressure test in cooling system. Check if
• Electronic fan water pump is leaking. If necessary, install a set of
new coolant expansion tank cap.
• Engine
Reference: Water pump (cooling system, removal
and installation).
• Test the thermostat components in the cooling
system. If necessary, install a set of new thermostat
housing and thermostat housing gasket.
Refer to: thermostat (cooling system, dismantling
and mounting)
• Check the condition of accessory drive belt.
Refer to: accessory drive belt (mechanical system,
dismantling and mounting)
• Diagnosis process of non-performance of electronic
fan.
• Check engine, cylinder head, cylinder block and
cylinder pad.
• Test the thermostat components in the cooling

system. If necessary, install a set of new thermostat
The engine cannot housing and thermostat housing gasket.
• Thermostat
reach normal working Reference: Thermostat (cooling system, removal
• Electronic fan and installation).
temperature.
• Diagnosis of low-speed rotation of electronic fan.
• Diagnosis of high-speed rotation of electronic fan.
Engine cooling system - Cooling system 21-7

Electronic water pump
Disassembly
1. Dismantle electronic water pump.
Note:
• Hot steam and hot coolant may cause burns.
• When the engine is under the operating temperature, the cooling system will be under
overpressure condition. Please cover the cooling liquid expansion tank cap with a cloth
and carefully open it, to relief the overvoltage.
• When the expansion tank cap is opened, the hot steam may overflow. Must wear
(a). Dismantle outlet hose clamp of electronic water

pump. (2) Expose hose connector.
3 (b). Dismantle outlet hose clamp of electronic water
pump. (1) Expose hose connector.
1
(c). Disconnect electronic pump wiring connector (3).
2 (d). Dismantle electronic pump bracket bolt (4).
LFWX-6470-06005
21
(e). Dismantle electronic pump bracket fixing bolt.
LFWX-6470-06006
21-8 Engine cooling system - Cooling system
(f). Dismantle electronic pump and connecting bolt

for electronic pump bracket.
(g). Get out electronic pump assembly.
LFWX-6470-06007
Installation
1. Mount electronic water pump.
(a). Mount electronic water pump onto electronic

pump bracket and tighten fixing bolt.
Torque: 11N•m
LFWX-6470-06007
(b). Mount electronic water pump and pump fixing

bracket bolt.
Torque: 18N•m
LFWX-6470-06006
(c). Mount electronic water pump bracket bolt (4).

Torque: 18N•m
3 (d). Connect electronic water pump wiring connector
(3).
1
(e). Mount electronic water pump inlet hose and
2
clamp(2).
(f). Mount electronic water pump inlet hose and
4 clamp(1).
LFWX-6470-06005
Thermostat assembly
Disassembly
1. Dismantle thermostat assembly.
(a). Disconnect water temperature sensor connector.

Refer to Dismantling and Mounting of Water
Temperature Sensor.
(b). Remove two bolts for combining water inlet hard
pipes.
(c). Dismantle fixing bolt for thermostat assembly.
Note:
• Hot steam and hot coolant may cause burns. 21
• When the engine is under the operating
temperature, the cooling system will be under
overpressure condition. Please cover the cooling
liquid expansion tank cap with a cloth and
LFWX-6470-06008 carefully open it, to relief the overvoltage.
• When the expansion tank cap is opened, the
hot steam may overflow. Must wear protective
glasses and protective clothing, to avoid burns
and other injuries.
(d). Dismantle water pump inlet pipe limit card.

(e). Take out thermostat assembly.
LFWX-6470-06009
Installation
1. Installation thermostat assembly.
(a). Mount thermostat assembly and pump inlet pipe

limit card.
Note:
Before installing the thermostat assembly, check
the thermostat seal ring for damage and replace
the seal ring if so.
LFWX-6470-06010
(b). Mount fixing bolt for thermostat assembly.

Torque: 11N•m
(c). Install two bolts for combining water inlet hard
pipes.
(d). Connect water temperature sensor connector.
LFWX-6470-06008
Water pump assembly

Disassembly
1. Dismantle water pump assembly.
Note:
(a). Dismantle engine accessory belt. Refer to

Dismantling and Mounting of engine accessory
belt.
(b). Use water pump dismantling wrench -351147-
to fix water pump belt pulley and use appropriate
tool to dismantle bolt for water pump belt pulley.
(c). Take out pump belt pulley.
LFWX-6470-06011
(d). Dismantle fixing bolt for water pump assembly.

(e). Take out water pump assembly. 21
LFWX-6470-06012
Installation
1. Installation water pump assembly
(a). Replace with new water pump seal ring.
LFWX-6470-06013
(b). Mount water pump assembly and fixing bolt for

water pump assembly.
Torque: 11N•m
LFWX-6470-06012
(c). Use water pump dismantling wrench -351147- to

fix water pump belt pulley, and use appropriate
tool to mount bolt for water pump belt pulley.
Torque: 18N•m
Note:
In case of failure in water pump assembly, replace
LFWX-6470-06011
Oil cooler
Disassembly
1. Dismantle oil cooler.
Note:
(a). Catalyst assembly before dismantling.

Refer to Dismantling and Mounting of Front
Catalyst Assembly.
(b). Remove oil cooler fixing bolts and oil cooler
connecting hose.
LFWX-6470-06011
(c). Remove the generator assembly.

Reference: Generator assembly removal and
installation.
21
(d). Dismantle fixing bolt for oil cooler.
(e). Take out seal gasket for engine oil cooler and oil
cooler.
LFWX-6470-06011
Installation
1. Mount engine oil cooler.
(a). Change with new oil cooler seal gasket and

mount oil cooler.
(b). Mount fixing bolt for oil cooler.
Torque: 11N•m
(c). Mount generator assembly.
LFWX-6470-06011
(d). Mount fixing bolt for connecting pipe of oil cooler.

Torque: 11N•m
(e). Mount front catalyst assembly.
(f). Install oil cooler connecting hose and make up
cooling liquid.
LFWX-6470-06011
Maintenance Tools
Special tools
Water
Water pump removal pump pulley
1 351147
wrench removal
tool
21
Lubrication system- Lubrication system (1.8L) 16-a
Lubrication system
Lubrication system��1
Precautions�� 2
Engine oil, filter��4
Inspection�� 4
Change�� 6
Front housing with
oil pump assembly��8
Overhaul�� 8
16
16-b Lubrication system- Lubrication system (1.8L)
Lubrication system- Lubrication system (1.8L) 16-1
Lubrication system
Preparations
1. Special tools
Install the front crankshaft oil

2 Oil sump remover
seal.
16
1 Oil manometer To test engine oil pressure

16-2 Lubrication system- Lubrication system (1.8L)
Maintenance data
800r/min 100 ～ 200 kPa
Oil pressure 3000r/min 280 ～ 380 kPa
5800r/min 300 ～ 460 kPa
Oil filling 3.5L
Item N•m
Oil drain plug 44±2
Oil filter 28±2
Oil sump fixing bolt 11±1
23±2 (3×M8×40 2×M8×45)

Engine front housing fixing bolts
11±1 (6-M6×25)
Fixed bolts of oil strainer 11±1
Precautions
1. During the work of Lubrication system, be sure to start the work after the engine is cooled.
2. During the work, don’t splash the oil on drive belt.
3. Collect the old engine oil, and deal with the used oil and filter in the designated site, in order to
protect the environment.
4. Note the following several points for the use of sealant:
• Use a scraper to thoroughly remove the residual sealant on the mounting surfaces (including
the grooves of the applied surface of sealant, fixed bolts and bolt mounting holes) of oil
pan and cylinder block.
• When using sealant, wipe the applied surface of sealant and remove the water or other
foreign matters.
• Remove the foreign matters from sealant immediately, if any.
5. Long-term repeated exposure to mineral oil will remove the skin's natural fat, resulting in
dryness, irritation and dermatitis. In addition, the used engine oil contains harmful pollutants
that may cause skin cancer.
6. Take care, and minimize the time and frequency of skin contact with the used engine oil. Wear
blue protective clothing and gloves. Wash the skin thoroughly with soap and water or use
an anhydrous hand sanitizer to remove any used engine oil. Do not use gasoline, thinner or
solvents.
7. Lifan Xuanlang series are equipped with LFB479Q, LF483Q, LF477ZLQ00 engines, and the
engine lubrication systems are repaired basically in the same way, so this paper only takes
LFB479Q-h as an example.
Fault diagnosis
Oil pressure sensor damage Replace the oil pressure sensor
Oil level is too low Add oil
Check the reasons for low oil viscosity and

repair the problem. For example:
Oil brand is not suitable for the use of local
cars, so you need to replace the oil.
The engine temperature is too high
Oil viscosity is too low
Cylinder head gasket is damaged, and coolant
is mixed with oil; replace the head gasket
Cylinder head or cylinder block cracks, and
coolant mixed with oil; repair the cylinder head
Oil pressure is not or cylinder block, and replace if necessary
normal The oil filter is clogged Replace the oil filter
The clearance between main

Replace the main bearing shell and connecting
bearing shell and connecting
rod bearing shell 16
rod bearing shell is too big
Check the reasons for oil pump failure, and

The active rotor and slave rotor of oil pump are
Oil pump failure serious worn; replace the oil pump
Oil pump inlet is blocked; clean the oil pump
Pressure regulating valve failure of oil pump;
replace the oil pump
Engine oil, filter

Inspection
1. Check the engine oil

(a). Check whether the engine oil level is between the
upper and the lower level limits.
Tipe:
After the oil level is stable, remove the dipstick,
wipe the oil on it with a clean cloth, insert it into its
tube, and remove it for oil level check.
LFWX-6470-16001
(b). Drain a little volume of oil into a container and

check the oil quality.
Tipe:
Check if the engine oil deteriorates, changes in
color or mixes with water (A.engine oil, B: water).If
yes, repleace it.
(c). Check the engine oil for poor quality, water
entering, fading or thinning. If the oil quality is
deteriorated, replace it.
LFWX-6470-16002
2. Check of oil pressure

(a). Remove the oil pressure alarm switch.
LFWX-6470-16003
(b). Install the oil pressure gauge.

(c). Preheat the engine to normal operating
temperature.
(d). Check the pressure value of oil pressure gauge.
Oil pressure: 100~200kPa (800 r/min)
280~380kPa (3000r/min)
300~460kPa (5800r/min)
LFWX-6470-16004
(e). Remove the oil pressure gauge.

(f). Apply the sealant to the threads of the oil
pressure alarm switch.
(g). Install the oil pressure alarm switch.
(h). Start the engine and check for leaks.
16
LFWX-6470-16005
Change
1. Discharge the engine oil.

(a). Unscrew the oil filler cap.
(b). Remove the drain plug of oil pan, and drain the
engine oil into collector.
Note
• After the engine is cooled, perform the
operation.
• During operation, prepare a piece of rag to
clean up spilled or splashed engine oil.
• Do not splash the engine oil onto the drive
belt.
• Thoroughly clean the oil splashed on the
engine or body.
LFWX-6470-16006
2. Replace oil filter

(a). Use a special tool to remove the oil filter.
Note:
• After the engine is cooled, perform the
operation.
belt.
engine or body.
LFWX-6470-16007
(b). Clear the foreign matter adhering to the oil filter

mounting surface.
(c). Apply a clean layer of oil to the oil seal surface of
the new oil filter.
Note:
Check that the part number of new oil filter is the
same as the original one.
LFWX-6470-16008
(d). Use a special tool to install the oil filter.

Torque: 16 N•m
Note:
To install the oil filter, first install the oil filter on the
filter base by hand until the "O" seal ring is fully
seated on the filter base. Then use a special tool to
fasten the oil filter.
LFWX-6470-16007
3. Refuel engine oil

(a). Clean the drain plug, replace the gasket, and
reinstall the drain plug.
Torque: 30 N•m
(b). Remove the oil filler cap from the cylinder head
cover.
16
LFWX-6470-16009
(c). Refuel engine oil.

Note:
• Refer to the maintenance instructions to
select the specified oil.
• Use the oil level gauge to check that the
refueling amount is appropriate.
Filling volume: 3.5L
(d). Install the oil filler cap.
4. Start the engine and check for oil leakage
5. Recheck the engine oil level
LFWX-6470-16010
Front housing with oil pump assembly

Overhaul
1. Remove the cylinder head cover (see Chapter

11: A. Mechanical System - Camshaft,
Replacement).
2. Remove the oil pan.
(a). Remove the fixed bolts of oil pan.
LFWX-6470-16011
(b). Insert a special blade between the crankcase and

oil pan, cut the sealant, and remove the oil pan.
Note:
• Do not use the special tool to cut the gasket
between the oil pump and the crankcase, or
between the crankshaft rear cover and the
crankcase.
• Be careful not to damage the flange surface
of the oil pan.
LFWX-6470-16012
(c). Remove the fixed bolts of oil strainer, and remove

the oil strainer and gasket.
LFWX-6470-16008
(d). Remove the fixed bolts of front housing of engine

with oil pump assembly.
(e). R e m o v e t h e f r o n t h o u s i n g w i t h o i l p u m p
assembly.
LFWX-6470-16014
3. Install the front housing with oil pump

assembly
(a). Install the front housing of engine in place, and
fasten the fixed bolts.
Torque: 9 ~ 11N•m
16
LFWX-6470-16014
4. Install the oil pan

(a) Scrape off the gasket higher than the lower end
face of the crankcase.
(b) Install the gasket and oil strainer, screw and
fasten the fixed bolts.
Torque: 11±1N.m
(c) Remove any old plane sealants from the
crankcase and oil pan. Be careful not to drip oil
through the contact surfaces of the oil pan and
the crankcase.
• Remove all old plane sealants from the gasket
surface and seal groove using blade and gasket
cleaner.
• Thoroughly clean all parts and remove any loose
matters.
LFWX-6470-16013 • Clean the sides of the sealing surface with
residue-free solvent.
Note:
Do not use solvents that may affect the paint surface.
(d). Apply the sealant to the oil pan.

Tipe:
The parts must be assembled within 5 minutes
after application of the plane sealant. Otherwise,
the sealant must be removed and reapplied.
LFWX-6470-16015
(e). Install the oil pan and fixed bolts, and fasten the
fixed bolts.
Torque: 9 ~ 11N•m
LFWX-6470-16011
5. Install the cylinder head cover (see Chapter 11: Mechanical System - Camshaft, Replacement).
6. Inject the engine oil.
7. Start the engine and check for leaks.
8. Recheck the engine oil level.
16
Lubrication system- Lubrication system (2.0L) 16-a
Lubrication system
Precautions�� 3
Schematic diagram�� 3
Oil��7
Change�� 7
Oil filter��9
Change�� 9
Oil pan�� 11
Inspection��11
Oil pan��12
Change�� 12 16
Oil pump��14
Inspection�� 14
Change�� 15
Oil scale��28
Change�� 28
16-b Lubrication system- Lubrication system (2.0L)
Lubrication system
Preparations
1. Special tools
Install the front crankshaft oil

2 Oil sump remover
seal.
16
1 Oil manometer To test engine oil pressure

Maintenance data
Engine oil grade above 5W-30-SF
Oil filling 4L
Idle speed 80~300kPa

Oil pressure
Calibrated speed 330~430kPa
Clearance for the oil pump Minimum clearance value 0.023mm

driving rotor/driven rotor
0.069mm
top:
Clearance for the rotor (driving/driven) / oil pump housing

0.025~0.071mm
top
Clearance between the driven rotor and oil pump housing 0.260~0.325mm
Items N.m
Oil sump drain bolt 42~46
Oil filter 25~30
Oil sump fixing bolt 10
Oil pump mounting bolt 11
Oil pump cover fixing screw 11
Oil pump relief valve plug 37
Oil pressure sensor 14~16
Set bolt of the flexible rail of timing chain 19
Timing chain fixed rail mounting bolts 13
Front enclosure mounting bolts 23
Tensioner hold-down nuts 11
Crankshaft pulley fixing bolts 138
Oil level stick guide fixing bolt 10~12
Engine front suspension bracket mounting bolts 52
Set bolt and nut of the belt tension pulley 69 (bolt) 29 (nut)
Generator fixing bolt 25 (short bolt) 54 (long bolt)
Cylinder head cover fixing bolt 11
Water pump assembly fixing bolt 11
Ignition coil fixing bolt 11

Precautions
1. During the work of Lubrication system, be sure to start the work after the engine is cooled.
2. During the work, don’t splash the oil on drive belt.
3. Collect the old engine oil, and deal with the used oil and filter in the designated site, in order to
protect the environment.
4. Note the following several points for the use of sealant:
• Use a scraper to thoroughly remove the residual sealant on the mounting surfaces (including
the grooves of the applied surface of sealant, fixed bolts and bolt mounting holes) of oil pan
and cylinder block.
• When using sealant, wipe the applied surface of sealant and remove the water or other foreign
matters.
• Remove the foreign matters from sealant immediately, if any.
5. Long-term repeated exposure to mineral oil will remove the skin's natural fat, resulting in
dryness, irritation and dermatitis. In addition, the used engine oil contains harmful pollutants
that may cause skin cancer.
6. Take care, and minimize the time and frequency of skin contact with the used engine oil. Wear
blue protective clothing and gloves. Wash the skin thoroughly with soap and water or use
an anhydrous hand sanitizer to remove any used engine oil. Do not use gasoline, thinner or
solvents.
7. Lifan Xuanlang series are equipped with LFB479Q, LF483Q, LF477ZLQ00 engines, and the
engine lubrication systems are repaired basically in the same way, so this paper only takes
LF483Q-h as an example.
Schematic diagram
16
Main oil passage
Main oil passage

of cylinder head
VVT sieve
Bearing bore of first intake camshaft
Filter Main bearing
Oil Control Valve
Intake camshaft oil passage
Left cylinder head oil passage Right cylinder head oil passage
Crankshaft
Timing chain lubrication
Pressure relief
Automatic tensioner
valve
spindle diameter
Intake camshaft First camshaft bearing
cap oil passage First camshaft First camshaft
Oil pump bearing cap oil bearing cap oil
passage passage
Crankshaft connecting Exhaust camshaft

rod shaft diameter
Intake camshaft Exhaust camshaft
oil passage oil passage
Air intake 2, 3, Air intake 2, 3,

4, 5 camshaft 4, 5 camshaft
bearing hole bearing hole
Connecting VVT（Valve timing adjuster）
Filter
rod bearing
Intake camshaft Exhaust camshaft

and mechanical and mechanical Remark：
stand stand 1.Splash mode for lubricating cam and stand
2.VVT return oil is done by OCV internal spool
Oil Pan
Fault diagnosis
Oil pressure sensor damage Replace the oil pressure sensor
Oil level is too low Add oil
Check the reasons for low oil viscosity and

Oil brand is not suitable for the use of local
cars, so you need to replace the oil.
The engine temperature is too high
Oil viscosity is too low
Cylinder head gasket is damaged, and coolant
is mixed with oil; replace the head gasket
Cylinder head or cylinder block cracks, and
coolant mixed with oil; repair the cylinder head
Oil pressure is not or cylinder block, and replace if necessary
normal The oil filter is clogged Replace the oil filter
The clearance between main

Replace the main bearing shell and connecting
bearing shell and connecting
rod bearing shell
rod bearing shell is too big
Check the reasons for oil pump failure, and

The active rotor and slave rotor of oil pump are
Oil pump failure serious worn; replace the oil pump
Oil pump inlet is blocked; clean the oil pump
Pressure regulating valve failure of oil pump;
replace the oil pump
Component drawing
4
2
1
5
17 6
18 7
19
15
16
8
14
13 4
16
12
11
10
9 LFWX-6470-16003
1 Oil pump assembly 11 Oil drain plug
2 Oil pump gasket 12 Oil drain plug gasket
3 Oil dipstick assembly 13 Oil sump assembly
4 Bolt 14 Oil filter assembly
5 Oil dipstick guide tube assembly 15 Oil filter nut
6 Oil filter connecting pipe 16 Hexagon flange bolt
7 Engine oil filter 17 Oil suction filter stud
8 Oil pan stud 18 Oil pump guide pin
9 Nut 19 Oil filter gasket

10
assembly
1. Check the engine oil
(a). Check the engine oil
Method is as follows:
• Warm up the engine, stop and wait 5min.
• Check whether the oil level is between the upper
and lower limit scale of the oil dipstick.
 Tipe:
Draw out the oil level gauge after the oil level
becomes stable, and wipe off the oil on the gauge
with a clean rag. Insert the oil level gauge into
the pipe, take the gauge out, and check the liquid
level.
LFWX-6470-16001
(b). Discharge a little oil into a container and check

the oil quality.
 Tipe:
Check that the oil is deteriorated, colored or mixed
with water (A: oil, B: water); replace the oil, if any.
The normal oil is transparent and thick. If the oil
becomes black and thin, it should be replaced.
LFWX-6470-16002
2. Check the oil pressure

(a). Disconnect the connector of oil pressure sensor.
(b). Dismount the oil pressure sensor and install oil
pressure gauge.
(c). Warm the engine and observe the oil pressure
gauge.
Oil pressure at idling: 80~300kPa
Oil pressure at rated speed: 330~430kPa
 Tipe:
If the pressure is not within the rated range, check
the oil pump.
(d). Remove the pressure gauge, install the oil
pressure sensor and connect the sensor
LFWX-6470-16004 connector. Remove the pressure gauge
Oil Pressure Sensor Torque: 14~16N•m
 Tipe:
When installing the oil pressure sensor, coat the
sensor threads with glue.
Note:
It is prohibited to start the engine right after
installing the oil pressure sensor.Wait a while
before starting the engine.
Oil
Change 16
1. Discharge the engine oil.

(a). Unscrew the oil filler cap.
(b). Remove the drain plug of oil pan, and drain the
engine oil into collector.
Note:
• After the engine is cooled, perform the operation.
• During operation, prepare a piece of rag to clean
up spilled or splashed engine oil.
• Do not splash the engine oil onto the drive belt.
• Thoroughly clean the oil splashed on the engine
or body.
LFWX-6470-16005
(b). Install the oil drain bolt of oil sump.

Torque: 42~46 N•m
LFWX-6470-16006
2. Refuel engine oil.

(a). Remove oil filler cap on cylinder head cover.
LFWX-6470-16007
(b). Refuel engine oil.

Note:
• Choose the engine oil above grade 5W-30 SF.
• Use the oil level gauge to check that the
refueling amount is appropriate.
LFWX-6470-16008
(c). Install the cover of oil filler port.
LFWX-6470-16007
Oil filter
Change
1. Dismount the oil filter.

(a). Drain the engine oil.
16
LFWX-6470-16005
(b). Use the remover of oil filter to dismount the oil

filter.
Note:
• After the engine is cooled, perform the operation.
belt.
engine or body.
LFWX-6470-16009
2. Install the oil filter.

(a). Clear the foreign matter adhering to the oil filter
mounting surface.
(b). Apply a clean layer of oil to the oil seal surface of
the new oil filter.
Note:
Use the genuine oil filter.
LFWX-6470-16010
(c). Use the remover of oil filter to install the oil filter.
Torque:25~30N•m
Note:
When installing the oil filter, fit it to the filter seat
by hand until the O-ring completely sits in the filter
seat. Then use the filter remover to tighten it.
LFWX-6470-16009
(d). Refuel engine oil

Oil pan
Inspection
1. Check the oil sump

(a). Thoroughly clean oil pan.
(b). Use high pressure air to dry the oil pan.
LFWX-6470-16011
(c). Check whether oil pan has cracks or damage

or not, if yes, repair it, and change it when
necessary.
16
LFWX-6470-16012
Oil pan
Change
1. Remove the oil pan.

(a). Drain the engine oil.
LFWX-6470-16005
(b). Remove the fixed bolts of oil pan.
(c). As shown in the Figure, install oil pan replacer on

the contact surface of oil pan and cylinder block.
(d). Slightly knock the lateral surface of oil pan
replacer, and move it along the sealing surfaces
of oil pan and cylinder block, and take down the
oil pan.
LFWX-6470-16014
2. Install the oil pan.

(a). As shown in the Figure, uniformly smear sealant
on the mounting surface of oil pan.
Note:
• Before applying the new sealant, ensure to
clear the old sealant away from the cylinder
block and oil pan.
(b). Install oil pan on cylinder block, and fasten all oil
pan fixing bolts.
Torque:10N•m
 Tipe:
When installing the oil pan fixing bolts, apply an
appropriate amount of clean oil evenly into the
threaded portion of the bolts.
Note: 16
• During the tightening, start from the middle
and then the side.
LFWX-6470-16016
(b). Refuel engine oil.
LFWX-6470-16008
Oil pump
Inspection
1. Check the subassembly of oil pump.

(a). Use a thickness gauge to measure the top
clearance between the drive and driven rotators
as shown in the diagram.If it is more than the
maximum value, replace the oil pump.
Minimal gap: 0.023mm
Maximum gap: 0.069mm
LFWX-6470-16017
(b). Use a thickness gauge to measure the top

clearance between the 2 rotators and the housing
of oil pump as shown in the diagram.If it is more
than the maximum value, replace the oil pump.
Standard gap:0.025~0.071mm
LFWX-6470-16018
(c). Use a thickness gauge to measure the top

clearance between the driven rotator and the
housing of oil pump as shown in the diagram.If it
is more than the maximum value, replace the oil
pump.
Standard gap:0.260~0.325mm
(d). Coat a layer of clean oil on the pressure relieve

valve of oil pump.Check and confirm if the oil
valve can slide into the valve hole by its own
weight.If not, replace the oil pump.
Change
1. Remove the oil pump

(a). As shown in the Figure, use box spanner to
clockwise apply acting force on tensioner, and
take down the transmission belt.
16
(b). Remove the ignition coil fixing bolts and take out
all the ignition coils in turn.
Note:
• Do not damage the insulations of the ignition
coil.
• During the removal, identify the ignition coil
of each cylinder to facilitate the subsequent
installation.
LFWX-6470-16022
(c). As shown in Figure 1, remove PCV valve

hose fastening clamp, and disconnect hose
connection.
(d). As shown in Figure 2, disconnect ventilation
hose.
(e). Remove the cylinder head cover fixing bolt and

take out the cover.
(f). Remove generator assembly fixing bolt and take

down generator assembly.
(g). Remove the belt tightener assembly fixing bolt

and nut, take out the belt tightener.
(h). Remove front engine mounting and support

assembly.
16
(i). Remove water pump fixing bolt, and take down

(j). Remove the crankshaft pulley fixing bolts.

 Tipe:
When removing the crankshaft pulley fixing
bolt, fix the flywheel in advance to prevent the
crankshaft rotating.
(k). Take the crankshaft pulley out with the puller.
Note:
Do not damage the crankshaft pulley whe using
the puller.
(l). Remove the tensioner fixing bolt and take out the
tensioner.
(m). Remove the fixing bolt of front housing and take

down the front housing.
 Tipe:
Before removing the front housing, as the sealant
makes it difficult to remove, tap the timing cover
with the rubber hammer gently to facilitate the
removal.
Note:
Do not use the steel hammer or hard tool.
(n). Remove the timing chain slide rail and fixed rail
assembly fixing bolt and take out the slide rail
and fixed rail assembly.
Note:
To prevent damage of valve tappet due to the
rotation of camshaft or crankshaft after the timing
chain is removed, rotate the crankshaft to bring
cylinder 1 to TDC and ensure the timing gear mark
aligns with the marking point before the removal.
(o). Take out the timing chain.
(p). Remove the crankshaft timing sprocket ring.

(q). Remove the crankshaft timing sprocket ring and
locating pin.
Note:
Store all the guide pins together to avoid loss.
16
(r). Remove the fixing bolts of oil pump, and remove

the oil pump and oil pump gasket.
Note:
The removed gasket cannot be reused. Ensure to
replace the gasket.
LFWX-6470-16034
2. Disassemble the oil pump

(a). Remove oil pump fastening screw and take down
oil pump cover.
(b). Take out the driving rotor and the driven rotor of
oil pump.
(c). As shown in the Figure, remove oil pump

pressure reducing valve screw plug, and take
out pressure reducing valve spring and pressure
reducing valve.
3. Assemble the oil pump

(a). Install oil pump pressure release valve and spring
in valve holes.
(b). Install oil pump pressure reducing valve screw
plug.
Torque: 37N•m
(c). As shown in the Figure, install the driving rotor

and the driven rotor of oil pump.
Note:
During the installation, align the installation signs
as shown in the figure.
16
(d). Install oil pump cover and fasten fastening screw.

Torque:11N•m
LFWX-6470-16040
4. Install oil pump

(a). I n s t a l l o i l p u m p a n d o i l p u m p g a s k e t o n
installation site, and fasten fixing bolt of oil pump.
Torque:11N•m
(b). Install crankshaft timing sprocket and location

pin.
(c). Install crankshaft timing sprocket retainer ring.
(d). Install the timing chain.

Note:
As shown in the drawing, when install the timing
chain, the timing mark should be aligned.
(e). Install timing chain moving rail (as shown in

Figure 1) and fixing rail assembly (as shown in
Figure 2), and fasten fixing bolt.
Moving track fixing bolt

Torque:19N•m
Fixed track fixing bolt
Torque:13N•m
(f).As shown in the Figure, uniformly smear sealant

on the mating surface of front housing.
Note:
Ensure to clear the old sealant away before
applying the new sealant.
16
(g). Install front housing on engine, and fasten all

fixing bolts.
Torque: 23N•m
(h). Put tensioner on its installation site and fasten

two retaining nuts.
Torque: 11N•m
 Tipe:
Before installing the tensioner, lock the tensioner
plunger with the lock plate. After the tensioner
tightening bolts are installed, rotate the crankshaft
anticlockwise to allow the locking piece to be detached
from the clasp.
(i). Clockwise rotate the crankshaft, and check

whether the tensioner is installed rightly or not.
(j). Install the crankshaft pulley and tighten the bolts.

Torque:138N•m
 Tipe:
When installing the crankshaft pulley fixing
bolt, fix the flywheel in advance to prevent the
crankshaft rotating.
(k). Install water pump assembly and fasten bolt.

Torque: 11N•m
(l). Install front engine mounting and support

assembly and fasten bolt.
Torque: 52N•m
16
(m). Install belt tensioner assembly and fasten bolt

and nut.
Bolt torque: 69N•m
Nut torque: 29N•m
(n). Install generator assembly and fasten bolt.

Long bolt torque: 25N•m
Short bolt torque: 54N•m
(o). Install the cylinder head cover assembly and

tighten all the bolts.
Torque: 11N•m
(p). As shown in Figure 1, mount the PCV valve hose

and tighten the hose clamp.
(q). As shown in Figure 2, mount the ventilation hose.
(r). Install all the ignition coils in turn and tighten the
bolts.
Torque: 11N•m
Note:
Install according to the identification made during
the removal.
(s). As shown in the figure, apply the force to the

tensioner counterclockwise with the box wrench
to remove the belt.
16
Oil scale
Change
 Tipe:
To facilitate the removal of oil dipstick guide tube, remove the alternator in advance.
1. Remove the oil dipstick and dipstick guide

tube
(a). Remove the oil dipstick
LFWX-6470-16049
(b). As shown in the figure, apply the force to the

tensioner clockwise with the box wrench to
remove the belt.
(c). Remove the generator assembly fastening bolts,

and remove the generator assembly.
(d). Remove the oil dipstick guide tube fixing bolts

and take out the guide tube.
2. Remove the oil dipstick and dipstick guide

tube
(a). Install dipstick conduit on installation site, and
fasten its fixing bolt.
Torque: 10~12N•m
16
(b). Install the generator assembly and fixing bolts

Short bolt Torque: 25N•m
Long bolt Torque: 54N•m
(c). As shown in the figure, apply the force to the

tensioner clockwise with the box wrench to
remove the belt.
LFWX-6470-16050
(d). Install the oil dipstick.
LFWX-6470-16049
16
Lubrication system - Lubrication system (1.5T) 21-a
Lubrication system
Material specifications�� 1
Lubricating oil specification�� 1
Oil pump assembly�� 2
Oil pan assembly�� 2
Check oil pressure �� 5
Check oil level�� 5
21
Diagnosis of low engine oil pressure�� 6
Abnormal oil consumption�� 8
Discharge and fill oil�� 9
Disassembly�� 9
Engine oil filter�� 10
Oil pan assembly�� 12
Oil pump�� 14
21-b Lubrication system - Lubrication system (1.5T)
Lubrication system - Lubrication system (1.5T) 21-1
Lubrication system
Material specifications
Description Specifications Volume
Sealant 1596 -
Pipe thread sealant 1567 -
Part specifications
Description Specifications
Oil pump type Rotor-type
(80~200 kpa/750 rpm)

Oil pressure (200~320 kpa/2500 rpm)
(280~350 kpa/4850 rpm)
Lubricating oil specification
Description Size
Level SN/5W-40
Volume 4L
21
Name Nm Lb-ft Lb-in
Oil sump drain bolt 23 17 -
Bolts and nuts for oil sump assembly 11 8 -
Tightening torque for oil pump 23 17 -
Tightening torque for oil filter 30 23 -
Tightening torque for oil pressure

23 17 -
alarm
21-2 Lubrication system - Lubrication system (1.5T)
Operating principle
System Overview
After being filtered in oil filter, oil will be diverted into two directions. One is going into cylinder and
oil pipe for cross structure of main bearing cover to lubricate and supply pressure for piston rod
mechanism and cylinder hydraulic tappet. The other is lubricating and cooling turbocharger.
Part instructions
Oil pump assembly
Oil pump is designed to extract oil from oil sump and exert pressure to deliver it to each part of
engine. The pressure regulating valve inside oil pump will regulate oil pressure within specified
range.
Oil pump assembly

The oil pressure alarm is mounted on rear end of
cylinder cover that belongs to end of lubricating
system. If oil pressure is decreased to required value,
the switch will send alarm to driver by energizing low
oil pressure on the instrument panel.
LFWX-6470-07001
Oil pan assembly

Besides applying glue to prevent oil leaking when mounting oil sump, special attention should
be paid so that corrosion-proof coating on the surface of housing is not scratched; otherwise,
the scratched part will be easily corroded leading to serious accident of leaking housing. When
dismantling oil sump, make sure to wipe off glue on bolts and gap, or it will cause unexpected
damage to oil sump.

2
1
21
LFWX-6470-07002
1 Engine oil filter 2 Oil pressure announciator

Part exploded view
6
1
5
3
4
2
7
16
25
24
14 13
12 11
23 9
18 10
17
22 15
21 19
20 LFWX-6470-07003
1 Oil dipstick assembly 14 Crankshaft sleeve gasket
2 Oil and gas separator bolt 15 Oil pump sprocket cover
3 Oil-air separator 16 Crankshaft timing sprocket
4 Timing cover gasket 17 Oil pump chain
5 Fuel filler cap assy. 18 Oil pump bolt
6 Oil filter 19 Oil pan stud
7 Timing cover assembly 20 Hexagon flange bolts
8 Timing cover assembly bolts 21 Oil pan assembly bolts
9 Crankshaft pulley bolt 22 Oil pan assembly
10 Crankshaft pulley 23 Oil suction filter bolt
11 Crankshaft front oil seal 24 Oil suction filter
12 Crankshaft sleeve 25 Oil pump assembly
13 Crankshaft sleeve O ring


Check oil pressure
Warning:
In the lab, the mice contacted in the long termwith used oil has made skin cancer. After
working in contact with the oil, please immediately wash your kin with soap and water, to
protect your skin.
Warning:
Hot engine and engine oil can cause serious burns. Shut down the engine, wait for some
time until the engine and engine oil is cooled down.
Note:
Before check the oil pressure, please first check the following items:
• Oil level in oil sump.
If oil level is low, fill oil to full oil level on the gauge.
• Oil quality.
If oil is discolored or deteriorated in quality, replace it.
• Oil leakage.
If it is discovered to leak oil, repair it.
1. Place vehicle on level ground.
2. Ensure that the vehicle is under cooling state.
3. Dismantle oil pressure alarm.
4. Dismantle oil pressure alarm and rotate it into oil pressure tester.
• Replace oil pressure alarm with oil pressure tester and rotate it into cylinder cover.
• Brown wire of tester should be grounded (negative pole).
• Use auxiliary wire in auxiliary test tool kit to

connect electric test pen to the positive pole (+)
of battery and oil pressure alarm.
21
• If LED is on, replace oil pressure alarm.
• If LED is off, start the engine and slowly increase
+ - engine rotary speed. LED should be on between
0.3 bar ~ 0.6 bar, or replace oil pressure alarm.
• Continue to increase engine rotary speed. When
it is running at 2000 rpm with oil temperature of
80ºC, oil pressure should at least be 2.0 bar.
• At higher rotary speed, oil pressure shall not
exceed 7.0 bar.
LFWX-6470-06004
Check oil level

• Place vehicle on level ground.
• Ensure that the vehicle is under cooling state.
• Dismantle oil level gauge and check if oil level is
between MAX and MIN marks on the gauge.
1
2
LFWX-6470-06004

If any fault occurs to the car, and engine control unit ECM fails to detect any fault code, and
no obvious faulted positions can’t be found out after visual check or general inspection, it’s
recommended to remedy the faults as per the diagnostic idea and process described in the table
below.
• leakage
• Low-quality oil • Check the leakage position.
• Excessive use • Replace the oil.
• Crankshaft box ventilation is blocked. • Replace the oil.
Engine oil pressure
• Turbocharger is worn. • Repair or replace abnormal parts.
is too low.
• Throttle guide pipe or rod is worn or • Repair or replace the turbocharger.
improperly mounted. • Repair the fault position.
• Piston or piston ring is improperly • Repair the fault position.
mounted.
• Check the leakage position.

• leakage
Abnormal oil • Repair sealing between piston and
• Blow-by consumption
consumption cylinder.
• Combustion chamber burning
• Repair or replace failed parts.
Diagnosis of low engine oil pressure

1. Check if engine oil is leaking.
A. Verify if engine oil is leaking.

→Yes
Check the leaking part of engine.
→No
To step 2.
2. Check if engine oil viscosity is unusual and if low-quality oil is used.
A. Verify if engine oil viscosity is unusual and if low-quality oil

is used.
→Yes
Change engine oil.
→No
To step 3.
3. Check if the vehicle is running at high speed continuously/or excessively used.
A. Verify if the vehicle is running at high speed continuously/

or excessively used.
→Yes
Change oil in time and maintain the engine.
→No
To step 4.
4. Check if forced ventilation system of crankshaft box is blocked and if parts are unusual.
A. Verify if forced ventilation system of crankshaft box is

blocked and if parts are unusual.
→Yes
Repair unusual parts.
→No
To step 5.
5. Check if oil consumption of turbocharger is unusual.
A. Verify if oil consumption of turbocharger is unusual.

→Yes
Repair or replace the turbocharger.
→No
To step 6.
6. Check if throttle guide or rod is worn and if throttle sealing is worn, missing or improperly installed.
A. Verify if throttle guide or rod is worn and if throttle sealing

is worn, missing or improperly installed.
→Yes
Repair the fault position.
→No
To step 7.
7. Check if piston and piston ring is improperly mounted.
A. Verify if piston and piston ring is improperly mounted.

→Yes
Remount piston and piston ring. 21
→No
To step 8.
8. Check if piston ring is properly sealed and if piston ring is cracked or worn. Properly deal with failed
parts as necessary.

Abnormal oil consumption
1. Check leakage.
A. Check each sealing part of engine.

If there is any oil leaking?
→Yes
Repair leaking part.
→No
To step 2.
2. Check blow-by amount.
A. Check and verify if the engine has blow-by.

→Yes
Repair sealing between engine piston and cylinder.
→No
To step 3.
3. Check for burning engine oil.
A. Start the engine.

B. Visually check exhaust color from exhaust pipe.
If the exhaust pipe is discharging blue exhaust?
→Yes
Repair engine gas distribution mechanism and gap between
engine piston and cylinder.
→No

Discharge and fill oil
Disassembly
1. Discharge
(a). Unscrew filling cap assembly.
LFWX-6470-07006
(b). Lift the vehicle

(c). Place oil collector under discharge bolt of oil
sump.
(d). Dismantle discharge bolt to discharge engine oil.
Torque: 23 N•m
21
LFWX-6470-07007
2. Filling
(a). Mount discharge bolt of oil sump and replace discharge bolt and seal ring as necessary.
(b). Lower the vehicle.
(c). Fill in the engine with oil of the type and amount specified in the table.
Engine oil filter

Disassembly
1. ismantle oil filter.
(a). Lift the vehicle

(b). Remove the oil drain plug to drain the oil from the
engine.
LFWX-6470-07007
(c). Lower the vehicle.

(d). Dismantle oil filter.
(e). Use a piece of clean cloth to wipe out the
mounting surface.
LFWX-6470-07008
Installation
1. Mount oil filter.
(a). Mount oil filter

Note:
Before mounting oil filter, apply lubricating oil on
filter sealing.
Torque: 30 N•m
LFWX-6470-07008
(b). Lift the vehicle

(c). Install the oil drain plug.
Torque: 23 N•m
(d). Fill right amount of oil.
(e). Start the engine and ensure there is no oil
leaking.
21
LFWX-6470-07007
Oil pan assembly

Disassembly
1. Dismantle Oil pan assembly
(a). Lift the vehicle

(b). Remove the oil drain plug to drain the oil from the
engine.
LFWX-6470-07007
(c). Dismantle bolts and nuts on oil sump assembly.

(d). Remove oil sump assembly.
0
X2
LFWX-6470-07009
Installation
1. Mount oil sump assembly.
(a). Before mounting oil sump, apply glue of 2~3mm

on cylinder surface (surface connecting with oil
sump) by following the trace illustrated in the right
diagram. Make sure to mount it before sealing
glue is not hardened.
LFWX-6470-07010
(b). Mount oil sump. Cross ore use tightener to

tighten fixing bolts and nuts for oil sump.
X2
0 Torque: 11 N•m
21
LFWX-6470-07009
(c). Install the oil drain plug.

Torque: 23 N•m
(d). Lower the vehicle.
(e). Fill lubricating oil for engine as instructed.
(f). Check that there is no oil leaking at each
connecting points.
LFWX-6470-07007
Oil pump
Disassembly
1. Dismantle oil pump assembly.
(a). Dismantle oil pump assembly.

Reference: Oil sump assembly removal and
installation.
(b). Dismantle oil pump sprocket cover.
LFWX-6470-07011
(c). U s e s c r e w d r i v e r t o p r e s s o i l p u m p r a i l
components in arrow direction,and take away the
oil pump chain
LFWX-6470-07012
(d). Dismantle fixing bolts for oil filter and take away
oil filter.
LFWX-6470-07013
(e). Dismantle fixing bolts for oil pump and take away
oil pump.
LFWX-6470-07014
Installation
1. Install oil pump assembly
(e). Dismantle fixing bolts for oil pump and take away
oil pump.
21
LFWX-6470-07014
oil filter.
LFWX-6470-07013
oil filter.
LFWX-6470-07015
(a). Remove Oil pan assembly

Reference: Oil sump assembly removal and
installation.
(b). Dismantle oil pump sprocket cover.
LFWX-6470-07011
Maintenance Tools
General tool
Quick wrench,
socket
2 Screwdriver -
3 Torsion wrench -
21
4 Oil filter pullover -
5 Locating wrench -
Emission control system of Engine
Emission control system��1
Positive crankcase vent system�� 1
Fuel evaporative emission
(EVAP) control system �� 1
Oil-air separator�� 2
Activated carbon canister
solenoid valve�� 2
Evaporative emission carbon canister�� 2
Oil - air separator valve assembly�� 2
Oil-gas separation valve inspection �� 4
Carbon canister inspection�� 4
List of fault symptoms�� 5 21
Oil - air separator tube�� 6
Disassembly�� 6
Installation �� 7
Canister solenoid valve
combination tube�� 8
Disassembly�� 8
Oil-air separator�� 9
Disassembly�� 9
Starting system of engine - Starting system (1.5T) 21-1
Emission control system

Name Nm Lb-ft Lb-in
Exhaust manifold assembly bolt 4 - 36
Operating principle
System Overview
Positive crankcase vent system
At the end of the effective engine combustion process, a certain mixture that not be burned under
high pressure is leaked into the crankcase from the piston rings, which is called as “Channeling
Gas”. The channeling gas contains nitrogen oxides, carbon monoxide and hydrocarbons. If the
channeling gas is not exhausted, it can dilute the oil in the crankcase, and degrade the oil, resulting
in premature wear of the engine parts. The channeling gas may escape into the atmosphere from
the crankcase, resulting in the pollution. In order to avoid the emission deterioration and prevent
channeling gas to be emitted into the atmosphere and prevent the oil deterioration, the positive
crankcase vent system is used to guide the channeling gas in the crankcase back into the air
intake system, to lead the channeling gas into the combustion chamber for combustion via the oil -
gas separation valve assembly and the intake manifold.
Fuel evaporative emission (EVAP) control system

The fuel stored in the fuel tank can produce fuel vapor due to temperature, shaking and other
factors, the fuel vapor may be release from the fuel tank into the atmosphere, resulting in pollution. 21
In order to avoid the emission deterioration, the fuel evaporative emission (EVAP) control system
is used to control the emissions of fuel vapor, which belongs to the active carbon filter tank storage
method. This method can transfer the fuel vapor from the fuel tank into the active carbon storage
device, i.e., the gasoline vapor flows from the fuel tank into the fuel vapor recovery pipe, and then
is absorbed by the carbon canister, and is stored when the vehicle is parked. After the engine has
been operated for specified time, based on the requirements of the purification working conditions,
the engine control module can provide a grounding circuit, to power on the carbon canister
discharge solenoid valve, suction the air into the carbon canister and mix it with fuel vapor. The fuel
vapor mixture is sucked out from carbon core and lead into the intake manifold, for consumption
in the cylinder in the process of normal combustion. The operations of carbon canister drainage
solenoid valve is controlled by pulse width modulation (PWM) signal. Depending on the operating
conditions determined with air flow, fuel control and intake temperature, the carbon canister
discharge solenoid valve PWM duty ratio changes.
21-2 Starting system of engine - Starting system (1.5T)
Part instructions
Oil-air separator
The oil-gas separator is installed in the timing cover
components, and its inlet port is connected with the
engine crankcase; the oil-gas mixture with a certain
pressure passes throng the oil-gas separator, and the
separated oil is returned into the engine oil sump; the
purified gas (containing a small amount of oil steam)
is entered into the intake manifold via the vent pipe, to
participate in combustion; under high oil-gas pressure,
in order to protect the engine, the check valve in the
oil-gas separator connected with the vent pipe will be
opened for pressure relief, playing a role of the relief
valve; at the same time, the gas containing a lot of oil
can be entered into the intake side of the turbocharging,
resulting in abnormal oil consumption, or the oil can be
LFWX-6470-12001 directly drained out of the vehicle or in the air.
Activated carbon canister solenoid valve

The carbon canister discharge solenoid valve is a normally closed type solenoid valve, and is used
to control the vapor flow from the evaporative emission control system into the intake manifold.
The pulse width modulation of solenoid valve is performed by the engine control module, in order
to accurately control the fuel vapor flow into the engine. In some tests of the evaporative emission
system, the solenoid valve is also opened, to allow the engine vacuum to enter into the evaporative
emission system. The carbon canister control valve consists of electromagnetic coil, armature and
valve, and its inlet is equipped with a filter mesh. On the one hand, the gas flow through the carbon
canister control valve is related to the electrical pulse duty ratio output from ECU to the carbon
canister control valve; on the other hand; it is also related to the pressure difference between inlet and
outlet of the carbon canister control valve. When there is no electrical impulses, the carbon canister
control valve will be closed. Based on the signals provided by all sensors on the engine, ECU can
control the polarization time of carbon canister solenoid valve, so as to the cleaning air flow rate.
Evaporative emission carbon canister

The evaporative emission carbon canister is an emission control device containing activated
carbon particles. The evaporative emission carbon canister is used to adsorb and store fuel vapor
from fuel tank. The fuel vapor is always stored in carbon canister, when certain conditions are
meet, the engine control module will power on the canister sewage solenoid valve, to allow the fuel
vapor to enter into the engine cylinder for consumption.
The following conditions can lead to poor idle, loss of idle and poor control performance:
• The carbon canister solenoid valve does not action.
• The carbon canister is damaged.
• The hose is disconnected broken, or not connected with the proper pipeline.
Oil - air separator valve assembly

Oil - air separator valve assembly is a check valve.
LFWX-6470-12002

Part exploded view
1 2 3 4
21
6 5
LFWX-6470-12003
1 Oil - air separator valve assembly 4 Timing cover component
2 Oil - air separator tube 5 Canister solenoidvalve combination tube
3 Oil - air separator 6 Oil - gas separation valve vent pipe


Oil-gas separation valve inspection
Warning:
• In the lab, the mice contacted in the long term with used oil has made skin cancer.After
working in contact with the oil, please immediately wash your kin with soap and water,
to protect your skin.
• Hot engine and engine oil can cause serious burns. Shut down the engine, wait for some
time until the engine and engine oil is cooled down.
Note:
Before check the oil pressure, please first check the following items:
If the engine idle speed is instable, check that the oil-gas separation valve is clogged, the vent filter
and the air filter are too dirty or the hose is clogged. Perform the following procedure: if the oil level
is too low, add the oil to the full level marker on the scale.
1. Remove the crankcase vent valve from the valve chamber cover.
2. Operate the engine at idle speed.
3. Put your finger at the valve end, check the vacuum; if there is no vacuum in the valve, check
the following conditions:
• Whether the hose is plugged
• Whether the manifold port is plugged
• The crankcase vent valve is plugged
The clogging of the oil-gas separation valve or its hose can lead to the following faults:
• The engine idle speed is not stable
• The engine is stall or the idle speed is too low
• The engine oil is leaked
• The oil enters into the air filter
• The oil dirt enter into the engine
• The engine crankcase pressure is too high
The oil-gas separation valve leakage or its hose leakage can lead to the following conditions:
• The engine idle speed is not stable
• The engine is stall
• The engine idle speed is too high
Carbon canister inspection

1. Check the filter in the vent pipe on the canister for clogging, rupture, deformation and etc.; if
necessary, replace the filter.
2. Carbon canister appearance inspection: no rupture, deformation; if necessary, replace it.
3. Remove the carbon canister and shake it manually, if there is any abnormal sound, replace it.
4. Check the connecting hose on the carbon canister for clogging or breakage; if necessary,
replace it.
5. Use the appropriate air source, to blow in one port on the carbon canister, there should be air
outflow at the other two ports; otherwise, replace the carbon canister.

• Check the oil-gas separation valve

• The oil-gas separation valve or
system components for clogging; if
hose is clogged or damaged
necessary, clean them or install new
The pressure in the • The crankcase vent oil separator
components.
crankcase is too high is clogged
• Reference: Mechanical system (engine
• The engine components is worn
mechanical system, removal and
or damaged
installation).
The evaporative emission • The drainage pipe is broken • Replace the drain pipe.
system is leaked • The carbon canister is broken • Replace the canister.
• Clean the vent pipe.
• The vent pipe is clogged • Replace the vent pipe.
• Replace the vent pipe filter.
The evaporative emission
• Clean the drainage outlet.
system is clogged • The drainage pipe is clogged
• Replace the drain pipe.
• The carbon canister pipe is • Clean the carbon canister pipe.

clogged • Replace the canister.
21

Oil - air separator tube
Disassembly
1. Remove the oil-gas separation pipe.
(a). Remove the oil-gas separation valve vent pipe

connector (1).
(b) Remove the carbon canister solenoid valve
combination pipe connector (2).
1 2
(c) Remove the oil-gas separation pipe fixing bolts
(3).
LFWX-6470-12004
(d). Remove the oil-gas separation pipe fixing bolts.

(e) Remove the oil-gas separation pipe.
LFWX-6470-12005
Starting system of engine - Starting system 21-7
Installation
1. Install the oil-gas separation pipe.
(a). Install the oil-gas separation pipe fixing bolts.

Torque:11 N•m
LFWX-6470-12005
(b). Install the oil-gas separation pipe fixing bolts (3).

Torque:11 N•m
(c) Install canister solenoid valve combination tube
connector(1).
1 2
(d) Install canister solenoid valve combination tube
connector(2).
3 21
LFWX-6470-12004
21-8 Starting system of engine - Starting system
Canister solenoid valve combination tube

Disassembly
1. Remove the carbon canister solenoid valve combination pipe.
(a). Remove the carbon canister solenoid valve

combination pipe and oil-gas separation valve
vent pipe connector.
1
2
Reference: Removal and installation of oil-gas
separation pipe.
(b) Remove the oil-gas separation valve vent pipe
connector (1).
(c) Remove the carbon canister solenoid valve
LFWX-6470-12006
Installation
1. Install the carbon canister solenoid valve combination pipe.
(a). Install the oil-gas separation valve vent pipe

connector (1).
(b) Install the carbon canister solenoid valve
1
2
(c) Install the canister solenoid valve combination
pipe and oil-gas separation valve vent pipe
connector.
LFWX-6470-12006
Starting system of engine - Starting system 21-9
Oil-air separator
Disassembly
1. Remove the oil-gas separator.
(a). Remove the timing cover components.

Reference: Removal and installation of timing
chain components.
1
2 (b) Remove the oil-gas separator fixing bolts.
(c) Remove the oil-gas separator assembly.
LFWX-6470-12006
Installation
1. Install the canister solenoidvalve combination tube
(a). Install the oil-gas separator assembly and the oil-

gas separator fixing bolts.
Torque:4 N•m
1
2 (b). Install the timing cover components.
21
LFWX-6470-12006
Exhaust gas emission control - Exhaust gas emission control 17-a
Exhaust gas emission control

Exhaust gas emission control��1
schematic diagram�� 2
Positive crankcase ventilation
(PCV) system��2
Inspection�� 2
Fuel evaporative emission
(EVAP) control system��3
Inspection�� 3
Adjustment�� 4
17
17-b Exhaust gas emission control - Exhaust gas emission control
Exhaust gas emission control - Exhaust gas emission control 17-1

System description
1. Overview
System Abbreviations Purpose
1. Positive crankcase ventilation Reduce the gas leakage (HC compounds) in

PCV
system the crankcase
2. Fuel evaporative emission

EVAP Reduce the evaporation of HC compounds
control system
Adjust the operation conditions of engine

3. Electronic fuel injection system EFI
components to reduce the emission
(a). EVAP on Lifan Myway series of models consists mainly of a exhaust emission control system,
positive crankcase ventilation (PCV) emissions (EVAP) control system, fuel evaporation
system, and etc.
(b). Exhaust emission control system mainly comprises one exhaust manifold, front muffler and
evolver assembly and rear muffler assembly, wherein the exhaust manifold and front muffler
catalytic carrier (TWC) are used to transform carbureted hydrogen (HC), carbon monoxide (CO)
and oxynitride (NO) in exhaust gas to carbon dioxide (CO2), nitrogen (M2) and water vapor.
(c). The positive crankcase ventilation (PCV) system is used to prevent the cylinder mixture
emission in the atmosphere. PCV valve contains a spring-loaded plunger; during the engine
starting, the piston in PCV valve rises, its rising level is proportional to the vacuum degree in
the intake manifold, so as to directly inhale the cylinder mixture into the intake manifold. 17
(d). The fuel evaporative emission control system (EVAP) is used to reduce the fuel vapour
emissions in the atmosphere, in order to reduce the emissions of hydrocarbons (HC). The
system mainly includes:
• Activated carbon tank with evaporative emission (EVAP) control. It is used to temporarily
store the fuel vapour, until the fuel vapour can be sent from EVAP controlled activated
carbon tank into the engine for combustion.
• Fuel tank steam purification control system. The inhaled fresh air is sent into the inlet hole
on the throttle body through the canister solenoid valve, where the purification is performed
in the activated carbon tank.
• Fuel tank steam control system. When fuel vapour pressure in the fuel tank is above the set
value of EVAP two-way valve, EVAP two-way valve will opened, to allow the fuel vapour to
flow into EVAP controlled activated carbon tank.
2. Lifan Xuanlang models are equipped with LFB479Q engine. The description of exhaust
emission control and maintenance are especially for LFB479Q engine.
17-2 Exhaust gas emission control - Exhaust gas emission control
Exhaust gas emission control schematic diagram
Activated carbon canister solenoid valve
Engine
harness
Positive crankcase
ventilation valve
Canister
Exhaust manifold
LFWX-6470-17001
Positive crankcase ventilation (PCV) system

Inspection
1. Remove PCV valve

Cylinder head side (a).
Remove PCV hose from PCV valve.
(b).
Remove PCV valve.
2. Install the cleaning hose on PCV valve
3. Check the operation of PCV valve
Cleaning hose (a).
Blow the air into PCV valve on the cylinder
head side, to check whether the air channel is
unclogged; if it is clogged, replace PCV valve.
Note:
Don`t blow the air into PCV valve, because the oil
materials in PCV valve is harmful.
LFWX-6470-17002
(b). Blow the air reversely into PCV valve, to check

Intake manifold side whether the gas channel is unclogged; if it is
unclogged, replace PCV valve.
LFWX-6470-17003
4. Remove the cleaning hose from PCV valve

5. Reinstall PCV valve
6. Visually check the hose and the hoop
(a). Check for cracks, leakage or damage.
17
Fuel evaporative emission (EVAP) control system
Inspection
Tips:
First check the exhaust manifold, three-way catalytic converter, and muffler for joint cracks,
welding rupture and corrosion that may cause the exhaust system leakage; check the clamp,
bracket and insulation pads for breakage and damage.
Check EVAP activated carbon tank cleaning system
Engine status Engine condition Applied vacuum degree, kPa Normal status
The engine is idling

Cold 50 Maintaining vacuum
Engine speed 3000r/min
The engine is idling 50 Maintaining vacuum
After starting for 3min, the

The vacuum degree
engine speed is 3000r/ Trial vacuuming
disappears
min
The vacuum degree

Hot persists and then
disappers. When the
After starting for 3min, the
altitude is above 2200
engine speed is 3000r/ 50
m or when the inlet
min
temperature is below
50ºC, the vacuum degree
will drop continuously.
Adjustment
The displacement of emission control system is usually the vibration of emission control system
parts, with a “Click” noise. Sometimes, the noise is difficult to be differentiated with the other noise
from the chassis. Check the clamp, heat insulation cover, cushion and bracket in the emission
control system for breakage or loosening; if necessary, tighten or replace the parts.
In maintenance, must pay attention to the followings:
(a). Do not coat any antirust material and primer on the floor heat shield cover of emission control
system. Allow to coat a thin layer of paint on the edge. The coating will greatly reduce the
effect of heat insulation cover, increase the floor temperature and issue an abnormal smell.
(b). When replacing any part on the emission control system, must use the original spare part (or
equivalent part).
(c). When removing or installing the muffler or exhaust manifold gasket, do not use lithium base
grease, because it may endanger the service life; but can use soap water.
(d). The operating temperature of the emission control system is very high; before the emission
control system is cooled, do not work or relax around it; must be careful when operating near
the three-way catalytic converter; after the engine is operated, the temperature of the three-
way catalytic converter in the short term will rise to the maximum.
1. Check the crankcase emission control system
The crankcase emission control system is mainly the positive crankcase ventilation (PCV)
system, and its core is PCV valve; when PCV valve is operated normally, the emissions from
the crankcase will be effective controlled.
(a). Check the operating conditions of the crankcase emission control system.
• Remove the vent hose from PCV valve.
• Remove PCV valve from the rocker cover.
• Re-connect the vent hose.
• Operate the engine at idle speed, and manually press the opening end of PCV valve, to
confirm the vacuum degree. Under normal circumstances, the vacuum should be felt (the
finger is sucted); otherwise the operation of the crankcase emission control system is
abnormal, and PCV valve and the vent hose should be cleaned with the cleaning fluid ; if
necessary replace it.
(b). Check PCV valve.
• Remove PCV valve.
• Insert a fine rod into PCV valve from the threaded end of PCV valve, to check the piston
in PCV valve for movement. Under normal circumstances, the piston in PCV valve can be
moved. If the piston can not be moved, the piston in PCV valve is clogged, and should be
cleaned or PCV valve should be replaced.
2. Check the fuel evaporative emission control system

Tips:
The fuel evaporative emission control system is mainly used to limit the HC exhaust.
(a). Check the activated carbon tank and fuel vapour

pipe.
• Check the fuel vapour pipe connections for any
loosening, dead bending, distortion, cracks,
damage, or fuel leakage.
• R emove EVAP activated carbon tank and
check it for cracks or damage.
(b). Check EVAP carbon tank solenoid valve.
• R e m o v e t h e v a c u u m h o s e f r o m E VA P
activated carbon tank solenoid valve, and
mark the marking on it, in order to facilitate its
installation.
• R emove the wiring connector on EVAP
activated carbon tank solenoid valve.
• Connect the vacuum pump to the vacuum hose
LFWX-6470-17004 connector.
• Vacuum it and check EVAP carbon tank
solenoid valve for normal operation in case
of power on and off. The normal condition
is: when connecting the battery voltage,
the vacuum should be established; when
disconnecting the battery voltage, the vacuum 17
should be maintained.
• Use a multimeter in Ω position to measure the
resistance between two terminals of EVAP
activated carbon tank cleaning solenoid valve.
Resistance: 26±4Ω
Charging system
Charging system��1
Self discharging of battery�� 2
Battery capacity loss after loading�� 2
Charging system�� 2
Battery�� 2
Structure and installation location�� 3
Inspection and confirmation�� 4
Inspection of battery�� 4
Battery charging�� 4
Battery parasitic current test�� 5
21
Alternator test�� 5
List of fault symptoms��6
Diagnosis procedure about
that the starting motor can
not be shutdown�� 7
Diagnosis of over-charging
of battery�� 8
Diagnosis process of
alternator noises�� 8
Alternator�� 9
Disassembly�� 9
Removal�� 10
Charging system of engine - Charging system (1.5T) 21-1
Charging system
Part specifications
Name Size
Maximum rotational speed of

15000 rpm
alternator
Regulating voltage of alternator 14.5±0.3 V
Rated alternator current 110 A
Fixing bolt for alternator 25 18 -
21
21-2 Charging system of engine - Charging system (1.5T)
Operating principle
System Overview
Self discharging of battery
Theoretically speaking, self discharging battery is unavoidable. Self discharging of maintenance-
free battery is far less than ordinary battery, but it still has automatic discharging to some degree.
Even it is placed with open circuit for long time, the battery will be consumed obviously. Self
discharging of battery is mainly affected by the following factors:
1. The higher the temperature is, the ratio of self discharging will be. Generally, for every increase
in temperature by 10ºC, the ratio of self discharging will increase by about 2.7 fold. Therefore,
self discharging of vehicle battery will vary greatly in summer and winter.
2. The condition of storage site will have great impact. High humidity and dust will increase self
discharging of battery.
Battery capacity loss after loading

After being loaded on vehicle, battery will lose capacity in the following ways:
1. Capacity loss during testing process;
2. Power consumed by some intermittent electrical units, such as anti-theft alarm;
3. Power leaking due to poor insulating performance of vehicle components;
4. Power loss caused by static current or power leaking due to connected negative wire.
Note:
The standing time of battery is dependent on many factors. Generally, fully charged batter
can still start the vehicle 6 months after disconnecting negative wire.
Charging system
One feature of alternator is that it has a solid regulator inside. All the parts of regulator are installed
in a closed box. The regulator together with electric brush assembly are mounted on sliding ring
and frame. Set voltage of alternator cannot be regulated.
As rotor bearing of alternator has enough lubricating grease, there is no need to lubricate it
regularly. Two electric brushes will enable current to flow to excitation coil through two sliding rings.
Under normal circumstances, there is no need to maintain electric brushes for long time.
Stator winding is mounted inside laminated core, which is alternator frame component. The rectifier
connected to stator winding is composed by 6 LEDs which transform AC voltage on stator to DC
voltage on alternator output column.
Center diode is used to transform central point voltage into DC and increase alternator output.
The capacitor mounted on regulator assembly will provide voltage protection for diode and control
interference of radio wave.
Part instructions
Battery
If the battery is tested to be good, but it always has under-voltage or failure to start overnight.
Consider the following causes for failure:
1. There is electric unit that is not switched off for the whole night.
2. The vehicle is running at low speed and stops at intervals.
3. The vehicle electrical load exceeds alternator output, especially when the vehicle is installed
with after-sales additions.
4. There is some problem in charging system, such as electrical short circuit, sliding alternator
belt, failed alternator or voltage regulator.
5. The battery is not properly used, such as failure to keep clean and tight battery terminal or
loosened battery fixing plate.
6. Mechanical failure in electrical system, such as wire short circuit or clamping.

Part exploded view
1 2 3 4 5
12 11 10
9
6
21
7
LFWX-6470-10001
1 Water pump pulley bolt 7 Air conditioning compressor bolt
2 Water pump pulley 8 Air conditioning compressor bolt
3 Alternator bolt 9 Crankshaft pulley bolt
4 Idler wheel 10 Crankshaft pulley
5 Alternator assembly 11 Tensioner assembly bolt
6 Compressor assembly 12 Tensioner assembly


Inspection and confirmation
3. If the observed or proposed problem is obvious and its cause is identified, rectify the cause
before proceeding with next step.
4. If the problem cannot be identified obviously, confirm the problem by referring to the symptom
form.
Mechanical Electric
• Fuse
• Attachment drive belt
• Wiring harness
• Alternator
• Electrical connector
General inspection
Inspection of battery
1. Visual inspection of battery: the battery surface shall be free from leaking trace, crack and
damage. The electrode shall be free from corrosion and reliably connected.
2. Check by discharging tester: press appropriate contacts on positive and negative poles of
battery. When the needle of discharging tester is within green range for 2S, it indicates that the
battery capacity can meet the requirement for high-current start. When the needle is within red
range without other abnormality, it means that the battery is out of power and it needs charging.
3. Use headlamp as load and connect voltmeter to the battery to measure battery voltage. Read
the voltage and turn on headlamp. If battery voltage does not decrease dramatically and
sustain above 10V, the battery can start the vehicle after being fully charged. If battery voltage
decreases quickly after turning on headlamp, charge the battery to restore its function. For
the battery that is not used for long time, charge it with longer time and for more times to fully
activate it.
Note:
For the charging/discharging or freshly charged battery, it is inappropriate to use discharging
tester to check it, because it will produce large amount of oxy-hydrogen gas during charging
process. By using discharging tester or resistance fuse to perform checking, it will produce
sparkle to explode the gas to cause physical injury and property loss.
Battery charging
Warning:
● Keep the battery out of reach of children. As battery contains sulfuric acid, avoid
contact with skin, eyes or clothes. When approaching battery for working, wear
protective glasses to avoid contact with acid solution. In case that acid solution touches
skin or eyes, immediately use clear water to wash it for at least 15min and hospitalize
the injured. If some eat acid solution by mistake, hospitalize him/her immediately. Fail to
follow these instructions may cause serious casualties.
● Battery will generate explosive gas that could result in casualty. Therefore, keep fire,
sparkle or inflammable materials away from battery. When approaching battery charging
or construction, wear protective mask to protect face and eyes. Keep it in well ventilated
place. Fail to follow these instructions may cause serious casualties.
● Follow all manufacturer instruction before using any charging equipment. Fail to follow
these instructions may cause serious casualties.
● Do not turn on the switch before connecting charger to battery. Fail to follow these
instructions may cause serious casualties.
● Turn off the switch before dismantling charger from battery. Fail to follow these
instructions may cause serious casualties.
Note:
● Do not charge the battery in car.
● Do not rely on alternator to charge discharged battery, because it will run for over 8h
with the charging system without electrical load.
1. Dismantle battery and place it in a basin of water.
2. Connect battery charger with battery and charge it by following the ways below.
Charging under constant voltage:
Under constant voltage of 14.8 V, charge it for 3h after charging current is decreased to 3 A to
complete charging. Note that charging current shall not exceed 25 A.
Charging under constant current:
Use 6 A to charge voltage to 14.8 V, and use 3 A to charge it for 3h to complete charging.
Battery parasitic current test

If the battery has continuous under-voltage, perform the following test process to check if it has
parasitic current.
1. Disconnect negative wire of battery.
2. Connect positive pen of multi-meter to the negative wire of battery and connect negative pen to
the negative pole of battery.
3. Ensure that all electrical units of tested vehicle are shut off. The door, engine cover and trunk
cover are well closed.
4. Select mA scale of multi-meter.
5. Measure parasitic current after vehicle module is in dormancy.
Note:
● Module in dormancy can vary depending on different equipment level.
Standard value of parasitic current: less than 30 mA
Alternator test 21
1. Connect test equipment

Select appropriate scale and connect voltmeter
between connecting column of alternator B and
ground. Connect ammeter between B connecting
column of alternator and positive column of battery.
2. No-load test
Start the engine to increase its rotational speed from
1. Load
2. Load switch idle speed to 2,000 rpm / min, and read the number in
3. Battery the instrument.
4. 100A scale of ammeter
V: 20V scale of voltmeter
B: output column of alternator
LFWX-6470-10002
Note:
• Consider that voltage can be different depending on different temperature of voltage
regulator. Do not perform this test on discharged battery. Fully charge the battery before
the test.
• When the engine is running, do not dismantle connecting column of battery, or it will
damage electronic parts.
Standard current: 10 A (maximum)

• Attachment drive belt Reference: Diagnosis process of

Battery is not adequately
• Generator regulator inadequate charging of battery (charging
charged.
• Alternator system, fault diagnosis and checking).
Reference: Diagnosis process of over-

• Generator regulator
Battery is overly charged. charging of battery(charging system,
• Alternator
fault diagnosis and checking).
• Drive belt is worn.

• Accessory drive belt tensioner is
Charging indicator is Reference: Diagnosis process of
damaged.
always on. charging indicator that is always on
• Alternator
• Circuit failure
• Instrument LED
• Instrument
• Circuit failure Reference: Diagnosis process of
Charging indicator is off.
• Electric brush is in poor contact charging indicator that is not on
with slide ring.
• Voltage regulator
• Attachment drive belt Reference: Diagnosis process of

Alternator noises • Bearing alternator noises (charging system, fault
• Stator and rotor diagnosis and checking).
Charging system of engine - Charging system 21-7
Diagnosis procedure about that the starting motor can not be

shutdown
1. Check the generator charging voltage.
A. Start the alternator to increase alternator rotational speed

from idle speed to 2,000 rpm.
B. Use multi-meter to measure the voltage of positive wire
against negative pole. Check if the voltage is no less than
14.2 V.
→Yes
To step 2.
→No
To step 3.
2. Check parasitic current of battery.
A. Perform the process to check battery parasitic current.

Reference: Test battery parasitic current (charging system,
fault diagnosis and checking).
Is it OK after checking?
→Yes
To step 3.
→No
Repair failed wiring or electric unit.
3. Check alternator.
A. Perform alternator test process.

Reference: Alternator test process (charging process, fault 21
diagnosis and checking).
Is it OK after testing?
→Yes
Charge the battery.
Or replace battery.
→No
Check the generator.
21-8 Charging system of engine - Charging system
Diagnosis of over-charging of battery

1. Check the generator charging voltage.
A. Start the engine to increase alternator rotational speed

from idle speed to 2,000 rpm.
B. Use multi-meter to measure the voltage of positive wire
against negative pole. Check if the voltage is higher than
14.8 V?
→Yes
To step 2.
→No
The system is normal.
2. Check alternator regulator.
A. Replace alternator regulator.

Is alternator charging voltage is OK?
→Yes
The system is normal.
→No
Check the alternator separately.
Diagnosis process of alternator noises

Diagnosis note: alternator noises could be from electrical or mechanical noises. Electrical noises
(electromagnetic buzz) will generally change with electrical load on alternator. As this is normal
operating characteristics of all alternators, note this during diagnosis; otherwise, it will result in
unnecessary complaint from customers. For the alternator diagnosed with mechanical noises,
check if the parts around alternator are loosened or mutually interfered. In some cases, gentle
noises inside cabin will be heard in passenger cabin. In this case, you cannot resolve the problem
by replacing alternator. You will misjudge it in this case.
1. Check accessory drive belt.
A. Check if accessory drive belt is lacking teeth.

B. Check tensioning force of accessory drive belt.
Reference: Checking of accessory drive belt (mechanical
system, dismantling and mounting).
Is accessory drive belt working properly.
→Yes
To step 2.
→No
Repair accessory drive belt.
2. Check alternator noises.
A. Dismantle accessory drive belt.

B. Start the engine to run.
Are there still alternator noises?
→Yes
Check the noises of compressor and power pump.
→No
Repair alternator.

Alternator
Disassembly
Note:
If B+ wire has not been fixed with specified tightening torque, there will exist the following risks:
• The battery cannot be fully charged.
• The vehicle electrical system or electronic unit will become totally out of control (the vehicle
cannot be started).
• Potential risk of burning as a result of sparkle generated.
• The electronic components and control unit will be damaged due to over-voltage.
• Check if battery wire is properly connected to right terminals.
• When performing quick charging on battery, disconnect battery wire.
• Do not use high-voltage insulating resistance tester for testing.
• Do not disconnect battery wire when the engine is running.
1. Dismantle the alternator.
(a). Disconnect negative connector of battery.

(b). Dismantle accessory drive belt.
Reference: Attachment drive belt (mechanical
system, removal and installation).
(c). Dismantle protective cover of B terminal line.
21
LFWX-6470-10003
(d). Disconnect alternator regulator wiring connector

(1) and dismantle B terminal line nut (2).
LFWX-6470-10004
(e). Dismantle fixing bolt for alternator.
LFWX-6470-10005
(f). Take out alternator assembly.
LFWX-6470-10006
Removal
Note:
When operated mounting accessory belt, pay attention to the running direction marked during
dismantling! Before mounting accessory belt, note that all the units (alternator, air conditioner
compressor) have been mounted and fixed. When mounting accessory belt, note right position of
accessory belt in the belt pulley!
1. Mount alternator.
(a) Mount the generator assembly.
LFWX-6470-10003
(b) Mount alternator fixing bolt.

Torque: 25 N•m
LFWX-6470-10005
(c). Connect alternator regulator wiring connector (1)

and mount B terminal line nut (2).
Torque: 18 N•m
21
LFWX-6470-10004
(d). Mount protective cover for B terminal line.

(e). Mount accessory drive belt. Reference:
Attachment drive belt (mechanical system,
removal and installation).
(f). Connect negative pole connector of battery.
LFWX-6470-10008
Maintenance Tools
General tool
1 Torque wrench -
21
Start the charge system - Start the charge system 18-a
Start the charge system

Battery��1
Repair parameter�� 2
Precautions�� 2
Battery��3
Inspection�� 4
Charge the battery�� 4
Change�� 4
Starter/ generator��5
Precautions�� 7
Starter component drawing�� 8
Generator component drawing�� 9
Starter inspection�� 10
Check the generator�� 14
Starter repair�� 16
Generator repair�� 21 18
One-touch start system( PEPS)��26
18-b Start the charge system - Start the charge system
Start the charge system - Start the charge system 18-1
Battery
System description
1. Function
The battery has the following functions:
When the engine is running, the generator will produce the electricity energy. .
To provide the power supply for engine starting and electrical appliances.
2. Composition
Battery
Special tools
S/N Tool External view Note
Measure the current, voltage and

resistance
Auxiliary measurement of voltage 18

2 Conductor assembly
or resistance
Quick wrench and Dismounting the fixing bolts and

3
flashlight components nuts
18-2 Start the charge system - Start the charge system
Repair parameter
Standard battery voltage 12V
Items N•m
Battery clamp plate fastening nut 6~12
Vehicle inside low frequency magnetic field

6~12
antennae bolt
Precautions

2. Other precautions
(a). The battery are prone to produce a flammable and explosive gas; when checking or maintain
the battery system, please be far away from any heat source and open flame.
(b). When checking and maintaining the battery system, do not allow the electrolyte to be infected
with the vehicle body and skin, if it is infected with skin, please rinse immediately it with plenty
of water and then see a doctor as soon as possible.
Battery
Component drawing
5 2
18
LFWX-6470-18001
1 Battery assembly 4 Battery installation base plate
2 Battery pressure plate 5 hexagon flange nut
3 Battery installation rod

Inspection
1. Check the battery
(a). Check the battery case for cracks and damage; if
any, replace it timely.
(b). Check the battery terminal for corrosion; if any,
clean or replace it timely.
(c). Use a digital multimeter with voltage position to
check the battery voltage; if the voltage is too
low, charge or replace the battery.
Standard voltage:12V
2. Check the battery load voltage
(a). Connect the digital multimeter to positive and
negative battery terminals, read the battery
voltage and open the headlamps, observe
whether the battery voltage drops rapidly; after
2 min, observe whether the battery voltage is
LFWX-6470-18002
greater than 10V; if it is less than 10V, must
replace the battery.
Charge the battery
1. Constant voltage charging

(a). Maintain the constant voltage of 14.8V; when the charging current drops to 3A, continuously
charge the battery 3 h, to complete the charging operation.
Note:
The charging current is no more than 25A.
2. Constant current charging
(a). With 6A current, charge the battery to the voltage of 14.8 V, and with 3A current, charge the
battery 3h, to complete the charging operation.
Change
1. Remove the battery
(a) Maintain the system power supply under OFF
status, disconnect the positive and negative
battery terminals.
LFWX-6470-18003
(b) Remove the battery pull rod fastening nut and

battery clamp plate fastening nut.
(c) Remove the battery pull rod and battery clamp
plate.
(d) Remove the battery.
LFWX-6470-18004
2. Install the battery

(a). I n s t a l l t h e b a t t e r y b o t t o m p l a t e o n t o t h e
installation location.
(b). Install the battery onto the battery installation
bottom plate.
(c). Install the battery pull rod and the clamp plate,
and install and tighten the fastening nut.
Torque:6~12 N•m
18
LFWX-6470-18004
(d). Connect the positive and negative battery cables.
LFWX-6470-18002
Starter/ generator
 Tips:
Lifan Xuanlang series of models include LF6470, LF6470B, LF6470C and LF6470G, on which
LFB479Q, LF483Q, LF477ZLQ00 engine and 5MT manual transmission or 8AT automatic
transmission are configured. Though the transmissions are different, the maintenance methods
are basically same, and described with LF6470 model configured with LFB479Q engine and 5MT
manual transmission as an example in this chapter.
Special tools

resistance
Auxiliary measurement of voltage

or resistance
Measure the starting commutator

3 Dial gauge
gear ring runout
4 Calipers Measure the diameter and length

Maintenance data
1. Technical specifications table
Commutator ring gear runout 0.05mm
Commutator diameter 29mm~30mm
Starter brush length 10mm~15.5mm
Exposed generator brush length 1.5mm~10.5mm
Nominal diameter 14.2mm~14.4mm

Slipping ring diameter
Slipping ring resistance 2.1Ω ～ 2.5Ω (Cold)
2. Tightening torque table
Items N•m
Commutator end cover bolt 20~25
Commutator end cover screw 9~11
Magnetic switch fastening screw 9~11
Starter wiring fastening screw 20~25
Starter fastening bolt 80~86
Pulley fastening nut 110.5 18

Rectifier end frame fastening bolt 3~4
Rectifier end frame fastening screw 3~4
Rear generator end cover fastening nut 9~11
Rear generator end cover fastening screw 5~6
Generator assembly fastening bolt 45~49
Precautions

(a). The duration for the starter test should be not more than 5s.
(b). When disassembling the starter or generator, do not to damage the insulation parts.
Starter component drawing
LFWX-6470-18048
1 Commutator end cover fixing bolt 8 Magnetic switch fixing bolt
2 Commutator end cover fixing screw 9 Gasket
3 Commutator cover 10 Starter pinion drive rod
4 Brush carrier 11 Magnetic switch
5 Armature 12 Gear
6 Starter track 13 Intermediate bearing clutch subassembly
7 Starter driving end cover

Generator component drawing
18
LFWX-6470-18049
1 Generator assembly
Starter inspection
1. Check the starter motor assembly
(a). As shown, connect the battery to the two
terminals A and B on the starter, to check the
clutch pinion for movement outward. If the clutch
pinion is no rotated or moved outward, replace
B the starter switch assembly.
A
LFWX-6470-18005
(b). As shown, connect the wiring A on the battery, to

check whether the clutch pinion is remained in
place; if not, replace the starter switch assembly.
B
A
LFWX-6470-18006
(c). As shown, disconnect terminal A wiring and

the housing wiring, to check whether the clutch
pinion can be returned in place; if not, replace the
starter switch assembly.
B
A
LFWX-6470-18007
(d). As shown, perform the no-load test for the starter,

and observe and record the current value.
B
A
C
+
LFWX-6470-18008
2. Check the starter magnetic switch

(a). As shown, push down the iron core, to check
it for quick return; if not, replace the magnetic
switch assembly.
18
LFWX-6470-18009
(b). As shown, use the multimeter at ohm position to

measure the resistance between the terminal A
and B; if it can not meet the requirement, replace
the magnetic switch.
Resistance: <1Ω
LFWX-6470-18010
(c). As shown, use the multimeter at ohm position

to measure the resistance between the terminal
B and the housing; if it can not meet the
requirement, replace the magnetic switch.
Resistance: <2Ω
LFWX-6470-18011
3. Check the armature coil

(a). As shown, use the multimeter at ohm position
to measure the conduction between any two
commutator segments; if not, replace the
armature coil.
LFWX-6470-18012
(b). As shown, use the multimeter at ohm position to

measure the conduction between the commutator
(as shown in Figure A) and the armature winding
spindle (as shown in Figure b); if yes, replace the
armature coil.
LFWX-6470-18013
4. Check the commutator

(a). Check the commutator surface for oil dirt or
burns; if any, use a sand paper to repair it.
(b) Put the commutator on a V-shaped block, and
use a dial gauge to measure the commutator ring
gear turnout; if the turnout is greater than the
maximum value, must repair or replace it.
Maximum gear ring runout: 0.05mm
LFWX-6470-18014
(c). Use a vernier caliper to measure the commutator

diameter ; if it is smaller than the minimum value,
must replace the armature.
Standard diameter:30mm
Minimum diameter:29mm
18
LFWX-6470-18015
5. Check the starter brush

(a). Use a vernier caliper to measure the brush
length; if the length is less than the minimum
value, replace the brush; if necessary, replace
brush holder and the starter magnetic moment
assembly.
Standard value:15.5mm
Minimum value:10mm
LFWX-6470-18016
Check the generator

1. Check the starter brush
(a). Use a vernier caliper to measure the exposed
brush length; if length is less than the minimum
value, replace the brush; if necessary, replace
the brush holder.
Standard exposed length: 10.5mm
Minimum value: 1.5mm
LFWX-6470-18017
2. Check the generator rotor assembly

(a). Visually check slipping ring surface and edge for
cracks or other damage; if any, replace the rotor
assembly.
LFWX-6470-18018
(b). Use a vernier caliper to measure the slipping ring

diameter; if it is less than the minimum value,
replace the rotor assembly.
Nominal diameter: 14.2~14.4 mmm
Minimum diameter:12.8 mm
LFWX-6470-18019
(c). As shown, use a multimeter at ohms position

to measure the resistance of the slipping ring;
if it can meet the requirement, replace the rotor
assembly.
Standard value(cold): 2.1~2.5Ω
LFWX-6470-18020
(d). As shown, use a multimeter at ohm position to

measure the conduction between the slipping ring
and the rotor; if yes, replace the rotor assembly.
18
LFWX-6470-18021
Starter repair
1. Remove the starter
(a). Place the system ignition switch under OFF
status, and disconnect the negative battery cable.
(b). Remove the starter power supply, and disconnect
starter wiring harness connectors.
(c). Remove the two starter fastening screws, and
remove the starter assembly.
LFWX-6470-18022
(d). Remove the wiring fastening bolt, and disconnect

the wiring connector.
LFWX-6470-18023
(e). Remove the two starter magnetic switch fastening

screws, and remove the magnetic switch.
 Tips:
When removing the magnetic switch, must first lift
the front of the magnetic switch, to allow it to be
disconnected from the the hook, and then remove
the magnetic switch.
LFWX-6470-18024
(f). Remove the starter commutator end fastening

bolt and screw, and remove the commutator end
cover.
LFWX-6470-18025
(g). Remove the starter brush holder assembly.
18
LFWX-6470-18026
(h). Remove the starter magnetic yoke

assembly ① and the armature assembly ②
LFWX-6470-18027
(i). As shown, remove the rubber seal and the

gasket.
LFWX-6470-18028
(j). R e m o v e t h e i n t e r m e d i a t e b e a r i n g c l u t c h
assembly ① and the starter pinion drive rod ② .
LFWX-6470-18029
2. Assemble the starter assembly

(a). Install the starter pinion drive rod ② and the
intermediate bearing clutch assembly ① into the
starter drive end cover.
LFWX-6470-18030
(b). Install the gasket and the rubber seal.
LFWX-6470-18028
(c). Install the starter armature into the starter

magnetic yoke.
(d). Install the starter magnetic yoke ① and the
armature assembly ② to the installation position.
18
LFWX-6470-18027
(e). Install the starter brush holder assembly into the

starter armature.
(f). Install the starter magnetic yoke ① and the
armature assembly ② to the installation position.
Note:
During installation, locate the rubber part of brush
holder into the slot on the the starter magnetic
yoke.
LFWX-6470-18026
(g). Install the starter commutator end cover, and

install and tighten the end cover fastening screw
and bolt.
Torque:20N•m~25N•m ( Bolt)
9N•m~11N•m( Screw)
Note:
Ensure the brush carrier harness rubber parts seat
in the groove of starter magnetic yoke.
LFWX-6470-18025
(h). Install the starter magnetic switch, and install and

tighten the magnetic switch fastening screws.
Torque: 9N•m~11N•m
Note:
During installation, make sure the starter magnetic
switch core is connected to the drive rod.
LFWX-6470-18024
(i). As shown, install the wiring and tighten the wiring

retaining bolt.
Torque: 20N•m~25N•m
Note:
Ensure the brush carrier harness rubber parts seat
in the groove of starter magnetic yoke.
LFWX-6470-18023
3. Install the starter assembly

(a). Install the starter assembly onto the installation
position, and install and tighten the fastening
bolts.
Torque:80N•m~86N•m
(b). Install the starter power cable and connector.
LFWX-6470-18022
Generator repair
1. Remove the generator assembly
(a). A s s h o w n , u s e a r i n g s p a n n e r t o a p p l y
counterclockwise a force on tensioner, and remove
the drive belt.
18
LFWX-6470-18050
(b). Remove the generator assembly fastening bolts,

and remove the generator assembly.
LFWX-6470-18031
(c). Remove the rear generator end cover fastening

nut and screw, and remove the rear end cover.
LFWX-6470-18032
(d). Remove the generator brush holder fastening

screw, and remove the generator brush holder
(with brush).
LFWX-6470-18033
(e). Remove the generator coil fastening bolt, and

remove the generator coil assembly.
LFWX-6470-18034
(f). Remove the generator pulley fastening nut, and

remove the generator pulley.
Note:
During removal, in order to prevent the pulley
rotation, must fix the generator rotor in advance.
(g). In turn, remove the generator rotor gasket, rear

rotor bearing cover and the rear rotor bearing.
(h). Remove the generator rotor assembly.
18
LFWX-6470-18036
2. Install the generator assembly

(a). Install the generator rotor assembly onto drive
end frame (stator).
(b). In turn, install the rear generator rotor bearing,
rear bearing cover and gasket onto the generator
rotor.
LFWX-6470-18037
(c). Install the generator pulley and install and tighten

the pulley fastening nut.
Torque:110.5 N•m
Note:
During installation, in order to prevent the pulley
rotation, must fix the generator rotor shaft in
advance.
LFWX-6470-18038
(d). Install the generator coil assembly onto the

rectifier end frame and tighten the fastening bolt.
Torque:3~4 N•m
LFWX-6470-18034
(e). Install the generator brush holder onto the

rectifier end frame and tighten the fastening
screw.
Torque:3~4 N•m
LFWX-6470-18033
(f). Install the rear generator end cover and tighten

the end cover fastening nut and screw.
Torque: 9~11 N•m (Nut)
5~6 N•m (Screw)
LFWX-6470-18039
(g). Install the generator assembly onto installation

position and tighten the fastening bolts.
Torque:45~49 N•m
18
LFWX-6470-18031
(h). As shown, use the ring spanner to apply

counterclockwise a force on the tensioner, and
install the drive belt.
LFWX-6470-11003
One-touch start system (PEPS)

System description
1. Function
One key start system can provide convenience for on/off-vehicle of driver and passengers and
vehicle start.
2. Composition
One key start system consists of PEPS controller, electronic steering shaft lock, inside low
frequency magnetic antenna, trunk low frequency magnetic antenna, left front door handle
antenna, one key start switch, intelligent key and etc.
3. Principle
One key start system is an intelligent entry and start system; when the antenna in the vehicle
detects the smart key, the control unit in the vehicle will activate the power supply system. After
the starting conditions are met, PEPS controller will unlock the electronic steering shaft lock
and communicate with PEPS controller for jointly control of the engine start.
Start button valid

Power supply status = “OFF” or “ACC” Check the power
supply status
Power supply status = “IG ON”
Speed ≠ 0
Check the
Check the engine status speed
Speed = 0
Engine speed = 0
Check PS key
certification result
Invalid
Valid
failure
Not detected
Check whether the
IMMO certification End
key is in the vehicle
Engine speed ≠ 0 Pass

Send ESCL
unlock command
ESCL is not unlocked

Judge ESCL status (waiting time)
ESCL is unlocked
Vehicle speed≥3km
Check the speed
The gear, brake and clutch
do not meet the start conditions Vehicle speed < 3km
Power supply Check the brake pedal & Gear or clutch

switching gear signal & clutch pedal
Depress the brake pedal &

(P or N gear) or depress the clutch Not in N gear and
Engage gear N or depress pedal not depressed
IG2 and ACC are disconnected;
EMS initialization
IG1 and ST are connected
CAN bus sends a EMS initialization

is completed
random data RX
PEPS
EMS calculation
F=G(sk, RX)
PEPS calculation
F=G(sk, RX)
The data result returned
from CAN bus is F
EMS determined
F is consistent
CAN bus sends the result

Pass certification command
PEPS
CAN bus sends the engine status message

Is EMS engine started?
Certification failure or timeout Check the certification result

and wait for the start-up
success message (if the
time is over 5s, TBD) Start failure or timeout
Certification success
and start-up success
The power supply is The power supply is

switched to IG ON position switched to the initial status
End
LFWX-6470-18040
Special tools

resistance

or resistance
Left-hand rotation Remove the steering lock

3
screw tap fastening bolt
18
Maintenance data
Items N•m
PEPS controller fastening bolt 6~12
Inside low frequency magnetic antenna fastening bolt/nut 6~12
Precautions

(a). Before repair the one key start system, must place the system ignition switch in OFF position,
and disconnect the negative battery cable.
(a). After re-install the battery and before starting the engine, must wait at least 10s.
Component drawing
1 9
3
5 2 1
7
1
8
6
LFWX-6470-18041
Interior low frequency magnetic field

1 6 Electronic steering shaft lock
aerial
Tr u n k l o w f r e q u e n c y m a g n e t i c
2 7 Front left door handle aerial
antenna
3 PEPS controller component 8 One-touch start switch
4 Back door signal switch 9 Tire pressure monitoring sensor
5 Intelligent key
Terminal definition
(for details, refer to circuit diagram catalogue)
I15 to PEPS 4 (one-key start) I14 to PEPS 3 (one-key start)

10 9 8 7 6 5 4 3 2 1 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11
11 12 13 14 15 16 17 18 19 20

Function Function
No. color No. color
1 NC 1 0.5/R Host power B+
2 NC 2 NC
3 0.3/YG Front left door pull ground 3 0.3/VW Wheel speed signal acquisition
4 NC 4 0.5/O P/N Gear signal
5 NC 5 0.3/GBl Start button signal
6 NC 6 NC
7 NC 7 0.3/GW One-touch start switch LED power
8 NC One-touch start switch green LED

8 0.3/WV
lamp control
Front left door pull inching switch
9 0.3/GY One-touch start switch amber LED
signal detection 9 0.3/GO
lamp control
10 0.3/BrV Trunk low frequency antennae+ 10 0.3/BY Relay drive
18
11 NC 11 0.3/GBr One-touch start button ground
12 0.3/GrW Vehicle inside low frequency antennae 1 +
12 NC
13 0.5/GrG Vehicle inside low frequency antennae 1 -
13 NC
14 0.3/GrO Vehicle inside low frequency antennae 3 +
14 0.3/W Relay feedback
15 0.3/GrB Vehicle inside low frequency antennae 3 - 15 NC
16 NC
16 0.3/WY Front left door pull low frequency antennae+
17 NC
17 0.3/Gr Front left door pull low frequency antennae-
18 NC
18 0.3/GrBl Vehicle inside low frequency antennae 2 +
19 NC
19 0.3/GrY Vehicle inside low frequency antennae 2 -
20 0.5/B Ground
20 0.3/GrBr Trunk low frequency antennae-
I13 to PEPS 2 (one-key start) I12 to PEPS 1 (one-key start)

12 11 10 9 8 1
7 6 5 4 3 2
10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14
24 13
20 19 18 17 16 15 14 13 12 11

Function Function
No. color No. color
1 NC 1 NC
2 NC 2 NC
3 NC 3 NC
4 NC 4 0.5/GO Brake signal
5 NC 5 NC
6 NC 6 0.3/WG Start button signal
7 NC 7 0.3/BlR ESCL lock enabled
8 NC 8 0.85/R Host power B+
9 NC 9 0.3/GW IMMO antenna +
10 0.5/Br LIMPHOME 10 0.3/WR IMMO antenna -
11 NC 11 0.3/VW Luggage micro-switch signal
Rear right TPMS low frequency 12 NC

12 0.3/YW
antennae+
13 NC
Rear right TPMS low frequency
13 0.3/YV 14 0.3/BlB MQT ESCL unlocking feedback
antennae-
Front left TPMS low frequency 15 0.3/BlW LIN bus

14 0.3/YB
antennae+
16 0.3/W BCAN_H
Front left TPMS low frequency
15 0.3/YG 17 0.3/WB BCAN_L
antennae-
Rear left TPMS low frequency 18 0.3/OB IGN1 relay feedback

16 0.3/YR
antennae+
19 0.5/OBl IGN2 relay feedback
Rear left TPMS low frequency
17 0.3/GrR 20 0.3/O ACC relay feedback
antennae-
Front right TPMS low frequency 21 0.3/BG IGN1 relay drive

18 0.3/YBl
antennae+
22 0.3/BBl IGN2 relay drive
Front right TPMS low frequency
19 0.3/Y 23 0.3/BR ACC relay drive
antennae-
24 1.25/B Ground
20 NC
I23 to one-touch start switch I28 Connect to the central antenna (one-key start)
1 2
3 4 5 6 7 8 1 2

Function Function
No. color No. color
1 0.3/WR Antennae - Vehicle inside low frequency

1 0.5/GrBl
antennae 2+
2 0.3/GW Antennae +
Vehicle inside low frequency
3 0.3/GBl Start button switch 2 2 0.5/GrY
antennae 2-
4 0.3/GBr Start button ground wire
5 0.3/GW Power supply
6 0.3/WV Green lamp power
7 0.3/GO Amber lamp power
8 0.3/WG Start button switch 1
I38 Connect to the front antenna (one-key start) B3 Connect to the internal rear antenna(one-key start)

2 1 2 1

Function Function
No. color No. color
Vehicle inside low frequency 1 0.3/GrO Vehicle inside antennae +

1 0.3/GrG
antennae 1+ 18
2 0.3/GrB Vehicle inside antennae -
2 0.3/GrW
antennae 1-
V3 Connect to the trunk box antenna(one-key start) B1 Connect to the front left door control switch
2 1

1

Function Function
No. color No. color
Trunk low frequency antennae 1 0.3/O Front left door control switch
1 0.3/BrV
positive output
Trunk low frequency antennae

2 0.3/GrBr
negative output
keyless entry/one-button start (PEPS) I
B+
FS16
15A
Start the charge system - Start the charge system
7 1F
7 I1F
3 I15 9 I15 17 I15 16 I15 13 I15 12 I15 15 I15 14 I15 15 I15 14 I15 20 I15 10 I15 10 I12 9 I12 5 I14 11 I14 7 I14 8 I14 9 I14 6 I14 15 I12 14 I12 7 I12
11 1C
11 I1C
0.30 BlW
0.30 BlR
0.30 BlB
Special for
luxury model
0.30 GrW
0.30 GrBl
0.30 WY
0.30 GrB
0.30 GrO
0.30 GrG
0.30 GrY
0.30 BrV
0.30 YG
0.30 GY
0.3 GrBr
0.30 Gr
0.30 WG
0.30 GW
0.30 WV
0.30 GW
0.30 GBr
0.30 GO
0.30 GBl
0.30 WR
2 I20 4 I20 5 I20
21 ID 14 ID 4 ID 3 ID 10 IB1 9 IB1 16 IB1 17 IB1 LIN Unlocking Locking
feedback enabled
21 DI 14 DI 4 DI 3 DI 10 BI1 9 BI1 16 BI1 17 BI1
6 BV 5 BV
Motor power
6 VB 5 VB supply enabled
GND
Live, 12V
1 I20 6 I20 3 I20
0.50 RY

0.50 BW

0.50 B
Circuit diagram
1 I23 2 I23 3 I23 4 I23 5 I23 6 I23 7 I23 8 I23 15 I09 14 I09 13 I09
Sta
IMM IMM Sta
rt b
Sta
rt b
LE
Dp
Gre Am
ber sw rt butt
2 1 2 1 2 1 2 1 Oa
nte
Oa
nte utto utto ow en
lam it
lam ch 1 on
nna nna ns ng er p p
su
3 D2 D2 4 1 D2 D2 2 ε δ ε δ ε δ ε δ e- e+ witch rou
nd
pply
2 1 ε δ 2 wir
e
ε ,()3
Front left door handle antennae Vehicle inside Vehicle inside Vehicle inside Rear bumper G26
front antennae middle antennae rear antennae antennae
18-32
18
18-33
keyless entry/one-button start (PEPS) II
Engine
B+
FS09
20A
Hatch P/N gear
Speed inching signal
BCANH BCANL signal switch GND GND detection LIMPHOME
16 I12 17 I12 3 I14 11 I12 24 I12 20 I14 4 I14 10 I13 13 I13 12 I13 15 I13 14 I13 17 I13 16 I13 19 I13 18 I13 10 I14 14 I14
0.30 WB
0.30 W
18 IU1
0.30 GrR
0.30 VW
0.30 YW
0.30 YBl
0.30 YG
0.30 YV
0.30 vw
0.30 YR
0.30 YB
0.30 Br
0.50 O
0.50 B
1.25 B
0.30 Y
18 UI1
19 IU1
0.30 BY
2.0 R
19 UI1
Engine
2 5
0.3 W
K09
9 IG 15 IG 8 IU2 9 IU2 2 IB1 1 IB1 6 IU2 7 IU2
21 IB1 9 GI 15 GI 8 UI2 9 UI2 2 BI1 1 BI1 6 UI2 7 UI2 1 3
21 BI1
0.30 B
2.0 W
33 IU1 7 BL2
33 UI1 7 LB2
To engine
ECU pin 60
3 I01 11 I01 1 L10
1 I03
Hatch inching switch

UE1 15
EU1 15
2 G3 1 G3 2 E23 1 E23 2 E23 1 E23 2 E23 1 E23
2 L10
2 I03
Rear right tire Front left tire Rear left tire Front right tire
pressure pressure pressure pressure
To engine starter
antennae antennae antennae antennae
17 U14 17 I09
Special for luxury model
,()3
'(9
G34 G26 G24 G11
keyless entry/one-button start (PEPS) III
B+ B+
SB08
SB09
30A
30A
2 5 2 5 2 5
FS15
FS39
FS26
10A
10A
5A
ACC
I
1 3 1 3 1 3
6 1E 6 1B 10 1F 16 1F 11 1D 15 1F 10 1E 5 1F 16 1D
6 I1E 6 I1B 10 I1F 16 I1F 11 I1D 15 I1F 10 I1E 5 I1F 16 I1D
0.3 OBl
0.3 BBl
0.5 RG
0.3 BG
0.5 BR
0.3 OB
0.3 O
4 I05
Clutch
3 I05
0.5 GO
1.25 B
0.85 R
0.5 R
1 I14 8 I12 4 I12 23 I12 I12 22 I12 19 I12 21 I12 18 I12
Host power Host power Clutch signal ACC relay drive ACC relay IG2 relay drive IG2 relay IG1 relay drive IG1 relay
feedback feedback feedback
18 I09
G23
18-34
Check the system

(a). Check the system for evident mechanical or electrical damage and repair them if required.
(b). Check the system fasteners (such as bolts or nuts) for loosening; if any, retighten it.
2. Check the harness
(a). Check whether the system harness connector is installed reliable; if not, install it again.
(b). Check the system harness for fracture or damage and repair it if required.
3. Check the fuse
(a). Check the fuses FS15, FS16 and FS39 on PEPS power supply for blowing; if any, replace it
with the same specification.
 Tips:
PEPS power supply fuses are located in the fuse box in the cab.
(b). Check the starter fuse FS09 for blowing; if any, replace it with the same specification.
Tips:
The starter fuse is located in the fuse box in the engine compartment.
(c). Check ACC relay K18, IG1 relay K20 and IG2 relay K19 in the fuse box in the cab.
(d). Check the starter relay K09 in the fuse box in the engine compartment.
Tips:
Remove the starter relay K09, connect the power supply as shown, and use a digital
multimeter at ohm position to measure the conduction between the relay terminals 3 and 5;
if not, replace the relay with the same specifications.
18
One-touch start switch

Replacement
1. Remove the one key start switch
(a). Remove the instrument lower panel. (refer to
Chapter 85- Dashboard/console, replacement)
(b). Disconnect the one key start switch connector,
and remove the one key start switch from inside
to outside.
LFWX-6470-18042
2. Install the one-touch start switch

(a). Install the one key start switch onto the installation location on the dashboard.
(b). Install the lower dashboard shield panel. (refer to Chapter 85- Dashboard/console,
replacement)
PEPS controller
Replacement
1. Remove the PEPS controller
(a). Remove the lower left cover of the instrument
panel. (refer to Chapter 84- Dashboard/console,
replacement)
(b). Disconnect PEPS controller wiring harness
connector.
(c). Remove PEPS controller component mounting
bracket.
LFWX-6470-18043
(d). Remove PEPS controller fastening bolt, and

remove PEPS controller.
18
LFWX-6470-18044
2.Install PEPS controller

(a). Install PEPS controller onto the corresponding installation position, and install and tighten the
fastening bolts.
Torque: 6~12 N•m
(b). Install PEPS controller component mounting bracket.
(c). Connect PEPS controller wiring harness connector.
(d). Install the lower left cover of the instrument panel. (refer to Chapter 85- Dashboard/console,
replacement)
Electronic steering shaft lock

Replacement
1. Remove the electronic steering shaft lock
(a). Remove the upper steering shaft. (refer to
Chapter 61 - Hydraulic steering system - steering
shaft, replacement)
(b). Drill a hole on the electronic steering shaft lock
fastening bolt
(c). Use the reverse thread bolt tap to remove the
electronic steering shaft lock clamp fastening
bolt, and remove the electronic steering shaft
lock.
Tips:
The electronic steering shaft lock fastening bolt is
a special bolt, and must replace the removed bolt
with a new one.
LFWX-6470-18045
2. Install the steering shaft lock

(a). Install the electronic steering shaft lock onto the steering shaft, and install and tighten the
fastening bolt until that the bolt head is broken.
Note:
When tightening the electronic steering shaft lock fastening bolt, must prevent that the bolt
is broken suddenly, which may result in injuries of maintenance personnel.
(b). Install the upper steering shaft. (refer to Chapter 61 - Hydraulic steering system - steering
shaft, replacement)
Low frequency magnetic field aerial

Replacement
 Tips:
In addition that the left front door handle antenna is installed in the left front door outer
handle, the replacement methods for the rest antenna are basically the same; for example,
the front inner low-frequency magnetic antenna at the dashboard in this chapter.
1 4
5
3
2
18
LFWX-6470-18046
Front inner low frequency magnetic

1 4 Trunk low frequency magnetic antenna
antenna
Middle inner low frequency magnetic

2 5 Front left door handle aerial
antenna
Rear inner low frequency magnetic

3
antenna
1. Remove the front inner low frequency

magnetic antenna
(a) Remove the MP5 controller and panel. (refer to
Chapter 85- Dashboard/ Console, replacement)
(b). Disconnect front inner low frequency magnetic
field antenna wiring harness connector, remove
two bolts of front inner low frequency magnetic
field antenna, and take down internal low
frequency magnetic field antenna.
Torque:6 ~ 12N•m
LFWX-6470-18047
2. Install the front inner low frequency magnetic antenna

(a). Install the front inner low frequency magnetic antenna fastening clip in the corresponding
installation position.
(b). Connect the front inner low frequency magnetic antenna wiring harness plug.
(c). Install the MP5 controller and panel.(see Page 84 - Dashboard/Console, replacement)
18
Starting system of engine - Starting system (1.5T) 21-a
Starting system
Starting system��1
Starting motor assembly�� 1
Part Location Drawing �� 1
Pinion Return Test�� 3
No-load Test�� 3
Diagnosis procedure about that the
starting motor can not be shutdown��4
Diagnosis procedure about that
the starting motor is operated slowly�� 5
Starting motor assembly�� 6
21
Disassembly�� 6
21-b Starting system of engine - Starting system (1.5T)
Starting system
Starting motor fixing bolt I 65 48 -
Starting motor fixing bolt II 47 34 -
Operating principle
System Overview
The starting system mainly includes the starting motor and related circuits, all components are
connected with the wires. When the ignition switch is in “ST” position, the power supply will be
supplied to the starting motor electromagnetic switch, a magnetic field will be formed on the
electromagnetic switch coil, to move the plunger and the screw rod, resulting in the engagement
of the pinion and the engine flywheel gear ring, and the electromagnetic switch contacts will
be connected, to start the engine. After the engine is started, the pinion will overrun the clutch
protection armature, to avoid that the flywheel drives the pinion driving armature, until the switch is
disconnected, and then the return spring will make the pinion to return its original position.
Part instructions
Starting motor assembly
The starting motor consists of stator assembly,
armature assembly, overrunning clutch assembly,
electromagnetic switch assembly, front housing, rear 21
housing, brush holder and driving rod. The starting
motor is reducer type; via a planetary gear unit, it can
reduce the armature speed and increase the drive
torque. The armature is integrated with the solar gear,
the planetary frame is connected to the drive pinion,
and the gear ring is fixed.
LFWX-6470-09001

LFWX-6470-09002
1 Starting motor assembly


Warning:
Each test must be completed within 3 ~ 5 s, to avoid the coil burns.
Electromagnetic switch test

Note:
Before the test, must disconnect the excitation coil from the wiring terminal “M”.
M 1. Remove the starting motor armature wire from

A the electromagnetic switch.
2. Use the jumper wires to connect reliably the
starter housing and electromagnetic switch
housing with the battery negative terminal.
3. Connect one end of another jumper wire to the
battery positive terminal, and the other end to the
starting motor wiring harness plug terminal A.
4. The starter motor pinion should be moved out.
LFWX-6470-09003
M 5. Remove the negative wire from the terminal “M”,

the starting motor pinion should not be returned.
6. As mentioned above, connect the wire to the
pinion, and then remove the negative wire from
the terminal “M”, check whether the pinion is
turned outwards; otherwise the electromagnetic 21
switch should be replaced.
LFWX-6470-09004
Pinion Return Test

1. Use the jumper wires to connect reliably the
starter housing and electromagnetic switch
A
housing with the battery negative terminal.
2. Connect one end of another jumper wire to the
battery positive terminal and the other end to the
starting motor wiring harness plug terminal A.
3. The starter motor pinion should be moved out.
4. Disconnect the battery positive jumper wire, the
pinion should be returned quickly.
LFWX-6470-09005
No-load Test
1. Ensure that the battery has been charged fully.
2. As shown, connect the starting motor, the battery
and the tester.
3. Operate the starting motor, and confirm that it
can be rotated freely.
4. If the starting motor can not be rotated freely,
please check the starting motor.
5. Measure the voltage and the current on operation
starting motor.
6. If they are beyond the specified scopes, please
replace the starting motor.
LFWX-6470-09006

• Battery
• Starter relay
Reference: Starter not operate
Starter not operate • Circuit
diagnoses procedure
• Starting motor
• Ignition switch
• Ignition switch
Reference: Starter not stop operating
Starter not stop operating • Starter relay
diagnoses procedure
• Starting motor
• Battery
Reference: Starter operates slowly
Starter operates slowly • Circuit
diagnosis procedure
• Starting motor
• Check whether the starter motor is
properly secured.
The starter operates
• Starting motor If the problem persists, install a new
but the engine fails to
• Flywheel starting motor.
operate
• Check whether the flywheel ring gear
has the missed teeth.
• Check whether the starter is aligned

or its housing is broken. Make sure
• Starting motor that all the retaining bolts are locked. If
Abnormal starter noise
• Flywheel gear ring necessary, install a new starting motor
and the fixing bolts.
• Check the flywheel ring gear.
Diagnosis procedure about that the starting motor can not be

shutdown
1. Check the starter relay.
A. Replace a new relay.

B. Turn the ignition switch to “ST” position, and release the
key quickly.
Can the starting motor be shutdown?
→Yes
Replace the relay.
→No
To step 2.
2. Check whether the electromagnetic switch power supply circuit is shorted to the power supply.
A. Turn the ignition switch to “ST” position, and release the

key quickly.
B. Measure the voltage between the starter electromagnetic
switch wiring harness plug terminal A and the body
grounding wire.
Standard voltage value: 0 V
Is the voltage normal?
→Yes
To step 3.
→No
Repair the faults that the starter electromagnetic switch
wiring harness plug terminal A and the engine compartment
main wiring harness plug terminal are shorted to the positive 21
pole of the power supply.
3. Replace the starting motor
A. Turn the ignition switch to “Lock” position.

B. Remove the wiring harness from the negative battery
terminal.
Replace the starting motor
Reference: Starting motor (starting system, removal and
installation).
Diagnosis procedure about that the starting motor is operated

slowly
1. General inspection.
A. Check battery anode wiring harness plug for damage,

oxidation and poor contact, loosening, etc.
B. Check the wiring harness plug to connect the battery
positive terminal and the starter for damage, aging, poor
contact, loosening, etc.
C. Check the engine grounding wiring harness plug for
damage, aging, poor contact, loosening, etc.
Are the test results normal?
→Yes
To step 2.
→No
Repair the fault position.
2. Check the engine and the belt drive system.
A. Check the engine and the belt drive system for mechanical
binding (engine binding, generator binding).
Is there any click?
→Yes
Repair the binding fault.
→No
To step 3.
3. Check the starting motor.
A. Perform the no-load test.

Reference: No-load test (starting system, fault diagnosis and
inspection).
Is the starting motor test qualified?
→Yes
Repair the engine mechanical fault.
→No
Replace the starting motor.
Reference: Starting motor assembly (starting system,
removal and installation).

Starting motor assembly
Disassembly
1. Remove the starting motor assembly.

(b). Remove the starting motor fixing bolts.
(c). Disconnect the starting motor wiring harness plug
and remove starter grounding wire.
LFWX-6470-09007
(d). Remove the starting motor assembly.
21
LFWX-6470-09008
Installation
1. Install the starting motor assembly.
(a). Install the starting motor assembly
LFWX-6470-09009
(b). Install the starting motor fixing bolts.

Tightening torque for upper bolts: 47 N.m
Tightening torque for lower bolts: 65 N•m
(c). Connect the starter wiring harness plug and
install the grounding wire.
(d). Connect the negative battery terminal.
LFWX-6470-09007
21
Ignition System
Ignition System��1
Part instructions��1
Visual inspection table�� 3
Ignition spark test�� 3
Spark plug test�� 3
Diagnosis procedure about
lack of engine power�� 4
21
Ignition coil assembly�� 4
Disassembly�� 5
Spark plugs�� 6
Disassembly�� 6
Ignition System of Engine-Ignition System (1.5T) 21-1
Ignition System
Part specifications
Name Size
Spark plug clearance 0.7~0.8 mm
Apply Size
Ignition order 1-3-4-2
Spark plugs 30 22 -
Operating principle
System Overview
The engine equipped with no-distributor ignition system without, the system components is mainly
composed of ECU, ignition coil assembly, spark plugs, crankshaft position sensor, camshaft
position sensor, knock sensor and etc.
With no distributor ignition system, ECU can control the optimal ignition timing based on various
engine load conditions, to ensure that the engine output power, acceleration, economy and exhaust 21
emissions are reach the ideal status, and the voltage on the ignition system will not be decreased
with the increase of the speed. Since there is no mechanical component, there is no mechanical
error.
The ignition coil assembly can not be repaired; if necessary, it must be replaced as an assembly.
Part instructions
Oil pump assembly
Oil pump is designed to extract oil from oil sump and exert pressure to deliver it to each part of
engine. The pressure regulating valve inside oil pump will regulate oil pressure within specified
range.
● Crankshaft position sensor
The crankshaft position sensor is electromagnetic induction type.
Reference: Part instructions (control system, working principle).
● Camshaft position sensor
The camshaft position sensor is Hall type.
Reference: Part instructions (control system, working principle).
● Knock sensor
The knock sensor is piezoelectric type, a voltage signal to ECU will be produced when the knock
occurs.
Reference: Part Description(control system, working Principle)
21-2 Ignition System of Engine-Ignition System (1.5T)

Part exploded view
LFWX-6470-08001
1 Ignition coil assembly plug 4 Spark plugs
2 Bolt 5 Engine assembly
3 Ignition coil assembly


Visual inspection table
Electric
• Circuit
• Wiring harness
• Electrical plug
• Spark plugs
• Engine control unit (ECU)
3. If the causes about the fault observed or proposed have been found, the causes must be
processed before entering into the next step.
4. If the visual inspection is passed through, confirm the fault and refer to the fault symptom table.
General inspection
Ignition spark test
Warning:
• Use directly the ignition coil assembly to test possible personal injuries and the module
damage caused by sparks, it is strictly prohibited to directly use the ignition coil
assembly for spark ignition test.
• The engine temperature is very high under operation, any burn should be avoided when 21
working on the engine just shut down.
1. Place the transmission shift level in “Neutral” position and apply reliably the parking brake.
2. Turn the ignition switch to “Lock” position, and disconnect the fuel injector plug.
Warning:
The connection of the fuel injector may cause a fire.
3. Disconnect the ignition coil assembly, and remove the spark plug.
4. Connect the ignition coil assembly with the spark plug, and ground the spark plug at the
reliable engine grounding point.
5. Start the engine and observe the spark plug status.
6. Shutdown the engine and turn the ignition switch to “Lock” position.
7. Install the spark plug and the ignition coil assembly.
8. Connection the fuel injector plug.
Spark plug test

1. Check the spark plug appearance
• Electrode wear
• Carbons
• Insulator damage
2. Measure the spark plug clearance
LFWX-6470-08002 3. Measure the spark plug resistance
Standard value: 1.5±0.5 KΩ


• Perform the spark plug test procedure.
• Spark plugs
The spark plug is not • Reference: Spark plug test (ignition
fired system, fault diagnosis and
• ECU
inspection).
• Circuit
• Spark plugs • Perform the spark plug test procedure.

The engine is shaken • Ignition coil assembly Reference: Spark plug test (ignition
• Engine system, fault diagnosis and inspection).
• Spark plugs Refer to the diagnosis procedure for

Insufficient engine power • Ignition coil assembly insufficient engine power (ignition
• Engine system, fault diagnosis and inspection).
Diagnosis procedure about lack of engine power

1. Check the spark plug
A. Perform the spark plug test procedure.

Reference: Spark plug test (fault diagnosis and inspection).
Is the spark plug normal?
→ Yes
To step 2.
→ No
Replace the spark plug.
2. Check the ignition coil assembly
A. Perform the ignition coil assembly test procedure.

Reference: Ignition coil assembly test (fault diagnosis and
inspection).
Is the ignition coil assembly normal?
→ Yes
To step 3.
→ No
Replace the ignition coil assembly.
Reference: Ignition coil assembly (ignition system, removal
and installation).

Ignition coil assembly
Disassembly
1. Remove the ignition coil assembly.

(b). Disconnect the ignition coil assembly wiring
2 2 2 2 harness plug (1) and remove the ignition coil
1 1 1 1 assembly fixing bolts (2).
Note:
When the engine is operated or started, do not
contact or pull out the ignition coil assembly. The
wire on the ignition device (ignition coil assembly
and measurement gauge wire) can be connected
or disconnected only when the ignition switch is
turned off. If it is required to use the starting motor
to drive the engine in case that the engine is not
LFWX-6470-08003 started (such as, compression pressure test),
remove the plugs of ignition coil assembly and the
nozzle. After operation, query the fault memory
and delete the fault record. The engine can be
cleaned only when the ignition switch is turned
off. Only when the ignition switch is turned off,
the batteries can be connected or disconnected;
otherwise it may damage ECU.
(c). Remove the ignition coil assembly. 21
LFWX-6470-08004
Installation
1. Install the ignition coil assembly.
(a). Install the ignition coil assembly.
LFWX-6470-08004
(b). Install the ignition coil assembly fixing bolts (2)

and connect the ignition coil assembly wiring
2 2 2 2 harness plug (1).
1 1 1 1 Torque: 11 N•m
LFWX-6470-08003
Ignition System of Engine-Ignition System 21-7
Spark plugs
Disassembly
1. Remove the spark plug.

(b). Remove the ignition coil assembly. Reference:
Ignition coil assembly (ignition system, removal
and installation).
(c). Use the proper tools to remove the spark plug.
LFWX-6470-08006
Installation
1. Install the spark plug.
(a). Use the proper tools to install the spark plug.

Torque: 30 N•m
(b). Install the ignition coil assembly.
Reference: Ignition coil assembly (ignition
system, removal and installation).
21
LFWX-6470-08006
Maintenance Tools
Special tools
Remove the
1 Puller 351143 ignition coil
assembly
Ignition coil - Ignition coil 19-a
Ignition coil
Ignition System�� 1
Precautions�� 2
System inspection�� 3
Inspect the ignition coil�� 4
Check the spark plug�� 6
Diagnosis�� 6
Ignition coil�� 9
Replacement�� 9
Spark plugs�� 10
19
19-b Ignition coil - Ignition coil
Ignition coil - Ignition coil 19-1
Ignition System
System description
1. Function
Ignition system has the following functions:
Providing a high voltage for engine ignition to ignite the compressed gas in the
cylinder at the end of compression stroke.
Igniting the compressed gas at the right time according to the engine operating
conditions to increase the engine power and improve fuel efficiency.
2. Composition
The ignition system is mainly composed of an ignition coil and a spark plug.
Preparations

resistance
19

2 Wiring group
or resistance
3 Thickness gauge Check the spark plug clearance
Disassembling tool for

4 Disassemble the spark plug
spark plug
19-2 Ignition coil - Ignition coil
Maintenance data
Spark plug clearance 0.6mm~0.7mm
Item N•m
Ignition coil fixing bolt 10~12

Spark plugs 25~31
Precautions
(a). The fixed bolts for parts of spark plugs and other ignition systems must be tightened
by the specified torques.
(b). When removing the ignition coil, be careful not to damage the insulation sleeve of
ignition coil.
(c). When removing the spark plug, be careful not to knock against the spark plug.
Component drawing
19
LFWX-6470-19001
1 Spark plugs 2 Ignition coil
General inspection
System inspection
required.
(b). Check if the system has obvious mark of deformation after collision. If so, perform
maintenance.
(c). Check the system fasteners (such bolts and nuts) for loossening; if any , retighten it.
(a). Check whether the system harness connector is installed reliable; if not, install it
again.
(b). Check the system harness for fracture or damage and repair it if required
Inspect the ignition coil

△ Tips:
LF6470 Xuanlang Series are equipped with the ignition coil of Delphi, with both following
the same inspection method, so this chapter only takes Delphi 1-cylinder ignition coil as an
example.
1. Check the power cord of ignition coil

(a). Leave the system power supply in "OFF"
and disconnect the ignition coil harness
connector.
(b). Leave the system power supply in "ON".
Use the "V" of digital multimeter to check
that there is voltage between terminal 1
1 2 3 of ignition coil harness connector and the
body's grounding terminal; if the voltage is
0, repair relevant harness according to the
circuit book.
2. Check the grounding wire of ignition

coil
(a). Leave the system power supply in "OFF"
connector.
(b). Use the "Ω" of digital multimeter to check
that terminal 2 of ignition coil harness
connector is connected with the body's
1 2 3
grounding terminal; if not, repair relevant
harness according to the circuit book.
3. Check the control wire of ignition coil

ECU (a). Leave the system power supply in "OFF",
connector and the engine's ECM harness
81 80 79 78 77 76 75 74 73 72 71 70 69 68 67 66 65 64 63
1 2
3 62 61 60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44
4 5
43 42 41 40 39 38 37 36 35 34 33 32 31 30 29
24 23 22 21 20 19 18 17 16 15 14 13 12 11 10
28 27 26 25
9 8 7 6
connector.
that terminal 3 of ignition coil harness
connector is connected with terminal 4 of
the engine's ECM harness connector; if
1 2 3
not, repair relevant harness according to
the circuit book.
△ Tips:
The above is the inspection of ignition coil A
terminal number. The engine ECU terminals vary
from the ignition coil. For details, refer to below:
Ignition coil B: Check terminal 3 of ignition coil
harness connector and terminal 81 of the engine's
ECM harness connector.
Ignition coil C: Check terminal 3 of ignition coil
harness connector and terminal 62 of the engine's
Ignition coil D: Check terminal 1 of ignition coil
harness connector and terminal 62 of the engine's 19
4. Check the working condition of ignition
coil
(a). Leave the system power supply in the
"OFF" position and disconnect the ignition
coil harness connector.
that terminal 1 and terminal 3 of ignition
coil harness connector are connected; if
1 2 3 not, replace the ignition coil.
Check the spark plug

1. Check the working condition of spark plug
(a). Disassemble each cylinder's ignition coil and spark plug in turn.
(b). Install the spark plug of 1-cylinder ignition coil onto the ignition coil, and connect the
ignition coil connector.
(c). Bond the spark plug, and check for sparks in the spark plug during engine start.
Note:
For non-push-to-start cars, do not start the engine for more than 2s.
(d). Use the same method to check the spark plugs of cylinders 2, 3 and 4.
2. Check the damage status of spark plug
(a). Use a brush to clean the spark plug.
Note:
Do not apply force between the electrodes as this may damage the center electrode.
(c). Check that the carbon near the spark plug electrodes is seriously deposited; replace,
if yes.
(d). Check that spark plug electrodes are seriously burnt; replace, if yes.
(e). Check that the ceramic insulator spark plug has cracked; replace, if yes.
(f). Use a thickness gauge to measure the

spark plug electrode clearance; replace the
spark plug, if unqualified.
Spark plug clearance:0.6mm ～ 0.7mm
LFWX-6470-19002
Diagnosis
Fault diagnosis
Use below table to help the quick location of desired fault message.
Phenomenon Partly Recommended Measures
1.Relay (fault)
2. Harness (fault)
See 19- Ignition System Diagnosis -
The spark plug is not
3.Ignition coil (damaged) Fault Diagnosis (1.Spark plug does not
fired.
spark over)
5.Spark plug (fault)
6.Engine ECM (fault)
Fault diagnosis
1. Spark plug does not spark over


Check the working condition
of spark plug (see 19 –
Diagnosis is The spark plug is
General Inspection for Ignition Go to Step 1
finished not fired.
System - Check the spark
plug)
1 Check the relay Normal Faulty Instruction
Check the main relay for

Replace the
damage (see 15 - General
Go to Step 2 Relay is damaged relay of the same
Inspection for Cooling System,
specification
Check the system)
2 Check the harness Normal Faulty Instruction
Check that the power cord of

main relay is continuous (see Check the relevant
harness according
15 - General Inspection for Go to Step 3 Unconnected
to the circuit
Cooling System - Check the diagram
system)
Check that the power cord

of ignition coil is continuous Check the relevant
harness according
(see 19 - General Inspection Go to Step 4 Unconnected
to the circuit
for Cooling System - Check diagram
the ignition coil) 19
Check that the grounding wire

harness according
to the circuit
the ignition coil)
Check that the control wire

harness according
to the circuit
the ignition coil)
6 Inspect the ignition coil Normal Faulty Instruction
Check that the ignition coil is Replace (see 19

damaged (see 19 - General Ignition coil - Ignition Coil of
Go to Step 7
Inspection for Cooling System damage Ignition System -
- Check the ignition coil) Replacement)

Check that the spark plug is Spark plug Replace(see 19

damaged (see 19 - General deposits too much - Spark plugs of
Go to Step 8
Inspection for Ignition System carbon or has Ignition System -
- Check the spark plug) been damaged Replacement)
Replace the engine ECM with Locate the causes

Diagnosis is
the same type and inspect The fault still exists from other fault
finished
whether the fault is eliminated phenomenon
Ignition coil
Replacement
1. Disassemble the ignition coil
(b). Disassemble the engine trim cover. (See Section 81 – Inner and outer trims - Engine
trimming cover - replacement)
(c). Disconnect the ignition coil harness

connector ① .
(d). Remove the fixed bolts of ignition coil ② ,
and take out ignition coil ② .
2
1
LFWX-6470-19003
2. Install the ignition coil

(a). Install the ignition coil in place, and fasten the fixed bolts.
(b). Connect the ignition coil harness connector.
(c). Install the engine trim cover. (See Section 81 – Inner and outer trims - Engine
trimming cover - replacement)
Spark plugs
Replacement
1. Disassemble the spark plug
(a). Disassemble the ignition coil. (see 19 - Ignition Coil of Ignition System -
Replacement)
(b). Disassemble the spark plug using

dedicated tool.
△ Tips:
If the spark plug is not easy to remove, one can
use the ignition coil to remove it.
Note:
Be careful not to knock against the spark plug.
LFWX-6470-19004
2. Install the spark plug

((a). Install and fasten the spark plug using dedicated tool.
Torque: 25 ~ 31N•m 19
(b). Install the ignition coil. (see 19 - Ignition Coil of Ignition System - Replacement)
Turbocharger and inter-cooler system
Turbocharger and inter-cooler
system��1
Turbocharger pressure relief valve� 3
Turbocharger bypass solenoid valve 3
Water inlet and outlet pipes on the
turbocharger�� 3
Oil inlet and return pipes on the
turbocharger�� 4
��5
Fault diagnosis and inspection�8
Turbocharger assembly inspection� 8
Diagnosis procedure about oil leakage at
the turbocharger inlet side�� 9 21
Removal and Installation�� 11
Turbocharger assembly�� 11
Inspection�� 15
General tool �� 22
21-1
Turbocharger and inter-cooler system of engine - Turbocharger and inter-cooler system (1.5T)
Turbocharger and inter-cooler system

Name Nm Lb-ft Lb-in
Exhaust manifold assembly bolt 23 17 -
Exhaust manifold heat shield bolt 11 8 -
Turbocharger oil inlet pipe bolt 23 17 -
Turbocharger oil inlet pipe fixing bolt 11 8 -
Heat resistant nut 23 17 -
Heat resistant bolt 23 17 -
Bolt, bracket, turbocharger 11 8 -
Exhaust gas bypass valve self tapping

3 - 27
screw
21
21-2 Turbocharger and inter-cooler system of engine - Turbocharger and inter-cooler system (1.5T)
Operating principle
System Overview
The turbocharger is a kind of air compressor,
and is used to compress the air to increase the
engine air inflow. It is installed on the engine
exhaust manifold, and the turbine in turbine
chamber is driven by the inertia force of engine
exhaust, to drive the compressor impeller on the
same shaft, which pressurizes and sends the
air from the air filter pipe into the cylinder. When
the engine speed is increased, the exhaust gas
LFWX-6470-11001 turbine speed will be faster, and the compressor
impeller will compress more air into the cylinder,
to increase the air density and pressure for more
fuel combustion, so as to increase the engine
power output.
The inter-cooler is installed on the intake manifold

assembly, and is used to reduce engine intake
temperature. When the air is compressed, its
density rise is proportional to the temperature
rise;the intake temperature rise can reduce
engine intake efficiency, and result in abnormal
combustion in the engine, so the pressurized
air should be cooled in the inter-cooler before
entering into the cylinder.
LFWX-6470-11002
21-3
Part instructions
Turbocharger pressure relief valve
It is installed at the turbocharger inlet, and directly
controlled by ECU; when the engine speed is
suddenly decreased (by applying the brake or
release the throttle pedal), the turbocharger relief
valve will be opened, to avoid the impact on the
throttle valve piece and inlet pip from the large air
flow, so as to protect the turbocharger system.
LFWX-6470-11003
Turbocharger bypass solenoid valve

The turbocharger bypass solenoid valve is
installed on the turbocharger intake pipe, and
the turbocharger pressure is controlled via ECU
control for exhaust gas flow through the turbine, to
ensure that the pressurized gas pressure is within
the normal range.
21
LFWX-6470-11004
Water inlet and outlet pipes on the turbocharger

They are installed on the turbocharger, and are
used to decrease the turbocharger temperature
with the engine cooling fluid circulation, to ensure
that the turbocharger is operated under normal
conditions.
LFWX-6470-11005
Oil inlet and return pipes on the turbocharger

They are installed on the turbocharger, and used
to lubricate the turbocharger with the engine oil
circulation, to ensure that the turbocharger is
operated under normal conditions.
LFWX-6470-11006
21-5

1
2
3
5
4
21
LFWX-6470-11007
1 Turbocharger water outlet pipe 4 Oil return pipe, turbocharger
2 Turbocharger assembly 5 Oil inlet pipe, turbocharger
3 Turbocharger water inlet pipe

Part exploded view

1
3
2 5
6
7
21 4
8
20
9
19
10
11
18
17 13
16
15 12
14 LFWX-6470-11008
Turbocharger oil return pipe fixing bolt (at

1 Turbocharger oil inlet pipe fixing bolt 12
cylinder block side)
Turbocharger oil return pipe sealing
2 Turbocharger water outlet pipe bolt 13
gasket II
3 Turbocharger oil inlet pipe bolt 14 Exhaust manifold assembly bolt
4 Heat resistant bolt 15 Exhaust manifold lower pressure plate
5 Turbocharger water outlet pipe 16 Exhaust manifold assembly
6 Turbocharger water inlet pipe O-ring 17 "Gasket, exhaust manifold"
7 Turbocharger water inlet pipe bolt 18 Exhaust manifold upper pressure plate
8 Turbocharger water inlet pipe 19 Turbocharger oil inlet pipe bolt
9 Turbocharger assembly 20 Copper backing

Turbocharger oil return pipe sealing gasket
10 21 Oil inlet pipe, turbocharger
I
Turbocharger oil return pipe fixing bolt (at
11
turbocharger side)
Turbocharger and inter-cooler system of engine - Turbocharger and inter-cooler system 21-7
1 2
3
4
12
11 5
6
9
7
10
21
8
LFWX-6470-11009
Exhaust gas bypass control valve self

1 Turbocharger assembly 7
tapping screw
2 Oil-gas separation hose 8 Turbocharger hose
3 Compressor inlet pipe assembly 9 Turbocharger hose
4 Turbocharger hose 10 Exhaust manifold assembly
5 Steel strip elastic clamp 11 Turbocharger positioning pin
6 Turbocharger bypass solenoid valve 12 Turbocharger gasket

21-8 Turbocharger and inter-cooler system of engine - Turbocharger and inter-cooler system

Turbocharger assembly inspection
Warning:
Hot engine and engine oil can cause serious burns. Shut down the engine; wait for
some time until the engine and engine oil is cooled down.
• Check the appearance.
Check the intake and exhaust pipe connection flanges and connectors outside the turbine
and the compressor impeller for cracks, leakage and other abnormalities; especially,
check the “Oil leakage” from the turbocharger for severity, which may be most obvious at
the turbocharger hose connectors. A slight oil leakage is a normal phenomenon. If the oil
leakage is serious, the connectors between the turbocharger hose and the turbocharger
bypass solenoid valve, the compressor inlet pipe assembly must be processed. In addition,
after the engine is shutdown, use a stethoscope to hear the sound of the turbocharger rotor
inertia rotation; if the sound lasts over 1 min, the turbocharger is under good conditions.
• Check the turbocharger compressor impeller.
Remove the connection between the compressor and the compressor inlet pipe assembly;
observe the friction condition between the compressor impeller and the housing, leakage
and impeller damage. If there is a friction between the impeller and the housing, and
the attached matters at the friction position on the housing is firm, it indicates that the
compressor impeller is damaged. If it is found that the compressor impeller is damaged
by foreign matters, or there is a serious leakage at the impeller shaft, must repair the
turbocharger.
• Check the turbocharger turbine.
Remove the front catalyst at the turbine outlet; check the turbine blades and the housing
for friction, leakage and impeller damage. If there is friction between the impeller and
the housing, and there are hard and firm matters attached on the housing, the turbine is
damaged and must be removed for repair. If the oil is leaked seriously, observes whether
the oil is leaked from the exhaust system or from the turbine shaft center; if the oil is leaked
from the turbine shaft center and is serious, it indicates that turbine shaft seal is damaged
and the turbocharger should be removed for repair and maintenance. If the oil is leaked
from the exhaust system, and the oil deposition is serious on the turbine impeller, the
turbine blades should be removed for cleaning.
• Check the rotating components.
If there is no obvious damage on the turbine and the compressor impeller, quickly and
manually turn the turbocharger rotor shaft, it should be rotated freely and no obvious
grinding noise and block phenomenon; otherwise the shaft may be burned. Use a
micrometer to check the rotor shaft axial clearance and the radial clearance at turbine end
and pump wheel end, the measurement values can not be beyond the standard range.
• Check the turbocharger electrical parts
Check whether the turbocharger electrical wiring harness plugs are connected properly,
whether the supply voltage on the plug is normal, and whether the measured sensor data
are within the standard range.

• The turbocharger bearing is
• Repair or replace the Turbocharger.
damaged
The turbocharger rotation • Repair or replace the Turbocharger.
• The compressor impeller or the
is suddenly shutdown • Replace the bearing or the
turbine blades are damaged
Turbocharger.
• The rotor shaft is damaged.
• The compressor impeller or the

turbine blades are frictioned with
• Clean the turbine or the compressor
The turbocharger has the housing.
impeller.
a strong vibration and • The turbine and the compressor
noise impeller surfaces are too dirt.
• Clean or replace the oil pipe.
• The rotor shaft is worn badly
• The oil pipe is clogged.
The turbocharger is • The air filter is clogged or the air • Replace the air filter or clean the inlet
surged inlet duct is dirty. duct.
• The air inlet duct is clogged. • Clean the air inlet tube.
• The rotor shaft or the bearing is • Replace the bearing or the
The turbocharger
worn, Turbocharger.
pressure drops
• The turbine or the compressor • Repair or replace the Turbocharger.
impeller is damaged.
• The rotor shaft is worn badly

Reference: Diagnosis about oil
There is oil leakage at • The internal oil seal is damaged.
leakage at the turbocharger inlet side
the turbocharger turbine • The engine is operated at idle
(turbocharger and inter-cooler system,
or the pump wheel end speed for a long time.
fault diagnosis and inspection).
21
Diagnosis procedure about oil leakage at the turbocharger inlet side
1. Check the turbocharger compressor impeller for damage.
A. Confirm the turbocharger compressor impeller for

damage.
→ Yes
Clean and repair the air intake system; replace the
turbocharger.
→ No
To step 2.
2. Check whether the turbocharger axial or radial clearance is too large.
A. Confirm whether the turbocharger axial or radial

clearance is too large.
→Yes
Eliminate the factors to result in too big axial or radial
clearance; replace the turbocharger.
→No
To step 3.
3. Check whether the air filter is clogged.


A. Confirm whether the air filter is clogged.
→ Yes
Clean or replace the air filter.
→ No
To step 4.
4. Check whether the turbocharger oil return pipe is clogged.
A. Confirm whether the turbocharger oil return pipe is

clogged.
→ Yes
Clean or replace the turbocharger oil return pipe
→ No
To step 5.
5. Check whether the turbocharger pressure relief valve is normal.
A. Confirm whether the turbocharger pressure relief

valve is normal.
→ Yes
Replace the turbocharger pressure relief valve
→ No
To step 6.
6. Check whether the exhaust pipe is loosened or broken.
A. Confirm whether the exhaust pipe is loosened or

broken.
→ Yes
Fasten the pipe or replace the broken pipe.
→ No
To step 7.
7. Check whether the engine idle operation time is too long.
A. Confirm whether the engine idle operation time is too

long.
→ Yes
Clean the turbocharger; avoid too long idle operation
time.
→ No
To step 8.
8. Check the engine faults; whether there is channeling gas at piston and the crankcase pressure
is too high; if necessary, repair the engine.


Turbocharger assembly
Disassembly
1. Remove the turbocharger assembly.
(a). Remove the generator assembly;

Reference:
Removal of the generator assembly in
charging system.
(b). Remove the turbocharger intake pipe
components.
Note:
Before the turbocharger assembly is removed,
must shut down the engine and wait for engine
temperature decrease.
LFWX-6470-11010
(c). Remove the turbocharger shield fixing bolts

and remove the turbocharger shield.
Note:
Before the heat shield is removed, please
make sure that the engine has been shut down
and the exhaust pipe has been cooled. 21
LFWX-6470-11011
(d). Disconnect the turbocharger pressure relief

1 valve wiring harness plug (1).
(e). Disconnect the turbocharger bypass
solenoid valve wiring harness plug (2).
LFWX-6470-11012
(f). Remove the clamp, and remove the oil-gas

separation hose.
LFWX-6470-11013
1 (g). Remove the clamp (1), and remove the

turbocharger hose.
(h) Remove the self tapping screw, and remove
1
the turbocharger bypass solenoid valve (2).
1 1
1
2
LFWX-6470-11014
(i). Remove the bolts and remove the

compressor intake pipe.
LFWX-6470-11015
(j). Remove the turbocharger water inlet and

outlet pipe fixing bolts, and remove the
turbocharger water inlet and outlet pipes.
(k). Remove the front catalyst. Reference:
Removal and installation of the front catalyst
in the intake and exhaust system.
LFWX-6470-11016
(l). Remove the turbocharger oil inlet pipe fixing

bolts, and remove the turbocharger oil inlet
pipe.
21
LFWX-6470-11017
(m). Remove the turbocharger oil return pipe

fixing bolts, and remove the turbocharger oil
return pipe.
LFWX-6470-11018
(n). Remove the turbocharger bracket fixing

bolts, and remove the turbocharger bracket.
LFWX-6470-11019
(o). Remove the exhaust manifold heat shield

fixing bolts, and remove the exhaust
manifold heat shield.
LFWX-6470-11020
(p). Remove the exhaust manifold assembly

fixing bolts, and remove the exhaust
manifold upper and lower pressing plates
and the exhaust manifold assembly.
LFWX-6470-11021
(q). Remove the turbocharger assembly

fixing heat-resistant nuts and remove the
LFWX-6470-11022
Inspection
1. Check the turbocharger assembly
(a). Loosen the hose clamp and disconnect the

hose from the turbocharger actuator.
21
LFWX-6470-11023
(b). Connect the tester connector to the

turbocharger actuator.
LFWX-6470-11024
(c). Open the turbocharger tester, and operate

the manual vacuum pump to set up 800
mbar pressure.
LFWX-6470-11025
(d). Install the dial indicator on the turbocharger,

and use the dial indicator to measure the
push rod stroke.
LFWX-6470-11026
(e). Based on the measured results, adjust the

screw piece on the rotating rod to the rated
value.
LFWX-6470-11027
Installation
1. Install turbocharger
(a). Align the positioning pins on the

turbocharger assembly and the exhaust
manifold assembly, and tighten the heat-
resistant nut.
Torque: 23 N•m
Note:
During installation of the turbocharger
assembly; replace the turbocharger sealing
gasket and install the turbocharger positioning
pin.
LFWX-6470-11028
(b). Install the exhaust manifold assembly onto

the exhaust manifold studs, install the upper
and lower pressing plates of the exhaust
2 3 8
manifold, install the exhaust manifold
6
assembly fixing nuts, preload and tighten
them in the order as shown.
Torque: 23 N•m 21
Note:
9 5 1 4 7 When installing exhaust manifold assembly,
must replace the exhaust manifold gasket;
during the installation; check whether the
upper and lower pressure plates of exhaust
LFWX-6470-11028 manifold are installed in place or missed.
(c). Install the exhaust manifold heat shield on

the exhaust manifold assembly, and tighten
the fixing bolts.
Torque: 11 N•m
LFWX-6470-11029
(d). Install and tighten the heat-resistant bolts

(1).
Torque: 23 N•m
2 (e). Install and tighten the turbocharger bracket
1 fixing bolts (2).
2
Torque: 11 N•m
LFWX-6470-11030
(f). Install the turbocharger oil return pipe and

tighten the fixing bolts.
Torque: 11 N•m
Note:
When installing the oil return pipe, must
replace the oil return pipe sealing gasket.
LFWX-6470-11018
(g). Install and tighten the turbocharger oil inlet

1 pipe fixing bolts (1).
1
Torque: 11 N•m
(h). Install and tighten the turbocharger oil inlet
pipe fixing bolts (2).
Torque: 23 N•m
Note:
2
When installing the oil inlet pipe, must replace
the oil inlet pipe O-ring and copper gasket; the
smooth surface of the copper gasket must be
toward the turbocharger oil inlet pipe.
(i). Install the front catalyst. Reference:
LFWX-6470-11031 Removal and installation of the front catalyst
in the intake and exhaust system.
(j). Install the turbocharger water outlet pipe

1 onto the turbocharger bracket and tighten
turbocharger water outlet pipe fixing bolts
2 (1).
Torque: 11 N•m
(k). Install water inlet hard pipe of supercharger
to supercharger and fasten its bolt (2) for
several circles.
Note:
When installing the water inlet and outlet
pipes, must replace the water pipe O-rings.
LFWX-6470-11032
(l). Install the compressor air intake pipe and

Torque: 11 N•m
(m). Tighten the water inlet hard pipe bolt of
supercharger.
Torque: 11 N•m
21
LFWX-6470-11015
1 (n). Install the turbocharger bypass solenoid

valve (2), and tighten the self-tapping
screws.
1
Torque: 3 N•m
(o). Install the turbocharger hose, and fasten it
with the clamp (1).
1 1
1
2
LFWX-6470-11014
(p). Install the oil-gas separation hose and

fasten it with the clamp.
LFWX-6470-11013
(q). Connect the turbocharger pressure relief

valve plug (1).
(r). Connect the turbocharger bypass solenoid
valve plug (2).
1
LFWX-6470-11033
(s). Install the turbocharger heat shield and

Torque: 11 N•m
LFWX-6470-11011
(t). Install the turbocharger air intake pipe

components.
(u). Install the generator.
LFWX-6470-11010
21
Maintenance Tools
General tool
1 T-shaped spline -
....2 M-shaped spline -
3 Manual vacuum pump -
Quick wrench and

4
socket
-
5 Torsion wrench -
6 Dial indicator -
7 Dial indicator bracket -
8 Clamp pliers -
21
Transmission - Transmission (1.5T-5MT) 21-a
Transmission
Transmission��1
Precautions�� 4
Structure of the transmission��4
Overview �� 4
Gear shift mechanism �� 5
General inspection��7
Transmission inspection�� 7
Fault diagnosis and maintenance��7
On-board maintenance�� 9
1 Replacement of oil�� 9
2 Replace the left and right
oil seal of differential �� 9
Transmission maintenance��9
General rules for transmission
maintenance�� 9 21
21-b Transmission - Transmission (1.5T-5MT)
Transmission - Transmission (1.5T-5MT) 21-1
Transmission
Preparations
1. Special tools
Used to pull out the input fifth gear

1 Puller
hub and fifth output gear
1: Pressing-in
locating sleeve
Get the inner ring "5" from the front
2: Input shift
bearing of input shaft; and get the
disassembling tooling
2 fourth input gear, the inner ring from
1
the rear bearing of input shaft, and
3: Input shift the fourth output gear gasket
2
Input shift
Press the inner ring into the rear 21
3 bearing of the input shaft; and press
the fourth output gear shaft sleeve
Press the first and second

gear synchronizer hubs and
1: Angle iron "1"
corresponding gear sleeves, the
4 2: Installation of
gear output shaft of the first output
locating sleeve "2"
gear, intermediate bearing, and
bearing pressure plate
Transmission housing Used to erect transmission housing

5
oil seal erecting tools oil seals
21-2 Transmission - Transmission (1.5T-5MT)
Clutch housing oil For installing the clutch housing oil

6
seal mounting tool seal
1 Circlip pliers To remove and install the snap ring
To suck out the self-locking spring,

2 Bar magnet
steel ball and other small objects
3 Spacer gauge To measure the gap

Maintenance data
1. Technical specification table
Transmission model LD525MFA07
Transmission type 5MT
1 gear 3.778
2 gear 2.118
3 gear 1.36
Reduction ratio 4 gear 1.091
5 gear 0.814
R gear 3.6
Final drive 3.938
Gear oil capacity 2±0.1L

Item N·m
Reverse gear swing arm bracket bolt 23 ± 1.5
Connecting bolts for transmission housing and clutch

23 ± 1.5
housing (18 PCS)
Cable bracket bolt (3 PCS) 23 ± 1.5

21
Output plate nut (4 PCS) 25~28
Reverse gear stopper lock bolt M8x32 20±1.5
Transmission housing end face bolt 20±1.5
Release fork support beam bolt 20±1.5
Gear shift box bolt 20±1.5
Counterweight with pan head nut 25z~28
Output lock bolt 105±3
5th gear shift fork guide pin bolt 23±1.5
Input 5th/reverse gear shift guide block bolt 20±1.5N
End cover bolt 10±1
Oil filler and oil drain plug 25±1.5

Precautions
For maintenance work, it is necessary to use sealant or the equivalent. Apply the sealant to
corresponding position on the surface of the transmission housing. If the housing is made
of aluminum, the fastening bolts on the housing must be fastened to a specific torque with
a torque wrench. In addition, it is very important to clean all the parts with the detergent or
cleaning solution and dry air before reinstallation.
(1). Compressed air tools can cause dust and other particles to fly out, resulting in damage to the
eyes; so you should wear goggles in the use of compressed air.
(2). Check and make sure that all parts are cleaned before assembling the transmission (except
rubber parts and gaskets)
(3). Replace all disposable parts (all kinds of oil seals, spring pins, O seals, etc.).
(4). When sealing elements are installed, it is necessary to clean the residual sealant on the
bonding surface.
(5). To ensure that the sealing elements are oil-tight, the assembly should be completed within 3
minutes after the sealant is applied.
(6). The removed rings, bearings, oil covers, etc. cannot be reused.
(7). All bolts and nuts must be tightened in accordance with the specified tightening torque.
(8). When installing the moving parts, apply some gear oil to these moving places, and then use
some lubricating grease to the seal lips.
(9). When the bearings are installed, do not use any rolling body to transfer the pressure. Press fit
each oil seal without titling.
(10). When the transmission is working normally, there shall be no leakage of lubricating oil.
(11). Old clamping rings must be replaced with new ones, and the new clamping rings installed in
place shall not be excessively open so as to avoid deformation.
(12). The bolts and nuts used to fix the end caps, housings or brackets shall be loosened or
tightened diagonally.
2. Level II maintenance
(1). First-level maintenance
• In first-level maintenance, we should check the lubricant level which should be aligned to
the lower edge of the filler port; add lubricant when the level is low, because too low level
may cause poor lubrication and burn the bearings and gears, while too high oil level may
cause overheating and oil spills.
• In first-level maintenance, we should remove the ventilation valve for inspection and
cleaning, because ventilation valve blockage will result in too high internal pressure and
thus transmission fluid leakage.
(2). Level II maintenance
• In the first second-level maintenance for a new car, replace the transmission lubricant and
clean the transmission with kerosene.
• After the first second-level maintenance, regularly check the quality of the lubricant.
• In case the lubricant becomes diluted, thick, dirty and so on, it should be replaced.
(3). Level III maintenance

• For third-level maintenance, we should conduct disassembling inspection, cleaning and
replacement of oil.
Structure of the transmission

Overview
Transmission can supply 5 drive gears and 1 reverse gear through 3 synchronizers and 3 shafts
- input shaft, countershaft and reverse gear shaft. All the gears are constant meshing type except
the reverse gear combining one constant meshing gear and one slide gear.
The first and second gears' synchronizer is mounted on the output shaft and interlocked with the
first or second gear of the output shaft; the third and fourth gears' synchronizer is also mounted on
the output shaft and interlocked with the third or fourth gear of the output shaft.
The fifth gear synchronizer on the input shaft is meshed with the fifth gear mounted on the input
shaft.
The output shaft drives the main reduction gear and the differential device to force the front wheel
driving shaft.
corresponding position on the surface of the transmission housing. If the housing is made of
aluminum, the fastening bolts on the housing must be fastened to a specific torque with a torque
wrench. In addition, it is very important to clean all the parts with the detergent or cleaning solution
and dry air before reinstallation.
Gear shift mechanism

The movement of gear shift lever drives the transmission shaft and the shift shaft via the
transmission control shaft, then driving the transmission, shift lever, and fork via the transmission
arm and yoke. The shift mechanism contains shift box assembly, rear end cover of shift box,
shift shaft, shift positioning seat, reverse gear switch, shift rocker assembly, transposition rocker
assembly, transposition rocker clip, transposition pin bushes 1 and 2, and balancing weight tape
reel nuts; the internal shift mechanism contains reverse-gear rocker bracket assembly, shifting fork
assembly, fifth-gear shifting fork, fifth reverse gear shifting fork guide block and bolts.
In the shift mechanism, when shift rocker assembly and transposition rocker assembly change their
positions, the shift pendulum in shift shaft assembly drives the shifting fork to realize the conversion
between "R", "N" and "gears 1~5". As shown below:
21
LFWX-6470-21001
(1). Except the third and fourth gears that can be shifted directly, you have to push the lever to "N"
first for the other gears.
(2). If we need to push the lever to "R", we've to release the lock of the entire lever retainer; if not,
we cannot shift to "R".
Component drawing
LFWX-6470-21002
1 Transmission assembly
General inspection
Transmission inspection
1. Inspect the transmission housing for damage, cracks or other defects; if any, repair or replace
the damaged parts.
2. Check the transmission for oil leakage; if there is oil leakage, repair leakage place.
3. Start the engine, step on the clutch, check the transmission the gears for smoothness,
accuracy and abnormal sound; if problematic, solve the problem.
4. Remove the transmission oil filler screw plug and check whether the transmission lubricating
oil level is normal.
Tips:
The transmission lubricating oil level should be flush with the lower plane of the filler port. If the oil
level is too low, fill the oil.
5. Check the transmission lubricating oil for

deterioration, foreign matter or moisture and
replace the oil if any.
21
LFWX-6470-21003
Fault diagnosis and maintenance

Fault diagnosis
(1). Manual shift order: successive upshift and downshift.
(2). Check whether the gear shift is flexible without seizing, disorder or gear skip; the gear shift
transposition should be normal, the gear should be clear, the lever return should be evident
and there should be no fluid leak during the test;
(3). Reversing light switch assembly: the reversing lights should be on in the reverse position and
off in other gear positions.
(4). Neutral gear switch:
Start function: the starter cannot be connected and the engine cannot start unless the neutral
gear is engaged.
Signal function: to supply signal to ECU and inform ECU of engine under no load currently.
Then the on-board computer conrtrols the engine and transmission to work under the optimal
state through this signal.

Symptom Possible point of failure Recommended Measures
Gear shift shaft severe wear and Manually straighten the gear shift shaft in the case of
deformation shaft bending or abrasion
Gear shift rocker arm severe wear and

Replace the gear shift rocker arm
deformation
The excessive axial play of gear is mainly

Replace the gear gasket of the corresponding gear
caused by the severe gear gasket abrasion
In the case of fork bending deflection, straighten it by

Gear shift fork abrasion or deformation hand; in the case of severe wear, replace the gear shift
fork assembly
Gear off
Fork support pole or bearing wear or
Replace the worn or damaged parts
deformation
Synchronizer gear hub, sleeve or gear ring

Replace the wearing parts in the case of gear off
abrasion
After the adjustment, the transmission

does not return to neutral or the adjusting Turn the lever to neutral gear and adjust the cable length
mechanism is loose
The connection of engine and transmission

to the entire vehicle is too loose or the gap Adjust the gap
adjustment is improper
Transmission oil level low or dirty Fill oil or change the gear oil
Excessive axial play of gear Replace the gear or corresponding gear gasket
Replace the gear if the gear backlash exceeds the limit.

Transmission noise high Gear severe wear or gear teeth fracture The standard backlash is 0.1mm and the use limit is
or abnormal noise 0.3mm; replace the gear if the gear teeth break
Synchronizer gear ring abrasion or external

Replace the gear ring
tooth fracture
Bearing damage or wear Replace the bearing
Gear shift shaft or gear shift fork

Replace the worn or deformed parts
deformation or uneven abrasion
Excessive taper abrasion of synchronizer

gear ring; too small clearance of gear
ring big end face and gear meshing teeth Replace the new gear ring
end face; the wear limit (the minimum
clearance) is 0.5mm
Difficult gear shift
Synchronizer spring damage Replace the synchronizer spring
Sleeve teeth end abrasion or gear ring key

Replace the corresponding part
groove widened due to abrasion
Shift mechanism middle gear shift rocker

arm abrasion
Oen is the oil plug tightening torque is less than specified

Transmission assembly value. In such a case, check the tightening torque and
oil leak Oil leak at the oil filler and oil drain plug tighten the plug if required; the other one is the fitting
deviation is high or the threads are damaged. In such a
(Note: when performing
case, replace the related part
the maintenance work
with the vehicle jacked,
Sealing element oil leak Replace the sealing element and operate correctly
check the transmission
for oil leak as well) Check the connecting bolt and tighten it to the required
Case body junction plane oil leak
torque
On-board maintenance
1 Replacement of oil
(1). When changing and inspecting lubricating oil, be sure to stop engine and jack up your vehicle
stably.
(2). Oil level and oil leakage condition of vehicle can be only checked when it is jacked up; in case
of oil leakage, please immediately take remedial measure.
(3). Empty old lubricating oil and feed new regulated lubricating oil.
(4). Torque specifications of oil filler plug and oil drain plug are shown as follows:
Gear oil: GL -4-75W
Oil filling capacity: 2.0±0.1L
Note:
When performing the maintenance work with the vehicle jacked, check the transmission for oil leak
as well.
2 Replace the left and right oil seal of differential
(1). Jack up vehicle, remove oil drain plug and empty transmission lubricating oil.
(2). Use socket head wrench to remove drive shaft from axle shaft flange.
(3). Remove axle shaft flange from transmission.
(4). Use slot type screwdriver and hammer to remove oil seal, and use differential oil seal tooling to
install a new oil seal.
(5). Coat lubricating grease on oil seal edge, and check the disassembly part of drive shaft and oil
seal to make sure grease is smooth.
(6). Use socket head wrench to install the axle shaft flange in differential.
(7). Install the drive shaft on the axle shaft flange.
Note:
When inserting the axle shaft flange, protect the oil seal lip and edge against scratch. Ensure to
fully insert the axle shaft flange and lock the screw rod as original.
(8). Feed gear oil to regulated oil level from injection hole, and make sure oil has been tightly 21
blocked by oil seal. After filling oil, fasten oil filler plug according to regulated torque.
The sealing gasket is one-off part and must be replace each time during the maintenance.
Transmission maintenance
General rules for transmission maintenance
(1). Transmission should be maintained as carefully and cleanly as possible. It is also very
important to choose tools with good performance, and operate according to basic safety
criterion on vehicle maintenance.
(2). After transmission is removed, residual sealant on junction surface must be thoroughly
cleaned; new sealant should be coated when transmission is installed; sealant should be
coated uniformly, but not thickly.
(3). Change O-shaped sealing ring each time.
(4). The removed collar cannot be reused; do not expand the collar too much during the installation
so as to prevent deformation.
(5). The bolt and nut fixing the end cover, shell or bracket must be loosened or tightened crosswise.
(6). Transmission must be disassembled/assembled according to maintenance manual
requirements.
(7). Installation direction of spare parts must conform to maintenance manual regulations.
1. Dismantle of gearbox assembly

(a). After unscrewing oil plug and draining lubricating
oil, use socket head wrench to remove screws on
two ends of the semiaxis flange and take out the
semiaxis flange;
(b). Remove 5 end cap bolts M7×20“1”, end cap
“2” and end cap gasket “3” of transmission, and
switch the transmission to neutral gear;
LFWX-6470-21003
(c). Take out the adjusting and fastening bolt “7” of

the fifth speed gear shifting fork; take down the
fifth speed gear shifting guide block “6”, remove
the fixing bolt “4” of the fifth speed gear shifting
fork location pin, withdraw shifting fork location
pin “5”, and take down the fifth speed gear
shifting fork “8”.
(d). Remove the fifth speed gear synchronizer spring
“2”, unplug the fifth speed gear sleeve “3”, and
take down the fifth speed gear synchronizer
sliding block “1”.

LFWX-6470-21004

(e). Reinstall the fifth speed gear synchronizer gear

sleeve on the fifth speed gear synchronizer gear

hub; when it is turned down as arrow “4”, the fifth
speed gear can be engaged.
(f). Use gear shift rock arm assembly to switch the
transmission to the third speed gear arrow “3”;
at this time the transmission is simultaneously
switched to the third and the fifth speed gears,
and the transmission is locked.
LFWX-6470-21005
(g). Use pneumatic wrench to remove the output

shaft lock bolt “1” on the fifth speed gear end
HOT surfaces on input shaft and output shaft.
(h). Use special tool (LD525 fifth speed gear puller) “1”
and 10mm nut “2” to plug out the fifth speed gear
COLD synchronizer gear hub “3” and output shaft fifth
speed gear “6”.
LFWX-6470-21006
(i). Remove three bolts “1”, “2” and “3” of reverse

stop block.
21
LFWX-6470-21007
(j). First, take down gear shift rock arm clamp

“1”, remove gear shift rock arm “3”, then use
pneumatic wrench to remove balance weight tape
disk nut “5”; and take down the balancing weight
“4”.
LFWX-6470-21008
(k). Regulate the gear shaft to neutral gear, remove

the gear shift box bolt “1” and remove the gear
shift box assembly “2” from transmission housing.
LFWX-6470-21009
(l). Remove rear locating seat “4” of gear shift box

as well as 4 fork support beams “2” and support
beam bolts “3” (another 2 in the opposite).
LFWX-6470-21010
(m). Remove release bearing “2” and release fork “1”.
LFWX-6470-21011
(n). Remove 8 connecting bolts “2” for fixing

transmission housing from clutch housing, and
remove 4 output pressure plate nuts “3”.
LFWX-6470-21012
(o). Remove connecting bolts “1” in fixed differential

area from transmission housing, and remove one
gear shifting stay wire support bolt “2”.
21
LFWX-6470-21013
(p). Remove transmission housing, pay attention

not to damage its sealing surface, take out gear
shifting fork assembly “1”, remove reverse swing
arm support bolt “3’, take out reverse swing arm
support “4” and remove reverse limiting block “2”.
LFWX-6470-21014
(p). Remove the reverse gear shaft “3” and reverse

gear 1 “2” and reverse gear 2 “1”. Remove the
input shaft assembly “4” and output shaft assembly
“5”, and remove the differential assembly “6”.
LFWX-6470-21015
2. Disassemble the input shaft assembly

(a). Use shaft disassembly tooling “1”,“2”,“3” and
other special tools to press out front bearing inner
race “5” of input shaft;
Note:
If the input shaft front bearing is intact, do not
remove it.
LFWX-6470-21016
(b). Use bearing stripping and cleaning tooling “1” to

press out input fourth speed gear, input-shaft rear

bearing inner race and output fourth speed gear

washer.

LFWX-6470-21017
(c). Use special tool and hydraulic machine to press

out input third speed gear “2”, and take out input
third-fourth speed gear spacer “3”.
LFWX-6470-21018

3. Assemble the input shaft assembly

(a). Use special tools to press in third speed gear; the
end surface of the gear inner race boss faces to
the fourth speed gear in installation.

21
LFWX-6470-21019
(b). Install the input third-fourth speed gear spacer

and then use special tool “1” to press in the fourth

speed gear. When the end face of the gear inner

race with boss is installed, it should face to the
third speed gear.

LFWX-6470-21020
(c). Use special tools to press in input-shaft rear

bearing inner race.
LFWX-6470-21021

(d). Install output fourth speed gear gasket and press

it in output fourth speed gear shaft sleeve by
special tools.
LFWX-6470-21022
4. Disassemble the output shaft

2
(a). Output shaft structure chart.
2 1
1
LFWX-6470-21023
1 Clutch housing 2 Output front bearing washer
3 Output shaft front bearing 4 Output shaft
5 Output shaft middle bearing 6 Output shaft intermediate bearing plate
7 Output 1st gear collar 8 Output shaft 1st gear assembly
9 1st gear needle bearing 10 1st gear internal gear
11 1st gear intermediate ring 12 1st gear external gear ring
Output 1st/2nd gear synchronizer

13 14 Output 1st/2nd gear synchronizer collar
assembly
Output 2nd gear roller pin spacer

15 16 1st gear external gear ring
ring
17 1st gear intermediate ring 18 1st gear internal gear
19 Output shaft 2nd gear assembly 20 2nd gear needle bearing
21 Output 2nd gear washer 22 Output 3rd gear assembly
23 Output 3rd bearing 24 3rd gear needle bearing
Output 3rd/4th gear synchronizer

25 Output 3rd gear gear ring 26
assembly
Output 3rd/4th gear synchronizer

27 28 4th gear needle bearing
assembly
29 Output 3rd gear gear ring 30 Output shaft 4th gear assembly
31 Output 4th gear washer 32 Output shaft rear bearing
33 Transmission housing 34 Output shaft 5th gear 21

35 Locking bolt shim 36 Output shaft lock bolt
(b). Use special tools “1” and “2” to press out input
second speed gear and third speed gear as
well as third-fourth speed gear synchronizer
assembly, output fourth speed gear, output fourth
speed gear gasket (flat gasket) and output rear
bearing inner race.
LFWX-6470-21024
(c). Use circlip pliers to remove the first-second

speed gear synchronizer collars.
LFWX-6470-21025
(d). Use angle iron “1” and special tooling “2” to press
18
9 8 out the first-second speed gear synchronizer
gear hub and first-second speed gear sleeve as
10
17 well as neck bearing pressure plate of output first
6 7 4 15
14 speed gear output shaft.
13
6
12
5
5 6 11
19
16
LFWX-6470-21026
3
2 7
1
5. Assemble the output shaft
(a). Check the wear patterns of the first-second speed
gear synchronizing rings; put inner synchronizing
rings on the circular conical surface of shifting
gear, and use feeler gage to measure clearance
size –a-, and see standard size in the Table below;
Clearance -a- Installation dimension Wear limit
First/second
0.75-1.25mm 0.3mm
gear
LFWX-6470-21027
(b). Then put the internal tooth ring, intermediate

ring and outer tooth ring of synchronizer on the
circular conical surface of shifting gear, and use

feeler gauge to measure clearance size –a-, and
see standards as the Table below;
First/second
1.25-1.85mm 0.5mm
gear
LFWX-6470-21028
(c). Check the wear patterns of the third-fourth speed

size –a-, and see standard size in the Table
below;
Third/fourth
1-1.7mm 0.5mm
gear
21
LFWX-6470-21029
(d). Check the wear pattern of the fifth speed gear

synchronizing rings; put inner synchronizing rings
on the circular conical surface of shifting gear,
and use feeler gage to measure clearance size –
a-, and see standard size in the Table below;

Fifth gear 1-1.7mm 0.5mm
LFWX-6470-21030

(e). Place the output first gear washer with the boss
facing the bearing inner race. Install the 1st gear

needle bearing, output 1st gear and synchronizer
gear ring and align the synchronizer gear ring

notch with the boss position.
LFWX-6470-21031
(f). Install the first-second speed gear synchronizer

gear hub, and then install first-second speed gear

sleeves. One side “A” of the gear sleeve outer
face with reverse gear face to the second speed

gear, and the installation site of synchronizing
ring should be noticed.

LFWX-6470-21032
(g). Press in the 1st/2nd gear synchronizer gear

hub with the special tool. Note to align the 1st
gear synchronizer gear ring notch with the boss
position and support the output shaft with the
positioning seat 2.
LFWX-6470-21033
(h). Use circlip pliers to install input first-second

speed gear synchronizer collars on the end face
of the first-second speed gear hub, and then put
in the output second speed gear roller retainer
ring.
LFWX-6470-21034
(i). Install the 2nd gear synchronizer gear ring and

needle bearing as well as the 2nd gear and align
the synchronizer gear ring notch with the boss
position.
(n). Install output second speed gear washer (plain
washer) on the end face of the second speed
gear, and use special tools to press in output
third speed gear shaft sleeve.
21
LFWX-6470-21035
(j). Install the output 3rd gear assembly, 2 3rd gear

needle bearings and 3rd gear synchronizer gear
ring.
(o). Use press-fitting locating sleeve “3” to press
in third-fourth speed gear synchronizer
assembly, and pay attention to align the gap of
synchronizing ring with boss position.
LFWX-6470-21036
(k). Use press-fitting locating sleeve to press in

output fourth speed gear shaft sleeve.
LFWX-6470-21037
7
3 (l). Install the fourth speed gear synchronizing ring,
4
the fourth speed gear roller bearing and the
5
output fourth speed gear component, and pay
attention to align the gap of synchronizing ring
with the boss position.
5 2
4
(l). Install output fourth speed gear gasket (flat

5
5
gasket) on the end face of output fourth speed
gear, and use press-fitting locating sleeve to
1 6
1-4
6
5 press rear bearing inner race of output shaft in

5
output shaft.
LFWX-6470-21038
6. Gearbox assembly assembly

(a). Install differential assembly, input shaft assembly
and output shaft assembly in clutch housing,
and then install reverse gear (1)“6”, keep the
end surface of reverse gear (1) with boss to rear
cover, and then install reverse gear shaft, reverse
gear (2)“6” and reverse stop block.
Note:
Replace the output intermediate bearing plate
four O-rings (7.1×2) every time as shown in the
arrowhead.
LFWX-6470-21039
(b). As shown in the Figure, use height gauge to

measure out B1, B2, C1 and C2, and then
calculate out the height according to gasket
selection formula.
Differential bearing adjusting shim thickness S3
(thickness selection formula: C1 - C2 0.1 ≤ S1 ≤ C1 -
C2 - 0.01)
LFWX-6470-21040
(c). Install reverse gear swing arm support assembly;

sleeve swing arm support on reverse gear (2),
make reverse gear (2) at neutral gear, make the
location boss on support aligned with the location
hole on shell, and fasten the reverse gear swing
arm support bolt “2” according to regulations
(tightening torque is 23±1.5N.m).
21
LFWX-6470-21041
(d). Install gear shifting fork assembly “1”, pay

attention to install the shifting fork in gear sleeve
slot, wherein reverse fork should be installed on
reverse stop block.
1. First/second gear synchronizer spring

2. First/second gear synchronizer sleeve
3. First/second gear synchronizer hub
4. First/second gear synchronizer sliding block
LFWX-6470-21042
(e). Remove the sealant residue between the clutch

housing and transmission housing sealing
surfaces, apply the new sealant evenly by the
proper thickness and check whether the locating
ring is correct.
(f). Install transmission housing, install connecting
bolt “1” between the transmission housing
and the clutch housing, gradually fasten to the
regulated value in a crossing way according to
1. Shaft removal tooling
regulations (tightening torque is 23±1.5N.m), and
2. Positioning seat
3. Pressing-in locating sleeve tighten stay wire support bolt “2” according to
regulations (tightening torque is 23±1.5N.m).
LFWX-6470-21043
(g). Put transmission flatly and install connecting bolt

M8×60“2” of clutch housing, and gradually tighten
the bolt to regulated value (tightening torque
is 23±1.5N.m) in a crossing way according to
regulations, and finally tighten 4 output pressure
plate nuts “3” of output middle bearing pressure
plate (tightening torque is 23-28N.m) along
diagonal line.
LFWX-6470-21044
(h). Before mounting release fork “2” and release

bearing “3”, coat lubricating grese on
corresponding joint of separation wheel cylinder
and fork support beam.
LFWX-6470-21045
2. Positioning seat
3. Pressing-in locating sleeve
(i). Install reverse stop block lock bolt M8×32“2”,

install converter housing end face bolt “3”, install
reverse stop block lock bolt M8×38“1”, and
tighten the 3 bolts of reverse stop block according
to regulated torque (23±1.5N.m).
LFWX-6470-21046
2. Positioning seat
(j). Install four fork support beams “2” (another two

in the opposite) of gear shifting fork assembly;
change a new O-shaped ring on support beams;
use screwdriver to turn the gear shifting fork
assembly until corresponding fork support beams
can be installed in place, and tighten the bolt at
the tightening torque of 20±1.5N.m.
(k). After coating sealant on the rear locating seat “4”
± sealing surface of gear shift box, install the ger
shift box on converter housing.
21
LFWX-6470-21047
(l). Switch the gear shift box assembly to neutral

gear, coat sealant on the sealing surface of the
gear shift box assembly, install transmission
assembly, pay attention to the installation
direction “arrow” of the gear shift box assembly,
and fasten the gear shift box bolt at the tightening
torque of 20±1.5N.m.
1. Shaft removal tooling 2. Positioning seat 3. Pressing-in locating sleeve
LFWX-6470-21048
(m). Install gear shift rock arm assembly “1”, install

tape disk nut “2”, install gear shift rock arm
assembly “3” and use clamp “4” to clamp the
gear shift rock arm pin.
LFWX-6470-21049
1. Differential assembly 5. Reverse gear stopper 10. Reverse gear swing arm
2. Output plate O-ring 6. Reverse gear assembly bracket assembly
3. Output shaft assembly 7. Reverse gear swing arm 11. Reverse gear front thrust
4. Reverse gear rear thrust bracket bolt bearing
bearing 8. Input shaft assembly 12. Clutch housing assembly
9. Gear shift fork assembly
(n). Heat the fifth speed gear on output shaft to

100ºC, use press-fitting locating sleeve “1” to
install the fifth speed gear of output shaft; and
gear slot points to transmission housing as “arrow
direction”.
LFWX-6470-21050
(o). The fifth speed gear synchronizer gear hub, gear

sleeve and sliding block are assembled. The end
face of synchronizer gear hub inner race with
loss, the end face of gear sleeve “2” with sharp
tooth “arrow” and “arrow B” on one side of sliding
block with gap should face to the same direction;
synchronizer spring must be installed in the slot
of the synchronizer sliding block, and tail end
bent to hook shape should be always far away
from the synchronizer.
LFWX-6470-21051
(p). Mount the input five-speed gear assembly, five-

speed needle bearing and five-gear synchronizer
ring on the input shaft, and mount the input five-
speed synchronizer assembly.
Note:
The gear hub end with boss as shown by arrowhead 2
and the gear sleeve end with pointed tooth as shown
by arrowhead 1 should face the housing.
1.
2.
Differential assembly
Output plate O-ring
LFWX-6470-21052
6. Reverse gear assembly
7. Reverse gear swing arm
bracket assembly
3. Output shaft assembly bracket bolt 11. Reverse gear front thrust
4. Reverse gear rear thrust 8. Input shaft assembly bearing
bearing 9. Gear shift fork assembly 12. Clutch housing assembly
5. Reverse gear stopper
(q). Mount the five-gear synchronizer scale and gear

sleeve on the input shaft with the press-mounting
locating sleeve “1”.
Note:
The synchronizer gear ring notch should be aligned
with the boss position. Knock the 5th gear synchronizer
gear hub and sleeve in the input shaft with the hammer
while note to align the synchronizer gear ring notch
LFWX-6470-21053
21
(r). Engage the five-gear sleeve directly into the fifth

gear, and engage the gearbox assembly into the
third gear with gearbox assembly. With the
gearbox in the third and fifth gear simultaneously,
the gearbox will be locked.

2. Reverse gear bracket assembly bolt
LFWX-6470-21054
(s). Mount the locking bolt shim and the locking bolts
of the five-gear gear on top of the input and
output shaft. Tighten these two bolts with a torque
wrench (tightening torque: 105 ± 3N.m).
Note:
Installation position of lock bolt gasket (cone angle
facing upward).
1. Connecting bolt M8×60 (10 PCS)

2. Oil pipe bracket
3. Tie wire bracket bolt M8 × 35
LFWX-6470-21055
(t). Put the gearbox in neutral position, and mount

the five-speed selector fork “1”. Tighten the
locating pin bolts of five-speed selector fork
(tightening torque: 23 ± 1.5Nm) “arrow” and input
five-speed shift guide block bolt “2” (tightening
torque: 20 ± 1.5Nm).
1. Reverse gear limit
block locking bolt (1)
M8 × 38
block locking bolt M8
× 32
3. Variable housing end
bolt M8 × 25
LFWX-6470-21056
(u). Adjust the mounting position of input five-speed

selector fork assembly, engage the fifth gear, and
loosen the bolt “1”. Press the fifth gear sleeve
and the fork opening in the direction of the arrow,
and re-tighten the bolt “1”.
Note:
The feeler gauge of 0.2mm thick should not slide
between the 5th gear sleeve and input 5th gear. Adjust
it again if necessary. The gearbox is engaged in the
1. Shift box bolts M8 × 25 (2) 3. Fork support bolts M8 × 22 (4 pieces) neutral gear again, and the synchronizer ring must be
moving freely.
2. Shifting fork support column (4) 4. Gear shift case rear positioning seat
LFWX-6470-21057
(v). The gearbox should be free from failure when

engaged in any gear. Mount the end cover seal
gasket “3”, rear end cover “2” (end cover bolt
M7×20“1”; tightening torque: 10±1N.m) and the
peripheral parts of the gearbox assembly as
required.
1. Reverse lamp switch

2. Reverse lamp wire bracket assembly
3. Gear shift case assembly
LFWX-6470-21058
(w). Mount the semi-axle flanges into various

components as shown in the figure. The semi-
axle screw should be sealed with “O”-ring.
1. Gear shift rocker arm assembly

2. Fitted with the weight block with disk nut
21
3. Change the rocker clip
4. Transposition rocker arm assembly
LFWX-6470-21059
(x). Mount the semi-axle flange assembly on both

ends of the gearbox differential and press it
firmly. Tighten the screw into the flange nut with
the hexagon socket in the pressed state.
(y). Check the gearbox assembly for un-mounted
parts and for untightened bolts. After ensure no
item is missed, test the transmission for leak
tightness to ensure the transmission assembly is
free of oil leak.
2. Output pressure plate nuts (4 pieces)
3. Separation fork support column
LFWX-6470-21060
Transmission - Transmission（1.5T-8AT）
21-a
Transmission
Transmission …………………… 1 Replacement ……………………33
Preparations …………………… 1 4.11 Oil pan ………………………34
Maintenance data ……………… 3 Remove and replace …………34
Precautions …………………… 7 4.12 Filter …………………………34
Part drawing …………………… 8 Remove and replace …………34
Transmission …………………… 8 4.13 Cable bracket ………………35
Differential ……………………… 9 Remove and replace …………35
Gear shift case …………………10 5.1 Hydraulic valve plate assembly
Cable bracket ………………… 11 ………………………………………35
Inside gross structure sketch … 11 Removal …………………………35
General inspection………………12 5.2 Valve plate solenoid valve 36
Transmission inspection ………12 Remove and replace …………36
Fault diagnosis …………………13 5.3 Temperature sensor ………37
Main performance testing Remove and replace …………37
requirements ………………………13 5.4 Hydraulic pressure sensing
DTC and description …………13 hole site distribution ……………37
Transmission and engine………28 Transmission maintenance ……38
Disassembly ……………………28 ATF level ………………………38
Transmission and engine………28 Transmission fluid state ………38
Installation ………………………28 Inspection ………………………38 21
4.1 Speed sensor assembly …29 Transmission fluid ………………38
Replacement ……………………29 Replacement ……………………38
4.2 Gear sensor assembly ……30 8AT operating instructions ……40
Remove and replace …………30 Gear introduction ………………40
4.3 Gear shift drag arm …………30 Precautions ……………………40
Remove and replace …………30 8 AT t r a n s m i s s i o n f u n c t i o n
4.4 Oil dipstick pipe assembly 30 description …………………………41
Remove and replace …………30 Vehicle towing …………………41
4.5 Oil cooler ……………………31 Electronic control schematic
Remove and replace …………31 diagram and diagnosis operating
4.6 Oil cooler plug board ………31 specification ……………………42
Remove and replace …………31 Electronic control system ……42
4.7 Axle shaft oil seal …………32 TCU pin diagram ………………42
Remove and replace …………32 Cylinder-through connector pin
4.8 Hydraulic torque converter 32 diagram ……………………………44
Remove and replace …………32 Sensor description ……………45
4.9 TC oil seal ……………………33 Output shaft (G11) speed sensor45
Remove and replace …………33 C4/G4 speed sensor …………45
4.10 Gear shift shaft oil seal …33 Gear sensor ……………………45
TCU diagnostic function ………46
21-b Transmission - Transmission（1.5T-8AT）
21-1
Transmission
Preparations
1. Special tools
Used to pull out the input fifth gear

1 Puller
hub and fifth output gear
1: Pressing-in locating
Get the inner ring "5" from the front
sleeve
bearing of input shaft; and get the
2: Input shift
2 fourth input gear, the inner ring from
disassembling tooling 1
the rear bearing of input shaft, and
3: Input shift
the fourth output gear gasket
disassembling tooling 2
Press the inner ring into the rear

Input shift 21
3 bearing of the input shaft; and press
the fourth output gear shaft sleeve
Press the first and second gear

1: Angle iron "1" synchronizer hubs and corresponding
4 2: Installation of locating gear sleeves, the gear output shaft
sleeve "2" of the first output gear, intermediate
bearing, and bearing pressure plate
Transmission housing Used to erect transmission housing

5 oil seal erecting tools oil seals
21-2 Transmission - Transmission（1.5T-8AT）
Clutch housing oil For installing the clutch housing oil

6
seal mounting tool seal

2 Bar magnet

21-3
Maintenance data
1. Technical specification table
Transmission model 8AT300F02
Transmission type 8AT
1 gear 4.17
2 gear 2.65
3 gear 1.69
4 gear 1.42
6 gear 1.00
7 gear 0.84
8 gear 0.64
R gear 3.35
Final drive 3.56
Transmission total oil volume (L) 7.5±0.2L
2. Gear shift logic

Brake Clutch
Gear
B1 C1 C2 C3 C4
P ON OFF OFF OFF ON
R ON OFF ON OFF ON
N ON OFF OFF OFF ON
1 ON ON OFF OFF ON
2 ON OFF OFF ON ON 21
3 OFF ON OFF ON ON
4 OFF OFF ON ON ON
5 OFF ON ON OFF ON
6 OFF ON ON ON OFF
7 ON ON ON OFF OFF
8 ON OFF ON ON OFF
The thick black line indicates the power transmission path

(1) R gear of power transmission path（B1、C2、C4）
(2) 1st gear of power transmission path（B1、C1、C4）
(3) 2nd gear of power transmission path（B1、C3、C4）

21-5
(4) 3rd gear of power transmission path（C1、C3、C4）
(5) 4th gear of power transmission path（C2、C3、C4）
21

(8) 7th gear of power transmission path（B1、C1、C2）
(9) 8th gear of power transmission path（B1、C2、C3）

21-7

Item N·m
Oil pan fixing screw 7~9
Main housing: 32 ~ 36
Oil draining bolt
Oil pan: 40 ~ 45
Transmission oil dipstick fixing bolt 15 ~ 18
Speed sensor fixing bolt 2.4 ~ 2.8
Oil filler bolt 40 ~ 45
Oil passage plug bolt I 10 ~ 11
Oil passage plug bolt II 3~4
Gear shift rocker arm fixing screw 2 ~ 2.4
Gear shift rocker arm fixing nut 15 ~ 18
Position sensor bracket fixing screw 5.5 ~ 6.5
Position sensor fixing screw 2 ~ 2.4
Oil passage plug bolt III 7~8
Oil cooler connecting bolt 30 ~ 35
Oil cooler fixing screw 7~9
Precautions
(a). Compressed air tools can cause dust and other particles to fly out, resulting in damage to the
eyes; so you should wear goggles in the use of compressed air. 21
(b). Check and make sure that all parts are cleaned before assembling the transmission (except
rubber parts and gaskets).
(c). Replace all disposable parts (all kinds of oil seals, spring pins, O seals, etc.).
(d). When sealing elements are installed, it is necessary to clean the residual sealant on the
bonding surface.
(e). To ensure that the sealing elements are oil-tight, the assembly should be completed within 3
(f). The removed rings, bearings, oil covers, etc. cannot be reused.
(g). All bolts and nuts must be tightened in accordance with the specified tightening torque.
(h). When installing the moving parts, apply some gear oil to these moving places, and then use
(i). When the bearings are installed, do not use any rolling body to transfer the pressure. Press
fit each oil seal without titling.
(g). When the transmission is working normally, there shall be no leakage of lubricating oil.
(k). Old clamping rings must be replaced with new ones, and the new clamping rings installed in
(l). The bolts and nuts used to fix the end caps, housings or brackets shall be loosened or
2. Third-level maintenance of transmission
(a). First-level maintenance
• In first-level maintenance, we should check the lubricant level which should be aligned to the
lower edge of the filler port; add lubricant when the level is low, because too low level may cause
poor lubrication and burn the bearings and gears, while too high oil level may cause overheating
and oil spills.
• In first-level maintenance, we should remove the ventilation valve for inspection and cleaning,
because ventilation valve blockage will result in too high internal pressure and thus transmission
fluid leakage.
(b). Level II maintenance
• In the first second-level maintenance for a new car, replace the transmission lubricant and clean
the transmission with kerosene.
(c). Level III maintenance
replacement of oil.
Part drawing
Transmission
LFWX-6470-21001
1 Hydraulic torque converter 6 Oil pan gasket

2 Differential oil seal 7 Oil sump assembly
3 Input shaft seal 8 Oil pan fixing screw
4 Cable bracket 9 Oil drain bolt gasket
5 Filter 10 Oil draining bolt
Note: the items marked with SHENGRUI in the back indicate the designation of LIFAN parts is different from
that of SHENGRUI. For the items without SHENGRUI, the designation is the same.
21-9
Differential
21
LFWX-6470-21002
1 Transmission oil dipstick fixing bolt 7 Speed sensor II

2 Oil dipstick oil pipe assembly 8 Oil filler bolt
Upper mounting threaded stud -
3 9 Oil filler bolt gasket
short
4 Respirator assembly 10 Oil passage plug bolt I
5 Speed sensor fixing bolt 11 Oil passage plug bolt II
6 Speed sensor
Note: the items marked with SHENGRUI in the back indicate the designation of LIFAN parts is different
from that of SHENGRUI. For the items without SHENGRUI, the designation is the same.
Gear shift case
LFWX-6470-21003
1 Gear shift shaft oil seal 7 Position sensor bracket

2 Gear sensor magnetic device gasket 8 Position sensor bracket fixing screw
3 Gear sensor magnetic device 9 Position sensor
4 Shifting rocker arm 10 Position sensor fixing screw
5 Gear shift rocker arm fixing screw 11 Position sensor bracket
6 Gear shift rocker arm fixing nut
from that of SHENGRUI. For the items without SHENGRUI, the designation is the same.
21-11
Cable bracket
LFWX-6470-21004
1 Oil passage plug bolt Ⅲ 6 Oil cooler connecting bolt

2 CBPV valve retaining bolt O-ring 7 Oil cooler O-ring
3 CBPV valve retaining bolt 8 Oil cooler
4 Oil cooler plug board gasket 9 Oil cooler fixing screw
5 Oil cooler plug board
from that of SHENGRUI. For the items without SHENGRUI, the designation is the same. 21
Inside gross structure sketch

1 Valve plate assembly 8 P3 Planetary row assembly

2 C3 clutch assembly 9 Differential final drive bull gear
3 C4 clutch assembly 10 Intermediate bulkhead
4 B1 clutch assembly 11 P2 Planetary row assembly
5 Input axis 12 C2 cluch
6 Oil pump assembly 13 P1 Planetary row assembly
7 Hydraulic torque converter 14 C1 clutch assembly
General inspection
the damaged parts.
△ Tips：

LFWX-6470-21028
21-13
Fault diagnosis
Main performance testing requirements
1. Automatic shift order: successive upshift and downshift.
2. Check whether the gear shift is flexible without seizing, disorder or gear skip; the gear shift
3. Reversing light switch assembly: the reversing lights should be on in the reverse position and
4. Neutral gear switch:
Start function: the starter cannot be connected and the engine cannot start unless the neutral gear
is engaged.
Signal function: to supply signal to ECU and inform ECU of engine under no load currently. 。
Then the on-board computer conrtrols the engine and transmission to work under the optimal state
through this signal.
DTC and description
TCU taking
DTC Description Diagnostic procedure Troubleshooting Terminal
measures
1. Connect the diagnostic
meter and read the DTC.
2. Clear DTC.
Hydraulic
3. Read the DTC again. If
P0741 torque OBD MIL on
any DTC occurs, locate
converter NO
the possible causes or
contact the technician of
the manufacturer.
2. Clear DTC.
Hydraulic
P0742 torque con- OBD MIL on
4. Read the DTC again. If 21
any DTC occurs, locate
verter OFF
the possible causes or
the manufacturer.
1. Connect the diagnostic 1. The gearbox oil
meter and read the DTC. temperature is higher than
Gearbox oil 2. Clear DTC. 120 ℃
temperature Transmission 3. Read the DTC again. If 2. Check the gearbox oil
P0218
is higher too MIL on any DTC occurs, locate level and oil condition
high the possible causes or 3. Check the cooling state of
contact the technician of oil cooler
the manufacturer. 4. Temperature sensor fault
2. Clear DTC. 1. C h e c k t h e c o n n e c t i o n
G4 speed
3. Read the DTC again. If harness
P0716 exceeds the OBD MIL on
any DTC occurs, locate 2. Speed sensor or replace
software limit
the possible causes or the speed sensor
the manufacturer.
2. Clear DTC. 1. C h e c k t h e c o n n e c t i o n
Go to limp
G4 rate signal 3. Read the DTC again. If harness
P0718 home mode
value instable any DTC occurs, locate 2. C h e c k o r r e p l a c e t h e
OBD MIL on
the possible causes or speed sensor
the manufacturer.
TCU taking
measures
1. Connect the diagnostic meter and
read the DTC.
1. Check the connection
G4 speed sig- Go to limp 2. Clear DTC.
harness
P171E nal value is not home mode 3. Read the DTC again. If any DTC
2. Check or replace the
true OBD MIL on occurs, locate the possible causes
speed sensor
or contact the technician of the
manufacturer.
read the DTC.
G4 speed 2. Clear DTC.
harness
P0792 exceeds the OBD MIL on 3. Read the DTC again. If any DTC
software limit occurs, locate the possible causes
speed sensor
manufacturer.
read the DTC.
Go to limp 2. Clear DTC.
C4 rate signal harness
P0794 home mode 3. Read the DTC again. If any DTC
value instable 2. Check or replace the
OBD MIL on occurs, locate the possible causes
speed sensor
manufacturer.
read the DTC.
C4 speed 1. Check the connection
sensor signal harness
P171D home mode 3. Read the DTC again. If any DTC
value is not 2. Check or replace the
true speed sensor
manufacturer.
read the DTC.
Output speed 1. Check the connection
exceeds the harness
limit set by the 2. Check or replace the
software speed sensor
manufacturer.
read the DTC.
Output speed Go to limp 2. Clear DTC.
harness
P0723 signal value home mode 3. Read the DTC again. If any DTC
instable OBD MIL on occurs, locate the possible causes
speed sensor
manufacturer.
read the DTC.
Output speed Go to limp 2. Clear DTC.
harness
P0724 signal value home mode 3. Read the DTC again. If any DTC
untrue OBD MIL on occurs, locate the possible causes
speed sensor
manufacturer.
read the DTC.
Temperature 2. Clear DTC.
Transmission harness
P0714 sensor signal 3. Read the DTC again. If any DTC
MIL on 2. Check or replace the
value unstable occurs, locate the possible causes
temperature sensor
manufacturer.
21-15
TCU taking
measures
1. Connect the diagnostic meter and read
the DTC. 1. Check the connection
Temperature
Transmission 2. Clear DTC. harness
P0711 sensor signal
MIL on 3. Read the DTC again. If any DTC occurs, 2. Check or replace the
value untrue
locate the possible causes or contact temperature sensor
the technician of the manufacturer.
the DTC.
Position Go to limp harness
2. Clear DTC.
P0706 sensor signal home mode 2. Temperature sensor
3. Read the DTC again. If any DTC occurs,
value untrue OBD MIL on or replace the
locate the possible causes or contact
temperature sensor
EMS_Engine the DTC.
TorqueStatus 2. Clear DTC. Engine ECM1 signal
U0400 OBD MIL on
Signal check 3. Read the DTC again. If any DTC occurs, check sum incorrect
sum error locate the possible causes or contact
EMS_ the DTC.
EngineRPM 2. Clear DTC. Engine ECM2 signal
U0401 OBD MIL on
signal check 3. Read the DTC again. If any DTC occurs, check sum incorrect
and error locate the possible causes or contact
SubRom The TCU unable to identify
the DTC.
chip is empty due to cylinder-through
2. Clear DTC.
P1830 or the chip OBD MIL on harness pin K27 - K30
is connected bending or admission of
poorly. water
the technician of the manufacturer. 21
1. Switch on and off the vehicle power for
3 cycles at an interval of 10s
SubROM Data
the DTC.
P1831 check and OBD MIL on
3. Clear DTC.
error
1. Switch on and off the vehicle power for
3 cycles at an interval of 10s
SubROM Data the DTC.
P1832 OBD MIL on
out of range 3. Clear DTC.
the DTC.
CAN message Go to limp
2. Clear DTC.
U0442 key signal is home mode
invalid OBD MIL on
TCU taking
measures
the DTC.
Go to limp
Safety system 2. Clear DTC. Check or replace the
P0613 home mode
RAM failure 3. Read the DTC again. If any DTC occurs, TCU
OBD MIL on
locate the possible causes or contact the
technician of the manufacturer.
Safety limit
function -
the DTC.
hydraulic Go to limp
2. Clear DTC.
P1803 torque home mode
converter OBD MIL on
signal value
untrue
Safety limit
the DTC.
function - Go to limp
2. Clear DTC.
P1804 incorrect home mode
clutch OBD MIL on
engagement
1. Check the oil level
Excessive the DTC.
and oil color
clutch 2. Clear DTC.
P1821 OBD MIL on 2. Check for other
slippage in 3. Read the DTC again. If any DTC occurs,
DTCs of the same
first gear locate the possible causes or contact the
period
Excessive the DTC.
and oil color
DTCs of the same
second gear locate the possible causes or contact the
period
Excessive the DTC.
and oil color
DTCs of the same
third gear locate the possible causes or contact the
period
Excessive the DTC.
and oil color
DTCs of the same
fourth gear locate the possible causes or contact the
period
Excessive the DTC.
and oil color
DTCs of the same
fifth gear locate the possible causes or contact the
period
21-17
TCU taking
measures
read the DTC. 1. Check the oil
Excessive clutch 2. Clear DTC. level and oil color
P1826 slippage in sixth OBD MIL on 3. Read the DTC again. If any DTC 2. Check for other
gear occurs, locate the possible causes DTCs of the
or contact the technician of the same period
manufacturer.
P1827 slippage in OBD MIL on 3. Read the DTC again. If any DTC 2. Check for other
seventh gear occurs, locate the possible causes DTCs of the
manufacturer.
eighth gear occurs, locate the possible causes DTCs of the
manufacturer.
reverse gear occurs, locate the possible causes DTCs of the
manufacturer.
1. Connect the diagnostic meter and 21
Go to limp 2. Clear DTC. level and oil color
Low speed
P183A home mode 3. Read the DTC again. If any DTC 2. Check for other
slippery friction
OBD MIL on occurs, locate the possible causes DTCs of the
manufacturer.
read the DTC.
1. Incidental fault
Lose 2. Clear DTC.
upon TCU power-
U0100 communication OBD MIL on 3. Read the DTC again. If any DTC
on
with EMS occurs, locate the possible causes
2. ECM fuse failure
manufacturer.
read the DTC.
1. Incidental fault
Lose 2. Clear DTC.
upon TCU power-
U0121 communication OBD MIL on 3. Read the DTC again. If any DTC
on
with ABS/ESP occurs, locate the possible causes
2. ABS fuse failure
manufacturer.
1. Check the K6
read the DTC.
Position sensor connection disconnected
(Pin 10) short harness K94
to ground/open 2. Check or replace disconnected
circuit the position K10
sensor disconnected
manufacturer.
TCU taking
measures
1. Connect the diagnostic meter and read 1. Check the
Position the DTC. connection
Go to limp
sensor (Pin 2. Clear DTC. harness K94 disconnected
P0709 home mode
10) short to 3. Read the DTC again. If any DTC occurs, 2. Check or K10 disconnected
OBD MIL on
power locate the possible causes or contact replace the
the technician of the manufacturer. position sensor
Position
the DTC.
sensor (Pin Go to limp Check or replace
2. Clear DTC.
P0707 10) signal home mode the position
period too OBD MIL on sensor
short
Position
the DTC.
sensor (Pin Go to limp Check or replace
2. Clear DTC.
P0708 10) signal home mode the position
period too OBD MIL on sensor
long
Position
the DTC. connection
sensor (Pin Go to limp K6 disconnected
2. Clear DTC. harness
P2800 18) short to home mode K94 disconnected
3. Read the DTC again. If any DTC occurs, 2. Check or
ground/open OBD MIL on K18disconnected
locate the possible causes or contact replace the
circuit
Position
the DTC. connection
sensor (Pin Go to limp
2. Clear DTC. harness K94 and K18
P2804 18) short to home mode
3. Read the DTC again. If any DTC occurs, 2. Check or short-circuited
ground/open OBD MIL on
locate the possible causes or contact replace the
circuit
Position sen- the DTC.
Go to limp Check or replace
sor (Pin 18) 2. Clear DTC.
P2802 home mode the position
signal period 3. Read the DTC again. If any DTC occurs,
OBD MIL on sensor
too short locate the possible causes or contact
Position sen- the DTC.
Go to limp Check or replace
sor (Pin 18) 2. Clear DTC.
P2803 home mode the position
signal period 3. Read the DTC again. If any DTC occurs,
OBD MIL on sensor
too long locate the possible causes or contact
1. Check the
connection
1. Connect the diagnostic meter and read harness
the DTC. 2. Check and
Temperature
Transmission 2. Clear DTC. measure the K33 and K38
P0710 sensor short
MIL on 3. Read the DTC again. If any DTC occurs, transmission short-circuited
to ground
locate the possible causes or contact cylinder-
the technician of the manufacturer. through pin
3. Temperature
sensor fault
21-19
TCU taking
measures
1. Connect the diagnostic meter 1. Check the connection
and read the DTC. harness
Temperature
2. Clear DTC. 2. Check and measure the
sensor short Transmission K33 or K38
P171C 3. Read the DTC again. If any transmission cylinder-
to power or MIL on disconnected
DTC occurs, locate the possible through pin
open circuit
causes or contact the technician 3. Te m p e r a t u r e s e n s o r
of the manufacturer. fault
Temperature 2. Clear DTC. 2. Check and measure the
Transmission
P0712 sensor voltage 3. Read the DTC again. If any transmission cylinder-
MIL on
low DTC occurs, locate the possible through pin
Temperature 2. Clear DTC. 2. Check and measure the
Transmission
P0713 sensor voltage 3. Read the DTC again. If any transmission cylinder-
MIL on
high DTC occurs, locate the possible through pin
1. Connect the diagnostic meter
and read the DTC.
Output speed
Go to limp 2. Clear DTC. 1. Check the connection
sensor short K93 or K56
P0720 home mode 3. Read the DTC again. If any harness
to ground or disconnected
OBD MIL on DTC occurs, locate the possible 2. Speed sensor fault
open circuit
causes or contact the technician
of the manufacturer.
and read the DTC. 21
Output speed Go to limp 2. Clear DTC. 1. Check the connection
K93 and K56
P0722 sensor short home mode 3. Read the DTC again. If any harness
short-circuited
to power OBD MIL on DTC occurs, locate the possible 2. Speed sensor fault
and read the DTC.
C4 speed
sensor short K31 or K55
P0791 home mode 3. Read the DTC again. If any harness
to ground or disconnected
OBD MIL on DTC occurs, locate the possible 2. Speed sensor fault
open circuit
and read the DTC.
C4 speed Go to limp 2. Clear DTC.
harness from TCU to K31 and K55
P0793 sensor short home mode 3. Read the DTC again. If any
sensor short-circuited
to power OBD MIL on DTC occurs, locate the possible
2. Speed sensor fault
and read the DTC.
G4 speed 1. Check the connection
sensor short harness from TCU to K30 or K54
P0715 home mode 3. Read the DTC again. If any
to ground or sensor disconnected
OBD MIL on DTC occurs, locate the possible
open circuit 2. Speed sensor fault
TCU taking
measures
and read the DTC.
G4 speed Go to limp 2. Clear DTC. 1. Check the connection
K30 and K54
P0717 sensor short home mode 3. Read the DTC again. If any harness
short-circuited
to power OBD MIL on DTC occurs, locate the possible 2. Speed sensor fault
K73 ground
1. Connect the diagnostic meter K50 ground
K41 ground
Solenoid and read the DTC.
K49 ground
valve power Go to limp 2. Clear DTC.
Check the connection K42 ground
P0785 supply line home mode 3. Read the DTC again. If any
harness K73 ground
short to OBD MIL on DTC occurs, locate the possible
K50 ground
ground causes or contact the technician
K41 ground
of the manufacturer. K49 ground
K42 ground
Solenoid and read the DTC.
valve power Go to limp 2. Clear DTC.
C h e c k t h e c o n n e c t i o n K42 Short circuit to
P0786 supply line home mode 3. Read the DTC again. If any
harness battery
short to OBD MIL on DTC occurs, locate the possible
power causes or contact the technician
and read the DTC.
Solenoid
valve power C h e c k t h e c o n n e c t i o n K73 disconnected
P0787 home mode 3. Read the DTC again. If any
supply line harness K29 disconnected
OBD MIL on DTC occurs, locate the possible
open circuit
and read the DTC.
B1 solenoid
valve short
P0753 home mode 3. Read the DTC again. If any harness K43 disconnected
to ground or
OBD MIL on DTC occurs, locate the possible 2. B1solenoid valve fault
open circuit
and read the DTC.
B1 solenoid Go to limp 2. Clear DTC. 1. Check the connection
P0751 valve short home mode 3. Read the DTC again. If any harness
to power OBD MIL on DTC occurs, locate the possible 2. B1solenoid valve fault
and read the DTC.
B1 solenoid Go to limp 2. Clear DTC. 1. Check the connection
P0752 valve current home mode 3. Read the DTC again. If any harness
value low OBD MIL on DTC occurs, locate the possible 2. B1solenoid valve fault
21-21
TCU taking
measures
1. Check the
the DTC.
B1 solenoid Go to limp connection
2. Clear DTC.
P0754 valve current home mode harness
value high OBD MIL on 2. B1solenoid valve
fault
the DTC.
Go to limp
B1 solenoid 2. Clear DTC. B1 solenoid valve
P0750 home mode
valve fault 3. Read the DTC again. If any DTC occurs, fault
OBD MIL on
1. Check the
C1 solenoid the DTC.
Go to limp connection
valve short 2. Clear DTC. K44
P0758 home mode harness
to ground or 3. Read the DTC again. If any DTC occurs, disconnected
OBD MIL on 2. B1solenoid valve
open circuit locate the possible causes or contact the
fault
1. Check the
the DTC.
C1 solenoid Go to limp connection
2. Clear DTC.
P0756 valve short to home mode harness
power OBD MIL on 2. C1solenoid
valve fault
1. Check the
the DTC.
2. Clear DTC.
value low OBD MIL on 2. C1solenoid 21
valve fault
1. Check the
the DTC.
2. Clear DTC.
value high OBD MIL on 2. C1solenoid
valve fault
the DTC.
Go to limp
C1 solenoid 2. Clear DTC. C1 solenoid valve
P0755 home mode
OBD MIL on
1. Check the
valve short 2. Clear DTC. K29 and K45
to ground or 3. Read the DTC again. If any DTC occurs, disconnected
OBD MIL on 2. C2solenoid
valve fault
TCU taking
measures
1. Check the
the DTC.
2. Clear DTC.
P0761 valve short home mode harness
to power OBD MIL on 2. C2solenoid valve
fault
1. Check the
the DTC.
2. Clear DTC.
value low OBD MIL on 2. C2solenoid valve
fault
1. Check the
the DTC.
2. Clear DTC.
value high OBD MIL on 2. C2solenoid valve
fault
the DTC.
Go to limp
P0760 home mode
OBD MIL on
1. Check the
valve short 2. Clear DTC.
to ground or 3. Read the DTC again. If any DTC occurs,
OBD MIL on 2. C3solenoid valve
fault
1. Check the
the DTC.
2. Clear DTC.
P0766 valve short home mode harness
to power OBD MIL on 2. C3solenoid valve
fault
1. Check the
the DTC.
2. Clear DTC.
value low OBD MIL on 2. C3solenoid valve
fault
1. Check the
the DTC.
2. Clear DTC.
value high OBD MIL on 2. C3solenoid valve
fault
21-23
TCU taking
measures
the DTC.
Go to limp
P0765 home mode
OBD MIL on
1. Check the
valve short to 2. Clear DTC. K47
ground or open 3. Read the DTC again. If any DTC occurs, disconnected
OBD MIL on 2. C4 solenoid
circuit locate the possible causes or contact
valve fault
1. Check the
the DTC.
2. Clear DTC.
P0771 valve short to home mode harness
power OBD MIL on 2. C4 solenoid
valve fault
1. Check the
the DTC.
2. Clear DTC.
value low OBD MIL on 2. C4 solenoid
valve fault
1. Check the
the DTC.
2. Clear DTC.
value high OBD MIL on 2. C4 solenoid
valve fault
the technician of the manufacturer. 21
the DTC.
Go to limp
P0770 home mode
OBD MIL on
1. Check the
Main oil cir- connection
the DTC.
cuit pressure Go to limp harness
2. Clear DTC. K50
P0748 solenoid valve home mode 2. Main oil circuit
3. Read the DTC again. If any DTC occurs, disconnected
short to ground OBD MIL on pressure
or open circuit solenoid valve
fault
1. Check the
connection
Main oil circuit the DTC.
Go to limp harness
pressure 2. Clear DTC.
P0746 home mode 2. Main oil circuit
solenoid valve 3. Read the DTC again. If any DTC occurs,
OBD MIL on pressure
short to power locate the possible causes or contact
solenoid valve
fault
TCU taking
measures
Main oil circuit the DTC. connection
Go to limp
pressure 2. Clear DTC. harness
P0747 home mode
solenoid valve 3. Read the DTC again. If any DTC occurs, 2. Main oil circuit
OBD MIL on
current low locate the possible causes or contact the pressure solenoid
technician of the manufacturer. valve fault
Main oil circuit the DTC. connection
Go to limp
pressure 2. Clear DTC. harness
P0749 home mode
solenoid valve 3. Read the DTC again. If any DTC occurs, 2. Main oil circuit
OBD MIL on
current high locate the possible causes or contact the pressure solenoid
Main oil circuit the DTC.
Go to limp Main oil circuit
pressure 2. Clear DTC.
P0745 home mode pressure solenoid
solenoid valve 3. Read the DTC again. If any DTC occurs,
OBD MIL on valve fault
fault locate the possible causes or contact the
Hydrau-
lic torque
the DTC. connection
converter Go to limp K41 dis-
P2759 solenoid home mode connec-
3. Read the DTC again. If any DTC occurs, 2. Hydraulic torque
valve short OBD MIL on ted
locate the possible causes or contact the converter solenoid
to ground or
open circuit
Hydraulic
the DTC. connection
torque con- Go to limp
P2761 verter sole- home mode
noid valve OBD MIL on
short to power
Hydraulic
the DTC. connection
current low
Hydraulic
the DTC. connection
current high
Hydraulic
the DTC.
torque con- Go to limp Hydraulic torque
2. Clear DTC.
P2756 verter sole- home mode converter solenoid
noid valve OBD MIL on valve fault
fault
21-25
TCU taking
measures
1. Connect the diagnostic meter and read the
DTC.
TCU Power Battery voltage
Transmission 2. Clear DTC.
P0880 supply voltage and harness
MIL on 3. Read the DTC again. If any DTC occurs,
is not true inspection
DTC.
is too high inspection
DTC.
is unstable inspection
DTC.
TCU Power Battery voltage Voltage
P0882 supply voltage and harness less than
is too low inspection 6V
DTC.
TCU abnormal Transmission 2. Clear DTC.
P1718
resetting MIL on 3. Read the DTC again. If any DTC occurs,
locate the possible causes or contact the 21
DTC.
TCU abnormal Transmission 2. Clear DTC.
P1719
resetting MIL on 3. Read the DTC again. If any DTC occurs,
TCU Internal
DTC.
chip tempe-
Transmission 2. Clear DTC. Check or replace
P0669 rature sensor
MIL on 3. Read the DTC again. If any DTC occurs, the TCU
signal value is
too high
TCU Internal
DTC.
chip tempe-
P0668 rature sensor
signal value is
too low
TCU taking
measures
TCU Internal
the DTC.
chip tempe-
P0666 rature sensor
signal value is
not true
the DTC.
TCU Internal
P062F chip EEPROM
failure
1. Connect the diagnostic meter and read K49
Shift lock low the DTC. 1. C h e c k t h e discon-
Go to limp
end line short 2. Clear DTC. connection nected
P0928 home mode
to the ground 3. Read the DTC again. If any DTC occurs, harness -K73
OBD MIL on
or open circuit locate the possible causes or contact the 2. Check the relay discon-
technician of the manufacturer. nected
the DTC. 1. C h e c k t h e
Shift lock low Go to limp
2. Clear DTC. connection
P0929 end line short home mode
3. Read the DTC again. If any DTC occurs, harness
to power OBD MIL on
locate the possible causes or contact the 2. Check the relay
Reverse lamp
the DTC. 1. C h e c k t h e
relay low end
2. Clear DTC. connection
P171A line short to OBD MIL on
3. Read the DTC again. If any DTC occurs, harness
the ground or
locate the possible causes or contact the 2. Check the relay
open circuit
Reverse lamp the DTC. 1. C h e c k t h e
relay low end 2. Clear DTC. connection
P171B OBD MIL on
line short to 3. Read the DTC again. If any DTC occurs, harness
power locate the possible causes or contact the 2. Check the relay
the DTC.
Go to limp
Output safety 2. Clear DTC. Check or replace
P1701 home mode
system fault 3. Read the DTC again. If any DTC occurs, the TCU
OBD MIL on
TCU Cycle the DTC.
Go to limp
clock signal 2. Clear DTC. Check or replace
P1702 home mode
value is too 3. Read the DTC again. If any DTC occurs, the TCU
OBD MIL on
low. locate the possible causes or contact the
21-27
TCU taking
measures
the DTC.
Sensor 9V
2. Clear DTC. Check the con-
P1703 power supply OBD MIL on
3. Read the DTC again. If any DTC occurs, nection harness
short to power
the DTC.
Sensor 5V Go to limp
2. Clear DTC. Check the con-
P1708 power supply home mode
3. Read the DTC again. If any DTC occurs, nection harness
short to power OBD MIL on
Sensor 9V the DTC.
power sup- 2. Clear DTC. Check the con-
P1704 OBD MIL on
ply short to 3. Read the DTC again. If any DTC occurs, nection harness
ground locate the possible causes or contact the
Sensor 5V the DTC.
Go to limp
power sup- 2. Clear DTC. Check the con-
P1709 home mode
ply short to 3. Read the DTC again. If any DTC occurs, nection harness
OBD MIL on
ground locate the possible causes or contact the
the DTC.
Go to limp
ROM check 2. Clear DTC. Check or replace
P0605 home mode
sum fault 3. Read the DTC again. If any DTC occurs, the TCU
OBD MIL on 21
the DTC.
Safety system Go to limp
2. Clear DTC. Check or replace
P1705 core detection home mode
3. Read the DTC again. If any DTC occurs, the TCU
fault OBD MIL on
Safety system the DTC.
Go to limp
response 2. Clear DTC. Check or replace
P1706 home mode
management 3. Read the DTC again. If any DTC occurs, the TCU
OBD MIL on
fault locate the possible causes or contact the
the DTC.
Go to limp
Watchdog 2. Clear DTC. Check or replace
P1707 home mode
hardware fault 3. Read the DTC again. If any DTC occurs, the TCU
OBD MIL on
TCU taking
measures
read the DTC.
Go to limp
2. Clear DTC. K87 or K65 short
home mode K87
U0073 CAN bus off 3. Read the DTC again. If any DTC circuit or open
OBD MIL K65
occurs, locate the possible causes circuit
on
manufacturer.
Transmission and engine

Disassembly
Transmission hydraulic torque 1. Drain the gearbox before removal;
converter and engine drive plate
connecting threaded hole 2. When dismantling the gearbox and engine,
you should remove the bolts that connect the
gearbox torque converter and the engine drive
plate before removing the bolts that connect the
gearbox and the engine;
3. During the disassembly process, ensure that the
torque converter does not come out;
4. Take care not to damage the gearbox peripheral
parts during the disassembly process;

connection guide pin hole
LFWX-6470-21009

Installation
Transmission hydraulic torque 1. When the gearbox and engine are assembled,
converter and engine drive plate
connecting threaded hole
first align the pin holes on both sides;
2. The locating pin hole in two locating pins must
be complete without any wear on the surface;
3. After alignment, mount the bolts in place that
connect the gearbox and the engine, and tighten
them with the specified torque; then mount the
bolts that connect the gearbox torque converter
and the engine drive plate.
4. When mounting the bolts that connect the
gearbox torque converter and the engine drive
plate, screw six screws clockwise and tighten
connection guide pin hole them; avoid misalignment of the connection hole
after a single screw is tightened to affect the
LFWX-6470-21009
mounting of the remaining bolts;
5. Before assembling the transmission and engine,
ensure to install the transmission hydraulic
torque converter in position without falling off.
If the converter falls off by accident, restore
the inspection according to the installation
requirements for the hydraulic torque converter
(refer to 4.8) or contact the after service person
of SHENGRUI;
6. During the mounting process, take care not to
damage the gearbox peripheral parts;
21-29
4.1 Speed sensor assembly

Replacement
1. Removal procedures: Unscrew the sensor
G4 speed fastening bolt and take down the speed sensor;
sensor
HOT 2. During the assembly, apply ATF to the sensor
O-ring, install the speed sensor, bring the sensor
end face to contact the mounting hole shell end
COLD face tightly, install the fastening bolts and tighten
them to 2.4 - 2.8Nm.
3. 3. Tools: 3mm hexagon socket sleeve,
ratchet wrench, torque wrench
Note:
1. When installing the sensor, apply the force
LFWX-6470-21006 evenly and do not exert too high force;
2. Before the installation, carefully check the
mounting hole surface for burr or knock and
handl it as needed;
3. Ensure no dust or foreign matter in particular
the moisture enters the transmission inside
so as to prevent the ATF contamination.
G4 speed 1. Removal procedures: Unscrew the sensor
sensor
fastening bolt and take down the speed sensor;
2. During the assembly, apply ATF to the sensor
face tightly, install the fastening bolts and tighten
3. Tools: 3mm hexagon socket sleeve, ratchet
wrench, torque wrench 21
Note:
LFWX-6470-21007 evenly and do not exert too high force;
2. Before the installation, carefully check the
handl it as needed;
G11 speed fastening bolt and take down the speed sensor;
sensor
2. During the assembly, apply ATF to the sensor
face tightly, install the fastening bolts and tighten
wrench, torque wrench
Note:
evenly and do not exert too high force;
LFWX-6470-21008 2. Before the installation, carefully check the
handl it as needed;
4.2 Gear sensor assembly

Remove and replace
fastening bolt and take down the speed sensor;
2. Assembly process: mount the position sensor, so
Gear sensor that the end surface of sensor is in close contact
with that of the mounting bracket. Mount the
fastening bolts and tighten them with a torque of
2-2.4Nm.
Note:
After installing the position sensor again, check
whether the gear shift is normal;
LFWX-6470-2010
4.3 Gear shift drag arm

Remove and replace
1. Removal procedures: Unscrew the tightening
nut, take down the gear shift drag arm assembly,
unscrew the fastening bolt and separate the gear
shift drag arm assembly from the magnetic force
sensing unit;
2. Assembly process
(a). Install magnetic induction device on gear shift
draw arm assembly, align it with location pin hole,
and install fastening bolt at the torque of 1.8-
2.2Nm;
(b). Install gear shift draw arm assembly, install
fastening nut and tighten it at the torque of 15-
18Nm;
3. Tools: 13MM hexagonal sleeve, 3MM hexagonal
sleeve, ratchet wrench, torque wrench
Note:
LFWX-6470-21011
After installing the gear shift drag arm assembly
again, check whether the gear shift is legible and the
gear display is normal.
4.4 Oil dipstick pipe assembly

Remove and replace
1. Removal procedures:
(a). Withdraw oil dipstick (Figure 1);
(b). Unscrew fastening bolt and take out oil dipstick
tube;
2. Assembly process
(a). After O-shaped ring is coated with ATF oil, install
oil dipstick tube in mounting hole, install fastening
bolt and tighten it by 15-18Nm of torque;
(b). Remove oil dipstick.
3. Tools: 13mm hexagon sleeve, ratchet wrench,
torque wrench
Note:
LFWX-6470-21012
After installing the gear shift drag arm assembly
again, check whether the gear shift is legible and the
gear display is normal.
21-31
4.5 Oil cooler

Remove and replace
(a). Unscrew 8 fastening bolts;
(b). Take down the oil cooler and two O-shaped
sealing rings;
2. Assembly process
(a). Install O-shaped ring coated with ATF oil in
mounting hole;
(b). Install oil cooler, install 8 fastening bolts in the
sequence of 1, 2, 3, 4, 5, 6,7 and 8.
Note:
LFWX-6470-21013
(a). Before oil cooler is removed, cooling water
pipe connected on the oil cooler should be
first removed when vehicle is cool, and the
oil cooler should be removed after cooling
liquid in water pipe is drained;
(b). Ensure no dust or foreign matter in particular
4.6 Oil cooler plug board

Remove and replace
(a). Remove oil cooler and sealing ring according to
Section 4.7; 21
(b). U n s c r e w f a s t e n i n g b o l t a n d t a k e d o w n
connecting plate and gasket;
2. Assembly process
(a). After smearing ATF oil on gasket, rotate it in
mounting hole, install connecting plate and
install fastening bolt, and tighten the fastening
bolt at 30-35Nm of torque;
(b). Install oil cooler according to Section 4.7;
3. Tools: 5mm hexagon socket sleeve, 14mm
hexagon socket sleeve, ratchet wrench, torque
wrench
Note:
LFWX-6470-21013
(a). Connecting plate or connecting plate shim
can be independently changed and oil cooler
can be removed without removing cooling
water pipe, but when vehicle is cool;
(b). Ensure no dust or foreign matter in particular
4.7 Axle shaft oil seal

Remove and replace
(a). Use slot type screwdriver to pry out oil seal;
2. Assembly process
(a). Apply proper amount of ATF to the oil seal inside and
outside ring face;
(b). Install the oil seal to the special tool, align it with the
mounting hole and drive it in the shell with the rubber
hammer;
3. Tools: slotted head screwdriver, oil seal special
assembly tool
Note:
(a). Apply the force uniform while installing the oil
seal so as to prevent the oil seal damage;
(b). Transmission oil seal and oil seal mounting hole
should be clean; during installation, make sure
there is no dust or foreign matter, and particularly
prevent water falling in transmission to cause
ATF oil pollution.
LFWX-6470-21014
(c). Do not apply other sealant and cementing agent
to the oil seal;
4.8 Hydraulic torque converter

Remove and replace
(a). Use special tools to symmetrically screw hydraulic
torque converter in hydraulic torque converter bolt
hole;
(b). Horizontally put forth effort by double hands, and
uniformly take out the hydraulic torque converter
from transmission in vertical direction;
2. Assembly process
(a). Smear right amount of ATF oil on the socket of
hydraulic torque converter;
(b). Use special tools to symmetrically screw hydraulic
torque converter in hydraulic torque converter bolt
hole;
(c). Horizontally and uniformly lower hydraulic torque
converter assembly by your hands, carefully thread
the torque converter rim through TC oil seal and
push it to the first limit position, slightly rotate the
hydraulic torque converter towards the transmission
until jack of hydraulic torque converter is plugged in
oil pump rotor drive tooth, and it can be felt hydraulic
torque converter inwards slides in;
(d). When hydraulic torque converter can be slightly
LFWX-6470-21015 rotated by hand, and its overall perimeter is uniformly
located on the permanent position in transmission, it
represents the hydraulic torque converter is installed
rightly. Through inspecting depth A ('A' = 26.7 mm)
shown in Figure, torque converter is ensured to be
totally located in oil pump rotor.
Note:
(a). Do not install special tools tightly, or torque converter may be damaged;
(b). If torque converter is not extracted horizontally, the inside of torque converter, lip of TC oil seal and oil
pump bushing may be damaged. The torque converter should be carefully withdrawn and should not
fall down;
(c). Put the hydraulic torque converter disassembled in an appropriate container;
(d). When hydraulic torque converter is installed, keep horizontal and give uniform force to avoid damage
of TC oil seal and bushing;
(e). Ilegal installation of torque converter may damage the inside of torque converter and the lip of TC oil
seal, so that the torque converter should be installed carefully and should not fall down;
(f). Hydraulic torque converter pump wheel shaft is directly connected with oil pump rotor. Pay attention to
keep gear and slot aligned in assembly,
21-33
4.9 TC oil seal

Remove and replace
(a). Remove hydraulic torque converter according to
Section 4.8;
(b). Use screwdriver to pry out the oil seal, and pry
out along the hollow place of the oil seal;
2. Assembly process
(a). Apply proper amount of ATF to the oil seal inside
and outside ring face;
(b). Install the oil seal to the special tool, align it with
the mounting hole and drive it in the shell with
the rubber hammer;
3. Tools: slotted head screwdriver, oil seal special
assembly tool
Note:
(a). Protect the input shaft and oil pump brass
bush against bruising while prying the oil
seal;
LFWX-6470-21016 (b). Apply the force uniform while installing the
oil seal so as to prevent the oil seal damage;
(c). Transmission oil seal and oil seal mounting
hole should be clean; during installation,
make sure there is no dust or foreign matter,
and particularly prevent water falling in
transmission to cause ATF oil pollution.
(d). Do not apply other sealant and cementing
agent to the oil seal;
4.10 Gear shift shaft oil seal

Replacement
1. Removal procedures: 21
(a). Remove gear shift draw arm according to
Section 4.3;
(b). Remove position sensor according to Section
4.2;
(c). Unscrew fastening bolt and remove position
sensor support (Figure 1);
(d). Remove speed limit coil spring pin (Figure 2);
(e). Pick out gear shift shaft oil seal by picker, do
not scratch the gear shift shaft surface and shell
mounting hole surface in disassembly (Figure 3);
2. Assembly process
(a). Apply proper amount of ATF to the oil seal inside
LFWX-6470-21017 and outside ring face;

(b). Install the oil seal to the special tool, align it with
the mounting hole and drive it in the shell with
the rubber hammer;
(c). Install
position
sensor support, install fastening bolt and fasten it at the torque of 5.5-6.5Nm;
(d). Install position sensor according to Section 4.2;
(e). Install gear shift draw arm according to Section 4.3;
Note:
(a). Protect the input shaft and oil pump brass bush against bruising while prying the oil
seal;
(b). Apply the force uniform while installing the oil seal so as to prevent the oil seal
damage;
(c). Transmission oil seal and oil seal mounting hole should be clean; during installation,
make sure there is no dust or foreign matter, and particularly prevent water falling in
transmission to cause ATF oil pollution.
(d). Do not apply other sealant and cementing agent to the oil seal;
4.11 Oil pan

Remove and replace
(a). Remove oil drain plug of oil pan to empty ATF
oil;
(b). Remove 18 fastening bolts;；
(c). Use screwdriver to remove the oil pan from the
transmission;
2. Assembly process
(a). Clean up the junction surface of transmission
and oil pan.
(b). Take down the oil pan from the upper gasket,
Sealing gasket
and clean up the oil pan;
(c). Take an intact new sealing gasket, install oil
Oil pan pans and fasten them in the sequence of 1-2-3-
4-5-6-7-8-9-10-11- 12-13-14-15-16-17-18-1-2,
with the fastening torque of 8-11Nm.
LFWX-6470-21018 wrench
Note:
(a). Do not scratch the junction plane of transmission housing and oil pan while prying the
oil pan with the slotted head screwdriver;
(b). Tighten the bolts to the required torque and do not apply the excessive force;
(c). If the oil pan junction plane is found salient or caved during the oil pan removal,
replace the oil pan in time;
(d). Ensure no dust or foreign matter in particular the moisture enters the transmission
inside so as to prevent the ATF contamination.
4.12 Filter
Remove and replace
1.
Removal procedures:
(a). Remove oil pan according to Section 4.11;
(b). Take out the filter assembly;
2. Assembly process
(a). Smear right amount of ATF oil on the sealing
ring of new filter, and install filter assembly (as
shown in Figure LFWX-6470-21020);
(b). Install oil pan according to Section 4.11;
???? wrench
Note:
(a). D o n o t s c r a t c h t h e j u n c t i o n p l a n e o f
transmission housing and oil pan while
LFWX-6470-21019 prying the oil pan with the slotted head
screwdriver;
(b). Tighten the bolts to the required torque and
do not apply the excessive force;
(c). If the oil pan junction plane is found salient
or caved during the oil pan removal, replace
the oil pan in time;
(d). Ensure no dust or foreign matter in particular
LFWX-6470-21020

21-35
4.13 Cable bracket

Remove and replace
(a). Remove stay wire card and stay wire;
(b). Unscrew 2 fastening bolts (as shown in Figure)
Cable and take down cable holder.
bracket 2. Assembly process
(a). Take a intact support, install fastening bolt and
fasten it at the torque of 23-25Nm;
(b). Install stay wire and stay wire card;
3. Tools: 13mm hexagon sleeve, ratchet wrench,
torque wrench
Note:
(a). When removing cable mount, do not damage
other spare parts;
(b). After installation, check whether stay
LFWX-6470-21021 wire should be adjusted or not, and check
whether gear display is right or not.
5.1 Hydraulic valve plate assembly

Removal
1.
Removal procedures:
(a).
Remove the oil pan and filter according to
Sections 4.11 and 4.12;
(b). Remove the fastening nut of cylinder-through
Cylinder- joints (through clockwise rotation), and push
through
terminal these joints in transmission;
tightening nut (c). Remove hexagon socket head screws of lower 21
valve plate assembly and transmission housing
(No.1, 2,3, 9 and 10 bolts are M6×75 bolts;
No.4, 5, 6, 7 and 8 bolts are M6×75 bolts)
(d). Take down valve plate assembly.
LFWX-6470-21022
2. Assembly process
(a). Install cylinder-through joints in mounting hole,
2 align it with limit groove hole, tighten retaining
nut (in case of rotating the nut clockwise, a
“clicking” sound can be heard when nut is
fastened); after the retaining nut is fastened,
hold the joint tightly and rotate it; if joint can not
be rotated, it represents the joint is installed in
place;
2 1
1
LFWX-6470-21023
2. Assembly process
(a). Align location pin hole and hand valve core
hole; install valve board assembly; fasten 10
connecting bolts at the torque of 9-11Nm;
Locating
pin
LFWX-6470-21024
(b). Install filter and oil pan according to Sections
4.12 and 4.11, and feed ATF oil.
Note:
(a). Keep valve plate assembly clean when it is
replaced, and prevent foreign matters falling
down;
(b). Fasten bolts according to regulated torque
strictly.
LFWX-6470-21025
5.2 Valve plate solenoid valve

Remove and replace
(a). Remove the valve plate assembly according to
section 4.11, 4.12 and 5.1;
18
9 8 (b). Remove solenoid valve harness connector;
(c). Remove the 6 fixing bolts (M4×10) of solenoid
10 valve separation blade, and take down the
17 separation blade;
6 7 4 15 (d). Pull out solenoid valve.
14 2. Assembly process
13
6 (a). Take a new solenoid valve, smear ATF oil on
12
5 O-shaped ring, and install the solenoid valve;
5 6 11
19 (b). Install solenoid valve separation blade, and
16 screw in connecting bolt at the torque of 3-4Nm.
(c). Install valve plate assembly according to
Sections 4.11, 4.12 and 5.1;
LFWX-6470-21026
Note:
(a). Keep solenoid valve clean when it is replaced, and prevent foreign matters falling
down;
(b). Strictly observe the torque requirement to tighten the bolts;
(c). 3Do not apply the excessive force while installing the solenoid valve; otherwise it will
damage2 the solenoid valve O-ring.
7
1
21-37
5.3 Temperature sensor

Remove and replace
(a). Remove the valve plate assembly according to
section 4.11, 4.12 and 5.1;
(b). Re mo v e t e mp e ra t u re s e n s o r s e p a r a t i o n
blade fixing bolt (M4×10) and take down the
separation blade;
(c). Pull out the temperature sensor;
(d). Remove temperature sensor wiring harness
connector.
Note:
(a). When sensor is replaced, keep it clean, and
prevent foreign matters falling down;
LFWX-6470-21027 (b). Strictly observe the torque requirement to
tighten the bolts;
(c). Do not apply the excessive force while
installing the solenoid valve; otherwise it will
damage the solenoid valve O-ring.
5.4 Hydraulic pressure sensing hole site distribution

21
Oil cooler side

LFWX-6470-21028
1 B1 Brake oil pressure 5 C4 clutch oil line pressure

2 C1 clutch oil line pressure 6 Main oil circuit pressure
3 C3 clutch oil line pressure 7 TC Control oil pipe pressure
4 C2 clutch oil line pressure
ATF level
Inspection
1. The gearbox oil scale is divided into H (hot

state) and C (cold state). To obtain accurate
measurement results, usually the gearbox oil
temperature should reach 75 ± 5 ℃ when
measured in the hot state;
2. Park the vehicle on the level ground, and pull
the hand brake handle;
3. When the engine is in in idle operation, depress
the brake pedal, pull the shift lever, repeat 2
cycles in the sequence of P-R-N-D-N-R-P, stop
at each gear for 3 seconds, place the shift lever
in “P” position, and flame out the engine;
4. Remove the oil scale, wipe and re-insert it;
5. Remove the oil scale and check the oil scale
position. If it is within the upper and lower scale
LFWX-6470-21029 line range, you can determine the oil level meets
the requirements;
6. Reinsert the oil gauge and mount it in place.
Oil dipstick scale level H（hot state）（80±5℃） C（cold state）（＜ 40℃）
Oil level Within the scale range Within the scale range
Transmission fluid state

Inspection
1. When the oil is black or turbid with a lot of powder, replace the gearbox oil and check the
vehicle status;
2. The oil is milky white, indicating that there is water going into the gearbox. Replace the
gearbox oil, and check the water inlet point;
3. When the transmission oil has a pungent smell, check the vehicle status, and determine if
you need to replace the transmission oil according to the inspection results;
Note:
1. Oil dipstick should be wiped by downless paper rather than cloth;
2. When the automatic gearbox oil level is above or below the specified range, discharge
or fill it in time until the oil level reaches the required range;
3. When discharging or filling ATF oil, keep it clean and keep dust or water going into the
gearbox to contaminate ATF oil.
Transmission fluid
Replacement
(a). Open compartment cover and withdraw oil level
indicator;

LFWX-6470-21030
21-39
(b). Jack up the vehicle by lifting machine, and

remove transmission fluid drain plugs 1 and 2;

Oil draining bolt 1
Oil draining bolt 2
LFWX-6470-21031
(c). Drain all transmission fluid;

LFWX-6470-21032
(d). Jack up the vehicle by lifting machine, and
remove transmission fluid drain plugs 1 and 2;

21

Oil draining bolt 1
Oil draining bolt 2
LFWX-6470-21031
(e). Remove oil filling bolts or feed new transmission

ATF oil from oil dipstick tube opening; (feed
transmission oil from two places, namely oil filler
and oil dipstick tube opening)
(f). When new transmission is changed, oil cannot
Oil filler bolt be drained, it is only necessary to directly feed
transmission oil according to requirements after
changing transmission.
(g). After machining, inspect oil level according to
Section 5.1;
Filler port filling point
LFWX-6470-21033
(h). Transmission maintenance period and fuel

Oil dipstick nozzle filling point quantity specification:
The gearbox should be maintained for the first
time after being in service for 2 years or 40,000
km. It is recommended to replace it after being
in service for 40,000 km. The filter should be
replaced during the first maintenance. The
specific fuel amount to be filled:
When replacing the filter: filling volume 5±0.2L
In normal maintenance: filling volume 4.5±0.2L
When replacing the new transmission: filling
volume 4.2±0.2L
LFWX-6470-21034 Note:
(a). While maintenance, change oil pan seal and
oil drain plug copper gasket
(b). Only use transmission special ATF oil
designated by manufacturer, and do not use
other oil;
(c). Oil dipstick should be wiped by downless paper rather than cloth;
(d). When transmission oil is filled, prevent its spilling on high temperature compartment,
or timely wipe it out.
8AT operating instructions

Gear introduction
(1). P refers to the park neutral. Engine can be started in park neutral. Park neutral can be
only engaged when a vehicle is totally parked. After switching to park neutral, ride wheels
are locked by mechanical device and cannot rotate. To move the shift lever out of the park
neutral, you need to depress the brake pedal and press down the lock button on the shift
lever handle;
(2). R refers to reverse gear. Vehicle can be reversed when switching to reverse gear; only when
vehicle is still and engine runs at idle speed, reverse gear can be switched; when gear lever
handle button is pressed down, the shift lever can be shifted in or out of the reverse gear;
(3). N refers to neutral position, power output of power assembly is interrupted at neutral position,
there is no power output, and engine can be started at this gear;
(4). D refers to forward gear, which will be engaged when vehicle is running; driver should well
control accelerator and brake at forward gear, and should accelerate to depress accelerator
and decelerate to put on the brake;
(5). M refers to manual mode; at this time, driver should manually push the gear lever to shift
up and shift down (+: shift up; -: shift down); at D gear, you can enter M mode only through
pushing the shift lever to right;
Precautions
(1). When your vehicle is started, you need to depress the brake pedal, and switch to P
gear or N gear;
(2). P gear can be only engaged when vehicle totally stops, but not when vehicle is
running, or driving safety will be endangered and vehicle will be seriously damaged;
P gear only has parking function, it can not take the place of hand brake. P gear and
hand brake should be both used to stop vehicle;
(3). N gear can be only used in short term parking; N gear of AT vehicle is different from
neutral gear of MT vehicle; AT vehicle is forbidden to slide at N gear, or internal
lubricating capacity of transmission will be lowered, which will cause damage of
transmission;
(4). When switching to R from D or switching to D from R, the vehicle should be stopped
and its brake pedal should be stepped down, such gear switch is forbidden when
vehicle is running;
21-41
8AT transmission function description

1. Forced downshift function:
8AT gearbox software has a mandatory downshift function, which means that, when the vehicle
throttle is suddenly increased running in high gear, , the gear will suddenly decrease by irregularly,
from gear 8 to gear 4 or from gear 7 to gear 5, thus reducing the speed and increasing the torque;
2. Tiptroic function:
The 8AT gearbox is a Tiptronic front-mounted gearbox that enables quick switching between
automatic (D) and manual (M) transmission, allowing you to enter the M-mode by simply pushing
the shift lever to the right. In order to drive safely and prevent the engine flameout, you need
to push to upshift in the M mode. In addition to human control, the computer control software
will automatically control downshift based on the actual vehicle and engine speed and other
information;
3. Safe home gear:
In the case of transmission computer controlled system malfunction, the transmission will establish
the gear depending on the hydraulic system solely to transmit the power and ensure the vehicle
can run to the nearest maintenance center or a safe place. In such a case, the transmission only
allows two gears, reverse gear (R) and drive gear 5th gear (D5). This is an emergency state and
cannot stay long.
Vehicle towing
If the AT vehicle towing is required due to the vehicle malfunction, use the correct method to
prevent the transmission damage.
1. The correct way to tow the car:
(a). Use professional flat truck to haul vehicle after it
is completely erected up;
(b). Use hard pulling to jack up driving wheel and
then make hauling;
(c). Use hard pulling to jack up non-driving wheel
and then use small flat car to jack up driving
wheel for hauling. 21
2. Incorrect way to tow the car:
(a). Use soft pulling to drag driving wheels;
(b). Use soft pulling to tow the non-driving wheels.
Note:
(a). When vehicle is towed, its ignition switch
should be switched to ACC state;
LFWX-6470-21035 (b). When towing a vehicle, transmission should
be switched to N gear;
(c). While hauling, hand brake and foot brake
should be released.
Electronic control schematic diagram and diagnosis operating

specification
Electronic control system
Battery power supply Gear shift solenoid valve B1
Ignition switch Gear shift solenoid valve C1
Gear shift solenoid valve C2
Oil pressure signal Gear shift solenoid valve C3
Oil temperature signal Gear shift solenoid valve C4

Transmission input speed
Torque converter locking solenoid valve
Transmission output speed

Main oil pressure control solenoid valve
Gear lever position signal
Manual mode switch

Gear up
Gear down Starter relay

Reverse lamp relay
Hand brake switch
Foot brake switch
Foot brake switch
Mode switch
CAN bus
Diagnose
LFWX-6470-21036
TCU pin diagram
LFWX-6470-21037
Terminals no. Function 95 Terminal number Function

1 Power supply 48
2 Power supply 49 Shift lock solenoid valve signal
21-43
Main oil circuit solenoid valve feed-

3 Ignition switch 50
back signal
4 Ground 51
5 Ground 52
6 Position sensor ground 53 Reverse lamp relay signal
7 Allowing start signal 54 G4 (gear 4) speed
8 55 G4 (clutch 4) speed
9 Output axis speed
10 57 Clock signal
11 Position sensor signal 58 Read-write signal
12 59
13 60
14 61 Hand brake signal
15 62
16 Snow mode signal 63
17 Sport mode signal 64 Chip select signal
18 Position sensor signal (verification) 65 CAN1(L)
19 66
20 67
21 Manual gear up 68
22 Foot brake signal 69
23 Manual gear down 70
24 71
25 72
26 73 Solenoid valve power supply 21
27 74
28 75
29 Solenoid valve power supply 76
30 Sensor power supply 77
31 Sensor power supply 78
32 79
33 Temperature sensor - 80
34 81
35 82
36 83
37 84
38 Main oil circuit temperature ＋ 85

39 86
40 87 CAN1(H)
Torque converter locking solenoid
41 88
valve feedback signal
42 89
B1 (brake 1) solenoid valve feed-
43 90
back signal
C1 (clutch 1) solenoid valve feed-
44 91
back signal
45 92
back signal
46 93 Sensor power supply
back signal
47 94 Position sensor power supply
back signal
Cylinder-through connector pin diagram
3
7
4
5 2
4
5
5
1 6
1-4
6
LFWX-6470-21038
1 Unused 19 B1 (brake 1) solenoid valve feedback signal

2 Unused 20 Solenoid valve power supply
3 Unused 21 C1 (clutch 1) solenoid valve feedback signal
5 Unused 23 C2 (clutch 2) solenoid valve feedback signal
7 Unused 25 Main oil circuit temperature sensor
8 Unused 26 Temperature sensor ground
9 Unused 27 Position sensor power supply
10 Unused 28 Position sensor ground
Torque converter locking so-
11 29 Clock signal
lenoid valve feedback signal
21-45
12 Solenoid valve power supply 30 Read-write signal

Main oil circuit solenoid valve feed-
13 31 Chip select signal
back signal
14 Solenoid valve power supply 32 Unused
15 33 Unused
back signal
17 35 Unused
back signal
Sensor description
Output shaft (G11) speed sensor
Output speed
Speed sensor
power supply
LFWX-6470-21039
C4/G4 speed sensor
C4/G4 G4 speed
21
Speed sensor power

supply
LFWX-6470-21040
Gear sensor
1. Position sensor signal

(verification)
2. Position sensor signal
3. Position sensor power
supply
4. Position sensor ground
LFWX-6470-21041
TCU diagnostic function

Diagnostic
Item Description
function
With the vehicle in normal running state, TCU will monitor
Self-diagnostic the real-time input/output and inside status. Once the fault
program occurs, TCU will save DTC in the memory. In addition, it
decides to illuminate MIL or not according to the fault grade.
TCU diagnose
During the trouble vehicle maintenance, the maintenance
Exterior diagnostic man should communicate with the vehicle ECM through the
program fault diagnostic meter to read the DTC stored in TCU and
quickly locate the fault and repair.
In the case of transmission OBD fault, TCU will send fault
MIL request to illuminate MIL. (illuminating the MIL corresponding
to the fault)
Fault indication In the case of transmission non-OBD fault, TCU will send fault
request to illuminate AT MIL. The request falls into two types:
Transmission MIL
1) General failure will not activate safe home mode.
2) Failure of safe home mode activation.
Transmission -Transmission (1.8L 2.0L-5MT) 21-a
Transmission
Transmission��1
Preparations��1
Precautions��3
Structure of the transmission��4
Overview��4
Gear shift mechanism��4
Component drawing��5
Transmission structural sketch��6
Power transmission route��7
Transmission inspection��7
Main performance testing
requirements��8
List of fault symptoms��8
Transmission lubricating oil��9
Replacement��9
Transmission assembly��10
21
Replacement��10
Transmission assembly�� 11
Iuput shaft assembly��22
Disassembly��22
Output shaft��25
Output shaft assembly��26
Disassembly��26
Inspection��31
Check and adjustment
of main components��31
Transmission Operating
Mechanism��32
Replacement��33
21-b Transmission -Transmission (1.8L 2.0L-5MT)
Transmission -Transmission (1.8L 2.0L-5MT) 21-1
Transmission
Preparations
1. Special tools
Used to pull out the input fifth

1 Puller
gear hub and fifth output gear
1: Pressing-in locating Get the inner ring "5" from the

sleeve front bearing of input shaft; and
2: Input shift get the fourth input gear, the inner
2
disassembling tooling 1 ring from the rear bearing of input
3: Input shift shaft, and the fourth output gear
disassembling tooling 2 gasket
Press the inner ring into the rear 21

Input shift disassembling bearing of the input shaft; and
3
tooling press the fourth output gear shaft
sleeve
Press the first and second

gear synchronizer hubs and
1: Angle iron "1"
corresponding gear sleeves,
4 2: Installation of locating
the gear output shaft of the first
sleeve "2"
output gear, intermediate bearing,
and bearing pressure plate
Transmission housing oil Used to erect transmission

5
seal erecting tools housing oil seals
21-2 Transmission -Transmission (1.8L 2.0L-5MT)
Clutch housing oil seal For installing the clutch housing

6
mounting tool oil seal

2 Bar magnet
Maintenance data
Transmission model LD525MFA26
Transmission type 5MT

1 gear 3.889
2 gear 2.118
3 gear 1.458
5 gear 0.814
R gear 3.6
Final drive 4.313
Gear oil capacity 2±0.1L

Item N·m
Reverse gear swing arm bracket bolt 23 ± 1.5
Connecting bolts for transmission housing and clutch housing (18 PCS) 23 ± 1.5
Cable bracket bolt (3 PCS) 23 ± 1.5
Output plate nut (4 PCS) 25~28
Transmission housing end face bolt 20±1.5
Release fork support beam bolt 20±1.5 21

Gear shift box bolt 20±1.5
Counterweight with pan head nut 25~28
Output lock bolt 105±3
5th gear shift fork guide pin bolt 23±1.5
Input 5th/reverse gear shift guide block bolt 20±1.5N
End cover bolt 10±1
Oil filler and oil drain plug 25±1.5
Precautions
(a). Compressed air tools can cause dust and other particles to fly out, resulting in damage to the
eyes; so you should wear goggles in the use of compressed air.
(b). Check and make sure that all parts are cleaned before assembling the transmission (except
rubber parts and gaskets).
(c). Replace all disposable parts (all kinds of oil seals, spring pins, O seals, etc.).
(d). When sealing elements are installed, it is necessary to clean the residual sealant on the
bonding surface.
(e). To ensure that the sealing elements are oil-tight, the assembly should be completed within 3
(f). The removed rings, bearings, oil covers, etc. cannot be reused.
(g). All bolts and nuts must be tightened in accordance with the specified tightening torque.
(h). When installing the moving parts, apply some gear oil to these moving places, and then use
(i). When the bearings are installed, do not use any rolling body to transfer the pressure. Press fit
each oil seal without titling.
(g). When the transmission is working normally, there shall be no leakage of lubricating oil.
(k). Old clamping rings must be replaced with new ones, and the new clamping rings installed in
(l). The bolts and nuts used to fix the end caps, housings or brackets shall be loosened or

(a). First-level maintenance
• In first-level maintenance, we should check the lubricant level which should be aligned to
the lower edge of the filler port; add lubricant when the level is low, because too low level
may cause poor lubrication and burn the bearings and gears, while too high oil level may
cause overheating and oil spills.
• In first-level maintenance, we should remove the ventilation valve for inspection and
cleaning, because ventilation valve blockage will result in too high internal pressure and
thus transmission fluid leakage.
(b). Level II maintenance
• In the first second-level maintenance for a new car, replace the transmission lubricant and
clean the transmission with kerosene.
(c). Level III maintenance
replacement of oil.

Overview
Engine LFB479Q transmission can supply 5 drive gears and 1 reverse gear through 3
synchronizers and 3 shafts - input shaft, countershaft and reverse gear shaft. All the gears are
constant meshing type except the reverse gear combining one constant meshing gear and one
slide gear.
The first and second gears' synchronizer is mounted on the output shaft and interlocked with the
first or second gear of the output shaft; the third and fourth gears' synchronizer is also mounted on
the output shaft and interlocked with the third or fourth gear of the output shaft.
The fifth gear synchronizer on the input shaft is meshed with the fifth gear mounted on the input shaft.
The output shaft drives the main reduction gear and the differential device to force the front wheel
driving shaft.

The movement of gear shift lever drives the transmission shaft and the shift shaft via the
transmission control shaft, then driving the transmission, shift lever, and fork via the transmission
arm and yoke. The shift mechanism contains shift box assembly, rear end cover of shift box,
shift shaft, shift positioning seat, reverse gear switch, shift rocker assembly, transposition rocker
assembly, transposition rocker clip, transposition pin bushes 1 and 2, and balancing weight tape
reel nuts; the internal shift mechanism contains reverse-gear rocker bracket assembly, shifting fork
assembly, fifth-gear shifting fork, fifth reverse gear shifting fork guide block and bolts.
In the shift mechanism, when shift rocker assembly and transposition rocker assembly change their
positions, the shift pendulum in shift shaft assembly drives the shifting fork to realize the conversion
between "R", "N" and "gears 1~5". As shown below:
Gear shift fork assembly Shift mechanism
LFWX-6470-21032
Component drawing
2
21
LFWX-6470-21031
1 Transmission assembly 2 Gear mechanism

Transmission structural sketch
2
3
4
5
LFWX-6470-21026
1 Input shaft 4 Transmission housing
2 Clutch housing 5 Differential
3 Reverse gear shaft

Power transmission route
LFWX-6470-21030
General inspection
the damaged parts.
3. Start the engine, step on the clutch, check the transmission the gears for smoothness, 21
 Tips:

LFWX-6470-21028
Fault diagnosis
Main performance testing requirements
1. Manual shift order: successive upshift and downshift.
2. Check whether the gear shift is flexible without seizing, disorder or gear skip; the gear shift
3. Reversing light switch assembly: the reversing lights should be on in the reverse position and
4. Neutral gear switch:
Start function: the starter cannot be connected and the engine cannot start unless the neutral
gear is engaged.
Signal function: to supply signal to ECU and inform ECU of engine under no load currently.
Then the on-board computer conrtrols the engine and transmission to work under the optimal
state through this signal.

Symptom Possible point of failure Recommended Measures
Manually straighten the gear shift shaft in
Gear shift shaft severe wear and deformation
the case of shaft bending or abrasion
Gear shift rocker arm severe wear and
Replace the gear shift rocker arm
deformation
The excessive axial play of gear is mainly Replace the gear gasket of the
caused by the severe gear gasket abrasion corresponding gear
In the case of fork bending deflection,
Gear shift fork abrasion or deformation straighten it by hand; in the case of severe
wear, replace the gear shift fork assembly
Gear off Fork support pole or bearing wear or
Replace the worn or damaged parts
deformation
Synchronizer gear hub, sleeve or gear ring Replace the wearing parts in the case of
abrasion gear off
After the adjustment, the transmission does not
Turn the lever to neutral gear and adjust the
return to neutral or the adjusting mechanism is
cable length
loose
The connection of engine and transmission
to the entire vehicle is too loose or the gap Adjust the gap
adjustment is improper
Transmission oil level low or dirty Fill oil or change the gear oil
Replace the gear or corresponding gear
Excessive axial play of gear
gasket
Replace the gear if the gear backlash
Transmission noise
exceeds the limit. The standard backlash is
high or abnormal Gear severe wear or gear teeth fracture
0.1mm and the use limit is 0.3mm; replace
noise
the gear if the gear teeth break
Synchronizer gear ring abrasion or external
Replace the gear ring
tooth fracture
Bearing damage or wear Replace the bearing
Gear shift shaft or gear shift fork deformation

Replace the worn or deformed parts
or uneven abrasion
Excessive taper abrasion of synchronizer gear
ring; too small clearance of gear ring big end
Replace the new gear ring
face and gear meshing teeth end face; the
wear limit (the minimum clearance) is 0.5mm
Difficult gear shift
Synchronizer spring damage Replace the synchronizer spring
Sleeve teeth end abrasion or gear ring key
groove widened due to abrasion
Shift mechanism middle gear shift rocker arm
abrasion
Oen is the oil plug tightening torque is less
Transmission than specified value. In such a case, check
assembly oil the tightening torque and tighten the plug if
leak (Note: when Oil leak at the oil filler and oil drain plug
required; the other one is the fitting deviation
performing the is high or the threads are damaged. In such
maintenance work a case, replace the related part
with the vehicle
Replace the sealing element and operate
jacked, check the Sealing element oil leak
correctly
transmission for oil
leak as well) Check the connecting bolt and tighten it to
Case body junction plane oil leak
the required torque
Transmission lubricating oil

Replacement
1. Discharge the transmission oil

(a). Shut down the engine to cool down and then jack
up the vehicle.
(b). Collect the lubricating oil under the transmission 21
with a container.
(c). Remove transmission lubricating oil drain plug.
(d). Slowly remove the oil drain screw plug and drain
the transmission lubricating oil.
LFWX-6470-21027
2. Fill the transmission lubricating oil

(a). Use transmission lubricating oil filler to fill
transmission lubricating oil until it slowly spills
over the filler.
(b). Install transmission lubricating oil filler plug and
fasten it.
Torque:30 ~40 N•m
LFWX-6470-21029
Transmission assembly
Replacement
1. Remove the transmission assembly

(a). Lift up the vehicle.
(b). Discharge the transmission oil.
(c). Remove wiring harness connector connected
with transmission.
(d). Remove front wheels and transmission shaft.
(See 41 – Transmission Shaft, Transmission
Shaft Assembly, Replacement)
(e). Remove gear shifting and selecting flexible shaft
of transmission end.
LFWX-6470-21034
(f). Remove clutch operation hose.
LFWX-6470-21025
(g). Remove connecting bolts/nuts of front, rear

and left engine mounting as well as engine and
transmission assembly.
LFWX-6470-21072
(h). Remove 8 connecting bolts of transmission

and engine as well as 2 bolts connected with
1 dust guard plate. The Figure only displays bolt
1 position.
5 Mounting torque:  64 N·m
 23 N·m
2
 37 N·m
5  47 N·m
2
 Dust board 9 N·m
3
4
LFWX-6470-21071
4
Transmission assembly
Disassembly
1. Dismantle the gearbox

(a). Drain gear oil.
(b). Remove 5 end cap bolts M7×20“1”, end cap
“2” and end cap gasket “3” of transmission, and
switch the transmission to neutral gear;
21
LFWX-6470-21024
(c). Take out the adjusting and fastening bolt “7” of

the fifth speed gear shifting fork; take down the
fifth speed gear shifting guide block “6”, remove
the fixing bolt “4” of the fifth speed gear shifting
fork location pin, withdraw shifting fork location
pin “5”, and take down the fifth speed gear
shifting fork “8”.
(d). Remove the fifth speed gear synchronizer spring
“2”, unplug the fifth speed gear sleeve “3”, and
take down the fifth speed gear synchronizer
sliding block “1”.
LFWX-6470-21023
(e). Reinstall the fifth speed gear synchronizer gear

sleeve “4” on the fifth speed gear synchronizer
gear hub; if fifth speed gear shifting fork bolt
“4” is turned down, the fifth speed gear can be
engaged.
(f). Use gear shift rock arm assembly “3” to the
switch the transmission to the third speed gear;
at this time the transmission is simultaneously
switched to the third and the fifth speed gears,
and the transmission is locked.
(g). Use pneumatic wrench to remove the output
shaft lock bolt “1” on the fifth speed gear end
surfaces on input shaft and output shaft.
LFWX-6470-21022
(h). Use special tool (LD525 fifth speed gear puller) “1”
and 10mm nut “2” to plug out the fifth speed gear
synchronizer gear hub “3” and output shaft fifth
speed gear “6”.
LFWX-6470-21021
(i). Remove three bolts “1”, “2” and “3” of reverse

stop block.
LFWX-6470-21020
(j). First, take down gear shift rock arm clamp

“1”, remove gear shift rock arm “4”, then use
pneumatic wrench to remove balance weight tape
disk nut “6”; take down “9” backup light switch
from “8” backup light line support assembly, and
take down the balancing weight “3”.
LFWX-6470-21019
(k). Regulate the gear shaft to neutral gear, remove

the gear shift box bolt “1” and remove the gear
shift box assembly “2” from transmission housing.
21
LFWX-6470-21018
(l). Remove bolt “1” and rear locating seat “3” of gear
shift box, and then remove 4 fork support beams
“4” and 4 support beam bolts “3”.
LFWX-6470-21017
(m). Remove release bearing “2” and release fork “1”

and remove release fork jump ring “3”.
LFWX-6470-21016
(n). Remove 8 connecting bolts “1” for fixing

transmission housing from clutch housing, and
remove 4 output disk nuts “2”.
LFWX-6470-21015
(o). Re mo v e 1 0 c o n n e c tin g b o lts “1 ” in fi x e d

differential area from transmission housing, take
down oil pipe support “2” and remove one stay
wire support bolt “2”.
(p). Remove the gearbox housing, and take care not
to damage the sealing surface.
LFWX-6470-21014
(q). Remove the selector fork assembly “1”, remove

the reverse swing arm bracket “4”, and remove
the reverse stop block “2”.
LFWX-6470-21013
(r). Remove the reverse gear shaft “3”, reverse gear

“2” and “1”, and remove the input shaft assembly
“4” and output shaft assembly “5”. Remove the
differential assembly “6”.
21
LFWX-6470-21012
LFWX-6470-21050
2. Combination gearbox assembly

(a). Install differential assembly, input shaft assembly
and output shaft assembly in clutch housing,
and then install reverse gear (1)“6”, keep the
end surface of reverse gear (1) with boss to rear
1.
2.
Differential assembly
Output plate O-ring
6. Reverse gear assembly
bracket assembly
cover, and then install reverse gear shaft, reverse
3.
4.
Output shaft assembly
Reverse gear rear thrust
bearing
bracket bolt
8. Input shaft assembly
11. Reverse gear front thrust
bearing
12. Clutch housing assembly
gear (2)“6” and reverse stop block.
Note:
LFWX-6470-21049 Replace the output intermediate bearing plate O-ring
every time
(b). As shown in the Figure, use height gauge to

measure out B1, B2, C1 and C2, and then
calculate out the height according to gasket
selection formula.
Differential bearing adjusting shim S2:
Shim selection formulaB1-B2+0.1≤S1 ≤B1-B2+0.2);
Input shaft bearing adjusting shim thickness S3:
Shim selection formula C1-C2-0.1≤S1≤C1-C2-0.01
LFWX-6470-21051
LFWX-6470-21053
(c). Install reverse gear swing arm support assembly;

sleeve swing arm support on reverse gear (2),
make reverse gear (2) at neutral gear, make the
location boss on support aligned with the location
hole on shell, and fasten the reverse gear swing
arm support bolt “2” according to regulations.
1. Differential assembly 6. Reverse gear assembly 10. Reverse gear swing arm
2. Output plate O-ring 7. Reverse gear swing arm bracket assembly
3. Output shaft assembly bracket bolt 11. Reverse gear front thrust
4. Reverse gear rear thrust
bearing
bearing
12. Clutch housing assembly Torque:23±1.5N·m
LFWX-6470-21052
(d). Install gear shifting fork assembly “1”, pay

attention to install the shifting fork in gear sleeve
slot, wherein reverse fork should be installed on
reverse stop block.
(e). Remove the sealant residue between the clutch
housing and transmission housing sealing
surfaces, apply the new sealant evenly by the
proper thickness and check whether the locating
ring is correct.

2. Reverse gear bracket assembly bolt
LFWX-6470-21054
(f). Install transmission housing, install connecting

bolt “1” between the transmission housing
and the clutch housing, gradually fasten to the
regulated value in a crossing way according to
regulations, and install oil pipe support “2” and
tighten stay wire support bolt “3” according to
regulations.
Torque: 23±1.5N·m

2. Oil pipe bracket
3. Tie wire bracket bolt M8 × 35
LFWX-6470-21055
(g). Install reverse stop block lock bolt “2”,

install converter housing end bolt “3”, install
reverse stop block lock bolt “1”, and tighten
3 bolts on reverse stop block according to
regulations.
Torque: 20±1.5N·m

block locking bolt (1)
M8 × 38
block locking bolt M8
× 32 21
3. Variable housing end
bolt M8 × 25
LFWX-6470-21056
(h). Install four fork support beams “2” (another

two in the opposite) of gear shifting fork
assembly; change a new O-shaped ring
on support beams; use screwdriver to
turn the gear shifting fork assembly until
corresponding fork support beams can
be installed in place; install fork support
beam bolt “3” and tighten it according to
regulations.
Torque:20±1.5N·m
(i). After coating sealant on the sealing surface
of rear locating seat “4” of gear shift box,
1. Shift box bolts M8 × 25 (2) 3. Fork support bolts M8 × 22 (4 pieces)
install the gear shift box on the converter
2. Shifting fork support column (4) 4. Gear shift case rear positioning seat housing.
LFWX-6470-21057
(j). Switch the gear shift box assembly to

neutral gear state; coat sealant on the
sealing surface of the gear shift box
assembly and install it on transmission
assembly; pay attention to the installation
direction of the gear shift box assembly
“3”, pay attention to install backup light line
support “2” and fasten gear shift box bolt;
and pay attention to clamp the backup light
switch “1” in backup light line support hook.
1. Reverse lamp switch

2. Reverse lamp wire bracket assembly
LFWX-6470-21058
(k). Install gear shift rock arm assembly “1”,

install tape disk nut “2”, install gear shift
rock arm assembly “3” and use clamp “4” to
clamp the gear shift rock arm pin.

2. Fitted with the weight block with disk nut
3. Change the rocker clip
4. Transposition rocker arm assembly
LFWX-6470-21059
(l). Put the transmission flatly, install 8 off-shell

connecting bolts “2”, and gradually fasten
them to regulated value in a crossing way
according to regulations, and finally fasten 4
output pressure plate nuts “3” of output neck
bearing pressure plate along diagonal line.
Torque:23±1.5N·m (bolt)
/25~28N·m (nut)

2. Output pressure plate nuts (4 pieces)
3. Separation fork support column
LFWX-6470-21060
(m). Before installing release fork “1” and release

bearing “2”, first install release fork jump
sring and coat lubricating grease on the
middle ball-shaped hole. Then install jump
spring “3” on release fork support beam.
1. Separation fork
2. Release bearing
3. Separation fork circlip
LFWX-6470-21061
(n). Heat the fifth speed gear

on output shaft to 100ºC,
use press-fitting locating
sleeve “1” to install the
fifth speed gear of output
shaft; and gear slot
points to transmission
housing as “arrow
direction”.
21
LFWX-6470-21062
(o). T h e f i f t h s p e e d g e a r
synchronizer gear hub,
gear sleeve and sliding
block are assembled.
The end face of
synchronizer gear hub
inner race with loss, the
end face of gear sleeve
“2” with sharp tooth
“arrow” and “arrow B” on
one side of sliding block
with gap should face
to the same direction;
synchronizer spring must
LFWX-6470-21063 be installed in the slot of
the synchronizer sliding
block, and tail end bent
to hook shape should be
always far away from the
synchronizer.
(p). M ount the input five-speed gear assembly,

five-speed needle bearing and five-gear
synchronizer ring on the input shaft. Mount
the input five-speed synchronizer assembly.
Note that the end of gear hub inner ring with
boss (Arrow 2) and the end of gear sleeve
with pointed tooth (Arrow 1) should face the
housing.
LFWX-6470-21064
1. Pressing-in locating sleeve (q). Mount the five-gear synchronizer gear hub and
gear sleeve on the input shaft with the press-
mounting locating sleeve “1”. Note that the
notch of the synchronizer ring is aligned with
the boss position. Use a hammer to knock
the five-gear synchronizer gear hub and gear
sleeve into the input shaft. Also note that the
notch of the synchronizer ring is aligned with
the boss position.
LFWX-6470-21065
(r). Engage the five-gear sleeve directly into the

fifth gear, and engage the gearbox assembly
into the third gear with gearbox assembly.
With the gearbox in the third and fifth gear
simultaneously, the gearbox will be locked.
1. Output shaft locking bolt (2)

2. Locking bolt gaskets (2 pieces)
LFWX-6470-21066
4. 5th gear synchronizer sleeve
(s). Mount the locking bolt washer and the locking

bolts of the five-gear gear on top of the input
and output shaft. Tighten these two bolts with
a torque wrench. Pay attention to the mounting
position of the locking bolt washer (cone angle
up).
Torque: 105±3N·m
LFWX-6470-21067
(t). Put the gearbox in neutral position, and mount

the five-speed selector fork “1”. Tighten the
locating pin bolts of five-speed selector fork
(arrow) and input five-speed shift guide block
bolt “2”.
Torque:23±1.5N·m (bolt“1”)
/20±1.5N·m(bolt“2”)
LFWX-6470-21068
21
(u). Adjust the mounting position of input five-speed

selector fork assembly, engage the fifth gear,
and loosen the bolt “1”. Press the fifth gear
sleeve and the fork opening in the direction of
the arrow, and re-tighten the bolt “1”. Criteria: a
0.2mm-thick feeler shall not slide between the
fifth gear sleeve and the input fifth gear. Adjust
it again if necessary.
The gearbox is engaged in the neutral gear
again, and the synchronizer ring must be
moving freely.
LFWX-6470-21069
(v). The gearbox should be free from failure when

engaged in any gear. Mount the end cover
seal gasket “3”, rear end cover “2” and the
peripheral parts of the gearbox assembly as
required.
Torque: 10±1N·m
(w).Check the gearbox assembly for un-mounted
parts and untightened bolts. After ensure no
item is missed, test the transmission for leak
1. End panel bolts tightness to ensure the transmission assembly
M7 × 20 (5 pieces)
2. End cover
is free of oil leak.
3. End cover gasket
LFWX-6470-21070
Please note the following items during the installation:

• Clean the dirt on the clutch housing and the bearing housing surface, apply the sealant evenly
to the mating surface, gently press it with the rubber hammer, and tighten it with bolts;
• Clean the dirt on the control cover assembly and the bearing housing surface, apply the
sealant evenly to the mating surface, gently press it with the rubber hammer, and tighten it with
bolts;
• Clean the dirt on the control cover assembly and the bearing housing surface, apply the
sealant evenly to the mating surface, gently press it with the rubber hammer, and tighten it with
bolts;
• Check the input shaft for rotation when engaging in various gears and check whether the
reverse switch has a signal when the reverse gear is engaged.
Iuput shaft assembly

Disassembly
1. Dismantle the input shaft assembly

(a). Use shaft disassembly tooling “1”,“2”,“3” and
other special tools to press out front bearing inner
race “5” of input shaft;
Note:
The collar cannot be reused.
If the input shaft front bearing is intact, do not
remove it.
LFWX-6470-21011
(b). Use bearing remove tooling “1” to press out input

fourth speed gear, input-shaft rear bearing inner
race and output fourth speed gear washer.
LFWX-6470-21010
(c). Use special tool and hydraulic machine to press

out input third speed gear “2”, and take out input
third-fourth speed gear spacer “3”.
LFWX-6470-21009
21
2. Assemble the input shaft assembly
(a). Use special tools “2” to press in third speed gear;
the end surface of the gear inner race boss faces
to the fourth speed gear in installation.
LFWX-6470-21008
(b). Install the input third-fourth speed gear spacer

and then use special tool “1” to press in the fourth
speed gear. When the end face of the gear inner
race with boss is installed, it should face to the
third speed gear.
LFWX-6470-21007
(c). Use special tool “1” to press in rear bearing inner

race of input shaft.
LFWX-6470-21007
(d). Install output fourth speed gear gasket and press

it in output fourth speed gear shaft sleeve by
special tools.
LFWX-6470-21006
Output shaft
Component drawing
LFWX-6470-21005
21
1 Clutch housing 19 Output shaft 2nd gear assembly
Output shaft front bearing

2 20 2nd gear needle bearing
washer
3 Output shaft front bearing 21 Output 2nd gear washer
4 Output shaft 22 Output 3rd gear assembly
5 Output shaft middle bearing 23 Output 3rd gear shaft sleeve
Output intermediate bearing

6 24 3rd gear needle bearing
plate
7 Output 1st gear washer 25 Output 3rd gear gear ring
8 Output shaft 1st gear assembly 26 Output 3rd/4th gear synchronizer assembly
9 1st gear needle bearing 27 Output 3rd/4th gear synchronizer assembly
10 1st gear internal gear 28 4th gear needle bearing
11 1st gear intermediate ring 29 Output 3rd gear
12 1st gear external gear ring 30 Output shaft 4th gear assembly
Output 1st/2nd gear

13 31 Output 4th gear washer
synchronizer assembly
Output 1st/2nd gear

14 32 Output shaft rear bearing
synchronizer collar
Output 2nd gear roller pin

15 33 Transmission housing
spacer ring
16 1st gear internal gear 34 Output shaft 5th gear
17 1st gear intermediate ring 35 Locking bolt shim
18 1st gear external gear ring 36 Output shaft lock bolt
Output shaft assembly

Disassembly
1. Disassemble the output shaft

(a). Use special tools “1” and “2” to press out input
second speed gear and third speed gear as
well as third-fourth speed gear synchronizer
assembly, output fourth speed gear, output fourth
speed gear gasket (flat gasket) and output rear
bearing inner race.
1. Shaft removal tooling 1 (2) 2. Pressing-in locating sleeve
LFWX-6470-21004
(b). Use circlip pliers to remove the first-second

speed gear synchronizer collars.
1. Circlip plier
LFWX-6470-21003
(c). Use angle iron “1” and special tooling “2” to press
out the first-second speed gear sleeve of the first-
second speed gear synchronizer gear hub, as
well as neck bearing pressure plate of output first
speed gear output shaft.
1. Edge iron (2) 2. Pressing-in locating sleeve
LFWX-6470-21002
1. Assemble the output shaft

(a). Check the wear patterns of the first-second speed
below;
Clearance -a- Installation Wear limit
dimension
First/second gear 0.75-1.25mm 0.3mm
21
LFWX-6470-21004
(b). Then put the internal tooth ring, intermediate ring

and outer tooth ring of synchronizer on the
circular conical surface of shifting gear, and use
feeler gauge to measure clearance size –a-, and
see standards as the Table below.
Installation Wear
Clearance -a-
dimension limit
First/second gear 1.25-1.85mm 0.5mm
LFWX-6470-21039
(c). Check the wear patterns of the third-fourth speed

below;
Third/fourth
1-1.7mm 0.5mm
gear
LFWX-6470-21040
(d). Check the wear pattern of the fifth speed gear

synchronizing rings; put inner synchronizing rings
on the circular conical surface of shifting gear,
and use feeler gage to measure clearance size –
a-, and see standard size in the Table below;
Fifth gear 1-1.7mm 0.5mm
LFWX-6470-21040
(e). Place the output first gear washer with the boss
facing the bearing inner race.
Install the 1st gear needle bearing, output 1st
gear and synchronizer gear ring and align the
synchronizer gear ring notch with the boss
position.
LFWX-6470-21041
(f). Install the first-second speed gear synchronizer

gear hub, and then install first-second speed gear
sleeves. One side “A” of the gear sleeve outer
face with reverse gear face to the second speed
gear, and the installation site of synchronizing
ring should be noticed.
1. First/second gear synchronizer spring

2. First/second gear synchronizer sleeve
3. First/second gear synchronizer hub
4. First/second gear synchronizer sliding block
LFWX-6470-21042
(g). Press in the 1st/2nd gear synchronizer gear

hub with the special tool. Note to align the 1st
gear synchronizer gear ring notch with the
boss position and support the output shaft
with the positioning seat 2.
21
2. Positioning seat
LFWX-6470-21043
(h). Use circlip pliers to install input first-second

speed gear synchronizer collars on the end
face of the first-second speed gear hub, and
then put in the output second speed gear
roller retainer ring.
Tips:
Install the 2nd gear synchronizer gear ring and
needle bearing as well as the 2nd gear and align
the synchronizer gear ring notch with the boss
position.
LFWX-6470-21044
(i). Install output second speed gear washer

(plain washer) on the end face of the second
speed gear, and use special tools to press in
output third speed gear shaft sleeve.
(j). Install the output 3rd gear assembly, 2
3rd gear needle bearings and 3rd gear
synchronizer gear ring.

2. Positioning seat
LFWX-6470-21045
(k). Use press-fitting locating sleeve “3” to press in

third-fourth speed gear synchronizer assembly,
and pay attention to align the gap of
synchronizing ring with boss position.

2. Positioning seat
LFWX-6470-21046
(l). Use press-fitting locating sleeve to press in

output fourth speed gear shaft sleeve.
(m). Install the fourth speed gear synchronizing ring,
the fourth speed gear roller bearing and the
output fourth speed gear component, and pay
attention to align the gap of synchronizing ring
LFWX-6470-21047
(n). Install output fourth speed gear gasket (flat

gasket) on the end face of output fourth speed
gear, and use press-fitting locating sleeve to
press rear bearing inner race of output shaft in
output shaft.
1. Shaft removal tooling 2. Positioning seat 3. Pressing-in locating sleeve
LFWX-6470-21048
Inspection
Check the main parts and replace them if the following conditions occur:
1. If there are significant damages (cracks, breakage, traces, peeling) on the gear teeth, they
should be replaced in pairs.
2. If there are following conditions on the gear teeth, they should be replaced in pairs.
(a). The gear presents the evident damage such as the flaw, crack, trace and flaking.
(b). The gear top abrasion exceeds 0.25mm.
(c). The tooth length abrasion exceeds 30%.
(d). The back lash exceeds 0.5mm.
3. The bearing should be replaced if the following conditions occur:
(a). Excessive looseness.
(b). Ball breakage, flaking or trace on the surface.
(c). Bearing abnormal noise.
21
4. The shaft should be replaced if the following conditions occur:
(a). Cracks or breakage.
(b). Deformation, radial runout of more than 0.05 mm (or perform the correction repair).
(c). Journal wear of more than 0.04 mm (or perform the surfacing repair or chrome plated repair)
Check and adjustment of main components

• Check the input shaft gear for tooth broken, tooth surface pitting, severe tooth surface wear
and tooth surface sticking and check the input shaft journal for pitting; If there is any of the
above situations, must replace the input shaft.
• Check the input shaft spline for serious wear and damage; if any, must replace the input shaft.
• Manually check the bearing for free rotation and no sticking, and check whether the needle
roller bearing cage is intact and whether there is pitting on the needle roller.
2. Countershaft assembly
• Check the intermediate shaft gear for tooth breakage, tooth surface pitting, serious tooth face
wear and tooth surface sticking, and check the intermediate shaft rolling bearing for pitting; if
there is any one of above situations, must replace the intermediate shaft.
3. Output shaft assembly
• Check the output shaft gear for tooth breakage, tooth surface pitting, serious tooth face wear
and tooth surface sticking, and check the output shaft hole for pitting; if there is any one of
above situations, must replace the output shaft.
• Check the input shaft spline for serious wear and damage; if any, must replace the input shaft.
Transmission Operating Mechanism

Component drawing
3
7
4
5 2
4
5
5
1 6
1-4
6
LFWX-6470-21038
1 Gear shift and select cable 5 Hexagon flange nut
2 Gear shifter 6 Hexagon flange nut
3 Gear shift hand ball 7 Gear shift rocker arm clip
4 Board
Replacement
1. Remove the subpanel. (refer to 85 - dashboard/subpanel- subpanel, Replacement)
2. Remove the gear shift mechanism

(a). Remove four nuts for connecting gear shifter
support and auxiliary instrument panel shift lever
support.
ounting torque: 20~26 N·m
LFWX-6470-21037
(b). Disconnect the connection of gear selecting and

switching flexible shaft link and gear shifter, and
take down the gear shifter.
21
LFWX-6470-21036
(c). Remove two nuts for connecting the gear shifting

and selecting cable assembly with car body from
the bottom of car body.
Mounting torque: 6~12 N·m
LFWX-6470-21035
(d). Enter from front engine room, and remove one

nut used to connect gear shifting and selecting
cable assembly with car body front panel.
Mounting torque: 6~12 N·m
LFWX-6470-21077
(e). Remove the gear shift rocker arm clamp used

to connect gear shifting and selecting cable
assembly and transmission.
Tips:
Before performing this step, remove the air filter
first to facilitate the removal of rocker arm clip.
LFWX-6470-21034
(f). Remove installing snap-gauge of gear shift cable,

and take down gear selecting and shifting flexible
shaft from gear selecting and shifting flexible
shaft support of transmission.
Tips:
To replace the gear selecting cable, push it
backward a little and take it out from the bracket
opening.
(g). Take out gear shifting and selecting cable.
LFWX-6470-21033
3. Mount the gearshift mechanism

The installation sequence is reverse to the removal sequence.
21
Transmission - Transmission（2.0L-CVT）
21-a
Transmission
Transmission ………………………1
Preparation ………………………1
Maintenance data …………………2
Precautions ………………………3
Structure of the transmission ……6
Overview …………………………6
Gear shift mechanism ……………6
Part drawing ………………………6
Transmission internal structure
sketch …………………………………7
General inspection…………………8
Transmission inspection …………8
Transmission fluid (ATF) …………9
Replacement ………………………9
Transmission maintenance …… 10
Power train disassembly/assembly
……………………………………… 10
Removal and installation of entire
vehicle harness connectors …… 11
Transmission maintenance …… 18 21
Transmission serviceable parts 18
Fault diagnosis ………………… 22
Terminology …………………… 22
DTC inspection and clearing … 23
Diagnostic trouble code (DTC)
diagnostic description …………… 24
Fault phenomenon table ……… 24
21-b Transmission - Transmission（2.0L-CVT）
21-1
Transmission
Preparation
1. Special tools
No. Tool External view Note
Differential oil seal

1 For installation of differential oil seal
installation and tooling
Locating pin (shift rocker

2 removal / installation For removal / installation of shift rocker
and tooling)
No. Tool External view Note

21
1 Spacer gauge For removal and installasion of bolt
2 Torque wrench For removal and installasion of bolt

21-2 Transmission - Transmission（2.0L-CVT）
Maintenance data
1. Technical specification table
Transmission model QR019CHD-BA
Transmission form Continuously variable transmission (CVT)
Layout Transversal front drive
Starting clutch device Hydraulic torque converter
Control modes Electronic hydraulic control
Dimension (L×W×H) 85mm×555mm×505mm
Weight (no cooling lubricating oil contained) 78Kg
Centre distance 204mm
Maximum permissible input torque 190 Nm
Main reduction ratio 5.141
Pulley speed ratio range 0.427-2.465
Oil type ATF SP- III（Hereinafter referred to as CVTF）
Transmission oil level in total 8±0.2L

Item N·m
Filler bolt 42~50
Connecting bolts for hydraulic torque converter 50~60
Two fastening bolts of hydraulic torque converter
75~85
installation guide pin/pinhole
Hexagon flange bolt Q1840614/Q1840620 10~12
Oil pressure sensor assembly 15~22
Hexagon flange bolts Q1860816 20~26
Hexagon nut Q341C10 10~25
Hollow bolt 019CHA-1502122 27~33
21-3
Precautions
For maintenance work, it is necessary to use sealant or the equivalent. Apply the sealant to corresponding
position on the surface of the transmission housing. If the housing is made of aluminum, the fastening bolts
on the housing must be fastened to a specific torque with a torque wrench. In addition, it is very important to
clean all the parts with the detergent or cleaning solution and dry air before reinstallation.
(1). Compressed air tools can cause dust and other particles to fly out, resulting in damage to the eyes; so
you should wear goggles in the use of compressed air.
(2). Check and make sure that all parts are cleaned before assembling the transmission (except rubber
parts and gaskets).
(3). Replace all disposable parts (all kinds of oil seals, spring pins, O seals, etc.).
(4). When sealing elements are installed, it is necessary to clean the residual sealant on the bonding
surface.
(5). To ensure that the sealing elements are oil-tight, the assembly should be completed within 3 minutes
after the sealant is applied.
(6). The removed rings, bearings, oil covers, etc. cannot be reused.
(7). All bolts and nuts must be tightened in accordance with the specified tightening torque.
(8). When installing the moving parts, apply some gear oil to these moving places, and then use some
lubricating grease to the seal lips.
(9). When the bearings are installed, do not use any rolling body to transfer the pressure. Press fit each oil
seal without titling.
(10). When the transmission is working normally, there shall be no leakage of lubricating oil.
(11). Old clamping rings must be replaced with new ones, and the new clamping rings installed in place
shall not be excessively open so as to avoid deformation.
(12). The bolts and nuts used to fix the end caps, housings or brackets shall be loosened or tightened
diagonally.
(1). First-level maintenance
• In first-level maintenance, we should check the lubricant level which should be aligned to the lower edge
of the filler port; add lubricant when the level is low, because too low level may cause poor lubrication and
burn the bearings and gears, while too high oil level may cause overheating and oil spills. 21
• In second-level maintenance, we should remove the ventilation valve for inspection and cleaning, because
ventilation valve blockage will result in too high internal pressure and thus transmission fluid leakage.
(2). Level II maintenance
• In the first second-level maintenance for a new car, replace the transmission lubricant and clean the
transmission with kerosene.
(3). Level III maintenance
• For third-level maintenance, we should conduct disassembling inspection, cleaning and replacement of oil.
3. User instructions
019CH series stepless gearbox includes: 1 parking gear (gear P), 1 reverse gear (gear R), 1 neutral gear (gear
N) and 1 forward gear (gear D), which can be switched through the shift handle. According to vehicle needs,
019CH series stepless gearbox can also provide: low gear (gear L), S/M gear (sports/manual mode), snow
mode and other functions.
Note:
The low gear and manual mode can be switched through the gear lever;
The snow mode and sport mode can be enabled and disabled through the mode button;
Sport mode activation and release: the mode will be activated if the gear lever is pushed to S/M gear from D
gear; the mode will be released if the gear lever returns to D gear or the gear is up or down;
Manual mode: activation and release: the mode will be activated upon gear up or down; the mode will be
released when the gear lever returns to D gear;
Snow mode activation and release: through the mode switch;
Mode priority: manual mode > snow mode > sport mode. If more than one mode is triggered at the same
time, the system will enable the higher priority mode as default.
Before operating the vehicle equipped with 019CH series CVT, learn about the following information:
(1). Before driving, look around and make sure nobody in front/at back of your vehicle;
(2). Child can only get into vehicle with adult;

(3). Every TCU should be self learnt in first work; self-learning steps are shown as Article 3.1;
(4). Shift the transmission ahead of forward gear (D or R) from stop gear (N or P), keep the engine at idle
speed; step on the foot brake or pull up the hand brake; let off the foot brake and the handle brake
after gear switch, and then the vehicle will start running;
(5). When engine speed is beyond idle speed, do not switch the transmission from stop gear (N or P) to
forward gear (D or R);
(6). After vehicle comes to a full stop, gear lever is switched to P gear, and vehicle can be switched off
when pulling up the hand brake;
(7). When vehicle is started, if you press hard on the accelerator, transmission will be delayed to shift up,
so as to enable the transmission to run at high rotation speed area and guarantee big power output;
(8). In case of pressing hard on accelerator when vehicle is running, transmission will quickly decelerate to
low gear, engine speed will be increased and power will be increased;
(9). Vehicle equipped with automatic transmission can not be started up by traction (or cart). In case of
battery feed, vehicle should be started by jumper cable and battery with electricity.
4. The gearbox self-learning
In the event of the following circumstances, the transmission needs to learn by itself, or you may feel not so
smooth when you shift gears or start the car:
(1). Driven for the first time as a new car;
(2). TCU was replaced;
(3). Transmission assembly was overhauled;
The detailed self-learning procedures are as follows:
(1). Switch the transmission to P (or N) gear;
(2). Start the engine;
(3). Standing for 2min;
(4). Self-learning is completed;
Note:
In order to achieve a good driving effect in a variety of conditions, the transmission needs to perform a self-
learning operation at high temperature, low temperature, room temperature and other conditions.
5. Gear description
5.1. P (parking)
Get the output shaft of the transmission locked to prevent the driving wheels from moving, and use the
handbrake when the vehicle is stopped for a long time.
When the transmission stops at P (or N), the engine can be ignited yet the other gears can not be ignited.
The shift mechanism has parking lock. To quit P, step on the brake pedal and switch the car to “KEY ON”.
If P gear cannot quit, unlock it through the mechanical unlocking means. For details, refer to the vehicle
user’s manual.
It is forbidden to move the lever to P before the car is completely stopped. Otherwise, the car will be prone to
being out of control.
Do not replace position P with the hand brake, and, after the vehicle is completely stopped, pull the hand
brake first before moving the lever to P.
Do not park the car on a long ramp, and a safe parking slope should not be greater than 30%.
5.2. R (Reverse)
R (Reverse) for reversing motion.
Before the shift lever is pushed to or pulled away from R, it is necessary to confirm that the car is completely
stopped, or the transmission may be easily damaged.
Before stopping the vehicle in D gear, check the environment and ensure the safety.
5.3. N (neutral)
When the lever stays at N, the driving wheels and transmission are both freely idling, which is suitable for a
short-time stop.
When the transmission stops at N (or P), the engine can be ignited yet the other gears can not be ignited.
When the lever stays at N, if you do not pull the hand brake or step on the foot brake, the car will be rolling
on the ramp, which may cause an accident.
It is forbidden put the shift lever at N when the car is moving at a high speed, or the transmission may be
easily damaged.
Neutral taxiing is prohibited after the stalling of engine, or the transmission can be easily damaged.
5.4. D (drive)
Normal forward mode for stepless speed variation: when the shift lever stays at D, the transmission will
automatically select the appropriate speed ratio according to the driver’s intention.
21-5
Make sure the car is completely stopped before moving the lever to D.
Before stopping the vehicle in D gear, check the environment and ensure the safety.
5.5. Moving mode
This mode is activated when the shift lever is pushed to S/M from D; quit the mode by moving the
lever back to D or shifting up or down.
Note:
Apply S/M as needed.
5.6. S/M (manual mode)
You can see a “+” and a “-” at S/M, also known as “M+” and “M-” .
M+: Move the shift lever forward to speed up.
M-: Move the shift lever backward to slow down.
CVT has seven forward gears. No matter the car is still or running, just push the shift lever to
switch between M and D; unlike manual transmissions, it is allowed to shift the gears when the
accelerator pedal is pressed. A driver can manually shift up or down to experience a shifting effect
similar to manual transmission for more driving pleasure.
Note:
Apply M as needed.
You can move the shift lever from speed 1 to speed 7 or vice versa.
In manual mode, the driver must shift the gear in a suitable operating condition to keep the engine
away from the red line -- running with high loads for a long time.
In manual mode：When the car slows down, the car will shift down automatically; when the engine
runs too fast, you have to shift the gears at certain accelerator and speed conditions in manual
mode. If these conditions are not met, the transmission does not perform any shift action even if
the shift lever is pushed.
When driving on ice or low-attachment roads, you can switch to manual mode and put the shift
lever at position 2 before starting the car, so that the car grips the ground well, or you can realize
this function through snow mode.
5.7. L (low speed)
When driving downhill or along long-distance ramps, you can brake with the engine at this gear.
Note:
Apply L as needed. 21
5.8. Snow mode
Press the “SNOW”button, and TCU will enter the snow mode program. Snow mode is suitable
for driving on low-grip roads. Press the button again to quit the snow mode.
In snow mode, TCU controls the transmission to start the car at the second gear to avoid slip.
When the car gets matched up with ESP, please do not turn on the snow mode of transmission and
TCS function in ESP at the same time, because they will conflict with each other and weaken each
other.
Note:
Apply “SNOW” mode as needed.
6. Vehicle traction
Tow the vehicle in the correct way to prevent the secondary damage to the vehicle.
Completely set up the vehicle with the flat bed lorry or large flatbed trolley and then tow it;
Set up the non-drive wheel with the rigid towing means and tow the driving wheels with the small
platform lorry (supporting wheels) after setting up the driving wheel;
Note:
Do not tow the drive wheel in soft means;
Do not tow the non-drive wheel in soft means.

Overview
The continuous variable speed of engine LF483Q21 transmission is achieved by the continuous
variation of the contact diameter of the driving/driven taper plate and the steel strip.
Transmission Control Unit (TCU) sends command signals to the four hydraulic valves in the
hydraulic system at the right moment as needed by the driving conditions (vehicle speed, load,
engine speed, etc.)
Solenoid valves continuously adjust the working condition according to the instructions from TCU.
These 4 solenoid valves work in different combinations of conditions, so that the flow and pressure
of hydraulic oil change in a timely manner, thus the accurate manipulation of hydraulic actuators (e.g.
cylinders, pistons, guiding valves, etc.).
When the piston chamber pressure of the hydraulic driving and driven conical platens is
continuously changed, the conical platens have corresponding axial movement with the changes
in pressure, thus changing the radius of rotation of the steel belt to achieve a continuous change in
transmission ratio for the purpose of stepless speed variation.
019CH series stepless gearbox achieves forward and reverse functions through a planetary gear
train. The speed ratio settings for forward and reverse gear are roughly the same, so that the
pressure change is small during gear switch, thus conducive to precise control of pressure and
improved gearshift comfort.
The piston chamber 1 in the reverse brake is connected with the solenoid valve body through the
transmission housing, and the pressure oil directly enters the piston chamber 1 of reverse brake
through the solenoid valve body.
The spring baffle in the forward clutch is provided with a sealing structure which, in addition to
acting as a spring baffle, cooperates with the piston to form a balancing chamber for balancing
the pressure in the piston chamber 2, and cushioning the impact from the forward clutch, which
improves the driving comfort during gear shift.
Part drawing
LFWX-6470-21001
1 Transmission assembly
21-7
Transmission internal structure sketch
21
LFWX-6470-21002
1 Rear housing assembly 2 Forward clutch assembly

Transmission converter housing
3 4 Hydraulic torque converter assembly
assembly
5 Torque converter housing assembly 6 Input shaft assembly
7 Thrust washer 8 Oil pump assembly
9 Output shaft assembly 10 Differential assembly
11 Steel strip 12 Output belt pulley shaft assembly
13 Input belt pulley shaft assembly
General inspection
the damaged parts.
△ Tips：
replace the oil if any
LFWX-6470-21003
21-9
Transmission fluid (ATF)

Replacement
1. Discharge the gearbox oil
(a). Shut down the engine to cool down and then
jack up the vehicle.
(b). Collect the lubricating oil under the transmission
with a container.
(c). Remove transmission oil drain plug.
(d). Slowly remove the oil drain screw plug and drain
the transmission lubricating oil.
Note:
The sealing gasket is one-off part and must be replace
each time during the maintenance.
Gasket
seal

Drain
plug
assembly

LFWX-6470-21003
2. Fill the gearbox oil

(a). Pull out breather plug, and feed fresh oil from
Breather plug
breather plug mounting hole.
A d d s a m e a m o u n t o f AT F a s t h e a m o u n t e d
Oil filler port
discharged.
If the transmission is new, you do not need to
discharge the oil, and add 4.8±0.1L of oil directly.
(b). Install transmission fluid filler plug and fasten it.
Torque: 42~50 N•m
(c). After filling oil, check oil level.
Note:
Wipe the oil dipstick with the lint-free paper to prevent 21
the foreign matter entering the transmission inside.
The engine compartment contains high-temperature
LFWX-6470-21004 parts. In order to avoid accidents, remember not to
spill the ATF onto these hot parts.
After filling ATF, wipe off the spilled fluid.
When replacing the ATF, the residual oil in the
transmission needn’t to be completely discharged.
When replacing the ATF, clean the oil cooler.
3. Inspection of transmission fluid level
(a). After a period of time of driving on the dynamic
road, the oil temperature of the transmission
reaches 80±5 ℃ or 25±5 ℃ (measured with a
diagnostic instrument).
HOT area
HOT
(b). Stop the car on the ground, and pull the parking
brake handle.
(c). While the engine is idling, step on the brake
COLD area
COLD pedal, switch between R, N, and D for 3 cycles
staying at each position for 5s; finally, stop the
selector lever in position “P” or “N”.
(d). Clear the dust and oil around the oil scale.
(e). Pull the vent plug from the conduit of the valve
housing, and wipe the oil scale with a lint-free
LFWX-6470-21006 paper and insert it into the conduit to prevent
foreign matter from falling into the transmission.
(f). Pull out the oil scale, record the scale position,
and determine if the oil level is acceptable
against the table. If the oil level is within the
corresponding range, the oil level is qualified.
If not within the corresponding range, fill or
discharge oil until the oil level rises to or falls
into the middle position of the corresponding
range to achieve the best performance.
(g). Finally, restore the vent plug into the conduit,
and ensure the installation in place.
HOT area COLD area

Oil level
Item Oil temperature: 80±5℃ , be Oil temperature: 25±5℃ , for
accurate reference
CVT A-A a-a
Note:
It’s not allowed to in the idle state to warm the ATF by slamming on the accelerator.
Use the “HOT” mark on the transmission fluid scale as the standard for detecting the amount of
transmission fluid. The “COLD” (or “C”) mark is for reference only.
When the transmission fluid is hot, the engine, the radiator and its piping system are very hot too,
and the fan may be started, so you must be very careful in the course of operation to avoid burns
After the transmission has been repaired or the oil has been replaced, the oil level must be
controlled at the middle position of the corresponding range.
Every 100ml of oil means 3mm change in the scale for your reference.
One side of the oil scale is used to measure the HOT oil level and the other side the COLD oil
level.
If the transmission fluid level is too low, the transmission fluid pump will suck air during normal
operation, and then the air is compressed into bubbles into the electromagnetic valve oil pipes to
lower the pressure, then the clutches or brakes will work weakly due to lack of pressure.
If the transmission fluid is too much, the revolving parts in the transmission will stir the liquid to
produce foam during the high-speed rotation, thus the same result as above.
If there are too many bubbles, they are easy to get the transmission fluid oxidized at high
temperatures and this affect the normal operation of the solenoid valves, clutches and brakes; and
this can also cause the transmission fluid to spill out from the transmission vent holes, which may
be easily mistook for transmission fluid spill.
Power train disassembly/assembly
Disassembly of power train:
(1). First remove other vehicle components which will influence removal of transmission
according to related technical requirements;
(2). Separate the connector clips on the joint of vehicle wiring harness and transmission;
(3). Separate gear shift stay wire from transmission gear shift arm;
(4). Separate the left/right transmission shaft from the transmission;
(5). Separate the transmission cooling hose from transmission;
(6). Separate the transmission from engine;
Assembly of power train:
The assembly of power train is reverse to the disassembly.
21-11
Removal and installation of entire vehicle harness connectors

To achieve the automatic gear shift, acquire the transmission data information and supply to TCU.
Therefore, the transmission is equipped with the corresponding sensors to transmit the signal
through the harness. The connection of the sensor and harness is achieved through the connector.
CVT19 transmission is equipped with 3 speed sensors, 2 oil pressure sensors, 1 gear switch, 1
harness general terminal and 1 TCU.
Note:
Most connectors adopt the jet molding buckle structure. The forced pulling may result in the sensor
fracture, buckle looseness/fracture or harness open circuit.
1. Remove the speed sensor connector
(a). Press the position shown in the above figure
forcibly;
(b). Pull the harness connectors upward at the same
time;
(c). Complete the removal.
LFWX-6470-21007
2. Mount the speed sensor connector
(a). The installation process is the opposite of the
disassembly process.
Note:
Install the connectors in position: a click can be heard
if installed in position. 21
LFWX-6470-21008
3. Remove the oil pressure sensor connector

forcibly;
time;
LFWX-6470-21009
4. Mount the oil pressure sensor connector
Note:
if installed in position.
LFWX-6470-21010
5. Remove the gear switch connector

forcibly;
time;
LFWX-6470-21011
21-13
6. Mount the gear switch connector

Note:
LFWX-6470-21012
7. Remove the harness connector

forcibly;
time;
LFWX-6470-21013 21
8. Mount the harness connector
Note:
LFWX-6470-21014
9. Remove the TCU connector

(a). Rightwards pull out connector contraction end
according to above Figure.
time;
LFWX-6470-21015
10. Install the TCU connector

Note:
LFWX-6470-21016
Gear shift

cable bracket 11. Remove the gear shift cable
(a). Switch the gear lever in cab to N gear
(transmission gear shift arm is also
correspondingly switched to N gear);
Gear shift

(b). At this time, location hole on gear shift arm and
cable location hole on gear switch are aligned, and
location pins are plugged in these holes.
(c). Separate the gear shift stay wire from gear shift
arm; and separate the gear shift stay wire from
gear shift stay wire support.
Gear
shift (d). Take down location pin.
switch 12. Mount the gear shift cable
(a). Install gear shift stay wire and gear shift stay
wire support;
Shift arm
Locating pin
(b). Align the location hole on gear shift arm with the
LFWX-6470-21017 location hole on gear switch, and plug in location
pin;
(c). Switch the gear lever in cab to N gear;
(d). Install gear shift stay wire and gear shift arm in
place;
(e). Take down location pin.
Note:
When removing or installing the gear shift cable bracket, ensure to use the correct guide pin so as
to avoid the gear disorder;
Since the gear shift cable and transmission connection form varies from vehicles, the tools used for
the removal and installation are different.
21-15
13. Remove the left and right drive shafts

(a). Plug flat head crowbar on the joint of left/right
Left propeller Right propeller transmission shaft and transmission;

shaft shaft
(b). Operate the crowbar to remove the left/right
transmission shaft from transmission;
14. Mount the left and right drive shafts
(a). Change a new differential oil seal;
(b). Install a spline protecting jacket on the outer
spline where left/right transmission shaft and
transmission are matched;
(c). Align the left/right transmission shaft with inner
spline hole of differential axle shaft gear and
install transmission;
(d). Make sure of taking down spline protecting
LFWX-6470-21018 jacket after outer splines on left/right
transmission shaft have passed differential oil
seal;
(e). Push the left/right transmission shaft towards
transmission by force to make sure it is installed
in place;
Note:
Because of the interference fit between the oil seal and transmission, deformation is inevitable in
the removal process, and the damaged parts cannot continue to be used.
The removal and installation of left/right propeller shaft require the gentle force; otherwise it will
damage the transmission or propeller shaft.
Oil tube
assembly 15. Remove the cooling hose
(a). Use appropriate clamp pliers to remove the
Clamp
clamp;
(b). Separate the transmission cooling hose and
transmission outer oil pipe assembly; 21
16. Mount the cooling hose
Note:
The removal and installation should be gentle so as to
prevent damaging the transmission oil pipe assembly;
Prevent the foreign matter entering the transmission
from the oil pipe assembly nozzle;As the gearbox
Gearbox cooling hose
cooling hose is connected to the transmission internal
oil pipe, you need to ensure that the hose is clean
LFWX-6470-21019 inside;
Engine
17. Remove the gearbox
(a). Put vehicle on elevator and rise it to appropriate
height.
(b). Drain transmission fluid;
(c). Respectively separate vehicle wiring harness,
gear shift stay wire, left/right transmission shaft
and cooling hose from transmission;
Transmis-
(d). Remove dustproof baffle; check whether
sion
connecting bolts of hydraulic torque converter
are visible or not, if not, rotate the crankshaft
until one bolt is exposed (4 bolts in total, which
are distributed uniformly on the periphery);
Dust prevention

panel
LFWX-6470-21020
(e). Remove the first hydraulic torque converter

connecting bolt;
Crank the crankshaft by 90 ° and remove the
second bolt;
Crank the crankshaft by 90 ° in the same
direction and remove the third one;
direction and remove the last one;
(f). Remove the connecting bolts of transmission
and engine;
(g). Separate the transmission from engine.
Connecting bolts forhydraulic

torque
converter

LFWX-6470-21021
Note:
Disassemble the transmission and engine after removing the power train from the vehicle as a
whole;
Before removing the power assembly, drain the transmission oil first;
During the disassembly of transmission, remove the bolt connecting the hydraulic torque converter
and flexible plate first. The hydraulic torque converter separates from the engine together with the
transmission. During the separation, maintain the engine and transmission coaxial as much as
possible to prevent the hydraulic torque converter falling out or even off;
If the hydraulic torque converter falls off by accident, install it back under the direction of the
technician; do not install the converter forcedly so as to prevent damaging the parts inside the
transmission;
The hydraulic torque converter is high precision component and demands high requirements for
the moment of inertia. In the case of knock or deformation, the converter must be replaced; when
separating the engine and transmission, protect the peripheral transmission accessories such as
the cooling oil pipe and pressure sensor and replace them if damaged;
The dust baffle, the number, specification and connecting direction of bolts connecting the engine
and transmission vary from the vehicles.
(h). Keep one of four holes connected with the
hydraulic torque converter on flexible disk on
the bottom oil pan of engine (so as to install
hydraulic torque converter connecting bolt
later). If the hole is not on the position shown
in Figure, crankshaft can be rotated to make the
flexible disk on right position;
Installation torque: 75~85 N·m
(i). Rotate the hydraulic torque converter, make
bolt hole connected with flexible disk on the
hydraulic torque converter on the lower portion,
so as to install connecting bolt of hydraulic
torque converter.
(j). Separate the transmission from engine.
LFWX-6470-21022
21-17
18. Mount the gearbox

(a). A dust-proof gasket is also designed between
the transmission and engine of some vehicles,
with 1.5mm thickness, and it will be installed in
?????
2 place according to related requirements.
(b). Assemble transmission with engine according
to the relations that location pin 1 corresponds
to location pin hole 1 and location pin 2
corresponds to location pin hole 2.
?????
1
?????
2
?????
1
LFWX-6470-21023
Note:
During the assembly, ensure the hydraulic torque converter will not fall out;
If the hydraulic torque converter falls off by accident, install it back under the direction of the
technician; do not install the converter forcedly so as to prevent damaging the parts inside the
transmission;
The hydraulic torque converter is high precision component and demands high requirements for
the moment of inertia. In the case of knock or deformation, the converter must be replaced;
(c). Install two fastening bolts of location pin/pin
hole, and install and fasten other generator-
transformer combination bolts;
(d). Observe and confirm whether hole connected
with hydraulic torque converter on flexible disk is
aligned with hole connected with flexible disk on
hydraulic torque converter or not, if not, rotate 21
crankshaft (or rotate hydraulic torque converter)
to make the two holes aligned.
LFWX-6470-21022
(e). Install and pre-fasten the first hydraulic torque
converter connecting bolt;
Crank the crankshaft by 90 ° , install the second
hydraulic torque converter connecting bolt and
pre-tighten it;
direction, install the third hydraulic torque
converter connecting bolt and pre-tighten it;
direction, install the fourth hydraulic torque
converter connecting bolt and pre-tighten it;
(f). Fasten connecting bolts of the fourth hydraulic
torque converter; rotate the crankshaft for 180° ,
and fasten the connecting bolt of the second
hydraulic torque converter;
LFWX-6470-21021
direction, install the first hydraulic torque converter
connecting bolt and tighten it;
direction, install the third hydraulic torque
converter connecting bolt and tighten it;
(g). Install dust cover;

(h). Respectively connect vehicle wiring harness,
gear shift stay wire, left/right transmission shaft
and cooling hose;
(i). Fill automatic transmission oil.
Note:
Pre-tighten the 4 bolts for the hydraulic torque converter properly to prevent the bolt head and
engine rear end face rib or other constructive interference when cranking the crankshaft later;
Do not directly tighten the bolt; otherwise it will be difficult to tighten the rest 3 bolts;
The requirements for the hydraulic torque converter connecting bolts are as follows:
1. Mechanical properties: Grade 10.9 GB/T 3098.1

2. Surface treatment: 48-hour salt spray test, no red rust, GB / T 10125
LFWX-6470-21025
If the transmission fault is detected, confirm it by the technician of WANLIYANG and repair or
replace the faulty component as required.
For the part maintenance instructions, see below text.
Transmission serviceable parts
21-19
18
9 8
10
17
6 7 4 15
14
13
6
12
5
5 6 11
19
16
21
3
2 7
1
LFWX-6470-21026
1 Drain plug assembly 2 Gasket seal

3 Differential oil seal 4 Speed sensor assembly ★
5 Speed sensor assembly 6 Hexagon flange bolts ★
7 Oil pressure sensor assembly 8 Hexagon flange bolts
9 Harness bracket 10 Gear shift cable bracket assembly
11 Shift switch assembly 12 Shift arm
13 Spring washer ★ 14 Hexagon nut
15 Hexagon flange bolts 16 Oil tube assembly
17 Gasket seal ★ 18 Hollow bolt
19 Hexagon flange bolts 20 Automatic transmission fluid
Note:
★ Indicates that this is a one-time part, that is, if you need to dismantle this part during
maintenance process, you must replace it with the new part;
ATF must be designated grade and should not be substituted by other oil; otherwise the
transmission damage will not be covered by the warranty;
Since the automatic transmission is high precision component and demands high requirements for
the cleanliness, ensure to maintain the field clean and wear the clean gloves (or ensure the hands
clean) when repairing and replacing the transmission components.
1. Dismantle the differential oil seal
(a). Use crowbar to directly pry down oil seal from
transmission;
2. Install the differential oil seal.
(a). Smear right amount of automatic transmission
fluid on the inner and outer rings of oil seal;
Differential oil
(b). 将 Align the oil seal with transmission, and install
the oil seal on the transmission by differential oil
seal
seal installing tools.
LFWX-6470-21027
Note:
Because of the interference fit between the oil seal and transmission, deformation is inevitable in
the removal process, and the damaged parts cannot continue to be used.
Oil seals should be installed with even force so as not to damage the oil seals.
The components of the transmission require high accuracy, so you should be careful in the
disassembling and assembling process so as not to scratch or damage them (i.e. finished surface
of housings).
When connecting the propeller shaft, ensure to use the oil seal sheath to prevent the propeller
shaft spline and snap ring damaging the oil seal.
3. Disassemble the speed sensor assembly
Speed
sensor
assembly (a). Unscrew hexagon flange bolt of sensor;
(b). Take down the speed sensor assembly.
Hexagon
4. Mount the speed sensor assembly
flange bolts (a). Smear right amount of automatic transmission
fluid on O-shaped ring of sensor;
(b). Install the sensor in position;
(c). Install the bolt and tighten.
Note:
When connecting the joints, check the contact pins to
ensure the pins are free of bending or damage.
LFWX-6470-21028
21-21
5. Remove the oil pressure sensor assembly

(a). Unscrew oil pressure sensor assembly；
(b). Take down the oil pressure sensor assembly.
6. Mount the oil pressure sensor assembly
(a). Smear right amount of automatic transmission
fluid on O-shaped ring of sensor;
(b). Install the sensor in position;
(c). Install the bolt and tighten.
Oil
pressure
sensor
assembly
Note:
When connecting the joints, check the contact pins to
ensure the pins are free of bending or damage.
LFWX-6470-21029
7. Remove the shift cable bracket and harness

bracket
Hexagon
flange
Harness

(a). Unscrew two hexagon flange bolts;
bolts bracket (b). Take down the wiring harness support；
(c). Ta k e d o w n g e a r s h i f t s t a y w i r e s u p p o r t
Gear shift cable assembly.
bracket assembly

8. Mount the shift cable bracket and harness
bracket
(a). Gear shift stay wire support assembly is
installed in place in the opposite sequence of
disassembly process;
(b). Install wiring harness support in place, and pre-
fasten two hexagon flange bolts.
Installation torque: 20~26N·m
21
LFWX-6470-21030
9. Disassemble shift arm and gear switch
(a). Align the location holes of gear shift arm and
gear switch assembly, and plug location pins in
Hexagon
nut
the location holes;
Spring
washer
(b). Unscrew the hexagon nut on gear shift arm;
Hexagon
flange
bolts
(c). Take down spring washer;
Shift
arm
(d). Take down location pin.
Shiftswitch
assembly
(e). Take down gear shift arm;
(f). Unscrew two hexagon flange bolts of static gear
switch;
(g). Take down gear switch assembly.
10. Mount the shift arm and gear switch
(a). Gear switch assembly is installed in place in the
opposite sequence of disassembly process.
LFWX-6470-21031 (b). Pre-tighten two hexagon flange bolts and tighten
them
Installation torque: 10~12N•m.
(c). Install the gear shift arm in place, make its
location hole aligned with the location hole on
gear switch;
(d). Plug location pin in location hole;
(e). Install spring washer.

(f). Install hexagon nut and fasten it;
(g). Take down location pin.
Note:
The spring washer for the gear shift arm is one-off part and cannot be reused;
Bring the gear shift arm to N gear after completing the assembly of this step;
To ensure the gear shift accurate, use the guide pin as well when connecting the gear shift cable
and gear shift arm:
(1). Switch the gear lever in cab to N gear and keep it;
(2). Location pin is plugged in location holes of gear shift arm and gear switch;
(3). Connect stay wires;
(4). Take down location pin;
(5). At this time, the vehicle is at N gear.
10. Disassemble oil pipe and oil cooler
(a). Unscrew hexagon flange bolts on oil pipe
Hollow
bolt
bracket;
Gasket
seal
(b). Unscrew two hollow bolts and take down four
sealing gaskets;
Oil tube
assembly (c). Take down oil pipe assembly.
11. Mount the oil pipe and oil cooler
(a). Install oil pipe assembly in place;
Hexagon (b). Put a sealing washer above and below the oil

flange bolts pipe joint respectively;
(c). Pre-fasten two hollow bolts in place;
(d). Pre-tighten and install hexagon flange bolts on
oil pipe bracket;
LFWX-6470-21032 (e). Fasten hollow bolt.
Note:
The gasket is one-off item and should not be reused. In addition, do not forget to install it;
When installing the hollow bolt, pre-tighten it first, then tighten it to the require torque and then re-
tighten it.
Fault diagnosis
Terminology
DTC： Diagnostic Trouble Codes
IG： Ignition
TCU/TCM： Transmission Control Unit
ECU： Engine Control Unit
kph: Kilometers Per Hour
21-23
DTC inspection and clearing

(1). Turn IG to OFF position;
(2). Connect diagnostic apparatus;
(3). Turn IG to ON position;
(4). Use diagnostic apparatus to check fault code;
(5). Read fault code, and then implement trouble clearing steps according to “DTC diagnostic
program”;
(6). Clear fault code;
(7). Disconnect the diagnostic meter;
DTC list
No DTC Fault name
1 P0703 Brake signal is abnormal
2 P0705 Transmission gear signal is abnormal
3 P0716 Turbine speed signal range is abnormal
4 P0730 Speed ratio control is abnormal
5 P0792 Speed signal range of input belt pulley shaft is abnormal
6 P0811 Forward clutch slips
7 P081E Reverse clutch slips
8 P0842 Pressure sensor circuit A (input pulley shaft) is short to ground or open
9 P0843 pressure sensor A circuit （input belt pulley shaft）short power supply circuit
10 P0847 pressure sensor B circuit （output belt pulley shaft）short to groundor open circuit
11 P0848 Pressure sensor circuit B (input pulley shaft) is short to power supply
12 P0890 TCU main relay control circuit is short or open
13 P0894 Hydraulic torque converter clutch slips
14 P0900 Clutch solenoid valve control circuit is open
15 P0902 Clutch solenoid valve control circuit is short to ground 21
16 P0903 Clutch solenoid valve control circuit is short to power supply
17 P0938 Transmission oil temperature too high
18 P0939 Transmission fluid temperature sensor circuit is short to ground
19 P0940 Transmission fluid temperature sensor circuit is short to power supply or open
20 P0960 Control circuit of pressure control solenoid valve "A" (input pulley shaft) is open
21 P0962 The control circuit of pressure control solenoid valve "A" (input pulley shaft) is short-circuited
22 P0963 Pressure control solenoid valve “A” （input belt pulley shaft）control circuit short power supply
23 P0964 Pressure control solenoid valve “B” （output belt pulley shaft）control circuit open circuit
24 P0966 Pressure control solenoid valve “B” （output belt pulley shaft）control circuit short circuit
The control circuit of pressure control solenoid valve "B" (output pulley shaft) is short to power
25 P0967
supply
26 P0968 The control circuit of pressure control solenoid valve "C" (torque converter) is open
27 P0970 The control circuit of pressure control solenoid valve "C" (torque converter) is short-circuited
28 P0971 The control circuit of pressure control solenoid valve "C" (torque converter) is short to power supply
29 P1706 Steel belt slips
30 P1745 Speed signal range of output belt pulley shaft is abnormal
31 P2797 Input pulley shaft pressure control is abnormal
32 P2798 output belt pulley shaft pressure control is abnormal
33 U0100 ECM communication failure
34 U0121 ABS communication fault
35 U0401 ECM data reception is abnormal
Diagnostic trouble code (DTC) diagnostic description

Most faults are caused by the loose contact of the sensor and harness connectors. Therefore,
thoroughly check the related connector and line for the terminal looseness/falling off, loose
connection, twisting, corrosion, dirt or aging. Since partial faults may be caused by the fact that the
history fault in TCU is not cleared after maintenance, clear DTC first:
DTC clearing:
(1). Turn IG to OFF position;
(2). Connect diagnostic apparatus;
(3). Turn IG to ON position;
(4). Enter CVT system and read fault code;
(5). Clear fault code;
(6). Operate vehicle according to startup conditions in failure mode, and check fault codes appear
or not;
(7). Recover transmission system;
(8). Exit diagnostic system;
(9). Disconnect the diagnostic meter;
(10). Switch IG to OFF.
Note:
During the DTC inspection, drive the vehicle carefully.
DTC Possible phenomena Possible fault causes Fault diagnosis operation
The brake signal is released
Powerless 1. Brake pedal switch failure
from ECM. Refer to the entire
acceleration 2. The brake pedal switch harness
P0703 vehicle maintenance manual for
Output belt pulley shaft is in poor contact or short-
troubleshooting
pressure abnormal circuited.
Clear the DTC.
1. Improper adjustment of the shift Inspection of gear shift cable
The vehicle is unable cable position or poor contact of connection
P0705 to start the connector Inspection of gear switch failure
Gear shift impact high 2. Harness break Harness continuity check
3. The gear switch is disabled Clear the DTC.
Transmission MIL on 1. The speed sensor is mounted
Inspection of speed sensor
Gear shift impact high incorrectly
P0716 Clear the DTC.
Powerless 2. Line loose contact or short circuit
Harness continuity check
acceleration 3. Speed sensor failure
Transmission MIL on
1. Self-learning is not completed Self adapting inspection
The vehicle does not
2. Input wheel shaft oil pressure Inspection of input belt pulley shaft
move with a gear
P0730 sensor failure oil pressure sensor
engaged
3. Input shaft solenoid valve failure Inspection of input shaft solenoid
Powerless
4. Hydraulic system fault valve Inspection of hydraulic system
acceleration
Transmission MIL on
Clutch and hydraulic
1. Line loose contact or short circuit Inspection of speed sensor
torque converter
P0792 2. Speed sensor failure Harness continuity check
slipping
Clear the DTC.
Powerless
acceleration
The vehicle does not 1. Turbine speed sensor failure
Inspection of turbine speed sensor
move with the drive 2. Clutch control solenoid valve
Inspection of clutch control solenoid
gear engaged failure
P0811 valve
Powerless 3. Hydraulic system fault
Hydraulic system troubleshooting
acceleration 4. The forward clutch friction plate
Inspection of clutch friction plate
Gear shift impact is damaged.
21-25
The vehicle does not 1. Turbine speed sensor failure；

move with the reverse 2. Clutch control solenoid valve failure；
gear engaged
P081E 3. Hydraulic system leakage; Refer to P0811.
Powerless
acceleration 4. The reverse clutch friction plate is
Gear shift impact damaged.
Transmission MIL on 1. Input belt pulley shaft pressure sensor Inspection of pressure sensor
P0842 Powerless line loose contact or short circuit; Harness continuity check
acceleration 2. Pressure sensor failure Clear the DTC.
1. The input belt pulley shaft pressure
Transmission MIL on sensor installation error;
P0843 Powerless 2. Input belt pulley shaft pressure sensor Refer to P0842.
acceleration line loose contact or short circuit;
3. Pressure sensor failure
1. The output belt pulley shaft pressure
Transmission MIL on sensor installation error; Inspection of pressure sensor
P0847 Powerless 2. Output belt pulley shaft pressure sensor Harness continuity check
acceleration line loose contact or short circuit; Clear the DTC.
1. The output belt pulley shaft pressure
Transmission MIL on sensor installation error;
P0848 Powerless 2. Output belt pulley shaft pressure sensor Refer to P0847.
acceleration line loose contact or short circuit;
Transmission MIL on TCM Power relay check
1. TCM power relay failure
P0890 Vehicle goes to limp TCM Power relay signal check
2. TCM power relay harness failure
home mode Clear the DTC.
1. Hydraulic torque converter lock control Inspection of hydraulic torque
Transmission MIL on converter locking control solenoid
solenoid valve or harness failure
P0894 Powerless valve or harness Inspection of
2. Hydraulic control circuit failure
acceleration hydraulic control circuit
3. Hydraulic torque converter failure Hydraulic torque converter failure
Inspection of oil clutch control solenoid 21
1. Clutch control solenoid valve harness valve failure
Transmission MIL on
P0900 fault Inspection of clutch control solenoid
Gear shift impact
2. Clutch control solenoid valve failure valve harness
Clear the DTC.
1. Clutch control solenoid valve harness
Transmission MIL on
P0902 fault Refer to P0900.
Gear shift impact
2. Clutch control solenoid valve failure
1. Clutch control solenoid valve harness
Transmission MIL on
P0903 fault Refer to P0900.
Gear shift impact
2. Clutch control solenoid valve failure
Inspection of oil temperature sensor
Gearbox failure light
1. CVT oil temperature sensor failure failure
P0938 flashing Powerless
2. Gearbox cooling system failure Troubleshooting of transmission
acceleration
radiator system
Inspection of oil temperature sensor
Transmission MIL on
1. Oil temperature sensor signal line fault Inspection of oil temperature sensor
P0939 Powerless
2. CVT oil temperature sensor failure signal line
acceleration
Clear the DTC.
Transmission MIL on
1. Oil temperature sensor signal line fault
P0940 Powerless Refer to P0939.
2. CVT oil temperature sensor failure
acceleration
Transmission MIL on
The vehicle does not 1. Oil pressure control solenoid valve A Inspection of oil pressure control
solenoid valve failure
move with a gear harness fault
P0960 Inspection of oil pressure control
engaged 2. Oil pressure control solenoid valve A
solenoid valve harness
Powerless failure Clear the DTC.
acceleration
Transmission MIL on 1. Oil pressure control solenoid valve

The vehicle does not move A harness fault
P0962 Refer to P0960.
with a gear engaged 2. Oil pressure control solenoid valve
Powerless acceleration A failure
The vehicle does not move A harness fault
Powerless acceleration A failure
Transmission MIL on 1. Oil pressure control solenoid valve Inspection of oil pressure control
solenoid valve failure
The vehicle does not move B harness fault
P0964 Inspection of oil pressure control
solenoid valve harness
Powerless acceleration B failure Clear the DTC.
Powerless acceleration B failure
Powerless acceleration B failure
1. Oil pressure control solenoid valve Inspection of oil pressure control
Transmission MIL on solenoid valve failure
C harness fault
P0968 Hydraulic torque converter Inspection of oil pressure control
2. Oil pressure control solenoid valve
clutch slips solenoid valve harness
C failure Clear the DTC.
Transmission MIL on
C harness fault
P0970 Hydraulic torque converter Refer to P0964.
clutch slips
C failure
Transmission MIL on
C harness fault
P0971 Hydraulic torque converter Refer to P0964.
clutch slips
C failure
1. Electrical device failure; Inspection of electrical part failure
2. Hydraulic system fault Inspection of hydraulic system
Transmission MIL on
P1706 3. Engine torque over-adjustment Inspection of engine torque over
Powerless acceleration
4. The gearbox parts are abnormally control
worn. Gearbox parts abnormal wear check
Transmission MIL on 1. The speed sensor wiring is in poor Inspection of speed sensor
P1745 Steel belt slips contact or short-circuited. Harness continuity check
Powerless acceleration 2. Speed sensor failure Clear the DTC.
Transmission MIL on 1. The pressure sensor signal fault; Inspection of pressure sensor failure
Powerless acceleration Inspection of pressure control
P2797 2. Pressure sensor solenoid valve
The vehicle does not move solenoid valve failure
with a gear engaged 3. Hydraulic system fault Inspection of hydraulic system fault
Transmission MIL on 1. The pressure sensor signal fault; Inspection of pressure sensor failure
Powerless acceleration Inspection of pressure control
P2798 2. Pressure sensor solenoid valve
Gear shift impact solenoid valve failure
Brake and stall engine 3. Hydraulic system fault Inspection of hydraulic system fault
1. Engine sensor failure; Detect the fault by referring to the
U0100 Powerless acceleration
2. CAN circuit fault vehicle service manual.
Brake and stall engine ABS sensor failure; Detect the fault by referring to the
U0121
ABS alarm light on CAN loop failure vehicle service manual.
Engine warning lamp on
After confirming the engine
1. Engine sensor failure; Detect the fault by referring to the
U0401 speed fault, shut down the
2. CAN circuit fault vehicle service manual.
main relay and enter the limp
home mode
21-27
21
Clutch - Clutch
22-a
Clutch
Clutch ………………………………1
Preparations ………………………1
Component drawing (clutch control
mechanism) …………………………3
System description ………………4
General inspection…………………5
Check the system …………………5
Check the clutch fluid (braking
fluid) …………………………………5
Check the clutch slave cylinder …5
LFWX-6470-22003 ………………6
Check the clutch master cylinder 6
Check the clutch pedal …………6
Fault diagnosis ……………………7
Fault phenomenon table …………7
Clutch pedal…………………………8 22
Replacement ………………………8
Clutch master cylinder ………… 12
Replacement …………………… 12
Clutch wheel cylinder ………… 15
Clutch oil pipe …………………… 16
Clutch fluid（brake fluid） …… 20
Exhaust ………………………… 20
Discharge ……………………… 21
Filling …………………………… 21
22-b Clutch - Clutch
Clutch - Clutch
22-1
Clutch
Preparations
1. Special tools
NO. Tool External view S/N Note
Clutch pressing Position the clutch pressing plate

1
plate positioning tool and driven disc
Flywheel snap Prevent the flywheel rotation when

2
deputy removing the clutch pressing plate
2. Recommended tool 22
1 Vernier caliper Measure the clutch wear
Remove the oil tubing bolts and the

2 Oil pipe wrench
clutch exhaust screw plug
22-2 Clutch - Clutch
Maintenance data
Clutch pedal height to the floor 155~165mm
Clutch driven plate wear limit 1.4mm
Free travel of clutch pedal 7mm

Items N•m
Connecting bolt between the clutch pedal and the
55 ~ 65
bracket
Clutch slave cylinder retaining bolt 20 ~ 26
Clutch oil outlet pipe hastening nut 16 ~ 20
Clutch master cylinder fastening nut 20 ~ 26
Clutch pressing plate fastening bolt 35
Clutch slave cylinder oil tube connector fastening nut 16 ~ 20
Precautions
1. The clutch hydraulic oil recommended is the brake fluid “DOT4”, do not use mineral oil,
such as gasoline or kerosene; otherwise it may corroded the rubber parts in the hydraulic
system.
2. Do not reuse the clutch hydraulic oil drained.
3. Do not splash the clutch hydraulic oil on the body paint surface.
4. Do not clean the clutch pressing plate with gasoline!
5. There is grease filled in the release bearing; do not clean it with fuels or liquids.
6. When installing the clutch, coat properly the heat resistance and pressure resistance grease
on the driven plate spline and the transmission 1st shaft spline, to ensure the free movement
of the driven plate on the transmission 1st shaft spline. Excessive grease will cause friction
plate slipping
7. When the friction plate is worn to the wear limit, the driven plate assembly should be timely
replaced, in order to prevent clutch slippage and scratch of the pressing plate and flywheel
surfaces.
Warning:
Please clean the clutch friction plate with the vacuum cleaner, instead of the compressed
air!
Clutch - Clutch
22-3
Component drawing (clutch control mechanism)
6 12
4 15
2 16
3
5 14
1
7 16
16
11
7
8 10 2
6
13
9
22
LFWX-6440-22001
1 Clutch master cylinder 9 Clutch manipulation oil tube II

2 Hexagon flange nut 10 Lock pin
3 Steel strip elastic hoop 11 Lock shaft
4 Clutch master cylinder oil inlet tube 12 Hexagon flange bolt
5 Clutch manipulation oil tube I 13 Clutch pedal assembly
6 Hexagon flange bolt 14 Switch 1
7 U-shaped clip 15 Switch 2
8 Clutch oil tube fixed clip 16 Hexagon nut
System description
1. 作用
Installed between the engine and transmission, the clutch is a component directly connected with
engine in transmission system. Clutch has the following functions:
• Letting the engine engage the transmission gradually to ensure a gentle start.
• Ensuring the transmission system works smoothly.
• Limiting the transmitted torque to prevent overloading of transmission system.
2. Composition
Clutch system is mainly composed of clutch pedal, clutch master cylinder, clutch tubing, clutch
slave cylinder, release fork, release bearing, clutch pressure plate, clutch driven plate and other
components.
4. Clutch control principle diagram
LFWX-6470-22002
1 Clutch pedal 5 Release yoke

2 Clutch master cylinder 6 Thrust disc
3 Clutch hydraulic oil tube 7 Driven disc
4 Clutch release cylinder 8 飞轮
Clutch - Clutch
22-5
General inspection
Check the system
1. Check system working conditions
(a). Depress the clutch pedal to feel if the pedal is spongy; if yes, make repair as per the following
related diagnostic contents.
(b). Depress the clutch pedal to feel if the pedal can be pedaled; if not, make repair as per the
following related diagnostic contents.
(c). Depress the clutch pedal to check if the clutch can be separated; if not, make repair as per
the following related diagnostic contents.
(d). Depress the clutch pedal to check if the pedal can return back normally; if not, make repair
as per the following related diagnostic contents.
(e). Start the engine in situ, depress the clutch pedal and engage gear 1; do not release the
parking brake this time; then slowly release the clutch pedal until it is fully lifted; the engine
should stall. If the engine does not stall, the clutch slips; make repair as per the following
related diagnostic contents.
(f). Depress the clutch pedal to check if the clutch makes abnormal sound; if yes, make repair as
per the following related diagnostic contents.
(a). Check the system for evident mechanical damage and repair them if required.
(b). Inspect the system for obvious collision deformation sign; if any, repair it.
3. Check system leakage
(a). Check if the system has oil leakage, if yes, make repair.
4. Check the system hydraulic lines 22
(a). Check if the system hydraulic lines are correctly installed; if not, re-install.
(b). Check if the system hydraulic lines are broken or damaged; if yes, replace.
Check the clutch fluid (braking fluid)

1. Check the working conditions of clutch fluid
(braking fluid)
(a). Check if the clutch fluid level is between the
“MAX” and “MIN”, if not, add.
Specifications: D0T4
Filling volume: 0.8L
(b). Discharge a small amount of clutch fluid into a
transparent container, and check if the clutch fluid
is contaminated; if yes, replace.
LFWX-6470-22012
Check the clutch slave cylinder

1. Check the working condition of the clutch slave cylinder
(a). Check if there is oil stain around the clutch slave cylinder; if not, it suggests the clutch slave
cylinder works well; if yes, wipe the stain. Continuously depress the clutch pedal for a few
times, and re-check if there is oil stain around the clutch slave cylinder; if yes, it suggests the
clutch slave cylinder is damaged and needs to be replaced.
Check the clutch master cylinder

1. Check the clutch master cylinder without equipment available
(a). Turn off the oil inlet on clutch master cylinder, and then block the pipe with a plug after
draining the air. If it’s hard to depress the pedal after the free stroke, the clutch master
cylinder has not leakage; if not, the clutch master cylinder has leakage and needs to be
replaced.
Note:
Check if the clutch master cylinder has free travel before exhaust. The detection is effective
only when the clutch master cylinder is installed correctly.
2. Check the clutch master cylinder with equipment available
(a). Install the dedicated pressure gauge to the outlet of the clutch master cylinder, and tighten
the pressure gauge connector after venting the air.
(b). Depress the clutch pedal, fix the pedal after the pressure gauge shows 3MPa~6MPa, and
check the pressure gauge.
△ Tips:
Because of pedal, bracket, front dash panel and tubing expansion, the pressure gauge value
will drop and become stable at a certain value. Keep this pressure for 30s. Pressure drop
cannot exceed 0.2MPa. That the pressure drops to 0MPa suggests the sealing cup of master
cylinder has been damaged; if so, replace the clutch master cylinder.
Check the clutch pedal

1. Check the clutch
(a). Under the engine idle speed status, depress the clutch pedal to the end to disconnect the
clutch; if the clutch pedal is depressed, the shift operation is difficult or there a harsh noise
form the transmission gear, or the clutch is not released after the shift operation, the vehicle
begins movement, the clutch may not be released completely.
(b). The clutch slipping reasons are as follows: the clutch pedal free stroke is too small, and the
release is often pressed on the diaphragm spring, to make the pressing plate in a half release
status; the clutch pressing plate spring is too soft or broken; the connection bolt between the
clutch and the flywheel is loosened, etc.
(c). Any abnormal noise during the clutch operation is not normal. The fault reasons are as
follows: the release bearing is worn severely, the bearing return spring is too soft or broken,
the diaphragm spring bracket has a fault, etc.
2. Check the clutch pedal
(a). Check whether the clutch pedal free height b is
correct. If it is incorrect, adjust it.
Reference height from the pedal to the floor: 150
~ 160mm
LFWX-6470-22003
Clutch - Clutch
22-7
Fault diagnosis
The engine or transmission fixing
Tighten the fixing bolt
bracket (loosened)
Clutch driven plate (excessive
Replace the driven disc
swing)
Clutch stuck/vibration Clutch driven disc (oil stain) Clean the driven disc
Clutch driven disc (polished) Replace the driven disc
Clutch driven disc (harden ) Replace the driven disc
Driven disc spring (low spring force
or spring fracture)
Clutch oil pipe (air admission) Clutch system bleeding
The clutch pedal is loosened Master cylinder cup (damaged) Replace the master cylinder
Wheel cylinder cup (damaged) Replace the cup
Clutch release bearing (wear and
Replace the release bearing
tear, damage)
Clearance between the
There is abnormal noise from the transmission input shaft outer
clutch spline and the spline groove in the
driven disc (too big)
22
or spring fracture)
Clutch driven disc (oil stain) Clean the driven disc
Clutch driven disc (polished) Replace the driven disc
Clutch slip Replace the driven disc
or spring fracture)
Clutch pressing plate (deformation) Replace the clutch plate
Flywheel (deformation) Change
Clutch oil pipe (air admission) Clutch system bleeding

Master cylinder cup (damaged) Change
Wheel cylinder cup (damaged) Replace the cup
Clutch driven plate (deformation) Replace the driven disc
Clutch driven plate (excessive
swing)
The clutch cannot be released
Clutch driven plate (friction
damage)
Clutch driven plate (dirty or burns) Replace the driven disc
Clutch driven disc (oil stain) Clean the driven disc
Clutch driven plate (lack of grease
Coat the grease
on spline location)
Clutch pedal
Replacement
1. Remove the clutch pedal
(a). Remove the left lower dashboard shield panel
(Refer to Chapter 85: Dashboard and deputy
dashboard – left lower dashboard shield panel,
replacement).
(b). Remove two connecting nuts and two
connecting bolts of cab fuse box and instrument
board pipe beam, and take down cab fuse box.
LFWX-6470-22077
(c). Remove the lock pin for connecting clutch pedal

and clutch master cylinder push rod and take
down the pin shaft.
LFWX-6470-22004
Clutch - Clutch
22-9
(d). Remove retaining nut of clutch master cylinder.
LFWX-6470-22018
(e). Remove combination instrument (See Chapter

74 Driver Information System – Combination
Instrument, Replacement).
(f). Take down bolt shown in the left Figure.
22
LFWX-6470-22034
(g). Switch the power supply to “OFF”, disconnect
clutch top switch wiring harness connector,
release clutch top switch lock nut and take down
clutch top switch.
LFWX-6470-22016
(h). Take out clutch pedal assembly; disconnect

bottom clutch switch wiring harness connector;
release bottom clutch switch lock nut; and take
out bottom clutch switch.
LFWX-6470-22017
2. Assemble the clutch pedal
(a). Install bottom clutch switch.
△ Tips:
The clutch switch installed should not affect the
clutch pedal height, and the clutch switch can
work properly.
LFWX-6470-22017
(b). Tighten the lock nuts of clutch switch.

Torque: 20 ～ 26 N•m
(c). Connect the clutch switch harness connectors.
LFWX-6470-22016
Clutch - Clutch
22-11
(d). Install bolts shown in the left Figure.

(e). Install combination instrument (see Chapter
74 Driver Information System – Combination
Instrument, Replacement).
LFWX-6470-22034
(f). Install clutch master cylinder retaining nut.
22
LFWX-6470-22018
(g). Install clutch pedal and clutch master cylinder

pin shaft, and install pin shaft lock pin.
(h). Adjust the height and free stroke of clutch pedal.
LFWX-6470-22004
(i). Install cab fuse box.

(j). Install the left lower apron of instrument board
(see Chapter 85 Instrument Board and Auxiliary
Instrument Board – Left Lower Apron of
Instrument Board, Replacement)
LFWX-6470-22077
Clutch master cylinder

Replacement
1. Remove the clutch master cylinder
(a). Open engine compartment, and remove
ventilating cover plate on engine compartment.
(refer to 81 - interior trims and exterior trims -
vent panel, replacement)
(b). Discharge brake fluid.(refer to Chapter 23 -
Clutch fluid, replacement)
(c). Remove vacuum booster and brake master
cylinder assembly. (refer to Chapter 51 Service
brake - vacuum booster, replacement)
/):;
(d). Remove clamping stirrup used to connect the

clutch master cylinder oil inlet pipe and clutch
master cylinder; and disconnect operation oil
pipe I and clutch master cylinder on pump end.
△ Tips:
The left large figure only displays the clutch
master cylinder position relative to the brake
master cylinder and does not indicate the removal
and installation of procedures since the brake
master cylinder is removed in the last step.
LFWX-6470-22067
Clutch - Clutch
22-13
(e). Remove the left lower apron of instrument

desk. (see Chapter 85 Instrument Board and
Auxiliary Instrument Board – Left Lower Apron
of Instrument Board, Replacement)
(f). Remove two connecting nuts and two
connecting bolts of cab fuse box and instrument
board pipe beam, and take down cab fuse box.
LFWX-6470-22076
(g). Remove connecting lock pin of clutch master

cylinder push rod and clutch pedal, and plug out
pin shaft.
22
LFWX-6470-22004
(h). Remove clutch master cylinder retaining nut.,

take out clutch master cylinder from engine
compartment.
LFWX-6470-22018
2. Install the clutch master cylinder

(a). Install the clutch master cylinder inlet tube into
the clutch master cylinder and fasten it with the
elastic hoop.
(b). Install clutch operation oil pipe I, and fasten oil
outlet hard pipe nipple nut of clutch.
Torque: 16~20 N·m
LFWX-6470-22067
(c). Install the clutch master cylinder into the chassis

installation hole in the engine compartment, and
install and tighten the fastening nuts in the cab.
Torque: 20~26 N·m
(d). Install the clutch master cylinder push rod pin
and install the pin lock.
△ Tips:
Adjust the clutch pedal height.
LFWX-6470-22018
(e). Install clutch pedal and clutch master cylinder

pin shaft lock pin.
(f). Install left lower apron of instrument desk.(see
Chapter 85 Instrument Board and Auxiliary
Instrument Board – Left Lower Apron of
Instrument Board, Replacement)
(g). Put cab fuse box on its installation site, install
two connecting nuts and two connecting bolts of
cab fuse box and instrument board pipe beam
and fasten them.
(h). Install vacuum booster and brake master
cylinder assembly.(refer to Chapter 51 Service
brake - vacuum booster, replacement)
(i). Fill the brake fluid.(refer to Chapter 23 - Clutch
fluid, replacement)
(j). Install ventilating cover plate on engine
LFWX-6470-22004 compartment. (refer to 81 - interior trims and
exterior trims - vent panel, replacement)
Clutch - Clutch
22-15
Clutch wheel cylinder

Replacement
1. Remove the clutch slave cylinder
(a). Lift the vehicle with the lifter.
(b). Disconnect the clutch outlet oil pipe.
LFWX-6470-22009
(c). Remove the clutch slave cylinder fastening bolts
and remove the clutch slave cylinder.
22
LFWX-6470-22010
2. Install the clutch slave cylinder assembly

(a). Install fixing bolt and fix it on transmission.
Torque: 20 ～ 26 N·m
LFWX-6470-22011
(b). Fasten the lock nut of oil outlet pipe of clutch

slave cylinder.
Torque: 16~20 N·m
(c). Exhaust the clutch slave cylinder (Refer to
Chapter 22: Clutch - hydraulic oil, exhaust).
LFWX-6470-22009
(e). Connect brake fluid exhauster ① on clutch slave
cylinder exhaust screw, and buckle up brake
fluid exhauster switch ② .
(f). Release the clutch slave cylinder exhaust screw,
and exhaust air from clutch system until there is
no air in the clutch system.
Note:
During the venting process, replenish the clutch
fluid and always keep the liquid level of the tank
between the “MAX” and “MIN”.
(e). Fasten the air vent screw of clutch slave
cylinder, remove the braking fluid venting device
2 ① , and install the dust cover of air vent screw.
LFWX-6470-22014
1
Clutch oil pipe

Replacement
1. Remove the oil inlet from the clutch master
cylinder
(a). Remove the hoops from the oil inlet of the clutch
master cylinder and the oil inlet in turn.
LFWX-6470-22029
Clutch - Clutch
22-17
2. Install the oil inlet of the clutch master

cylinder
(a). Install oil inlet and hoops in place; fasten the
hoops.
LFWX-6470-22029
3. Remove the clutch operation tube I

(a). Remove one end of clutch operation oil pipe I,
which is connected with clutch master cylinder.
22
LFWX-6470-22030
(b). Remove the connecting nut of clutch operation

oil pipe I and clutch operation oil pipe II, as
well as fixing bolt of clutch oil pipe mounting
bracket and connecting bolt of clutch operation
oil pipe and car body, then take down the clutch
operation oil pipe I.
LFWX-6470-22031
4. Install the clutch operation tube I

(a). Install the clutch operation tube I in place.
(b). Install the connecting nut of clutch operation oil
pipe I and clutch operation oil pipe II, as well
as fixing bolt of clutch oil pipe mounting bracket
and connecting bolt of clutch operation oil pipe
and car body.
Torque: 16~20 N•m（nut）
6 ~ 12 N•m（bolt）
LFWX-6470-22031
(c). Install one end of clutch operation oil pipe I,

which is connected with clutch master cylinder.
Torque: 16~20 N•m
LFWX-6470-22030
5. Remove the clutch operation tube II

(a). Remove one end ① of clutch operation oil pipe I,
which is connected with clutch operation oil pipe
II.
(b). Remove the U-shaped card ② .
LFWX-6470-22033
Clutch - Clutch
22-19
(c). Install the lock nuts between clutch operation

tube II and clutch slave cylinder
LFWX-6470-22032
5. Install the clutch operation tube II

(a). Install the clutch operation tube II in place.
(b). Fasten the lock nuts between clutch operation
tube II and clutch slave cylinder.
Torque: 16N•m ～ 20N•m
22
LFWX-6470-22032
(c). Fasten one end ① of clutch operation oil pipe I,
which is connected with clutch operation oil pipe
II, wherein the joint is on the oil pipe bracket.
(d). Install the U-shaped card ② .
LFWX-6470-22033
Clutch fluid（brake fluid）

Exhaust
Note:
When the clutch pipes, clutch master cylinder, clutch slave cylinder, hydraulic release
bearing is removed or when the clutch pedal is softened, must exhaust the system.
1. Clutch system air removal
(a). Remove the water tank upper beam trim panel.
(See Section 81 – Inner and outer trims – Water
tank upper beam trim panel - Replacement)
(b). Disengage the dust cover of air vent screw of
clutch slave cylinder.
(c). Connect the braking fluid venting device ① to
the air vent screw of clutch slave cylinder, and
buckle up the braking fluid venting device switch
②.
(d). Release the air vent screw of clutch slave
cylinder to vent the air from the clutch system
until no more air remains in the clutch system.
2 Note:
During the venting process, replenish the clutch
fluid and always keep the liquid level of the tank
1 between the “MAX” and “MIN”.
LFWX-6470-22014
(e). Fasten the air vent screw of clutch slave
cylinder, remove the braking fluid venting device
① , and install the dust cover of air vent screw.
(f). Install the water tank upper beam trim panel.
Clutch - Clutch
22-21
Discharge
1. Discharge the clutch fluid
(a). Remove the water tank upper beam trim panel.
(b). Disengage the dust cover of air vent screw;
connect one end of the hose to the air vent
screw, and put the other end to the collection
vessel.
(c). Open the tank, and release the air vent screw of
clutch slave cylinder.
(d). A technician will repeatedly depress the clutch
pedal with all his strength, until the clutch fluid is
completely discharged.
(e). Fasten the air vent screw, and install the dust
cover.
(f). Install the water tank upper beam trim panel.
LFWX-6470-22075 (See Section 81 – Inner and outer trims – Water
Filling
1. Fill the clutch fluid
(a). Remove fluid reservoir cover and feed clutch
fluid to “MAX” level.
Specifications: D0T4
Filling volume: 0.8L 22
(b). Exhaust air in clutch system. (See Chapter 22
Clutch- Clutch Fluid, Exhaust)
(c). Install fluid reservoir cover.
LFWX-6470-22011
Front suspension - Front suspension 31-a
Front suspension
Front suspension��1
Repair parameter�� 2
Precautions�� 2
Front suspension component drawing � 3
Front damper assembly
component drawing�� 4
Front damper assembly��13
Disassembly and assembly
of front damper assembly��16
Swing arm assembly��21
31
Sub-frame Assembly��23
Front stabilizer bar��28
Front suspension - Front suspension
31-b
Front suspension - Front suspension 31-1
Front suspension
Preparations
NO. Tool External view S/N Description
Compress springs for

Spring
1 disassembling shock
compressor
absorber spring
Ball-head
2 Remove the ball head
remover
31
Shock absorber Remove the fixing nut of

3
nut remover shock absorber
Support wheels and lift

4 Hydraulic bracket
the frame
Remove hubs and hub

5 Puller
bearings
31-2
Repair parameter
Items N·m
Front shock absorber assembly center nut 65~75
Front shock absorber assembly and installation plate

65~85
fastening nut
Front shock absorber assembly and steering knuckle

200~220
retaining bolt
Front shock absorber assembly and lateral stabilizer

110~130
bar connecting rod fastening nut
Swing arm and steering knuckle conencting bolt and

80~110
nut
Swing arm and front deputy frame assembly

280~320
connecting bolt and nut
Connect nut between front auxiliary frame and vehicle

280~320
body
Lateral stabilizer rod and connecting rod part

110~130
fastening nut
Precautions
1. The steering knuckle and other non-overhaul parts can not be removed.
2. Please clean the part surface before removal and installation.
3. In the operation, must avoid dirt the parts and prevent foreign body entered into the parts.
4. The removed parts (excluding rubber parts) should be cleaned with kerosene, and dried with
compressed air or fiberless cloth.
5. After the suspension parts is repaired, be sure to check the wheel alignment.
6. The oil will shorten the service life of rubber bushing. Must clean the spilled oil completely.
7. The no-load condition refers to that the conditions that the fuel, engine coolant and oils have
be filled normally and the spare tire, jack, accessory tools and foot cushions have been placed
in the specified locations.
8. The one-off parts should not be reused.
9. Check the parts carefully before repairing or replacing them.
10. After installation, must check the specified torques of all fasteners.
11. Plug the brake oil pipe with the rubber cap to prevent the brake fluid leak when removing the
pipe.
12. When installing the suspension or rubber bushing, must eventually tighten then under the
conditions of the tires are grounded and there is no-load on the vehicle.
Front suspension component drawing
10 7
6
11 16
11
18 8
12 19 15
11 17
13 8
10 19
11 12 26
4
5
7 6 25 20 9
16 3 9
2 11
15 16
18 2 4
11 5
17
8
21
20 1 23
8 11
5 11
5
9 3 16 14
4 5
5 14
11
11
9 4 11 22
21 11
11 24
11
31
22
LFWX-6470-31001
1 Lateral stabilizer bar 14 Stabilizer bar mounting cover plate
2 Lateral stabilizer bar buffer bushing 15 Swing arm assembly
3 Lateral stabilizer bar link rod assembly 16 Hexagon flange bolt
4 Spring washer 17 Slotted nut with hexagon flange
5 Hexagon flange nut 18 Split pin
6 Front vibration absorber mounting gasket 19 Hexagon flange nut
Hexagon flange bolt and big plain washer

7 All-metal hexagon flange lock nut 20
subassembly

8 21 Front truss girder assembly
subassembly
Hexagon flange bolt and big plain washer

9 Hexagon flange nut 22
subassembly
10 Bracket mounting support 23 Suspension connecting rod
11 Hexagon flange bolt 24 Front cross member assembly
12 Hexagon flange bolt 25 Vibration absorber assembly
Hexagon head bolt, spring washer and plain

13 Deputy frame assembly 26
washer subassembly
31-4
Front damper assembly component drawing
1-3
2
1-4
1-5
3
1-2
1-1
(Left and right) Front shock absorber

1 2 2 type full-metal locking nut
with spring assembly
1-1 Upper support assembly 3 Dust cover
1-2 Spring upper rubber pad
1-3 Helical spring
1-4 Limited block
(Left and right) Front shock absorber

1-5
assembly
System description
1. Function
The vehicle suspension is a force transmission device between frame and wheel. The front
suspension of the vehicle type is equipped with Mcpherson independent suspension system,
which roles are shown as follows:
• Reduce the impact of the frame or body from the road surface, and the resulting body
vibration, and ensure the driving stability comfort and safety.
• Transmit the driving force and braking force generated by the friction between the road
surface and the wheels to the frame and the body.
• Support the body and maintain proper geometric relationship between the body and the
wheels.
2. Composition
The front suspension is composed mainly of shock absorber strip spring assembly, subframe,
swing arm and transverse stabilizer bar.
1. Carry out preliminary inspection of front shock absorber.
(a). Press the front of vehicle with both hands, and release it immediately.
• The vehicle should swing 2 ~ 3 times up and down before the rest.
• If the vehicle does not swing or swings for too many times, then check the front shock
absorber strip spring assembly.
2. Check whether all connecting bushings are aged or damaged.
3. Check whether all connecting bolts are loose.
31
4. Check whether each connecting component is deformed or cracked.
5. Check the transverse stabilizer bar.
(a). Shake the transverse stabilizer bar up and down to check whether the transverse stabilizer bar
is loose.
• Ifthe transverse stabilizer bar is loose indicates the rubber sleeve of transverse stabilizer
bar is aged and shall be replaced.
6. Measure the body height

Vehicle height (front):167mm
Tips:
• Ensure the tire pressure reaches the standard
value when measuring the height of vehicle.
• The measuring point of front suspension is
the distance from the ground to the center of
swing arm mounting bolt when the vehicle is
unloaded.
Note:
I f th e h e i g h t o f v e h i c l e d o e s n o t me e t t h e
requirements, check whether there is any damage
or deformation for the front suspension of vehicle.
LFWX-6470-31036
31-6
7. Check and repair the suspension parts

(a). Check the stabilizer bar and bushing for damage,
wear or deformation; if any, replace it.
(b). C h e c k w h e t h e r s w i n g a r m h a s c r a c k s ,
deformation or damage or not, if yes, change it;
check whether the swing arm bolt is loose or not,
if yes, please timely fasten it.
(c). Check whether swing arm ball pin can rotate
flexibly or not; check whether fixing bolt and nut
of swing arm ball head and swing arm are loose
or not; check whether swing arm ball pin is loose
or not, if yes, change the swing arm ball head.
(d) Check the ball pin dust cover for damage; if any,
repair it.
LFWX-6470-31004
(e). Check the wheel bearing for noise, loosening,

etc,; if any, replace it.
LFWX-6470-31005
2. Check and repair the front shock absorber

assembly
(a). Check the performances of the front shock
absorber assembly: push the front end of the
body with the same force, to allow the body to
sway continuously 3 ~ 4 times, observe the shock
absorber damping capacity and the number of
swinging times after releasing the force. If the
shock absorber is normal, after releasing the
push force, the body swing will immediately stop
or there is a slight swing only 1 ~ 2 times; check
the other side of the body, to check the shock
absorber damping capacities on both sides of the
body for consistency.
LFWX-6470-31006
(b). Check the shock absorber for oil leakage; if any,

replace it.
(c). Check the front shock absorber assembly bearing
for wear or binding; if any, replace it.
31
LFWX-6470-31007
(d). Check the spiral spring for cracks or deformation;

if any, replace it.
(e). Check the rubber parts on the front shock
absorber assembly for aging or damage; if any,
replace it.
(f). Check the front shock absorber assembly upper
installation holder for cracks or deformation; if
any, replace it.
LFWX-6470-31006
31-8
Fault diagnosis
1. Tires (abnormal air pressure)
2. Vehicle (overload)
See 31 – front suspension
3. Spring (fault)
Body sinking/tilting diagnostics, troubleshooting (1.
4. Shock absorber (damage) vehicle body sink/title)
5. Transverse stabilizer bar (bent or

broken)
1. Tire (wear or abnormal pressure)
2. Wheel (unbalanced)
3. Wheel alignment (incorrect) See 31 – front suspension

Shimmy of front
4. Steering ball head (worn) diagnostics, troubleshooting (2.
wheels
Shimmy of front wheels)
5. Wheel bearing (wear)
6. Steering gear (misaligned or

damaged)
1. Tire (wear or abnormal pressure)
2. Wheel alignment (incorrect)
3. Wheel bearing (wear) See 31 – front suspension

Vehicle running
diagnostics, troubleshooting (3.
deviation 4. Spring (fault) Vehicle running deviation)
5. Shock absorber (damage)
6. Sub-frame or swing arm (deformed)
1. Tire (too high air pressure)
2. Suspension component (loose bolts)
3. Shock absorber (loose or damaged

See 31 – front suspension
Abnormal Suspension bolts)
diagnostics, troubleshooting (4.
Sound
4. Upper bearing (damaged) on shock Abnormal Suspension Sound)
absorber
5. Connecting rod ball head of transverse

stabilizer bar (worn)
Fault diagnosis
1. Body sinking/tilting
Correct the tire pressure (see

Check the tire Section 33 - Wheels and Tires
Go to Step 1 Insufficient tire pressure
pressure - Wheels and Tires, On-board
Inspection)
Measure the body

height
Measure the height of

vehicle body (See 31 Determine the front suspension
Go to Step 2 Body sinking/tilting
– front suspension, system is faulty
parking inspection)
Inspect the front

suspension
1. Replace the front shock absorber

(see Section 31 - Front Suspension
1. Front shock absorber
- Front Shock Absorber and Spring
fault
Assembly, Replacement)
Inspect the 2. Connecting bushing
2. Replace the connection bushing
performances of the aging or damage
(see 31 – Front Suspension
front suspension 3. Connecting bolt Subframe Assembly, Replacement)
parts (see Section 31 Go to Step 3 loosening 31
3. Tighten the bolt
- Front Suspension 4. Connecting part
- Front Suspension, 4. Replace the deformed or
deformation and
On-board Inspection) cracked part
cracking
5. Tighten or replace the stabilizer
5. Transverse stabilizer
bar (see Section 31 – Front
bar loosening
Suspension - Transverse Stabilizer
Bar, Replacement)
Measure the body

Diagnosis is Locate the causes from other fault
height and inspect the The fault still exists
finished phenomenon
fault phenomenon again
2. Shimmy of front wheels

Inspection)
1 Inspect the tire wear Normal Faulty Instruction
Inspect the tire wear

conditions (see
Eliminate the tire wear fault (see
Section 33 - Wheels Abnormal abrasion of
Go to Step 2 Section 33 - Wheels and Tires -
and Tires - Wheels tire
Diagnosis, Troubleshooting)
and Tires, On-board
Inspection)
31-10
Inspect the wheel

alignment
Inspect the front

wheel alignment (see Perform the wheel alignment
Section 33 - Wheels The wheel alignment operation (see Section 33 -
Go to Step 3
and Tires - Four- error is excessive Wheels and Wheel Alignment and
wheel Alignment, Adjustment)
Inspection)
Inspect the wheel

dynamic balance
Inspect the wheel

dynamic balance (see Adjust the wheel balance (see
Section 33 - Wheels Go to Step 4 Wheel out of round Section 33 - Wheels and Tires -
and Tires - Wheel Wheel Balance, Adjustment)
Balance, Inspection)
Inspect the Wheel

bearing
Inspect the Wheel

bearing wear (see
Replace the wheel bearing (see
Section 31 - Front Wheel bearing
Go to Step 5 Section 31 - Front Suspension –
Suspension - Front abnormal wear
Wheel Bearing, Replacement)
Suspension, On-
board Inspection)
Check the steering

ball head
Replace the steering gear ball head

Check the ball head Ball head is worn
Go to Step 6 (see 61 – steering gear of electric
wear of steering gear abnormally
steering system, replace)
Check the steering

gear
Check the operating Replace the steering gear (see 61

Steering gear is
condition of steering Go to Step 7 – steering gear of electric steering
misaligned or damaged
gear system, replace)
Carry out the road

test and re-inspect The fault still exists
finished phenomenon
the fault phenomenon
3. Vehicle Deviation

Inspection)
1 Inspect the tire wear Normal Faulty Instruction

Inspect the tire wear

conditions (see
Eliminate the tire wear fault (see
Section 33 - Wheels Abnormal abrasion of
Go to Step 2 Section 33 - Wheels and Tires -
and Tires - Wheels tire
Diagnosis, Troubleshooting)
and Tires, On-board
Inspection)
Inspect the wheel

alignment
Inspect the front

Section 33 - Wheels The wheel alignment operation (see Section 33 -
Go to Step 3
and Tires - Four- error is excessive Wheels and Wheel Alignment and
wheel Alignment, Adjustment)
Inspection)
Inspect the front

suspension
1. Replace the front shock absorber

(see Section 31 - Front Suspension
1. Front shock absorber - Front Shock Absorber and Spring
fault Assembly, Replacement)
Inspect the 2. Connecting bushing 2. Replace the connecting
performances of the aging or damage bushing (see Section 31 - Front
front suspension 3. Connecting bolt Suspension - Sub-frame Assembly,
parts (see Section 31 Go to Step 4 loosening Replacement)
- Front Suspension 4. Connecting part 3. Tighten the bolt
- Front Suspension, deformation and 4. Replace the deformed or
On-board Inspection) cracking cracked part 31
5. Transverse stabilizer 5. Tighten or replace the stabilizer
bar loosening bar (see Section 31 – Front
Suspension - Transverse Sabilizer
Bar, Replacement)
Inspect the Wheel

bearing
Inspect the Wheel

bearing wear (see
Replace the wheel bearing (see
Section 31 - Front Wheel bearing
Go to Step 5 Section 31 - Front Suspension –
Suspension - Front abnormal wear
Wheel Bearing, Replacement)
Suspension, On-
board Inspection)
Check the brake

block
Perform a road test to

check whether there Eliminate the block cause (see 51
Go to Step 6 There is a brake block
is any brake block at – service brake diagnostics)
one side
Carry out the road

test and re-inspect The fault still exists
finished phenomenon
the fault phenomenon
31-12
4. Abnormal Suspension Sound

Check the tire The tire pressure is Section 33 - Wheels and Tires
Go to Step 1
pressure too high - Wheels and Tires, On-board
Inspection)
Inspect the front

suspension
1. Replace the front shock

absorber (see Section 31 -
1. Front shock
Front Suspension - Front Shock
absorber fault
Absorber and Spring Assembly,
2. Connecting Replacement)
Inspect the bushing aging or
2. Replace the connecting
performances of the damage
bushing (see Section 31 -
front suspension 3. Connecting bolt Front Suspension - Sub-frame
parts (see Section 31 Go to Step 2 loosening Assembly, Replacement)
- Front Suspension 4. Connecting part 3. Tighten the bolt
- Front Suspension, deformation and
On-board Inspection) 4. Replace the deformed or
cracking
cracked part
5. Transverse
5. Tighten or replace the
stabilizer bar
stabilizer bar (see Section 31 –
loosening
Front Suspension - Transverse
Stabilizer Bar, Replacement)
Carry out the

road test and re- Locate the causes from other
Diagnosis is finished The fault still exists
inspect the fault fault phenomenon
phenomenon
Front damper assembly

Replacement
1. Remove the front shock absorber assembly
(a). Remove wheel bolt, and then jack up vehicle by
jack or elevator to remove wheels.
LFWX-6470-31009
(b). Remove hexagon flange bolts of brake hose
fixing support, and take down the brake hose
from the support.
31
LFWX-6470-31010
(c). Remove the retaining nut of front torsion-bar

spring connecting rod ball heads, and remove the
front torsion-bar spring ball head connecting rod.
(d). Remove fixing bolts and retaining nuts from the
shock absorber and the steering knuckle.
Tips:
• Carry out marking before disassembling
bolts. Install according to markers, and it
is not necessary to carry out four-wheel
positioning. If there is not any mark, be sure
to carry out four-wheel positioning after the
installation.
• When disassembling, tighten bolts at one
end with a wrench, and remove nuts from
the other end with a torque wrench. After
LFWX-6470-31011
disassembling the nuts, lift upward the
steering knuckle of brake strip to pull out the
fixing bolts one by one.
31-14
(e). Remove the ventilating cover plate (See Chapter

81 Interior & Exterior, Ventilating Cover Plate,
Replacement)
(f). Remove the fastening nut between the front
shock absorber assembly and the installation
plate, and remove the front shock absorber
assembly.
Warning:
• When removing the fixing bolts, pay attention
to the position for using the tool, so as to
avoid interfering with the windshield can
causing damage to the windshield.
LFWX-6470-31012
2. Install the front shock absorber assembly

(a). Install front shock absorber assembly on
installation site under front wheel cover, and
install and fasten retaining nuts of front shock
absorber and mounting plate.
Torque: 65~85 N•m
(b). Install the ventilating cover plate (See Chapter
81 Interior & Exterior, Ventilating Cover Plate,
Replacement)
LFWX-6470-31012
(c). Install and tighten 2 fastening bolts between

the front shock absorber assembly and the
installation plate.
Torque: 200~220 N•m
(d). Install and fasten retaining nuts of front shock
absorber assembly and front torsion-bar spring
connecting rod ball heads.
LFWX-6470-31011
(e). Install brake hose on hose fixing support, and

tighten hexagon flange bolts.
Torque: 6~12 N•m
(f). Check the working condition of front shock
absorber. (See 31 – General Inspection of
Front Suspension – Inspection of Front Shock
Absorber)
LFWX-6470-31010
(f). Install the wheels, and decrease the jack or the

lifting frame.
31
LFWX-6470-31009
31-16
Disassembly and assembly of front damper assembly

1. Disassemble the front shock absorber
assembly
(a) Tighten the front shock absorber assembly on a
bench vise.
(b). Remove the front shock absorber assembly dust
cover.
LFWX-6470-31013
(c). Install the spring compressor and loosen the

spring compressor, to allow the compressor claw
to be located between the spring top and bottom.
(d). Compress the spring until it is disconnected from
upper and lower spring holders.
Warning:
• Confirm that the compressor is completely
installed in place, and then compress the
spiral spring.
• Do not use any pneumatic tool to tighten the
spring compressor fastening bolt.
LFWX-6470-31037
(e). Remove the front shock absorber lock nut.

Tips:
Use the shock absorber nut removal socket to
slowly remove the fastening nut.
LFWX-6470-31014
(d). Remove the upper holder assembly.

(e). Remove the steering bearing, upper spring holder
and spring dust cover.
LFWX-6470-31015
(f). Remove upper rubber mat of shock absorber

spring.
31
LFWX-6470-31031
(g). Remove spring compressor and take out shock

absorber spring.
LFWX-6470-31016
31-18
(h). Remove the buffer block and the lower tray pad
from the front shock absorber.
LFWX-6470-31017
2. Check the front shock absorber

(a) Compress and lengthen the inner rod of shock
absorber. During the operation process, check
whether there is any abnormal resistance
or sound. If any, replace the shock absorber
assembly.
(b) Check whether there is any oil leakage from
shock absorber. If any, replace the shock
absorber assembly.
LFWX-6470-31038
(c). Check whether there is any crack in coil spring. If

any, replace the coil spring.
(d) M e a s u r e t h e f r e e l e n g t h o f s c r e w. I f t h e
measurement result is 5% less than the standard
free length, which means that the coil spring has
been deformed permanently, replace it.
The standard free length L of helical spring:
353mm
LFWX-6470-31039
(c). Check whether upper rubber mat of shock

absorber is damaged or not, if yes, change it.
LFWX-6470-31040
3. Install the front shock absorber assembly

(a) Install the lower tray pad of spring and the
cushioning block of shock absorber in sequence.
31
LFWX-6470-31041
(b). Install shock absorber spiral spring on shock

absorber.
LFWX-6470-31042
31-20
(c). Use spring compressor to fasten spiral spring,

and install upper rubber mat of front shock
absorber.
LFWX-6470-31019
(d). Install steering bearing, spring upper seat and

spring dust cover.
(e). Install upper support assembly.
LFWX-6470-31020
(f). Install the locking nuts of front shock absorber,

and tighten them.
Torque: 70N•m
Tips:
1. Use the shock absorber nut remove socket
to tighten the fastening nut to the specifed
tightening torque.
2. When install the locking nuts of shock
absorber, it is necessary to apply locking glue
at threads.
LFWX-6470-31014
(g). Remove the spring compressor.

(h) Install a dust cover for fixing nuts at the upper
end of front shock absorber.
LFWX-6470-31013
Swing arm assembly

Replacement
1. Remove the swing arm assembly
(a) Lift the vehicle, place the bracket under the front
wheels, and descend the vehicle slowly so that
the front wheels are supported slightly.
(b) Remove slot nuts and cotter pins from the swing
arm ball head assembly.
31
(c) Remove slot nuts from the swing arm ball head
assembly.
(d) Remove the swing arm ball head assembly with
a ball head puller.
LFWX-6470-31026
(e). Remove connecting bolts from the swing arm

and the subframe, and remove the swing arm
assembly.
LFWX-6470-31029
31-22
(f). Remove fixing bolts and nuts from the swing arm
ball head, and remove the swing arm ball head.
Tips:
Check whether the ball head is worn or loose
seriously. If any, replace the ball head.
(g) C h e c k w h e t h e r t h e s w i n g a r m a s s e m b l y
is deformed. If any, replace the swing arm
assembly.
LFWX-6470-31043
2. Install the swing arm assembly

(a) Install a swing arm ball head on the swing arm,
then install retaining nuts and fixing bolts, and
tighten them.
Torque: 75~95 N·m
(e). Install the swing arm assembly on the subframe

assembly, install fixing bolts, and tighten them.
Torque: 280~320 N·m
LFWX-6470-31029
(c). Install the swing arm ball head assembly on the

steering knuckle.
(d) Install slot nuts on the swing arm ball head
assembly, and tighten them.
Torque: 80~110 N·m
(e). Install cotter pins, and lock them.
(f) Lift the vehicle, and remove the bracket.
(g) Carry out four-wheel positioning (See 33 – wheel
and tire wheel positioning, adjust).
(h) Carry out road test to check the vehicle operating
conditions.
LFWX-6470-31026
Sub-frame Assembly
Replacement
Shake the stabilizer bar up and down by hand to check it for looseness. If so, it indicates the bar
fixed block or buffer jacket is aged and should be replaced.
1. Remove the auxiliary frame

(a). And jack up vehicle and support auxiliary frame
by bracket.
(b). Remove triangular swing arm. (See 31 – front
suspension swing arm assembly, replace) 31
(c). Remove the retaining nut for connecting the front
torsion-bar spring connecting rod and front shock
absorber assembly.
LFWX-6470-31044
(d). Remove connecting bolts and fixing bolts & nuts

of bracket, mounting bracket and car body.
LFWX-6470-31045
31-24
(d). Remove the fixing bolt and nut of auxiliary frame

and front bracket beam.
LFWX-6470-31046
(e). Remove the fixing bolt and nut of engine rear

mounting system and auxiliary frame.
(f). Remove the fixing bolt of suspension connecting
rod and auxiliary frame.
LFWX-6470-31047
(g). Remove the fixing bolt and retaining nut of

steering gear and auxiliary frame.
(h). Remove the fixing bolt of the oil inlet and outlet
pipes mounting bracket of steering gear.
(i). Take down auxiliary frame assembly.
Note:
In disassembly, it is necessary to ask two or more
people to cooperate so as to prevent the subframe
falling off.
LFWX-6470-31047
(j). Remove the fixing bolt of torsion-bar spring

mounting cover plate, and take out the torsion-
bar spring cover plate.
LFWX-6470-31030
(k). Remove the front transverse stabilizer bar from

the subframe, and then remove the rubber sleeve
from the front transverse stabilizer bar.
Tips:
Replace the new stabilizer bar buffer jacket.
31
LFWX-6470-31035
2. Install the subframe

(a). Install the front torsion-bar spring cushion collar
and install fixed block on the torsion-bar spring.
(b) Install the front transverse stabilizer bar on the
subframe.
LFWX-6470-31035
31-26
(c). Install torsion-bar spring cover plate on its

installation site, and install and fasten its fixing
bolt.
Torque: 85~105 N·m
LFWX-6470-31030
(d). Install swing arm assembly on auxiliary frame,

and install and fasten the fixing bolts and nuts of
swing arm assembly and auxiliary frame.
Torque: 280~320 N·m
LFWX-6470-31049
(e). Jack up vehicle.

(f). Use bracket to support auxiliary frame assembly,
and install bracket to install fixing bolt and nut of
support and car body and fasten the fixing bolt
and nut.
Green bolt torque: 85 ~ 105 N•m
Grey bolt torque: 280 ~ 320N•m
Note:
In disassembly, it is necessary to ask two or more
people to cooperate so as to prevent the subframe
falling off.
LFWX-6470-31045
(g). Install the fixing bolts and nuts of bracket beam

and auxiliary frame, and fasten them.
LFWX-6470-31046
(h). Install the fixing bolt and nut of rear engine

mounting and auxiliary frame and fasten them.
(i). Install the fixing bolt of suspension connecting
rod and auxiliary frame, and fasten it.
31
LFWX-6470-31047
(j). Install the fixing bolt and retaining nut of steering

gear and auxiliary frame, and fasten them.
(k). Install the fixing bolts of oil inlet and outlet pipes
mounting bracket of steering gear, and fasten
them.
LFWX-6470-31047
31-28
(l). Connect front transverse stabilizer bar with the

connecting rod of front transverse stabilizer bar,
install nuts on the ball head of front transverse
stabilizer bar, and tighten them.
(m). Install swing arm assembly. (See 31- Front
suspension swing arm assembly, Replacement).
(n). Take out bracket and lower vehicle.
LFWX-6470-31044
Front stabilizer bar

Replacement
Tips:
Replacement of front transverse stabilizer bar. (see 31 – front suspension subframe,
replace.)
31
Rear suspension - Rear suspension 32-a
Rear suspension
Rear suspension��1
Precautions�� 2
Rear suspension component drawing�� 3
Rear shock absorber assembly��5
Replacement�� 5
Longitudinal arm eye ring��6
Replacement �� 6
32
32-b Rear suspension - Rear suspension
Rear suspension - Rear suspension 32-1
Rear suspension
Preparations
1. Recommend tools
No. Tool External view S/N Note
Remove the oil pipe

1 Oil pipe wrench
joint nut
Wheel bolt Remove the wheel

2
remover bolts
32
Jack the rear axle

1 Bracket
assembly
Jack the body after

2 Jack
removing the wheels
32-2 Rear suspension - Rear suspension
Maintenance data
Rear wheel toe-in value 0
Items N·m
Rear suspension lower longitudinal arm parts

170~190
fastening bolt and nut
Rear shock absorber fastening bolt and nut 85~105
Fastening bolt to connect the lower longitudinal arm

6~12
and the brake cable
Rear axle and bodywork connecting bolt 260~300
Rear vibration absorber upper end and bodywork

40~50
connecting bolt
Rear vibration absorber lower end and rear axle
80~100
connecting bolt
Rear longitudinal arm eye ring reinforcing plate

50~70
assembly and bodywork connecting bolt
Rear suspension upper longitudinal arm parts

85~105
fastening bolt and nut
Precautions
1. When installing the suspension, must perform the final tightening under condition that the tires
are grounded and no-load condition.
2. After installation of the system, must perform the necessary check.
3. The one-off parts should not be reused.
4. Check the parts carefully before repairing or replacing them.
5. After the installation, must check whether the fasteners are tightened to the specified tightening
torque.
6. Plug the brake oil pipe with the rubber cap to prevent the brake fluid leak when removing the
pipe.
Rear suspension component drawing
11
10
11 2
10
1
5
4-2 4
3
6
5
4-1 9
8
8
9 4-1 5 7 32
6
8
8
LFWX-6470-32001
1 Rear spring 6 Hexagon flange bolt
Install the upper rubber pad to the Longitudinal arm and lifting lug reinforcement
2 7
spring plate assembly
Install the lower rubber pad to the Hexagon head bolt, spring washer and plain
3 8
spring washer subassembly
4 Rear axle assembly 9 Square nut
4-1 Rear axle (left/right) line bracket I 10 Hexagon flange bolt
4-2 Rear axle (left/right) line bracket II 11 All-metal hexagon flange lock nut
5
1. Measure the body height
(a). Body height (rear): 207mm
Tip:
• Ensure the tire pressure reaches the standard
value when measuring the height of vehicle.
• Measurement methods:
Measure the distance H from the ground to
the center of rear mounting longitudinal tie
mounting bolt with the vehicle under no load.
Note:
If the body height can not meet the requirements,
H check the rear suspension for any damage or
deformation.
LFWX-6470-32002
2. Check the rear suspension damping spring

(a). Check the spring for breakage.
(b). Check the upper and lower spring installation
rubber pad for wear or breakage; if any, replace
it.
LFWX-6470-32003
3. Check the rear shock absorber assembly

(a). Driven the vehicle on the poor road conditions
about 10km and then park it.
(b). Check for oil leakage; manually touch the rear
shock absorber housing; if it is not hot, there is
no resistance in the rear shock absorber and it is
not operated, must replace it.
LFWX-6470-32004
Fault diagnosis
Phenomena Fault cause Recommended Measures
1. The rear wheel hub bearing is

Replace the rear wheel hub
Off tracking worn
2. Rear suspension parts abrasion Replace the bearing and the wear parts
1. Vehicle overload Check the body after unloading
Body sinking 2. The spring is too soft Replace the spring
3. Rear damper assembly failure Replace the rear damper assembly
1. Tire abrasion or abnormal inflation Check the wheel tire

Swing/tilting
1. Tire abrasion or abnormal inflation Check the wheel tire
Rear wheel swing 2. The wheels are unbalance Check the wheel tire dynamic balance

1. Tire abrasion or abnormal inflation Check the wheel tire 32
Abnormal abrasion
of tire
3. Rear suspension parts abrasion Replace the worn parts
Rear shock absorber assembly

Replacement
1. Remove the rear shock absorber assembly
(a). Jack up vehicle by jack or elevator, and remove
wheels.
(b). Remove the retaining nut for connecting the rear
shock absorber assembly and torsion beam.
Warning:
• Due to the presence of the damping spring,
the operator should take care when removing
the bolts.
(c). Take down the rear shock absorber assembly
LFWX-6470-32005
(d). Press and extend the shock absorber push rod,

and check the shock absorber for any abnormal
resistance or abnormal noise.
LFWX-6470-32006
2. Install the rear shock absorber assembly

(a). Install the rear shock absorber assembly into the
installation position, and install and tighten the
fastening bolts and washers.
(b). Put down the vehicle by jack or elevator, and
install wheels.
LFWX-6470-32005
Longitudinal arm eye ring

Replacement
1. Remove the trailing arm lug
(a). Jack up vehicle by jack or elevator.
(b). Remove left side beam lower apron of rear floor
(see Chapter 81 Interior & Exterior System –
Floor Lower Apron, Replacement).
(c). Remove fixing bolts of trailing arm lifting lug
reinforcement plate components.
LFWX-6470-32007
(d). C h e c k w h e t h e r t r a i l i n g a r m l i f t i n g l u g
reinforcement plate components are bent,
deformed or damaged or not, if yes, change
them.
LFWX-6470-32008
2. Mount the trailing arm lug

(a). Install the fixing bolts of trailing arm lifting lug
reinforcement plate components.
Torque: 65~85 N•m
(b). Install left side beam lower apron of rear floor (see
Chapter 81 Interior & Exterior System – Floor
Lower Apron, Replacement).
(c). Put down vehicle by jack or elevator.
32
LFWX-6470-32007
Wheels and tires - Wheels and tires 33-a
Wheels and tires

Wheels and tires��1
Precautions�� 3
Typical faults and solutions of tire�� 4
Wheel assy��9
Tire rotation�� 9
Change�� 9
Spare wheel�� 11
Change��11
Use��11
Tire��12
33
Overhaul�� 12
Wheel balance block��14
Test and adjustment�� 14
Four-wheel alignment��15
Test and adjustment�� 15
Tire pressure monitoring sensor��18
33-b Wheels and tires - Wheels and tires
Wheels and tires - Wheels and tires 33-1
Wheels and tires

Preparations
1. Recommend tools
Check the wheels for axial and

1 Dial Gauge
radial runout
Tire pressure
2 Check the tire pressure
gauge
33
3 Wheel wrench Wheel nut wrench and crowbar
4 Jack Lift the vehicle
Wheel balance
5 Check and adjust the wheel balance
machine
33-2 Wheels and tires - Wheels and tires
Four-wheel
6 Check the wheel alignment
alignment machine
Wheel removal
7 Remove and install the wheel
machine
Maintenance data
Front Zero load/full

230kPa/250kPa
wheel load
Air pressure of tires
Rear Zero load/full
230kPa/250kPa
wheel load
Front wheel outer inclination

-0.05°±0.5°
value
Kingpin inner inclination

Wheel alignment 4.65°±0.5°
value
Kingpin rear inclination value 5.5°±0.5°
Front wheel toe-in value 1.3±0.5
Wheel rim model 17×7J 18×8J
Tire model 215/55R17 225/45R18
Left steering angle of left wheel: 39.7°

Leftward
Left steering angle of right wheel: 33.5°
Steering angle
Right steering angle of left wheel: 33.5°
Rightward
Right steering angle of right wheel: 39.7°
Item N·m
Wheel fixing nut 120

Precautions
1. Must use the special tires for lifan Myway series of models, and do not use meridian tires,
slash tire beam tires or fabric layer tires; otherwise it will cause dangerous manipulation and
even out of control of the vehicle.
2. In use, must perform the regular transposition of wheels, so as to reduce the eccentric wear of
front wheel tires and ensure the vehicle driving performance and prolong the service life of tires.
3. In use, must timely wash any mud and sand attached on the tires, to avoid wheel shaking at
high speed and damage of tires.
4. Do not allow any part of the body below the vehicle lifted with the jacks, so as to avoid any
injury.
5. When the vehicle is lifted with the jacks, the engine can not be started or operated.
6. Park the vehicle on a flat and solid ground, tightly apply the parking brake and set the
transmission in neutral position. If necessary, place the blocks below the tires to be replaced in
the diagonal direction.
7. When blocking the wheels, the blocks should be place before the front wheels and after the
rear wheels.
8. Confirm that the jack is placed on the flat and solid ground, confirm that the jack is arranged
on the right support point. Any incorrect support location will lead to vehicle damage or injuries
due to its falling off vehicle.
9. Do not jack the vehicle if there is person in the vehicle.
Component drawing
33
5
1
6
2
3 8 4
7
4
LFWX-6470-33001
215/55 R17 Tire assembly

1 5 T135 / 90R16 Spare tire assembly
(225/45R18 Tire assembly)
Spare wheel fixed pressure plate
2 Aluminium rim 6
assembly
3 Hub cap 7 Spare wheel rim assembly
4 Air valve assembly 8 Bevel wheel nut
System description
The wheels are the ultimate enforcers of most operating commands; they not only can bear
the body weight, transmit the driving force and braking force to the ground and keep the travel
direction, but also can absorb the road vibrations and improve ride comfort; in addition, the high
quality tires can also reduce the rolling resistance, and improve the fuel economy.
1. Check the tires
(a). Check the tires for any abnormal wear and tear; if
any, must find out the causes.
(b). Check the tires for cracks and damage; if any,
replace it.
(c). Check the tire surface for nails, gravels, or other
foreign materials; if any, remove it.
(d). Check whether the tire pressure can meet the
requirements in the technical specifications; if
any, adjust the pressure.
LFWX-6470-33002
Typical faults and solutions of tire

Case 1: The both tire crown shoulders is worn quickly
Fault judgment:
The tire crown grounding trace is widened due to lack
of tire pressure, and the both tire crown shoulders are
grounded because the tire centre is bent and slightly
arched outward, resulting in fast wear of both tire
crown shoulders; when the vehicle is driven at high
speed, the tread may be cracked.
Fault cause and solution:
The tire pressure is insufficient, the travel time is too
long, there is lack of transposition; charge the tire to
the specified pressure.
Case 2: The middle of the tire crown is worn quickly

Fault judgment:
Too high tire pressure can increase the load in unit
grounding area and accelerate the wear in the centre
of tire crown. Moreover, A big tensile stress applied on
the cord fabric layer can lead to the early damage of
the tire.
The tire pressure is too high, there is lack of
transposition; the tire pressure should be adjusted to
the standard value.
LFWX-6470-33004
Case 3: The inner or outer side of tire crown is
worn severely
Fault judgment:
The excessive wear at inner or outer side of the tire is
related to the wheel outer inclination angle. If the outer
side of tire crown is worn partially, the wheel outer
inclination angle is too big; if the inner side of tire crown
is worn partially, the wheel outer inclination angle is too
small;
The wheel outer inclination angle is too big or too
33
small. Must find out and rule out the causes of
abnormal wheel outer inclination angle, to ensure the
normal wheel outer inclination angle.
LFWX-6470-33005
Case 4: There is a zigzag wear from outside to

inside or from inside to outside on the tire crown
Fault judgment:
Such wear is related to improper toe-in adjustment, so
it always occurs on the steering wheels. If there is a
zigzag wear from outside to inside on the tire crown,
the toe-in may be too big; if there is a zigzag wear from
inside to outside on the tire crown, the toe-in may be
too small.
Any deformation of suspension bar parts or joint
loosening can change the wheel toe-in value. If the
toe-in value is too big or too small, must adjust it to the
specified value.
LFWX-6470-33006
Case 5: There is a local polished spots (bald) on

the tire tread
Fault judgment:
The wear is related to the wheel dynamic imbalance.
When the wheel rotation is imbalance, the vibration of
the wheels can cause the orientation wear of the tires,
forming the wear spots.
The tire with wear spots is under the wheel rotational
imbalance condition and must be balanced.
LFWX-6470-33007
Case 6: There is a fan wear on one side of the tire crown

Fault judgment:
The tire is located on a position for a long time and
is not transpositioned or the suspension position is
inappropriate, which may cause the fan wear of the
tire.
Perform regularly the tire transposition. and check and
rule out the suspension fault.
LFWX-6470-33008
Case 7: A single tire is worn seriously and the other tires in the same vehicle are worn slightly.
Fault judgment:
Check the suspension, wheel alignment, wheel hub bearing clearance, wheel balance and rim
deflection of the worn tire, to find out the causes of severe wear of the single tire. If one side of the
tire crown on the single tire is worn severely, the wheel outer inclination angle can not meet the
standard requirements.
If the wheel outer inclination angle is too big, the outside of tire crown may be early wear; if the
wheel outer inclination angle is too small, the inside of the tire crown may be excessive wear.
• For the tire with excessive wear, its suspension system may be not normal or its bearing part
may be deformed, resulting in abnormal single wheel position and too big wheel load; must
check the independent suspension spring, shock absorber and wheel positioning situation, find
out and ruled out the fault.
• If the wheel hub bearing clearance is too big, must adjust or replace the wheel hub bearing.
• If the wheel is imbalance, resulting in excessive wear due to too big dynamic load on single
tire, must perform the dynamic balance test for it.
• If the wheel rim is deformed, must replace it.
Case 8: There is local bulge or projection on the tire

Fault judgment:
The tire stress is too big and the cord layer is damaged
locally, resulting in tire bulge.
Too high tire pressure causes high stress in the tire
or the tire beat is damaged during artificial tire repair
or assembling and disassembling process, resulting
in the tire bulge. The tire with serious bulge must
be replaced. In addition, one of countermeasures to
eliminate or reduce tire bulge is to charge the air in the
tire to the specified pressure, and the tire should be
disassembled or assembled on special tire assembling
machine.
LFWX-6470-33009
Fault diagnosis
The tire pressure can not meet the requirement Adjustment 33

The front wheels are aligned incorrectly Perform the front wheel alignment
The tires on both sides The steering tie rod ball head is loosened Change
are worn unevenly Damper damage Change
The wheel bearing is loosened Adjust or replace
The brake can not be returned in place Adjust or replace
There are foreign bodies on the tire Remove them

Tire is a tire rolling Perform the troubleshooting methods
noise Abnormal abrasion of tire about “Tires on both sides are worn
unevenly”
The tire or rim is out of circle Change
Wheel runout There are bulges on the tire Change
The shock absorber has a fault Change
The tires are not matched or uneven Change
The tire pressure is improper Adjust the tire pressure
The spring is broken or loosened Replace the spring
The radial tire is warped by the transverse force Replace the tire
Wheel running
(running deflection) Check and adjust the front wheel
Front wheel alignment improper
alignment
A drive wheel is stuck (not released) Check the braking system
The front or rear suspension is loosened, bent

Tighten or replace the suspension parts
or damaged
The spring is loosened or damaged Replace the spring
The tire is unbalance Adjust the tire balance or replace the tire
Check and adjust the front wheel

alignment
The column has a fault Replace the column

The tire is abnormal The road conditions are poor Replace the tire
wear or excessive
wear The vehicle is overloaded Replace the tire
Replace the tire or perform the tire

The tires are not transpositioned
transposition
The wheel bearing is worn or loosened Replace wheel bearing
The wheel or tire is swing Replace the wheel or tire
The tire pressure is too low Adjust the tire pressure
Vehicle front wheel Balance the wheel or replace the tire or

The wheel is unbalance
shimmy, shock or run- wheel
out The wheel bearing is damaged or worn Replace wheel bearing
The steering tie rod ball head is worn Replace the steering tie rod ball head
The front swing arm ball head is worn Replace the front swing arm
The wheel radial runout is excessive Repair or replace the wheel or tire
There is a bulge or damage on the tire Replace the tire

Vehicle front wheel The wheel overload causes the radial runout Replace the tire or wheel
shimmy, shock or run-
out Check and adjust the front wheel
alignment
Tighten or replace the steering

The steering connecting rod is worn or loosened
connecting rod
Tighten the steering system fastening

The steering system fastening bolt is loosened
bolt
Front pillar defected Replacement
Wheel bearing damaged Replace the wheel bearing

There is concave on
Deflection of tyre and wheel is too large Replace the tire and rim
the tire
Front suspension ball has worn away Replace the front swing arm
Tyre unbalance Adjust the tire (dynamic balance)

Wheel assy
Tire rotation
1. Tire transposition
Tips:
In order to make even wear and prolong the service
life of tires, it is recommended to perform the tire
transposition once every 10000 km. However, the
most appropriate time for the tire transposition should
depend on the driver`s driving habits and road surface
conditions.
LFWX-6470-33010
Change
Tips:
33
• If the wheel is damaged, such as distortion, cracks or serious corrosion, it must be replaced.
• If the damaged wheel is not replaced, the tire may be out of the wheel or cause out of control.
1. Remove the wheel

(a). Loosen the wheel nuts for a half turn.
Tips:
• Must place the blocks below the wheels to be
replaced in diagonal direction.
• When blocking the wheels, the blocks should
be placed before the front wheels or after the
rear wheels.
LFWX-6470-33011
(b). Jack the vehicle body at the wheel removal side,

to allow the wheel off the ground.
(c). Remove the wheel fastening nuts, and remove
the wheel.
Note:
Don`t loosen the excessively tightened wheel in
the heating way, because the heating operation
may shorten the service life of the wheel.
LFWX-6470-33012
2. Install the wheel

(a). Install the wheel into the installation position, and
install and tighten manually the wheel fastening
nuts.
(b). Decrease the vehicle on the ground, and tighten
diagonally the wheel fastening nuts.
Torque: 120 N. m
Note:
• Before installing the wheel, must remove
the rust deposited on the wheel installation
surface and the brake disc surface with a wire
brush.
• When installing the wheel, must match fully
the wheel installation surface with the brake
LFWX-6470-33013 disc surface; otherwise it will cause that the
wheel nuts are loosened.
• Must tighten diagonally the wheel nuts to the
appropriate torque, so as to avoid that the
wheel or brake disc is bent.
• Do not coat the oil or lubricant on the bolts or
nuts; otherwise it will cause that the nuts are
tightened excessively and their threads are
damaged.
Spare wheel
Change
1. Remove and install the spare wheel
(a). Open bottom plate surface cover of trunk, and
take out tool box in vehicle;
(b). Screw off spare wheel pressure plate, and take
out spare tyre;
(c). Put in spare tyre, and then fasten spare wheel
pressure plate;
(d). Notes: put spare tyre rather than full-size tyre.
LFWX-6470-33014
33
LFWX-6470-33015
Use
Note:
The spare tire can only be used for a short time, and can not be used at high-speed (the
maximum speed can not exceed 90km/h and the travel mileage should be within 50km).
Tire
Overhaul
1. Remove the tire

Tips:
The tire should be removed on the tire removal machine, and do not remove manually the tire,
so as to avoid any damage to the bead and the rim; do not tap the rim, so as to prevent the
deformation and affect on air tightness. The tire and wheel should be matched and assembled in
the assembly plant, i.e., the “Light” point on the tire should be matched with the “Heavy” point on
the wheel, to ensure the most stable driving.
“Light” point on the tire is marked on outside of the tire wall with paint, and “Heavy” point on the
wheel is marked on the rim circle with paint. The marking points will finally washed off. If they are
appropriate assembled, the number should be aligned with the marking point on the tire. When the
tire is removed from the wheel, the wheel should be matched with the tire for re-assembly. If the
marking point on the tire can not be identified, the tire and the wheel should be marked with a line
before disassembling, to ensure the same assembling positions for installation.
(a). Vent full the residual air in the tire.

(b). Loosen the connection between the tire and the
rim on the tire removal machine, rotate the tire
and repeatedly squeeze it, and then flip the tire to
loosen the connection on the other side.
(c). Remove the counterweight on the rim.
(d). Place the convex surface of wheel rim on the
working plate 6 upward, slightly press it to make
it flat and operate the pedal to clamp the rim.
(e). Coat a little lubricant on the flange of the rim,
press it and fasten the lifting lever, to form a 3
mm clearance between the removers 7 and 8
and the rim flange.
Tips:
1 – Pressing plate; 2, 3, 4, 5 - Control pedals; 6
LFWX-6470-33016 - Working plate; 7, 8 - Remover; 9 - Handle; 10 -
Positioning lock.
(f). With F end of the remover as a fulcrum, use a

lever to pry up on the edge of the outer tire, to
allow it to contact with F end of the remover.
(g). Operate the pedal, to rotate the working plate,
until the upper edge of the tire is removed
completely.
(h). Remove the other side of the tire with the above
method.
LFWX-6470-33017
2. Repair the tire

Tips:
Most tire piercing can be repaired inside with the maintenance plug or sulfide repair piece; the two
repair methods are described respectively.
(a). Repair the tire piercing with the maintenance plug.
• Polish near the tire inside puncture with the tire repair file.
• tires inside with tire repair file file up near the hole.
• Select a suitable maintenance plug that is slightly big than
Pull forcely the piercing hole, and guide it into the hole in the repair
tool.
Tire crown • Use sulfide liquid to lubricate the maintenance plug and
guide tool.
• Use the guide tool to guide the maintenance plug into the
hole from the tire inside, and squeeze the head, to allow
Polishing location
the maintenance plug head to contact with the inside of
tire.
Maintenance plug • Allow the maintenance plug on about 0.8 mm range on
the tire crown surface and remove unwanted parts.
(b). Repair tire piercing with the cold repair piece.
• Polish near the tire inside puncture with the tire repair file.
• Coat sulfide liquid evenly on the polishing surface at tire
inside, and make it dry naturally until it is sticky.
LFWX-6470-33018
• Peel off the tire repair piece skin, make it center align
with the piercing hole at tire inside, and attach it on the
piercing hole.
• Move the pressing tool on the tire repair piece around, to
ensure that it can be attached tightly with the tire.
Tips:
Install the tire on the tire installing/removing device; during installation, the side with red 33
point mark should be outward; for repaired tire, the marks made during removal should also
be aligned.
(a). Clean the bead on the rim.

(b). Fix the rim on the working plate, and coat the lubricant on on
the outer surface of bead.
(c). Install the tire set around the rim, to install its left side and
adjacent side into the groove at the central of the rim.
(d). Adjust the removers 7 and 8 to proper positions, lock the
lifting lever, and allow that the tire edge that is not install the
rim groove is located above G end and below F end of the
remover.
(e). Press manually the tire, start the workbench, and install the
tire edge on one side.
(f). With the above method, install the other side of the tire
edge, to ensure that the tire is installed evenly on the rim;
and then charge the air into the tire, and then perform the
dynamic balance test.
Note:
LFWX-6470-33019 • The air charging personnel can not stand on the tires;
otherwise the tire burst may cause serious injury.
• The charging pressure can not exceed the prescribed
pressure. If the tire rim is not grounded, the tires should
be vented, lubricated, and re-charged.
Wheel balance block

Test and adjustment
Tips:
There are two wheel and tire balance methods of static balance and dynamic balance. The static
balance is to distribute equally the weight around the wheel.
The wheel without the static balance can cause the wheel runout, known as the vertical swing;
finally it will cause uneven wheel wear.
The dynamic balance is to distribute the weight evenly on both side of the wheel centerline, to
ensure that the wheel assembly is not moved around during its rotation. The dynamic imbalance
can not cause the lateral swing.
Note:
Must remove sludges and other deposition on the rim.
Warning:
In order to obtain a good balance, must remove the gravels in the tire tread, to avoid injury of the
rotation operator.
Static balance Dynamic balance
(A)/(C) : before balancing

(A)/(C) : after balancing
1. Wheel runout caused by serious defects
2. Balancing block installation position
3. Axle center line
LFWX-6470-33020
Four-wheel alignment
Test and adjustment
Tips:
The four-wheel misalignment may cause the steering deflection, incorrect steering wheel return,
the eccentric tire wear or serrated tire wear and other abnormities.
1. Preparations before test
(a). Check whether the tire size and tire pressure can
meet the requirements from its original factory.
(b). The rim deformation should be within the
prescribed scope (see below).
(c). The suspension system ball head pin should not
be loosened.
Tips:
Manually hold the wheel, move it up and down, left
and right, to check its swing.
(d). The braking performance should be under good
status.
LFWX-6470-33021
2. Site requirements
(a). The test site surface should be smooth, and in 33
the level status as far as possible.
(b). Place two angle gauges into the reserved pits
with the same thickness of the angle gauge
respectively.
Tips:
If there is no reserve pits, after the two front
wheels are placed on the angle gauge, the two rear
wheels should be padded with a flat board with the
same thickness of the angle gauge.
LFWX-6470-33022
3. Proper vehicle arrangement

(a). Lift the vehicle and place two front wheels on the
angle gauge, and allow the extension line of the
king pin centerline to pass through basically the
center of the angle gauge.
(b). Turn the steering wheel, to ensure that the
vehicle is in a straight line.
LFWX-6470-33023
4. Install the instrument
LFWX-6470-33024
5. Test order
(a). Test order and adjustment order of four-wheel
alignment: kingpin rear inclination angle,
kingpin inner inclination angle, front wheel outer
inclination angle and front wheel toe-in.
Note:
The kingpin inner inclination angle, kingpin rear
inclination angle and front wheel outer inclination
angle are ensured in the structure design, and not
required for adjustment; if any parameter exceeds
the prescribed scope, directly replace the steering
knuckle.
LFWX-6470-33025
6. Adjust the front wheel toe-in

(a). Loosen the steering tie rod lock nut.
LFWX-6470-33026
(b). Rotate the steering tie rod, until there is a correct

toe-in value displayed in the instrument.
Tips:
At the same time, with the same amplitude, adjust
reversely the wheel on the other side to obtain the
right toe-in value.
33
LFWX-6470-33027
(c). After adjustment, tighten the steering tie rod lock

nut.
Tips:
When tightening the steering tie rod lock nut (to
the torque of 45 N. m), must grip the steering tie
rod.
LFWX-6470-33028
7. Measure the the maximum steering angle of

4
front wheels
(a). Keep the vehicle placement status for the wheel
4
4
2
1
120
！
0
alignment test.
(b). Depress the brake pedal, to brake the wheels.
(c). Turn the steering wheel to the left and right limit
positions, to measure the maximum steering
angle of the both front wheels.
Maximum steering angle
To the left a: L eft steering angle of the left
wheel: 39.7°
Left steering angle of the right wheel: 33.5°
To the right b: Right steering angle of the left
whee:33.5°
Right steering angle of the right wheel:39.7°
Tips:
If the maximum steering angle to be measured
does not meet the requirements, must check the
suspension system parts for bending or damage.
LFWX-6470-33029
Tire pressure monitoring sensor

Replacement
1. Remove the tire pressure monitoring sensor
(a) Remove the tire. (see 33-wheel and tire
assembly, replacement)
(b) Unscrew the mounting bolts and remove the air
valve and tire pressure sensor assembly.
2. Install the tire pressure monitoring sensor
(a) Remove all dirt or debris on the tire pressure
monitoring sensor mounting position.
(b) Install the air valve and tire pressure monitoring
sensor assembly onto the mounting position.
Tire pressure sensor installation torque: 4 ±
0.6N•m
(c) Install the tire. (see 33-wheel and tire assembly,
replacement)
LFWX-6470-33030 Tips:
After replacing the tire pressure sensor, re-read
the identification code.
33
Drive Shaft - Drive Shaft 41-a
Drive Shaft
Drive Shaft��1
Precautions�� 2
Diagnosis��3
Drive Shaft assembly��9
Inspection�� 9
Replacement�� 9
Disassembly and Installation�� 12
41
41-b Drive Shaft - Drive Shaft
Drive Shaft - Drive Shaft 41-1
Drive Shaft
Preparations
Remove and install the upper circlip or

1 Circlip pliers
retaining ring on the drive shaft
Clamp fastening
2 Fasten the dust cover clamp
tool
41
Drive shaft Remove the drive shaft from the
3
removal Tool transmission
41-2 Drive Shaft - Drive Shaft
Maintenance data
Item N•m
Connecting nut between the drive shaft and the

220~280
front brake
Precautions
1. In the daily maintenance, check regularly the drive for scratches or interference with
other parts.
2. During the vehicle running, the drive shaft shield cover can not be long-term friction
with other parts; when it is removed, it can not bump sharp objects, so as not to
damage.
3. The removed disposable parts can not be used again.
4. Clean the outer surface of the parts before disassembling and assembling the drive
shaft.
5. Be careful not to contaminate the parts and prevent foreign matter from entering during
the maintenance.
6. Clean the disintegrated parts (except for rubber parts) with kerosene and blow them or
clean them with paper towels and rags.
System description
1. Function
The drive shaft is used to transfer to the power from the transmission to the wheels, and the
constant velocity knuckle of the drive shaft can ensure the direction variability and continuity of
the power transfer.
2. Composition
The dive shaft consists of left and right mandrels, constant velocity knuckle, dust cover and
other parts.
3. Working Principle
The transmission is used to transfer the engine power to the drive shaft, and the constant
velocity knuckles on both ends of the drive shaft can ensure the stable power transmission in
case of changing the wheel positions.
1. Check the system operation

(a). Apply the parking brake and start the engine, depress the accelerator pedal, check the
drive shaft during acceleration for shaking or vibration; if any, carry out the inspection and
maintenance with reference to the following diagnosis content.
(b) Carry out the road test for the vehicle; check the drive shaft for “Click” sound; if any, carry out
the inspection and maintenance with reference to the following diagnosis content.
(c) Carry out the road test for the vehicle; when the vehicle is accelerated, check the drive shaft
for dull metal sound; if any, carry out the inspection and maintenance with reference to the
following diagnosis content.
(d) Check the drive shaft for breaking or disengagement; if any, carry out the inspection and
maintenance with reference to the following diagnosis content.
(e) Carry out the road test for the vehicle; check the vehicle for low-speed swings; if any, carry out
the inspection and maintenance with reference to the following diagnosis content.
Diagnosis
1. Tripod knuckle (wear)
2. Ball cage knuckle (wear) See Section 41 - Drive Shaft -

Shaking or vibration Diagnosis, Troubleshooting
3. Knuckle (too big angle)
during acceleration (1. Shaking or vibration during
4. Suspension spring (too big height setting) acceleration)
5. Powertrain mount (wear or error)
1. Ball cage knuckle (wear) See Section 41 - Drive Shaft -

“Click” sound when Diagnosis, Troubleshooting
2. Knuckle dust cover (breakage)
operating (2. “Click” sound when
3. Knuckle (poor lubrication, contamination) operating)
1. Knuckle dust cover (breakage) See Section 41 - Drive Shaft -

Dull metal sound in the Diagnosis, Troubleshooting
2. Knuckle (poor lubrication, contamination)
slipping acceleration (3. Dull metal sound in the
3. Tripod knuckle (wear) slipping acceleration)
1. C-shaped clamp at the connection of

the drive shaft and the transmission 41
(deformation)
See Section 41 - Drive Shaft -
Drive shaft is 2. Drive shaft (deformation) Diagnosis, Troubleshooting
disengagement (4. Drive shaft is
3. Drive shaft slotted thin nut (damage) disengagement)
4. Front suspension (deformation or
distortion)
1. Wheels (unbalance)
2. Wheels (incorrect wheel alignment)

See Section 41 - Drive Shaft -
Vehicle low-speed
3. Wheel bearing (wear) Diagnosis, Troubleshooting
vibration
(5. Vehicle low-speed vibration)
4. Suspension (deformation, wear)
5. Drive shaft (damage)

Fault diagnosis
1. Shaking or vibration during acceleration

absorber (see Section
1. Front shock 31 - Front Suspension
absorber fault - Front Shock Absorber
and Spring Assembly,
Replacement)
2. Connecting 2. Replace the connecting
Check the performances bushing aging or bushing (see Section
of the front suspension damage 31 - Front Suspension
parts (see Section 31 - - Sub-frame Assembly,
Go to Step 1 Replacement)
Front Suspension - Front 3. Connecting bolt
Suspension, On-board loosening 3. Tighten the bolt
Inspection) 4. Connecting part 4. Replace the deformed
deformation and or cracked part
cracking 5. Tighten or replace
5. Front transverse the stabilizer bar
loosening Front Suspension -
Front Stabilizer Bar,
Replacement)
Check the drive shaft

dust cover
Replace the drive shaft

dust cover (see Section 41
Check the drive shaft Drive shaft dust cover
Go to Step 2 - Drive Shaft - Drive Shaft
dust cover for damage damage
Assembly, Removal and
Installation)

assembly
Remove the drive shaft

assembly and check the
performance of the drive
Drive shaft assembly assembly (see Section 41
shaft assembly (see Go to Step 3
fault - Drive Shaft - Drive Shaft
Section 41 - Drive Shaft
- Drive Shaft Assembly,
Inspection)
Check the powertrain

mount
Replace the transmission

Check the connection
The powertrain differential half-shaft gear
between the drive shaft
Go to Step 4 mount is excessive (see Section 21 - Manual
and the transmission for
wear Transmission Differential,
wear
Differential Assembly)
Check the ball cage

knuckle
Replace the ball cage

knuckle (see Section 41 -
Check the ball cage Ball cage knuckle
Go to Step 5 Drive Shaft - Drive Shaft
knuckle for wear wear
Installation)
5 Check the tripod knuckle Normal Faulty Instruction
Replace the tripod

knuckle (see Section 41
Check the tripod knuckle
Go to Step 6 Tripod knuckle wear - Drive Shaft Assembly,
for wear
Decomposition and
Assembly)
Repair the fault part

and re-check the fault The fault still exists
phenomenon
2. “Click” sound when operating
Start engine, operate it “Click” sound is from

Diagnosis is
at idling, and check for the rotating drive Go to Step 1
finished 41
“Click” sound shaft

dust cover

Installation)

assembly

Inspection)
Check the knuckle for

lubrication
The knuckle is poor

Go to Step 4 lubrication, sticking, Lubricate the knuckle
knuckle for lubrication
or blocking
Check the ball cage

knuckle

Check the ball cage Ball cage knuckle
Go to Step 5 Drive Shaft - Drive Shaft
knuckle for wear wear
Installation)

phenomenon
3. Dull metal sound in the slipping acceleration
Perform the slipping

Diagnosis is The dull metal sound
acceleration and check the Go to Step 1
finished is from the drive shaft
drive shaft for the noise

dust cover

Installation)

assembly

Inspection)
Check the knuckle for

lubrication
The knuckle is poor

Go to Step 4 lubrication, sticking, Lubricate the knuckle
knuckle for lubrication
or blocking
4 Check the tripod knuckle Normal Faulty Instruction

Check the tripod knuckle
Go to Step 5 Tripod knuckle wear Drive Shaft - Drive Shaft
for wear
Installation)

phenomenon
4. Drive shaft is disengagement
0 Initial inspection Normal Faulty Initial inspection

absorber (see Section
1. Front shock 31 - Front Suspension
absorber fault - Front Shock Absorber
and Spring Assembly,
Replacement)
2. Connecting
2. Replace the connecting
bushing aging or
Check the performances bushing (see Section
damage
of the front suspension 31 - Front Suspension
parts (see Section 31 - - Sub-frame Assembly,
Go to Step 4 3. Connecting bolt Replacement)
Front Suspension - Front
Suspension, On-board loosening 3. Tighten the bolt
Inspection) 4. Connecting part 4. Replace the deformed
deformation and or cracked part
cracking
5. Tighten or replace
5. Front transverse the stabilizer bar
loosening Front Suspension -
Front Stabilizer Bar,
Replacement)
Check the drive shaft Check the drive shaft dust

1 Normal Faulty
dust cover cover
41
Drive shaft dust cover
Check the drive shaft Check the drive shaft dust
Go to Step 2 damage or incorrect
dust cover for damage cover for damage
installation
Check the drive shaft Check the drive shaft

2 Normal Faulty
assembly assembly
Remove the drive shaft Remove the drive shaft

assembly and check the assembly and check the
performance of the drive Drive shaft assembly performance of the drive
Go to Step 3
shaft assembly (see Section fault shaft assembly (see Section
41 - Drive Shaft - Drive 41 - Drive Shaft - Drive
Shaft Assembly, Inspection) Shaft Assembly, Inspection)

3 Normal Faulty
C-shaped clamp C-shaped clamp

C-shaped clamp
C-shaped clamp for Go to Step 4 C-shaped clamp for
deformation
normal performance normal performance

4 Normal Faulty
slotted thin nut slotted thin nut

Slotted thin nut
slotted thin nut for normal Go to Step 5 slotted thin nut for normal
damage
operation operation
5 Verify and check Normal Faulty Verify and check
Repair the fault part Repair the fault part

Diagnosis is
and re-check the fault The fault still exists and re-check the fault
finished
phenomenon phenomenon
5. Vehicle low-speed vibration
Check the wheel balance Adjust the wheel balance

(see Section 33 - Wheels The wheels are (see Section 33 - Wheels
Go to Step 1
and Tires - Wheel unbalance and Tires - Wheel Balance,
Balance, Inspection) Adjustment)
Check the wheel

alignment
Check the front wheel Carry out the wheel

alignment (see Section alignment (see Section
The wheel alignment
33 - Wheels and Tires - Go to Step 2 33 - Wheels and Tires -
error is excessive
Four-Wheel Alignment, Four-Wheel Alignment,
Inspection) Adjustment)
2 Check the Wheel bearing Normal Faulty Instruction
Check the wheel bearing

Replace the wheel bearing
for wear (see Section
Wheel bearing (see Section 31 - Front
31 - Front Suspension - Go to Step 3
abnormal wear Suspension - Wheel
Front Suspension, On-
Bearing, Replacement)
board Inspection)
3 Check the suspension Normal Faulty Instruction
Check the suspension

parts for normal
performance (see Replace the damaged
Suspension
Sections 31/32 - Front parts (see Sections 31/32
Go to Step 4 deformation or parts
Suspension/Rear – Front suspension/Rear
loose or wear
Suspension - Front Rear/ Suspension)
Rear Suspension, On-
board Inspection)

dust cover

Drive shaft dust cover dust cover (see Section 41
Go to Step 5 damage or incorrect - Drive Shaft - Drive Shaft
dust cover for damage
installation Assembly, Removal and
Installation)

assembly

Inspection)

phenomenon
Drive Shaft assembly

Inspection
1. Check the drive shaft
Tips:
If any abnormity is found as described below, the
drive shaft must be disassembled for repair and
replacement of the damaged part.
(a) Check the wheel knuckle for obvious loosening.
(b) Check the axial movement of the knuckle at the
side of the transmission for sticking.
(c) Check the ball joint at the side of the transmission
for too large radial clearance.
(d) Check the dust cover for damage.
Note:
During the inspection, maintain the drive shaft on a
level plane.
LFWX-6470-41001
Replacement
Tips:
The replacement and maintenance methods for left and right drive shafts are basically the
same, and only the left drive shaft is exampled in this section.
41
1. Remove the left drive shaft assembly
(a). Lift the vehicle, and remove the front wheels (see Section 33 - Wheels and Tires - Wheel
(b). Remove the left drive shaft fixing nut.

Tips:
Make the installation marks on each drive shaft
joint flange and the drive shaft.
Note:
When perform the removal operation on the repair
gutter, if the vehicle needs movement, please pay
attention to the safety
LFWX-6470-41002
(c). Remove brake assembly bolts/nuts and brake

pipe fixing bolt.
LFWX-6470-41003
(d). Rotate the front brake and steering knuckle

assembly to the proper angle and take out the
drive shaft at the wheel side from the knuckle
hub.
LFWX-6470-41004
(e). Pull out the left drive shaft assembly from the
transmission.
Tips:
Must use the drive shaft removal tool to remove
the drive shaft assembly, and do not use a heavy
tool to tap directly the drive shaft assembly, to
avoid damage to the drive shaft.
Note:
• Be careful not to damage the dust cover and
the oil seal.
• Be careful not to drop the drive shaft assembly.
• Do not pull out the drive shaft assembly
directly; or it may cause the disengagement
of the left and right tripod knuckle ends or
even damage to the dust cover.
LFWX-6470-41005
2. Install the left front drive shaft assembly

(a) Check whether the drive shaft assembly spring
retainer at the transmission side is installed in
place.
Tips:
Replace the retainer after each removal.
(b). Apply the gear oil onto the driver shaft tripod
knuckle spline shaft at the transmission side.
LFWX-6470-41006
(c). Align the inner end of the drive shaft with the
differential center hole, slowly rotate the drive
shaft to allow the key teeth matching and force it
into and install the drive shaft at the transmission
side into the differential.
Tips:
• Rotate the drive shaft assembly, hear the
sound and feel to determine that the knuckle
spline shaft at the transmission side is
installed in place; or lightly pull the drive shaft 41
to determine that the knuckle spline shaft at
the transmission side is installed in place.
• Tap the drive shaft assembly with a rubber
hammer to push the knuckle spline shaft into
the differential.
LFWX-6470-41007
Note:
• When installation, maintain the spring retainer
opening downward.
• Be careful not to damage the dust cover and
the oil seal.
(d). Rotate the front knuckle and install the drive axle
at the wheel side into the knuckle hub.
LFWX-6470-41008
(e). Install brake calipers assembly bolt and nut.

Torque: 200 ~ 220 N•m (big bolt)
200~220 N•m (nut)
20 ~ 25 N•m (small bolt)
LFWX-6470-41009
(f). Install and tighten the drive shaft slotted nut.

Torque: 240 N•m
Tips:
Rivet the nut with a chisel.
(g) Install the front wheels (see Section 33 - Wheels
and Tires - Wheel Assembly, Replacement)
LFWX-6470-41010
Disassembly and Installation
1. Disassemble the tripod knuckle assembly at

the transmission side
(a) Pry the large clamp and small clamp on both
sides of the drive shaft dust cover with a
screwdriver.
Note:
Must replace the removed clamps, and do not
damage the dust cover when removal.
LFWX-6470-41011
(b). Pull out the dust cover from the tripod knuckle
and move it to the middle of the drive shaft.
(c) Clean the grease inside the tripod knuckle with a
cloth or paper towel.
(d) Draw the assembly marks on the tripod knuckle
housing and on the drive shaft.
Note:
Do not make the marks with a punch or chisel, and
do it with a marking pen.
LFWX-6470-41012
(e). Remove the tripod knuckle from the drive shaft.
41
LFWX-6470-41013
(f). Remove C-shaped retainer inside of the drive

shaft with clamp pliers.
LFWX-6470-41014
(g). Make the mark on the tripod shaft for easy

installation.
Note:
Do not make the marks with a punch or chisel, and
do it with a marking pen.
(h) Tap the tripod shaft from the drive shaft with a
copper rod or rubber hammer.
Note:
Do not tap the roller when removal.
LFWX-6470-41015
(i). Remove the dust cover from the drive shaft.

Note:
Remove it and wrap the spline with the tape to
prevent the damage to the dust cover.
LFWX-6470-41016
2. Dismantle the ball knuckle assembly at wheel

side
(a) Loosen the large and small clamps on both sides
of the dust cover at fixing end with a screwdriver.
Note:
The removed clamps can not be reused and must
be replaced; when dismantling, do not damage the
dust cover.
LFWX-6470-41017
(b). Pull out the dust cover from the ball knuckle
assembly and move the dust cover to the middle
of the drive shaft.
(c) Pull out the ball knuckle assembly at wheel side
from the drive shaft.
Tips:
Fix the drive shaft into a vise, and tap vertically out
the ball knuckle assembly in axial direction with a
rubber hammer or a copper bar.
LFWX-6470-41018
(d). Remove the wire retainer and the seal cover at

fixing end of the drive shaft.
Note:
When removal, wrap the drive shaft spline with a
tape, to prevent damage to the dust cover.
41
LFWX-6470-41019
(e). Tap the ball knuckle bearing cage with a copper

bar and a hammer to tilt it.
(f) When the ball knuckle bearing cage is tilted,
remove the first ball.
(g) Tilt the ball knuckle bearing cage in the opposite
direction and remove the opposite ball.
(h) Remove all balls one by one with this method.
LFWX-6470-41020
(i). Rotate the ball knuckle bearing cage and the

inner ring to the proper angle and remove it.
LFWX-6470-41021
(j). Remove the inner ring from the ball knuckle

bearing cage.
(k) Clean the disassembled parts, remove the
grease and contaminants, and dry all parts.
(l) Check all parts of the ball knuckle assembly
for abnormal wear, fracture, or damage; if any,
replace them.
LFWX-6470-41022
3. Assemble the tripod knuckle assembly at the

transmission side
(a) Wrap the spline on the drive shaft with a tape to
avoid damage to the dust cover and install the
dust cover at sliding side on the shaft.
Note:
• The removed dust cover clamps can not be
re-used.
• Remove the tape to wrap the drive shaft
spline after installation.
LFWX-6470-41023
(b). Align the mark and install the tripod shaft.

Note:
Install the tripod shaft with a copper bar or rubber
hammer.
LFWX-6470-41024
(c). Install C-shaped retainer inside of the drive shaft.

(d) Apply the grease on the tripod shaft assembly.
41
LFWX-6470-41014
(e). Align the marks, and install the drive shaft tripod
knuckle at the transmission side.
(f) Fill the appropriate amount of grease.
(g) Install the dust cover at sliding end onto the
constant velocity knuckle.
Note:
If the grease is stuck onto the dust cover fixing
surface, the dust cover may fall off; when installing
the dust cover, must clean the grease on the
surface.
LFWX-6470-41014
(h). Insert the flat screwdriver from the large-diameter

side of the dust cover at the sliding end to release
the air inside and adjust the installation length of
the dust cover to avoid the dust cover
deformation.
Note:
• If the installation length of the dust cover is
too long, it may damage the dust cover.
• Carefully use the flat-blade screwdriver to
avoid damage to the performance of the dust
cover.
LFWX-6470-41026
(i). Install a new clamp on the dust cover at sliding

end.
(j) Fasten the new clamp on the dust cover at sliding
end.
Note:
The removed dust cover clamp must be replaced,
and can not be reused.
LFWX-6470-41027
4. Assemble the ball knuckle assembly at the

wheel side
(a Install the inner ring into the ball bearing cage.
(b) Rotate the ball bearing cage and the inner ring to
an appropriate angle and install them into the ball
knuckle.
Note:
Ensure that the fixing side of the inner ring is
toward the drive shaft journal.
LFWX-6470-41028
(c). Insert the first ball, and then tilt the ball knuckle
bearing cage in the opposite direction and insert
the opposite ball.
(d) Install all balls one by one with this method.
(e) Apply a proper amount of grease onto the
toothed hole of the knuckle sub-assembly until
the grease flows out from the circular slot and
toothed hole. After applying the grease, clean the
flowed grease with a rag.
LFWX-6470-41020
(f). Wrap the drive shaft spline with a tape to avoid

damage to the seal and install the dust cover at
fixing end onto the shaft.
Note:
• Do not reuse the dust cover clamp.
• Remove the tape to wrap the drive shaft
spline after installation.
41
LFWX-6470-41029
(g). Install the wire retainer at fixing end onto the

drive shaft, so that the ball knuckle is arranged
vertically, and insert the drive shaft into the ball
knuckle center hole to the end.
Tips:
Ensure that the knuckle sub-assembly is correctly
engaged when the drive shaft is rotated.
(h) Evenly apply the appropriate amount of grease
into the dust cover from large diameter side at
the fixing side.
Note:
• If the grease is stuck onto the dust cover
fixing surface, the dust cover may fall off; the
grease on the surface must be cleaned when
installing the dust cover.
LFWX-6470-41030 • Clean all grease on the dust cover surface.
(i) Insert a flat screwdriver from the large diameter
side of the dust cover at fixing side to release the
air inside and adjust the installation length of the
dust cover to avoid the dust cover deformation.
Note:
• If the installation length of the dust cover is too long, it may damage the dust cover.
• Carefully use the flat-blade screwdriver to avoid damage to the performance of the dust cover.
(j). Install a new dust cover clamp at fixing end.

(k) Fasten the new dust cover clamp with the tool.
Note:
Do not reuse the dust cover clamp.
LFWX-6470-41031
41
Service Brake System - Service Brake System 51-a
Service Brake
Service Brake��1
Precautions�� 3
Diagnosis��6
Brake pedal�� 18
Adjustment�� 18
Brake master cylinder assembly 22
Vacuum booster�� 23
Brake fluid�� 26
Replacement�� 26 51
Exhaust�� 27
Front brake�� 28
Testing�� 29
Rear brake�� 33
Component drawing
(1.8L, 2.0L, 1.5T-5MT)�� 33
Component drawing
(2.0L-CVT, 1.5T-8AT)�� 34
Brake line�� 40
Component drawing (ABS)�� 40
Component drawing (ESC)�� 41
Component drawing (ESP)�� 42
51-b Service Brake System - Service Brake System
Service Brake System - Service Brake System 51-1
Service Brake
Preparations
1 Oil pipe wrench Remove the oil pipe joint nut
Rear brake piston

2 Remove the rear brake cylinder piston
remove tool
51
3 Dial Gauge Measure the front and rear brake discs
4 Micrometer Measure the brake disc thickness
5 Cup Receive the brake fluid

51-2 Service Brake System - Service Brake System
6 Pressure gauge Measure the vacuum booster
Maintenance data
Brake pedal height from the ground 125mm
Front/rear brake friction Standard thickness 10/10.7mm

lining Wear limit thickness 8/8.7mm
Standard thickness 26mm

Front brake disc
Wear limit thickness 24mm
Standard thickness 10mm

Rear brake disc
Wear limit thickness 8mm
Maximum swing clearance of brake disc 0.2mm
Brake fluid model DOT4
Brake fluid filling volume 0.55~0.58L
Item N•m
Brake pedal switch locking nut 8~12
Connecting nut between the brake master cylinder

14~17
and the vacuum booster
Brake pipe fitting 12~16
Connecting nut between the vacuum booster and

33~39
the body
Fixed bolt of brake caliper 45~50
Brake caliper bracket fixing bolt 100~110
Front brake hose hollow bolt 40~50
Rear brake hose hollow fastening bolt 40~50
Wheel speed sensor wiring harness bracket fixing

8~12
bolt
Precautions
1. The service brake performance has a serious impact on the traffic safety, so the brake system
must have a good performance and any fault must be timely maintained.
2. Check and maintain the brake system regularly to eliminate the potential safety risks.
3. Must use brake fluid recommended by Lifan, and do not mix it with any other type of brake
fluid.
4. Do not use any other liquid instead of the brake fluid, so as not to damage the hydraulic system
parts.
5. As the brake fluid has a strong corrosion maintenance, when the braking system is maintained,
any skin and body paint can not be contacted with the brake liquid; if any, it should immediately
washed with plenty of clean water.
6. During the maintenance process, the friction disc and brake disc should not be contaminated
with the oil; if any, it must be cleaned with a cloth.
7. When removing the brake caliper piston, do not depress the brake pedal, to avoid the piston
ejection, resulting in damage to the piston dust cover.
8. During the maintenance process, thoroughly clean the brake slave cylinder and the brake
friction lining, to minimize the damage caused by the particles and other substances in the air.
9. When servicing the caliper, clean all caliper parts with a clean brake fluid.
10. Do not reuse the drained brake fluid, and store it in a dedicated sealed container.
11. During exhaust process, must observe the brake fluid level in the brake fluid pot; if it is below
the minimum level, it should be timely added.
12. After filling the brake fluid and exhausting, check the brake system for leakage; if any, timely
solve it to ensure the traffic safety.
System description 51
1. Function
The service brake system is necessary to protect the normal driving of the vehicle; it not only
can reduce the speed and stop the vehicles, but also can ensure the travel safety; it can quickly
reduce the driving speed of the vehicle in case of emergency, to provide a safe response to
unexpected conditions and protect the personal safety.
2. Composition
The service brake system consists of brake pedal, vacuum booster, brake master cylinder,
brake pipes, ABS, brake calipers, friction linings and brake discs.
When the driver depresses the brake pedal, the vacuum booster will driver the oil in the brake
master cylinder to flow into ABS control unit and then distribute it into four wheel brake caliper
pistons, to push the friction linings to press tightly brake discs and slow down the vehicle.
1. Check all service brake system parts for damage or oil spills
(a). Check the brake master cylinder and the booster for oil leakage.
(b). Check the pipe connector between the brake master cylinder and the booster signs for damage
or oil leakage.
(c). Check the master cylinder mounting surface, oil pot installation surface and the brake pipe joint
for oil leakage.
(d). Check the pipe connector and the integral bolt connector for damage or oil leakage.
(e). Check the hoses and pipes for oil leakage.
(f). Check the pipes for distortion and excessive bending.
2. Check the brake pedal height

(a). Measure the free height from the brake pedal to
the floor h; if it is too low or too high, must adjust
the brake pedal.
Brake pedal height to the floor:125mm
LFWX-6470-51001
3. Check free stroke of brake pedal

(a). Shutdown the engine and repeatedly depress
the brake pedal until there is no vacuum in the
booster.
(b) Depress the brake pedal until a resistance is felt
and measure the free stroke of the pedal L.
Pedal free stroke: 12mm
Tips:
If the free stroke of the brake pedal can not meet
L the requirement, adjust the pusher length until the
requirement is met
LFWX-6470-51002
4. Check the brake fluid

(a). Check whether the liquid level in the brake fluid pot is
between the maximum and levels; if it is below the minimum
level, must fillfill the brake fluid.
(b). If the fluid level is too low, check the brake fluid pot
surrounding and the braking system for oil leakage; if any,
must replace the brake fluid pot or the oil pipe.
Note:
If there is oil or brake liquid leakage in the braking system,
must replace the part related to the leakage.
(c). Start the vehicle, release the parking handle, observe
whether the brake alarm indicator is turned off. If it is not
turned off, must check the parking brake switch and brake
fluid level switch for fault.
LFWX-6470-51003
5. Check the vacuum booster

(a). Check the vacuum booster; if there is any fault, must replace
the vacuum booster.
• Place the ignition switch in OFF position, repeatedly
depress the pedal and confirm that the pedal retention
distance is not changed.
• Depress the pedal and start the engine.
Tips:
If the pedal is slightly sunk, the operation is normal.
LFWX-6470-51004 Note: 51
The duration to depress and hold the brake pedal is 5 s.
(b). Perform the air tightness check; if there is any fault, must
replace the vacuum booster.
• Start the engine 1 ~ 2min and stop it, and slowly depress
the pedal several times.
Tips:
If the pedal position is decreased significantly in the first
depressing, but it is gradually increased in the second and
third depressing, it should have a good tightness.
• Depress the brake pedal while the engine is running, and
LFWX-6470-51005 then shutdown the engine.
Tips:
If there is no change in the pedal retention distance after30s
since it is depressed, the booster should have a good
tightness.
(c). Check the vacuum check valve.
• Remove the vacuum hose steel band spring hoop, pull
out the vacuum hose, and remove the check valve from
the vacuum booster.
• Check and confirm that there is air flow from the booster
to the engine, but no air flow from the engine to the
booster.
Tips:
If there is any fault, replace the vacuum check valve.
LFWX-6470-51006
Diagnosis
1. Brake hydraulic system (air intake)
2. Oil pipe connector (loosening or oil leakage)
3. Brake pipe (clogging)
4. Brake master cylinder and slave cylinder piston rubber bowls

(deformation, aging, damage, swelling or sticking)
5. Friction lining (excessive wear, surface hardening, oil dirt)

See Section 51 – Service
The braking 6. Brake pedal stroke (too big) Brake - Diagnosis, Fault
effect is poor Diagnosis
7. Vacuum booster(damage)
(1. The braking effect is poor)
8. Brake fluid volume (lack) or Brake pipe (clogging)
9. Brake master cylinder and slave cylinder bores (excessive

wear)
10. Brake slave cylinder piston (sticking)
11. Brake disc (buckling or serious deformation)
12. Vacuum check valve (damage)
1. Brake pedal (no free stroke)
2. Improper adjustment of parking brake (can't completely be

released)
3. Brake pipe (clogging, poor oil return)
4. Brake master cylinder and slave cylinder pistons (sticking,

cannot be returned)
The brake is 5. Brake disc (severe buckling deformation) Brake - Diagnosis, Fault
blocked Diagnosis
6. Brake caliper (loosening or loss of adjustment) (2. The brake is blocked)
7. Caliper (sticking)
8. Brake friction lining (cracks or deformation)
9. Brake friction lining (dirty)
10. Vacuum booster (poor airtight, air leakage)
1. Brake fluid (lack)
2. Brake pipe (breakage or loosening)

3. Brake hydraulic system (air intake)
Brake - Diagnosis, Fault
Brake fault
Diagnosis
4. Brake master cylinder or oil cylinder (poor airtight)
(3. Brake fault)
5. ABS control unit (fault)
6. Mechanical connection parts (loosening)

1. Brake pipe (leakage)

The brake
Brake - Diagnosis, Fault
pedal is too 2. Slave cylinder piston (leakage, rubber cup damage)
Diagnosis
soft
(4. The brake pedal is too soft)
3. Brake master cylinder (leakage, rubber cup damage)
1. Vacuum brake booster (fault)

The brake 2. Vacuum pipe (breakage or loosening) Brake - Diagnosis, Fault
pedal is too Diagnosis
heavy 3. Brake master cylinder and slave cylinder piston (sticking) (5. The brake pedal is too
heavy)
4. vacuum check valve. (damage)
1. Brake caliper bushing (poor lubrication)
2. Anti-noise clamp (incorrect installation) See Section 51 – Service

The brake has Brake - Diagnosis, Fault
an abnormal 3. Brake lining (excessive wear) Diagnosis
sound (6. The brake has an abnormal
4. Brake caliper, suspension system, bushing (loosening) sound)
5. Brake disc (excessive thickness difference)
1. Left and right wheel tire pressure (big difference)
2. Clearance between the Left or right wheel friction lining and the
Brake disc (big difference)
3. Individual friction lining (excessive wear, hardening or poor See Section 51 – Service
Brake contact) Brake - Diagnosis, Fault
deviation Diagnosis 51
4. Individual friction lining (oil or grease attached) (7. Braking deviation)
5. Front wheel alignment (incorrect)
6. Suspension guide mechanism (severe deformation)
1. Brake pedal (too small stroke) See Section 51 – Service

The brake Brake - Diagnosis, Fault
disc has an 2. Brake master cylinder and slave cylinder piston(sticking) Diagnosis
abnormal hot (8. The brake disc has an
3. Friction lining (incorrect installation) abnormal hot)
Fault diagnosis
1. The braking effect is poor
Check the brake fault The brake fault indicator is Eliminate the brake system
Go to Step 1
indicator turned on electric control fault
Check the brake

system
1. Depress the brake pedal;

if the pedal position is low, 1. Check whether the brake
depress the pedal some pedal free stroke is too
times, the pedal position large (see Section 51 –
will be increased and Service Brake - Brake Pedal,
the braking effect will be Adjustment)
improved; 2. Check the brake master
2. Depress the brake pedal; cylinder for damage (see
if the pedal position is low, Section 51 - Service Brake
depress the pedal some – Brake Master Cylinder,
times; if pedal position is Inspection)
still low, and after the first 3. Check the brake hydraulic
depressing the pedal, the system for leakage or lack
master cylinder piston is not of liquid (see Section 51
returned; – Service Brake – Service
3. Continuously depress the Brake, On-board Inspection)
Depress the brake
pedal some times and
pedal and check its 4. Check the brake hydraulic
Go to Step 2 maintain the pedal position,
braking performance system for air tightness (see
the pedal will be decreased
under different status Section 51 – Service Brake -
slowly or rapidly;
Brake Fluid, Exhaust)
4. Continuously depress the
pedal some times; the pedal 5. Check the brake liquid pot
position is slightly increased, for lack of brake fluid (see
and has a certain flexibly; Section 51 – Service Brake -
5. Continuously depress the Brake Fluid, Replacement)
pedal to the end some times; 6. Check the brake hydraulic
the pedal is no reaction; system for blockage (see
6. Continuously depress the Section 51 - Service Brake
pedal some times; the pedal – Service Brake, On-board
position is low and the pedal Inspection)
is soft; 7. Check the brake vacuum
7. Depress the brake pedal; the booster system for fault (see
pedal position is appropriate Section 51 - Service Brake –
but the pedal is too hard and Vacuum Booster, Inspection)
has a poor braking effect.
2 Check the brake fluid Normal Faulty Instruction
Check the brake fluid

Go to Step 3 Brake fluid is insufficient Add the brake fluid
level
Check the brake

3 pedal operating Normal Faulty Instruction
parameters
1. The pedal height is beyond

the specified range; Adjust the pedal operating
Check the brake
2. The pedal free stroke is parameters (see Section 51 –
pedal height, free Go to Step 4
beyond the specified range; Service Brake - Brake Pedal,
stroke and margin
3. The pedal margin is beyond Adjustment)
the specified range.

for leakage
Lift the vehicle and

check the brake
Go to Step 5 Obvious leakage sign Replace the leaked part
hydraulic system for
leakage
Check the brake

friction lining
1. Replace the friction lining

(see Section 51 – Service
1. Friction lining excessive Brake - Front Brake/Rear
wear Brake)
Check the brake
Go to Step 6 2. Check the oil source
friction lining for wear
2. Friction lining oil dirt 3. Replace the friction lining
3. Friction lining hardening (see Section 51 – Service
Brake - Front Brake/Rear
Brake)
Check the vacuum

booster
Check the vacuum

booster system Replace the fault part
for operation (see (see Section 51 - Service
Go to Step 7 Vacuum booster fault
Section 51 – Service Brake - Vacuum Booster,
Brake - Vacuum Replacement)
Booster, Inspection)
Check the brake

51
master cylinder
Check the brake

master cylinder Replace the brake master
for operation (see The brake master cylinder is cylinder (see Section 51 -
Go to Step 8
Section 51 – Service faulty Service Brake -Brake Master
Brake -Brake Master Cylinder, Replacement)
Cylinder, Inspection)
8 Check the brake disc Normal Faulty Instruction
Check the brake disc 1. Identify the oil source; 2.

for operation (see 1. The brake disc is dirty; 2. Replace the brake disc (see
Section 51 – Service Go to Step 9 The brake disc parameters are Section 51 – Service Brake
Brake - Front Brake, beyond the specified range. Front Brake/Rear Brake,
Inspection) Replacement)
Check the brake

slave cylinder
Check the brake

slave cylinder for Replace the brake caliper
operation (see assembly (see Section 51 –
Go to Step 10 Brake caliper piston sticking
Section 51 – Service Service Brake – Front Brake/
Brakes - Front Brake, Rear Brake, Replacement)
Inspection)
Operate the brake

Diagnosis is Locate the causes from other
system and re-check The fault still exists
finished fault phenomenon
the braking operation
2. The brake is blocked
Eliminate the brake system

Check the brake fault The brake fault indicator is electrical control faults (see
Go to Step 1
indicator turned on Section 53 - Anti-lock Braking
System Diagnosis)
Check the parking

brake
Fully release the Adjust the parking brake (see

parking brake and Section 52 - Parking Brake
Go to Step 2 Blockage
check the rotation of - Parking Brake Operating
each wheel mechanism, Adjustment)
2 Check the blockage Normal Faulty Instruction
Continuously apply
Check whether the blockage
the brake operations,
is caused by the brake itself,
and check whether
An individual brake disc is and check and repair the
the heating Go to Step 3
heated abnormality brake (see Section 51 –
conditions of all
Service Brake - Front/Rear
brake discs are the
Brakes)
same
Check the pedal free

stroke
Measure the pedal

free stroke (see Adjust the pedal free stroke
The pedal free stroke
Section 51 – Service (see Section 51 - Service
Go to Step 4 parameter value is beyond the
Brake – Service Brake – Brake Pedal,
specified range
Brake, On-board Adjustment)
Inspection)
Check the pedal

spring performance
Replace the pedal spring

Check the brake
or the pedal assembly (see
pedal spring for Go to Step 5 Spring fault
Section 51 - Service Brake –
operation
Brake Pedal, Replacement)

for returning
Open the brake fluid

pot cover, depress
the brake pedal to
The brake fluid has poor
the end, and then The brake fluid is rest or has
Go to Step 6 return, the hydraulic system is
suddenly release the small fluctuations
air intake or blockage
pedal, to check the
brake fluid conditions
in the pot
Check the vacuum

booster for returning
Replace the vacuum booster

Check the vacuum The booster is not returned or (see Section 51 - Service
Go to Step 7
booster for returning is returned difficultly Brake - Vacuum Booster,
replacement)
Check the brake

master cylinder
Check the brake

for operation (see cylinder (see Section 51 -
Go to Step 8 Brake master cylinder sticking
Section 51 – Service Service Brake -Brake Master
Check the brake

slave cylinder
Check the brake

Inspection)
Operate the brake

3. Brake fault
Steps Check contents Inspection result 51


Go to Step 1
System Diagnosis)
Add the brake fluid (see

Go to Step 2 Brake fluid is insufficient Section 51 – Service Brake –
level
Brake Fluid, Replacement)
Check the system

connection
Check the each

Reinstall the disconnected
connection status of Go to Step 3 Disconnection
part
the system

for leakage

check the brake
leakage

for returning

pot cover, depress
the brake pedal to
pedal, to check the
in the pot
Check the brake

master cylinder
Check the brake

Check the brake

slave cylinder
Check the brake

Go to Step 7 Slave cylinder piston clocking
Inspection)
Operate the brake

4. The brake is faulty

Go to Step 1
System Diagnosis)
Add the brake fluid (see

Go to Step 2 Brake fluid is insufficient Section 51 – Service Brake –
level
Brake Fluid, Replacement)
Check the pipe

connection
Check each pipe Reinstall the disconnected

Go to Step 3 Disconnection
connection status part

for leakage

check the brake
leakage
Check the brake

master cylinder
Check the brake

for operation (see No resistance in the brake cylinder (see Section 51 -
Go to Step 5
Section 51 – Service master cylinder Service Brake -Brake Master
Check the brake

slave cylinder
Check the brake

Go to Step 6 Slave cylinder seal fault
Brakes - Front Brake, Rear Brake, Replacement) 51
Inspection)
Depress the brake

pedal and re- Diagnosis is Locate the causes from other
The fault still exists
check the pedal for finished fault phenomenon
operation
5. The brake pedal is too heavy

Go to Step 1
System Diagnosis)
Check the vacuum

booster
Check the vacuum

booster system Replace the fault part
for operation (see (see Section 51 - Service
Go to Step 2 Vacuum booster fault
Section 51 – Service Brake - Vacuum Booster,
Brake - Vacuum Replacement)
Booster, Inspection)
Check the brake

liquid for blockage

pot cover, depress
Check the brake fluid for poor
the brake pedal to
return, the hydraulic system
Go to Step 3 for air intake or blockage (see
Section 51 – Service Brake -
pedal, to check the
Brake Fluid)
in the pot
Check the brake

master cylinder
Check the brake

Check the brake

slave cylinder
Check the brake

operation (see Brake slave cylinder piston assembly (see Section 51 –
Go to Step 5
Section 51 – Service sticking Service Brake – Front Brake/
Inspection)
Depress the brake

pedal and re- Diagnosis is Locate the causes from other
check the pedal for finished fault phenomenon
operation
6. The brake has an abnormal sound
Carry out the road 1. The abnormal sound occurs

1. Check the brake for fault;
test to identify Diagnosis is at a wheel side;
2. Find out the causes from
the position with finished 2. The abnormal sound occurs
other fault symptoms.
abnormal sound on other parts.
Check the
suspension system
Check the
Suspension part loosening or Fasten or replace the
suspension parts for Go to Step 2
damage defective part
installation status
Check the brake

calipers
1. Tighten the brake caliper

Check the brake
caliper mount 1. Loosening brake caliper;
Brake - Front/Rear Brakes,
and the brake Go to Step 3 2. Poor lubrication on brake
Replacement);
caliper bushing for caliper bushing.
2. Lubricate the brake caliper
lubrication
bushing.
Check the anti-noise

clamp
Re-install the anti-noise clamp

Check the anti-noise
Poor installation of anti-noise (see Section 51 – Service
clamp for installation Go to Step 4
clamp Brake - Front/Rear Brakes,
status
Replacement)
Check the brake

friction lining
1. Friction lining excessive 1. Replace the friction lining

wear (see Section 51 – Service
Check the brake Brake - Front Brake/Rear
lining for installation Go to Step 5 Brake)
and wea r 2. Re-install the friction lining
2. Improper friction lining (see Section 51 – Service
installation Brake - Front/Rear Brakes)
Check the brake disc

Replace the brake disc
for operation (see The brake disc measurement
Section 51 – Service Go to Step 6 parameter is beyond the 51
Brake - Front/Rear Brakes,
Brake - Front Brake, specified value.
Replacement)
Inspection)
Carry out the road

test and re-check the The fault still exists
fault phenomenon
7. The brake is deviated
1. Reinstall the wheels (see

Section 33 - Wheels and
Tires - Wheel Assembly,
Check the tire type, Replacement);
1. Incorrect wheel installation;
condition and tire 2. Find out the tire wear
Go to Step 1 2. Serious tire wear;
pressure on both causes;
3. Inconsistent tire pressure.
sides 3. Correct the tire pressure
(see Section 33 - Wheels and
Tires - Wheels and Tires, On-
board Inspection).
Check the
suspension system
Correct and replace the

Visually check the
Significant damage of the front front suspension system
front suspension Go to Step 2
suspension system (see Section 31 - Front
system status
Suspension)
Check the wheel

alignment
Check the front

Section 33 - Wheels The wheel alignment error is operation (see Section 33 -
Go to Step 3
and Tires - Four- excessive Wheels and Wheel Alignment
wheel Alignment, and Adjustment)
Inspection)
Check the brake

friction lining

1. Friction lining excessive (see Section 51 – Service
wear Brake - Front Brake/Rear
Brake)
Check the brake
Go to Step 4 2. Check the oil source
friction lining for wear
2. Friction lining oil dirt
3. Friction lining hardening Brake - Front Brake/Rear
Brake)
Check the brake disc 1. Identify the oil source; 2.

for operation (see 1. The brake disc is dirty; 2. Replace the brake disc (see
Section 51 – Service Go to Step 5 The brake disc parameters are Section 51 – Service Brake
Brake - Front Brake, beyond the specified range. Front Brake/Rear Brake,
Inspection) Replacement)
Check the brake

calipers
Replace the brake caliper

Check the brake
Brake slave cylinder piston assembly (see Section 51 –
slave cylinder piston Go to Step 6
sticking Service Brake – Front Brake/
condition
Rear Brake, Replacement)
Check the brake

pipeline
Check the brake Replace the brake pipe (see

pipe for clogging and Go to Step 7 Brake pipe damage Section 51 – Service Brake -
leakage Brake Pipe, Replacement)
Check ABS control

unit
Carry out the maintenance

Check ABS control
based on the fault code (see
unit for fault with the Go to Step 8 ABS control unit fault
Section 53 - Anti-locking
diagnosis instrument
Braking System, Diagnosis)
Carry out the road

fault phenomenon
8. The brake disc has an abnormal hot

Go to Step 1
System Diagnosis)
Check the heating

status
1. Check whether the fault

1. All brake discs are heated cause is from the brake
Carry out the road
abnormally; 2. Reinstall the friction lining
test and check brake Go to Step 2
2. A brake disc is heated (see Section 51 – Service
disc heating status
abnormally. Brake - Front/Rear Brakes,
Replacement)
Check the pedal free

stroke
Measure the free

stroke of the pedal Adjust the pedal free stroke
The pedal free stroke
(See Section 51 (see Section 51 - Service
Go to Step 3 parameter value is beyond the
- Service Brake - Brake – Brake Pedal,
specified range
Service Brake, On- Adjustment)
board Inspection)
Check the pedal

spring performance
51
Replace the pedal spring
Check the brake
or the pedal assembly (see
pedal spring for Go to Step 4 Spring fault
Section 51 - Service Brake –
operation
Brake Pedal, Replacement)

for returning

pot cover, depress
the brake pedal to
pedal, to check the
in the pot
Check the vacuum

booster for returning
Replace the vacuum booster

Check the vacuum The booster is not returned or (see Section 51 - Service
Go to Step 6
booster for returning is returned difficultly Brake - Vacuum Booster,
replacement)
Check the brake

master cylinder
Check the brake

Check the brake

slave cylinder
Check the brake

Inspection)
Carry out the road

fault phenomenon
Brake pedal
Adjustment
1. Adjust the brake pedal height

(a). Remove the lower dashboard shield panel
assembly.
(b) Disconnect the brake pedal switch connector.
LFWX-6470-51007
(e). Loosen the brake pedal switch locking nut.

(d). Remove the brake pedal switch.
(e) Loosen the vacuum booster puller locking nut
and rotate the puller to adjust its length, to adjust
the brake pedal to the appropriate height.
(f) Tighten the vacuum booster puller locking nut.
(g) Install the brake pedal switch and connect the
brake pedal switch connector.
(h) Depress the brake pedal for 5~15 mm, and
then turn the brake pedal switch until the brake
indicator is turned off, and then lock it in this
position with the locking nut.
(i) After installation, check whether the brake
indicator is turned on after depressing the brake
pedal for 5 ~ 15 mm.
LFWX-6470-51008 (j) Install the access cover assembly.
2. Adjust the brake pedal free stroke

Tips:
The brake pedal free stroke adjustment method is
same as the pedal height adjustment method; the
brake pedal free stroke can be adjusted with the
brake pedal height adjustment method.
LFWX-6470-51008
3. Adjust the brake pedal operating stroke

Tips:
If the brake pedal operating stroke is not normal, it generally is caused by the air or leakage
in the brake hydraulic system pipeline; if any, please find out the fault position and carry out
the troubleshooting.
4. Adjust the brake pedal margin
Tips:
The poor brake pedal margin is caused by incorrect brake pedal operating stroke and free
stroke; if the pedal margin is not normal, adjust the free stroke and operating stroke.
51
Replacement
1. Remove the brake pedal

(a). Remove the lower dashboard shield panel (Refer to Chapter 84: Dashboard and deputy
dashboard – lower dashboard shield panel, replacement).
(b). Disconnect the brake pedal switch wiring harness

connector.
(c). Loosen the brake pedal switch locking nut.
(d). Remove the brake pedal switch.
LFWX-6470-51007
(e). Remove the connection locking pin between the

vacuum booster puller and the brake pedal, and
remove the pin.
LFWX-6470-51009
(f). Remove the fixing bolt of brake pedal and

instrument board pipe beam.
LFWX-6470-51045
(g). Remove the brake pedal fixing bolt and nut and
remove the brake pedal.
LFWX-6470-51010
2. Install the brake pedal

(a). Install the brake pedal onto the mounting position,
and install and tighten the fixing bolt and nut.
Torque: 20 ~ 26N•m (bolt)
20~26N•m(nut)
Note:
When installing the brake pedal, must fix the
vacuum booster, to avoid the vacuum booster to
be ejected by the brake pedal bracket.
LFWX-6470-51010
(b). Install and fasten the fixing bolts of brake pedal

and instrument board pipe beam.
Torque: 20~26N•m(bolt)
51
LFWX-6470-51045
(c). Install the connecting pin between the vacuum

booster puller and the brake pedal and install the
locking pin.
(d) Install the brake pedal return spring onto the
mounting position.
Tips:
After installation, check and adjust the brake pedal
height.
(e) Install the brake pedal switch and adjust the
clearance. (See Section 51 – Service Brake –
Brake Pedal, Adjustment)
(f). Install the lower left dashboard shield panel.(See
Section 84- Dashboard/Sub-dashboard, Lower
Left Dashboard Shield, Replacement)
LFWX-6470-51009
Brake master cylinder assembly

Replacement
1. Remove the brake master cylinder
Knock down the engine compartment vent panel
first to facilitate the removal and installation. (refer
to 81 - interior trims and exterior trims - vent panel,
replacement)
(a). Remove the brake fluid filler cap.
(b). Discharge the brake oil in the brake fluid pot and
the pipe.
Note:
The brake fluid has a strong corrosion, do not
splash the brake fluid on the skin or body paint; or
must immediately clean it.
LFWX-6470-51011
(c). Disconnect liquid warning lamp switch connector.

(d). Remove front/rear cavity oil outlet pipe of brake
master cylinder.
LFWX-6470-51012
(e). Remove oil inlet pipe of clutch master cylinder.

(f). Remove the fixing bolt of brake master cylinder
and support.
(g). Remove the brake master cylinder
Note:
• Install the rubber cap or rubber plug into the
exposed brake pipe fitting, to prevent brake
fluid loss and contamination.
• When removing the brake master cylinder oil
pipe, mark it to prevent wrong installation.
• Install the rubber cap or rubber plug into the
exposed brake pipe fitting, to prevent brake
fluid loss and contamination.
• When removing the brake master cylinder oil
LFWX-6470-51013 pipe, mark it to prevent wrong installation.
2. Install the brake master cylinder

(a). Put the brake master cylinder on its installation
site, and install and fasten the brake master
cylinder and body bracket.
Torque: 14 ~ 17N•m
(b) Install the clutch master pump inlet pipes onto the
installation location, and install the fixing clamps.
LFWX-6470-51014
(c). Connect the liquid level warning indicator switch

connector.
(d). Connect front/rear cavity oil outlet pipe of brake
master cylinder.
(e) Fill the braking fluid within the specified marking
range, and exhaust the brake system.
(f) Install the brake fluid filler cap.
51
LFWX-6470-51012
Vacuum booster
Replacement
1. Remove the vacuum booster and master
cylinder assembly
(a). Discharge the brake oil in the brake fluid pot and
the pipe.
Note:
The brake fluid has a strong corrosion; if it
accidentally be splashed on the skin, must
immediately clean it from the skin with a cloth, and
use soap and water to wash it thoroughly again.
(b). Remove the power vacuum pipe and brake
master cylinder inlet pipe elastic clamps and
disconnect the vacuum booster and brake master
pump inlet pipes.
(c) Remove the check valve from the vacuum booster.
LFWX-6470-51015 (d). Using a pipe wrench to remove the brake master
cylinder outlet pipe connector.
Note:
Check the continuity of the check valve.
(e). Remove the lock pin to connect the vacuum

booster push rod and the brake pedal pin, and
remove the pin.
(f). Remove 4 retaining nuts used to connect vacuum
booster and brake master pump assembly with
car body.
LFWX-6470-51017
(g). Remove the vacuum booster and brake master

cylinder assembly and the gasket from the engine
compartments.
LFWX-6470-51018
2. Remove the vacuum booster and master

cylinder assembly
(a). Remove the fastening nuts to connect the brake
master cylinder and the vacuum booster, and
remove the brake master cylinder and the oil pot.
3. Assemble the vacuum booster and master
cylinder assembly
(a). Install the brake master cylinder and oil pot
assembly on the vacuum booster, and install and
tighten the fastening bolts.
LFWX-6470-51019
4. Install the vacuum booster

(a). Install the brake master cylinder and oil pot
assembly on the vacuum booster, and install and
tighten the fastening bolts.
LFWX-6470-51018
(b). In the cab, install and tighten fastening nuts onto

the vacuum booster bolts.
Torque: 33~39N•m
(c). Install the pin to connect the vacuum booster
push rod and the brake pedal pin and install the
lock pin.
51
LFWX-6470-51017
(d). Use a pipe wrench to install brake master cylinder

outlet pipe connector.
(e). Install wiring harness connector of vacuum
booster.
(f). Install the vacuum booster hose and the brake
master pump inlet pipe onto the installation
locations, and install the elastic clamps.
(g). Adjust the brake pedal height
(h). Fill the brake fluid and exhaust the brake system.
LFWX-6470-51015
Brake fluid
Replacement
1. Drain the brake fluid
(a). Remove the brake fluid filler cap.
(b) Park the vehicle on a smooth road surface, place
the transmission in the neutral position and apply
the parking brake.
(c) Remove the brake fluid filler cap.
LFWX-6470-51011
(d). Install a transparent plastic pipe onto the brake

vent screw plug, and place the other end of the
pipe into the brake fluid container.
(e). Unscrew the vent bolt, continuously depress the
brake pedal, until the brake fluid is no longer
outflowed.
Note:
• Must perform the operation for each wheel, to
drain completely the old brake fluid.
• The discharged brake fluid can not be reused.
LFWX-6470-51020
2. Fill the brake fluid

(a) Open the brake fluid filler cap.
(b). Fill the brake fluid into the brake fluid pot,
the liquid level is between the maximum and
minimum levels
Brake fluid type: DOT4
Note:
• Do not mix different types of brake fluids.
• Must exhaust the brake system after filling
the brake fluid.
• The brake fluid has a strong corrosive, can
not be splashed onto the skin and painting
surface; otherwise it should be cleaned
immediately.
(c) Tighten the brake fluid filler cap and install the
LFWX-6470-51021 brake fluid filling cap.
Exhaust
1. Exhaust the braking system
(a). Lift the vehicle to the appropriate height.
(b). Install a transparent plastic vent hose onto the
brake caliper vent screw plug.
(c). Place the other end of the transparent plastic
vent hose into a clean containers containing
some clean brake fluid.
(d). Depress the brake pedal several times and hold
it, and unscrew the exhaust valve bolt.
(e). When there is no bubble in the brake fluid, tighten
the exhaust bolt and release the brake pedal.
(f) Repeat Steps (d) and (e) until there is no air
bubble in the container.
(g) Repeat the above steps to exhaust the brake
system of each wheel in the order of Rear Right -
LFWX-6470-51020 Rear Left - Front Right - Front Left.
Note:
• When repairing or replacing the brake parts, if
the air is entered into the brake system, must
perform the exhaust process.
• If the air is entered due to too low liquid level
or the master pump brake pipe disconnection,
must exhaust all brake hydraulic systems.
• If the brake hose of a wheel is disconnected,
only exhaust the brake system of the wheel.
• If any connection of the brake pipe between the 51
master cylinder and the brake is disconnected,
only exhaust the corresponding brake system.
• During exhaust process, check whether the fluid
level in the brake fluid pot brake is below the
minimum level; if necessary, fill the brake fluid.
• The discharged brake fluid can not be reused.
• If the air is present in the brake master cylinder,
must exhaust the brake master cylinder.
2. Exhaust the brake master cylinder

(a). Loosen a brake master cylinder pipe, place a
cloth under the pipe, and depress the brake
pedal by other person in the cab until the air is
completely exhausted.
(b) Fasten the brake master cylinder pipe.
Torque: 12~16N•m
LFWX-6470-51022
Front brake
Component drawing
1-6-2
1-6-1
1-6
1-2
1-7
1-5
1 1-4 1-1
1-3
LFWX-6470-51023
1 Left / right front brake assembly 1-5 Wheel hub assembly

Left/right front brake caliper
1-1 Bearing connecting bolt 1-6
assemblies
Front brake lining assembly
1-2 Bracket bolt 1-6-1
(one pair)
Left/right front brake caliper
1-3 Left / right caliper assembly 1-7
assemblies
1-4 Left/right dust boot 1-8 Front brake disc
Testing
1. Check the brake friction lining and brake disc

(a). Check the front and rear brake friction linings for
wear; if it exceeds the wear limit thickness, must
replace it.
(b). Check whether the front and rear brake wear
indicator tabs have enough flexibility, no
deformation, fracture or wear; if any, must replace
it.
Tips:
Clean rust, oil traces and other debris on the
friction lining surface; if the oil is soaked into the
friction lining, must replace the friction lining.
LFWX-6470-51024
(c). Use a micrometer to measure the brake disc

thickness; if it exceeds the minimum thickness,
must replace it.
51
LFWX-6470-51025
(d). Install the brake disc fastening nuts, use a dial

indicator to measure the swing value of brake
disc at the location of 10mm to the edge of the
brake disc.
Tips:
If the swing value of the brake disc reaches or
exceeds the limit value, check the wheel hub
bearing radial clearance and the wheel hub swing;
if the bearing and the wheel hub are operated
normally, replace the brake disc.
LFWX-6470-51026
Replacement
1. Lift the vehicle and remove the front wheels

2. Remove the front calipers
(a). Discharge the brake fluid in the brake system.
(b) Remove the front brake pipe hollow bolt, remove
the seal and the brake hose.
(c) Remove the caliper bracket fixing bolt and
remove the caliper bracket and brake caliper
assembly.
LFWX-6470-51028
(d). Remove the brake pliers bolts, and remove the

front brake pliers
LFWX-6470-51029
(e). Remove the brake friction lining and clamps from

the caliper bracket, and check the brake lining
thickness.
Tips:
• Make the marks on the brake lining and the
mounting position and align the marks to
install them.
• Measure the brake lining thickness; if the
wear limit is exceeded, replace the brake
lining.
LFWX-6470-51030
3. Remove the front brake disc

(a). Remove the front brake disc from the front hub
and check whether the brake disc needs to be
replaced.
LFWX-6470-51031
4. Remove the front brake caliper sliding pin

(a). Remove the sliding pin from the brake caliper
bracket.
(b) Remove the sliding pin dust cover from the front
brake caliper bracket.
51
LFWX-6470-51032
5. Install the front caliper sliding pin

(a) Apply the grease onto the front brake caliper
bracket sliding pin dust cover and install it on the
front brake caliper bracket.
(b) Install 2 front brake caliper sliding pins.
LFWX-6470-51032
6. Install the brake disc

(a) Install the front brake disc onto the front hub.
Note:
There should be no oils on the contact surface of
the brake disc and the brake friction lining; if any,
must clean it completely.
LFWX-6470-51031
7. Install the brake caliper assembly

(a). Install the front brake friction lining and the clamp
onto the mounting position on both sides of the
brake caliper bracket.
(b) Install the brake caliper and friction lining
assembly onto the brake caliper bracket and
fasten it with bolts.
Torque: 45~50N•m
LFWX-6470-51030
(c). Install the brake caliper and bracket assembly

onto the mounting position and fasten it with
bolts.
(d) Install the front brake hose hollow bolt and the
seal ring.
(e) Install front wheel
(f) Fill the brake fluid and exhaust the brake system.
LFWX-6470-51028
Rear brake
Component drawing (1.8L, 2.0L, 1.5T-5MT)
2-1
1-5
2-2
1-4
1-3
1-1
1-2
3 1-6
51
1
LFWX-6470-51033
1 Left/right rear brake assemblies 1-6 Hub bearing

Left/right rear brake caliper
1-1 Hexagon flange bolt 2
assemblies
1-2 Hexagon socket sunk screw 2-1 Rear left/right caliper bracket
Rear brake lining assembly
1-3 Hexagon flange bolt 2-2
(one pair)
1-4 Left/right connecting plate 3 Rear brake disc
1-5 Left/right rear dust cover
Component drawing (2.0L-CVT, 1.5T-8AT)
1-1
1
1-2
1-3
3-1 1-4
3
3-2
4
LFWX-6470-51046
1 Rear left/right caliper bracket 3 Left/right rear wheel hub assembly

1-1 Rear left/right caliper bracket 3-1 Left/right rear dust cover
1-2 EPB motor 3-2 Left/right connecting plate
1-3 EPB motor fixing bolt 4 Hexagon flange bolt
Rear brake lining assembly
1-4
(one pair)
2 Hexagon flange bolt
Replacement
1. Lift the vehicle and remove the rear wheels

2. Remove the rear brake pliers
Tips:
The replacement of the left/right brake tongs is the same. Below is the removal and
installation of rear left brake tongs.
(a). Discharge the brake fluid in the brake system.
(b) Remove the rear parking brake cable. (See Section 52 - Parking Brake - Parking Brake Cable,
Replacement)
(c). Remove the rear brake hose hollow bolt and seal,
and remove the brake hose.
Tips:
Do not disconnect the brake hose from the
brake caliper without replacing the brake caliper
assembly.
(d) Remove the brake caliper mounting bolts and
remove the rear brake caliper and bracket
assembly.
Tips:
When the brake caliper is removed from the caliper
bracket but the brake hose is still connected, the
caliper should be supported with a heavy wire
or equivalent mean; otherwise, the weight of the
brake caliper may be applied on the brake hose,
LFWX-6470-51034 resulting in damage to the brake hose and brake 51
fluid leakage.
(e). Remove the rear brake caliper fixing bolt and

remove the rear caliper.
Tips:
When removal, secure the rear caliper sliding pin
with a wrench, to remove the brake caliper fixing
bolt.
(f). Remove the brake lining and the clamp slider

from the brake caliper bracket.
Tips:
To continue using the brake plate, mark the brake
lining and mounting position during the removal
so as to install them back exactly.
LFWX-6470-51036
(g). Remove the sliding pin and the sliding pin dust
cover from the rear brake caliper bracket.
LFWX-6470-51037
3. Remove the rear brake disc.

(a). Remove the rear brake disc from the rear hub
and check whether the brake disc needs to be
replaced.
LFWX-6470-51038
4. Install the rear brake disc

(a). Install the rear brake disc onto the rear hub.
Note:
There should be no oil dirt on the contact surface
between the brake disc and the brake friction
lining.
LFWX-6470-51038
5. Install the rear brake caliper

(a) Install the sliding pin dust cover and the sliding
pin onto the rear brake caliper bracket.
Tips:
Before installation, apply the grease onto the
sliding pin dust cover.
51
LFWX-6470-51037
(b). Install the brake friction lining and the clamp

slider onto the mounting position with the marks
made during removal process.
Note:
There should be no oil dirt on the contact surface
between the brake disc and the brake friction
lining.If it is contaminated with the oil, must clean
it with a cloth.
LFWX-6470-51036
(c). Install the brake caliper onto the rear brake

caliper bracket, and install and tighten the fixing
bolt.
Torque:45~50N•m
LFWX-6470-51035
(d). Install the brake caliper and bracket assembly

onto the knuckle, and install and tighten the fixing
bolt.
Torque: 45~50N•m
(e). Install rear brake hose hollow bolt and sealing
ring.
(f). Install the rear parking brake cable. (See Section
52 - Parking Brake - Parking Brake Cable,
Replacement)
(g). Install the rear wheels. (See Section 33 - Wheels
and Tire - Wheel Assembly, Replacement)
(h). Fill the brake fluid and exhaust the brake system.
LFWX-6470-51034
6. Remove the EPB motor

Tips:
The replacement of the left/right EPB motor is the same. Below is the removal and
installation of rear left brake tongs EPB motor.
(a). Remove the inside hexagonal erection bolt on the

rear brake EPB motor.
(b). Take out EPB motor.
LFWX-6470-51049
7. Mount the EPB motor

(b). Install the inside hexagonal erection bolt on the
rear brake EPB motor, and fasten it.
Torque: 40 ~ 50N•m 51
Brake line
Component drawing(ABS)
21 4
16
22 24
1
7
19 7
19
23 18
26
15
13
7 14
13
17 4 25 11
16 7 20 3
27 1
4
1
7 4 7
29 12
9 17
10
7
6
28
4 7
13 8 7
5
7
4 1
2
17
LFWX-6470-51039
1 Bolt with axial and radial hole 15 Brake oil pipe two-way joint
2 Rear left brake hose assembly II 16 Copper washer
3 Rear right brake hose assembly II 17 Front left brake hose
4 U-shaped clip 18 Front right brake hose
5 Rear left brake pipe assembly III 19 Single pipe clamp
6 Rear right brake pipe assembly III 20 ABS mechanism
Front brake master cylinder chamber
7 Hexagon flange bolt 21
outlet pipe
Rear brake master cylinder chamber
8 Rear left brake hose assembly 22
outlet pipe
9 Rear right brake hose assembly 23 Left front brake pipe
10 Left rear brake pipe II 24 Right front brake pipe
11 右后制动硬管Ⅱ 25 左后制动硬管
12 Fiv-pipe clamp IV 27 ABS rubber cushion

13 Single pipe clamp II 28 ABS mechanism mounting bolt
14 Hexagon flange nut 39 ABS bracket
Component drawing(ESC)
1
2 3
7
10
8
9
51
LFWX-6470-51047
Front brake master cylinder

1 6 Right rear brake pipe
chamber outlet pipe
Rear brake master cylinder
2 7 ESC control unit
chamber outlet pipe
3 Left front brake pipe 8 ESC bracket
4 Right front brake pipe 9 ABS mechanism mounting bolt
5 Left rear brake pipe 10 ABS rubber cushion
Component drawing(ESP)
1
6 4
2
3 5
7
8
9
Front brake master cylinder

1 6 Right rear brake pipe
chamber outlet pipe
Rear brake master cylinder
2 7 ESP control unit
chamber outlet pipe
3 Left front brake pipe 8 ESP bracket
4 Right front brake pipe 9 ABS rubber cushion II
5 Left rear brake pipe
Replacement
1. Remove the front brake hose
(a). Discharge the brake fluid.
(b) Remove the front brake hose hollow bolt and seal
ring.
LFWX-6470-51042
(c). Remove fixing bolts of the front brake pipe

bracket and the wheel speed sensor wiring
harness bracket.
(d) Remove the pipe connecting nut with a tubing
wrench, pull out the front brake pipe E-type
clamp, and remove the front brake pipe.
2. Install the front brake pipe
(a) Insert the front brake pipe through the body fixing 51
bracket, and install E-type clamp to fix the pipe.
(b) Tighten the pipe connecting nut.
Torque: 12~16N•m
(c) Install the front brake pipe bracket and the wheel
speed sensor wiring harness bracket, and install
and tighten the fixing bolts.
Torque: 20~26N•m
LFWX-6470-51043
(d). Install the front brake hose hollow bolt and seal
ring onto the brake, install and tighten the hollow
bolt.
Torque: 35~45N•m
(e) Fill the braking fluid into the brake system.
LFWX-6470-51042
51
Parking brake system- Parking brake system 52A-a
Parking brake system

Parking brake��1
Precautions�� 2
System desTcription�� 2
Part function and fault�� 4
Diagnosis��5
Parking brake control lever��9
Inspection�� 9
Adjustment�� 9
Parking brake cable�� 11
52A
52A-b Parking brake system- Parking brake system
Parking brake system- Parking brake system 52A-1
Parking brake
Preparations
Remove the parking brake cable rear

1 Long nose pliers
lock tab
Quick wrench
2 and socket Remove and install the fixing bolt
components
52A
Open-end
3 Adjust the parking brake cable
wrench
52A-2 Parking brake system- Parking brake system
Maintenance data
Item N•m
Parking brake cable bracket fixing bolt 8~12
Parking brake control lever fastening bolt 22~28
Precautions
(a). The parking brake cannot replace the service brake; only in case of emergency, the
parking brake can be used for deceleration.
(b). The parking brake cable has a plastic sheath and is not need for regular lubrication.
(c). Before checking the parking brake system, park the vehicle on a level ground and
use triangular woods to block the wheels.
(d). Carefully replace each part; otherwise it may affect the performance of the parking
brake system, and even may endanger personal safety.
(e). After the parking brake system is repaired, its performance must be tested to ensure
its safety and reliability.
(f). Must perform the regular check.
• Check the parking brake for operation.
• Check each connection of the parking brake operating mechanism for
loosening.
• Check the parking brake system for normal function.
System description
1. Function
The parking brake system can be used for long-term safe parking of the vehicle for
and facilitate the start on the ramp; during the vehicle running, if the service brake
system is faulty, the parking brake system can be used for emergency braking.
2. Composition
The parking brake system consists of the parking brake pedal, cable, brakes and
other devices.
When applying the parking brake, pull the parking lever, to drive the cable to allow
the brake to play the parking role.
Component drawing
6 4
2
3-1
6
3-2
1 3
52A
LFWX-6470-52001
Parking brake control mechanism

assembly
2 Hexagon flange bolt 5 Split washer
3 Front parking cable section assembly 6 Hexagon flange bolt
Left rear parking brake cable

3-1 Hexagon flange nut 7
assembly
Right rear parking brake cable

3-2 Hexagon thin nut 8
assembly
Part function and fault

Common part Vehicle fault
Part name Part function
fault phenomenon
Excessive wear
of the parking
brake operating The parking
Control mechanism, mechanism pawl brake operating
Apply the parking brake
parking brake and ratchet, parking mechanism can not
brake operating be positioned
mechanism
deformation
The parking brake

Breakage or
Brake cable Play the force transmission role is ineffective or
damage
faulty
The parking brake

Bolt Fix the cable Looseness
is ineffective
Improper The parking brake

Adjusting nut Adjust the parking brake
adjustment. performance is poor
1. Check the braking conditions of the
parking brake
(a) If the brake is normally operated, drive
the vehicle onto the slope with about
20%, depress the parking brake pedal
and depress the parking brake to park the
vehicle on the slope.
(b) Slowly release the brake pedal, the vehicle
should not slip down within at least 5min; if
the vehicle slips down, adjust the parking
brake (see Section 52AA - Parking Brake
- Parking Brake Operating Mechanism,
Adjustment).
LFWX-6470-52002 2. Check the parts
(a). Confirm whether each part is fastened
normally.
(b). Check the parking brake control lever assembly for bending, damage or cracks; If
any, must replace it.
(c). Check the parking brake cable for wear and damage; If any, replace it.
3. Parking brake indicator light switch
(a). Check whether the parking brake alarm indicator switch is operated correctly; If
necessary, must check or replace it.
• When the parking brake operating mechanism is depressed, the parking brake
indicator should be turned on.
• When the parking brake operating mechanism is released, the parking brake
indicator should be turned off.
Diagnosis
Use below table to help the quick location of desired fault message

1. Parking brake operating mechanism (the
travel is not correct)
2. Front cable section (loosening,

breakage)
3. Parking brake cable (breakage, sticking, See Section 52A - Parking Brake
disconnection) - Diagnosis, Troubleshooting
The parking brake is
1. Parking brake (poor
defective 4. Parking brake cable bracket
performance)
(deformation, loosening)
5. Rear brake friction lining (excessive

wear)
6. Rear brake slave cylinder (sticking)
7. Parking brake return spring (aging, fault)

travel is too small)
See Section 52A - Parking Brake
Parking brake dragging 2. Parking brake return spring (aging, fault) - Diagnosis, Troubleshooting 52A
3. Parking brake cable (sticking) 2. Parking brake (dragging)
4. Rear brake caliper (sticking)
1. Parking brake switch (damage)
2. Wiring harness between the parking See Section 52A - Parking Brake
The parking indicator is
brake switch and the instrument cluster - Diagnosis, Troubleshooting
turned on
(short-circuit) 3. Parking indicator (On)
3. Instrument cluster (damage)
1. Instrument cluster fuse (blown)
2. Instrument cluster power wire (open

circuit)
3. Instrument cluster grounding wire (open

circuit)
See Section 52A - Parking Brake
Parking status: When
4. Parking brake switch (damage) - Diagnosis, Troubleshooting
the ignition switch is
(4. Parking status: When the
in “ON” position, the 5. Parking brake switch wiring harness ignition switch is in “ON” position,
parking indicator is not connector (loosening) the parking indicator is not
turned on
turned on)
6. Wiring harness between the parking
brake switch and the instrument cluster
(open circuit)
7. Instrument cluster connector (loosening)

Fault diagnosis
1. The parking brake has poor performance

The parking
Check the parking brake Diagnosis is
brake is Go to Step 1
for operation finished
defective
Check the parking brake

1 operating mechanism for Normal Faulty Instruction
stroke

Adjust the parking brake
operating mechanism
stroke (see Section 52A -
for stroke (see Section The stroke is
Go to Step 2 Parking Brake – Parking
52A - Parking Brake - not correct
Brake Operating Mechanism,
Parking Brake, On-board
Adjustment)
Inspection)
cable
Cable Repair or replace the parking

Check the parking brake loosening, brake cable (see Section 52A
Go to Step 3
cable for operation damage or - Parking Brake - Parking
sticking Brake Cable, Replacement)
Check the front cable

section
Replace the front section

of the cable or the parking
Check the front section of Cable brake operating mechanism
the parking brake cable Go to Step 4 loosening or (see Section 52A - Parking
for operation breakage Brake – Parking Brake
Operating Mechanism,
Replacement)

4 return spring and the Normal Faulty Instruction
cable bracket
1. Replace the parking brake

return spring
2. Correct the cable bracket
and replace the rear
brake caliper assembly if
Check the parking
necessary (see Section 51 –
brake return spring and 1. Return spring
Go to Step 5 Service Brake - Rear Brake,
the cable bracket for fault
Replacement)
operations
Tips:
The cable bracket is
integrated with the rear brake
as one body and can not be
supplied separately
2. Cable
Check the rear brake bracket
5 Normal Instruction
friction lining loosening or
deformation
Replace the rear brake

Check the rear brake Friction lining friction lining (see Section
Go to Step 6
friction lining for wear excessive wear 51 – Service Brake - Rear
Brake, Replacement)
Check rear brake slave

cylinder
Check the rear brake

slave cylinder for
operation (see Section 51
– Service Brake – Front Replace the brake caliper
Brake, Inspection) Brake caliper assembly (see Section 51 –
Go to Step 7
Tips: piston sticking Service Brake – Rear Brake,
The rear brake slave Replacement)
cylinder is inspected with
the same method of the
front brake.
Apply the parking brake,

Diagnosis is The fault still Locate the causes from other
to re-check the fault
finished exists fault phenomenon
phenomenon
2. Parking brake dragging

52A
Check the parking brake Diagnosis is Parking brake

Go to Step 1
for operation finished dragging

1 operating mechanism for Normal Faulty Instruction
stroke

Adjust the parking brake
operating mechanism
stroke (see Section
for stroke (see Section The stroke is
Go to Step 2 52 - Parking Brake –
52 - Parking Brake - too small
Parking Brake Operating
Parking Brake, On-board
Mechanism, Adjustment)
Inspection)

cable
Cable Repair or replace the parking

Check the parking brake loosening, brake cable (see Section 52
Go to Step 3
cable for operation damage or - Parking Brake - Parking
sticking Brake Cable, Replacement)

return spring
Check the parking brake Return spring Replace the parking brake
Go to Step 4
return spring for operation fault return spring

friction lining
The friction
Check the rear brake lining is not
Go to Step 5 Reinstall the friction lining
friction lining for installation installed
correctly
5 Check rear brake caliper Normal Faulty Instruction

caliper for operation (see
Section 51 – Service
Brake – Front Brake, Replace the brake caliper
Inspection) Brake caliper assembly (see Section 51 –
Go to Step 6
Tips: piston sticking Service Brake – Rear Brake,
The rear brake slave Replacement)
cylinder is inspected with
the same method of the
front brake.
Apply the parking brake,

Diagnosis is The fault still Locate the causes from
to re-check the fault
finished exists other fault phenomenon
phenomenon
Parking brake control lever

Inspection
1. Check whether the parking operating

mechanism for flexible operation, if
it can not be returned automatically,
please replace it.
2. Check parking brake operating
mechanism pawl for wear.
LFWX-6470-52003
Adjustment
1. Adjust the parking brake operating
mechanism
(a) Remove the lower dashboard shield panel 52A
(See Section 85 - Dashboard and Sub-
dashboard – Lower dashboard Shield
Panel, Replacement)
(b) Adjust the brake cable adjustment nut.
(c) After the adjustment is completed, depress
the parking brake pedal, the vehicle
should be parked within the normal range;
otherwise it should be adjusted again.
(d) Install the lower dashboard shield panel.
LFWX-6470-52004
Panel, Replacement)
Replacement
1. Remove the sub-dashboard body
dashboard – Sub-dashboard Body,
Replacement)
2. Remove the parking brake control lever
(a) Disconnect the parking brake switch wiring
harness connector.
(b) Loosen the parking brake adjustment nut
and remove the E-type clamp and the brake
cable from the brake mechanism.
LFWX-6470-52004
(c) Remove the parking brake control

mechanism assembly fastening bolt, and
remove the parking brake control lever
assembly.
LFWX-6470-52005
3. Install the parking brake control

mechanism assembly
(a) Install the parking brake control mechanism
assembly onto the installation position, and
install and tighten the retaining bolt.
Torque:22~28N•m
LFWX-6470-52005
(b) Install the front section of the parking brake

cable and E-type clamp onto the mounting
positions.
(c) Connect the parking brake indicator switch
connector.
4. After the installation, adjust the parking
brake (Refer to Chapter 52: Parking
brake - parking brake control device,
adjustment)
5. Install the lower dashboard shield panel
Panel, Replacement)
LFWX-6470-52004
Parking brake cable

Replacement
1. Remove the lower dashboard shield

panel (See Section 85 - Dashboard and
Sub-dashboard – Lower dashboard
Shield Panel, Replacement)
2. Remove the driver ’s seat assembly 52A
(see Section 84- Seats - Front Seat,
Replacement)
3. Remove the carpet (see Section 81 -
Interior and Exterior Trims - Carpet
4. Remove the front parking cable section
assembly
(a) Remove the parking brake cable adjustment
LFWX-6470-52004 nut.
(b) Remove the connecting bolts and nuts

between the parking cable bracket and the
floor.
LFWX-6470-52006
(c) Disconnect the connection between the rear

parking cable assembly and the splitter.
(d) Remove the front parking brake cable
section assembly.
LFWX-6470-52007
5. Remove the left/right rear parking cable

assemblies
(a) Remove the connecting bolts and nuts
between the left/right rear parking cable
assemblies and the floor.
LFWX-6470-52008
(b) Remove the connecting bolts and nuts

between the left/right rear parking cable
assemblies and the frame.
LFWX-6470-52009
(c) Remove the connecting bolts between the

left/right rear parking cable assemblies and
the rear brake dust cover.
(d) Remove the left/right rear parking cable
assemblies.
6. Install the left/right rear parking cable
assemblies.
(a) Install the left/right rear parking cable
assemblies onto the rear brake dust cover
and install and tighten the fixing bolts.
Torque:8~12N•m
LFWX-6470-52010
(b) Sort the parking brake cable, install and

tighten the fixing bolts and nuts on all
brackets and pipe clamps for the parking
brake cable.
Torque:8~12N•m
52A
LFWX-6470-52009
7. Install the front parking cable section

assembly
(a) Install the front brake cable section
assembly onto the mounting position.
(b) Connect the left/right rear parking cable
assemblies and the splitter, as shown.
LFWX-6470-52008
(c) Install and tighten the front parking cable

section bracket fixing bolts and nuts.
8. Install the front parking cable section
assembly onto the parking operating
mechanism, install the adjustment nut
and adjust the parking brake pedal
travel (see Section 52A - Parking Brake
- Parking Brake Operating Mechanism,
Adjustment)
9. Remove the carpet (see Section 81 -
Interior and Exterior Trims - Carpet
10. Install the lower dashboard shield panel
LFWX-6470-52006 (See Section 85 - Dashboard and Sub-
Panel, Replacement)
11. I n s t a l l t h e d r i v e r ’s s e a t a s s e m b l y
(see Section 84- Seats - Front seats,
Replacement)
Parking brake system- Parking brake system 52B-a

Preparations��1
Precautions��2
System description��2
Part function and fault��4
On-board Inspection��4
Diagnosis��5
List of fault phenomenon��5
Parking brake control lever��9
Inspection��9
Adjustment��9
Parking brake cable�� 11
52B
52B-b Parking brake system- Parking brake system
Parking brake system- Parking brake system 52B-1
Parking brake
Preparations
Remove the parking brake cable rear

1 Long nose pliers
lock tab
Quick wrench
2 and socket Remove the fixing bolt
components
52B
Open-end
3 Adjust the parking brake cable
wrench
52B-2 Parking brake system- Parking brake system
Maintenance data
Item N•m
Parking brake cable bracket fixing bolt 6 ～ 12
Parking brake control lever fastening bolt 20 ～ 26
Precautions
1. The parking brake cannot replace the service brake; only in case of emergency, the
parking brake can be used for deceleration.
2. The parking brake cable has a plastic sheath and is not need for regular lubrication.
3. Before checking the parking brake system, park the vehicle on a level ground and
use triangular woods to block the wheels.
4. Carefully replace each part; otherwise it may affect the performance of the parking
brake system, and even may endanger personal safety.
5. After the parking brake system is repaired, its performance must be tested to ensure
its safety and reliability.
6. Must perform the regular check.
• Check the travel of the parking brake lever.
• Check the connection parts for loosening.
System description
1. Function
The parking brake system can be used for long-term safe parking of the vehicle for
and facilitate the start on the ramp; during the vehicle running, if the service brake
system is faulty, the parking brake system can be used for emergency braking.
2. Composition
The parking brake system consists of the control lever, cable, brakes and other
devices.
3. Operating principle
When applying the parking brake, pull the parking lever, to drive the cable to allow
the brake to play the parking role.
Component drawing
3
2
4 52B
LFWX-6470-52001
1 Parking brake control mechanism 4 Left rear parking brake cable assembly
Hexagon flange bolt and external

2 5 Right rear parking brake cable assembly
teeth serrated lock washer assembly
3 Hexagon flange bolt

Common part Vehicle fault

Part name Part function
fault phenomenon
Parking brake
lever spring failure,
excessive wear of The parking brake
Parking brake control
Apply the parking brake parking brake lever lever can not be
lever
pawl and ratchet, positioned
parking brake lever
deformation
The parking brake

Breakage or
Brake cable Play the force transmission role is ineffective or
damage
faulty
Bolt Fix the cable Looseness /
Improper The parking brake

Adjusting nut Adjust the parking brake
adjustment. performance is poor
On-board Inspection
1. Check the travel of the parking brake
lever
(a).After completion of the adjustment, pull up
the parking brake control lever with a 100N
force. Otherwise it should be adjusted
again.
Standard value: 5 ~ 7 teeth
△ Tips:
A “Click” will issue at each tooth; listen and count
the sound from the pawl to check the parking
brake.
2. Check the braking conditions of the
parking brake
LFWX-6470-52002 (a). If the brake is normally operated, drive the
vehicle onto the slope with about 20%, depress
the parking brake pedal and depress the parking brake to park the vehicle on the slope.
(b) Slowly release the brake pedal, the vehicle should not slip down within at least 5min;
if the vehicle slips down, adjust the parking brake (see Section 52B - Parking Brake
- Parking Brake Operating Mechanism, Adjustment).
3. Check the parts
(a). Confirm whether each part is fastened normally.
(b). Check the parking brake control lever assembly for bending, damage or cracks; If
any, must replace it.
(c). Check the parking brake cable for wear and damage; If any, replace it.
4. Parking brake indicator light switch
(a). Check whether the parking brake alarm indicator switch is operated correctly; If
necessary, must check or replace it.
• If pulling up the parking brake control lever, the parking brake indicator will be
turned on.
• If releasing the parking brake control lever, the parking brake indicator will be
turned off.
Diagnosis
List of fault phenomenon

travel is not correct)
2. Front cable section (loosening,

breakage)
3. Parking brake cable (breakage, sticking, See Section 52 - Parking Brake -

disconnection) Diagnosis, Troubleshooting
The parking brake is 1. Parking brake (poor
defective 4. Parking brake cable bracket performance)
(deformation, loosening)
5. Rear brake friction lining (excessive

wear)
6. Rear brake slave cylinder (sticking)
7. Parking brake return spring (aging, fault)

travel is too small)
See Section 52 - Parking Brake -
2. Parking brake return spring (aging, fault) Diagnosis, Troubleshooting
Parking brake dragging 2. Parking brake (dragging) 52B
3. Parking brake cable (sticking)
4. Rear brake caliper (sticking)
1. Parking brake switch (damage)

The parking indicator is Diagnosis, Troubleshooting
turned on 3. Parking indicator (On)
(short-circuit)
1. Instrument cluster fuse (blown)
2. Instrument cluster power wire (open

circuit)
3. Instrument cluster grounding wire (open

circuit)
Parking status: When 4. Parking brake switch (damage) Diagnosis, Troubleshooting
the ignition switch is (4. Parking status: When the
in “ON” position, the 5. Parking brake switch wiring harness ignition switch is in “ON” position,
parking indicator is not connector (loosening) the parking indicator is not
turned on turned on)
(open circuit)
7. Instrument cluster connector (loosening)

Fault diagnosis
1. The parking brake is defective

Check the parking Diagnosis is The parking brake

Go to Step 1
brake for operation finished is defective
Check the parking

1 brake operating Normal Faulty Instruction
mechanism for stroke
Check the parking

brake operating Adjust the parking brake
mechanism for stroke (see Section
The stroke is not
stroke (see Section Go to Step 2 52 - Parking Brake –
correct
52 - Parking Brake - Parking Brake Operating
Parking Brake, On- Mechanism, Adjustment)
board Inspection)
Check the parking

brake cable
Repair or replace the

Check the parking parking brake cable (see
Cable loosening,
brake cable for Go to Step 3 Section 52 - Parking
damage or sticking
operation Brake - Parking Brake
Cable, Replacement)
Check the front cable

section
Replace the front section

Check the front section of the cable or the parking
Cable loosening or
of the parking brake Go to Step 4 brake lever (See Section
breakage
cable for operation 52 - Parking Brake Lever,
Replacement)
Check the parking

4 brake return spring and Normal Faulty Instruction
the cable bracket
1. Replace the parking

brake return spring
2. Correct the cable
1. Return spring
bracket and replace
fault
the rear brake caliper
2. Cable bracket
assembly if necessary
Check the parking loosening or
brake return spring and deformation
Go to Step 5 Brake - Rear Brake,
the cable bracket for
Replacement)
operations
Tips:
The cable bracket is
integrated with the rear
brake as one body and
can not be supplied
separately

friction lining

Replace the rear brake
Check the rear brake Friction lining friction lining (see Section
Go to Step 6
friction lining for wear excessive wear 51 – Service Brake - Rear
Brake, Replacement)
Check rear brake slave

cylinder
Check the rear

brake slave cylinder
for operation (see
Section 51 – Service
Replace the brake caliper
Brake – Front Brake,
Brake caliper assembly (see Section 51
Inspection) Go to Step 7
piston sticking – Service Brake – Rear
Tips:
Brake, Replacement)
The rear brake slave
cylinder is inspected
with the same method
of the front brake.
Apply the parking

brake, to re-check the The fault still exists
fault phenomenon
2. Parking brake dragging

52B
Check the parking Diagnosis is Parking brake

Go to Step 1
brake for operation finished dragging
Check the parking

1 brake operating Normal Faulty Instruction
mechanism for stroke
Check the parking

brake operating Adjust the parking brake
mechanism for stroke stroke (see Section
The stroke is too
(see Section 52 - Go to Step 2 52 - Parking Brake –
small
Parking Brake - Parking Parking Brake Operating
Brake, On-board Mechanism, Adjustment)
Inspection)
Check the parking
brake cable

Check the parking parking brake cable (see
Cable loosening,
brake cable for Go to Step 3 Section 52 - Parking
damage or sticking
operation Brake - Parking Brake
Cable, Replacement)
Check the parking
brake return spring
Check the parking Replace the parking

brake return spring for Go to Step 4 Return spring fault brake return spring
operation

friction lining
Check the rear brake The friction lining

friction lining for Go to Step 5 is not installed Reinstall the friction lining
installation correctly
Check rear brake

caliper

caliper for operation
(see Section 51 –
Service Brake – Front Replace the brake caliper
Brake, Inspection) Brake caliper assembly (see Section 51
Go to Step 6
Tips: piston sticking – Service Brake – Rear
The rear brake slave Brake, Replacement)
cylinder is inspected
with the same method
of the front brake.
Apply the parking

brake, to re-check the The fault still exists
fault phenomenon
Parking brake control lever

Inspection
1. Check whether the parking operating
mechanism for flexible operation, if it can
not be returned automatically, please
replace it.
2. Check parking brake operating mechanism
pawl for wear.
LFWX-6470-52003
Adjustment
(a). Remove the sub-dashboard body (See 52B
Section 85 - Dashboard and Sub-
d a s h b o a r d – S u b - d a s h b o a r d B o d y,
Replacement)
(b) Adjust the brake cable adjustment nut.
(c) After the adjustment is completed, pull
the parking brake lever in the direction
perpendicular to the lever with the force
of 100N, to pass through 5 ~ 7 teeth;
otherwise it should be adjusted again.
△ Tips:
When passing through each tooth, there will be a
LFWX-6470-52004 “Click” sound; the inspection can be carried
out by hear “Click” sound from the pawl.
(d) Install the sub-dashboard body. (See Section
85 - Dashboard and Sub-dashboard – Sub-
dashboard Body, Replacement)
Replacement

Replacement)
2. Pull up the parking brake control lever,
and disconnect the brake indicator
switch connector.
3. Remove the parking brake control lever
(a) Lower the parking brake lever to the
end and release the parking brake cable
adjustment nut.
(b) Disconnect the connection between the
parking brake lever assembly and the rear
LFWX-6470-52005 cable end.
(c) Remove the parking brake control lever

assembly fastening bolt, and remove the
parking brake control lever assembly.
LFWX-6470-52006
4. Install the parking brake control lever

assembly
(a) Install the parking brake control lever
assembly onto the installation position, and
install and tighten the retaining bolt.
Torque:22~26N•m
LFWX-6470-52006
(b) Install the parking brake cable onto the

parking brake lever, and tighten the braking
lever cable adjustment nut.
5. Install the brake indicator switch
connector.
(a) Connect the parking brake light switch
connector.
6. After the installation, adjust the parking
brake (Refer to Chapter 52 Parking
brake - parking brake control device,
adjustment)
LFWX-6470-52007 7. Install the deputy dashboard (Refer to
Chapter 85: Dashboard and deputy
dashboard - deputy dashboard,
replacement)
Parking brake cable
Replacement
Replacement)
52B
2. Remove the left/right rear parking cable
assemblies
(a) Lift the vehicle
(b) Disconnect the connections between the
parking brake lever assembly and the left/
right rear parking cable assemblies.
LFWX-6470-52005
(c) Remove the connecting bolts between the

the floor.
LFWX-6470-52008
(d) Remove all fixing bolts and nuts on all

brackets and pipe clamps on the parking
brake cable assembly.
(e) Remove the connecting bolts between the
rear brake fixed circlip.
(f) Remove the left/right rear parking cable
assemblies.
LFWX-6470-52009
3. Install the left/right rear parking cable

assemblies.
(a) Install the left/right rear parking cable
assemblies onto the rear brake dust cover
and install and tighten the fixing bolts.
Torque: 6~12N•m
LFWX-6470-52010
(b) Sort the parking brake cable, install and

tighten the fixing bolts and nuts on all
brackets and pipe clamps for the parking
brake cable.
Torque: 6~12N•m
LFWX-6470-52009
(c) Install the connection bolts between the

the floor.
LFWX-6470-52008
4. Connect the parking brake lever

assembly and the left/right rear parking
cable assemblies as shown.
5. Adjust the travel of the parking lever
(see Section 52 - Parking Brake Lever,
Adjustment)
6. Install the sub-dashboard body (See
Sect ion 85 - Dashboard an d Su b - 52B
Replacement)
Torque:8~12N•m
LFWX-6470-52007
Parking brake system - Parking brake system 52-a

Precautions�� 2
Electronic parking brake switch�� 3
EPB control unit�� 4
EPB motor�� 5
Terminal definition��7
Read and clear the fault codes�� 7
DTC list�� 8
Electronic parking brake switch 10
Removal�� 10
Installation��11 52
EPB control unit�� 12
Removal�� 12
EPB motor�� 13
Removal�� 13
52-b Parking brake system - Parking brake system
Parking brake system - Parking brake system 52-1
Parking brake
Preparations
1. General tool
1 Long nose pliers Remove the brake hose lock tab
Quick wrench
2 and socket Remove and install the fixing bolt
components
52
Open-end
3 Adjust the parking brake hose
wrench
52-2 Parking brake system - Parking brake system
Maintenance data
Item N•m
EBP motor fixing bolt 20~30
Hexagon flange bolt 70~80
Precautions
1. The parking brake can not replace the service brake; only in case of emergency, the parking
brake can be used for deceleration.
2. The parking brake cable has a plastic sheath and is not need for regular lubrication.
3. Before checking the parking brake system, park the vehicle on a level ground and use
triangular woods to block the wheels.
4. Carefully replace each part; otherwise it may affect the performance of the parking brake
system, and even may endanger personal safety.
5. After the parking brake system is repaired, its performance must be tested to ensure its safety
and reliability.
6. Must perform the regular check.
• Check each connection of the parking brake operating mechanism for loosening.
System description
1. Function
The parking brake system can be used for long-term safe parking of the vehicle for and
facilitate the start on the ramp; during the vehicle running, if the service brake system is faulty,
the parking brake system can be used for emergency braking.
2. Composition
The parking brake system consists of the parking brake switch, parking brake controller and
parking brake motor etc.
To apply the parking brake, pull up the parking brake switch to drive the brake to work.
Component drawing
Electronic parking brake switch
52
LFWX-6470-52001
Cross recessed pan head tapping

1 Electronic parking brake switch 2
screw
EPB control unit
LFWX-6470-52002
1 EPB control unit 2 Hexagon flange bolts

EPB motor
52
LFWX-6470-52003
1 EPB motor 2 EPB motor fixing bolt

Engine compartment fuse box
LFWX-6470-52004
B+ B+ B+ B+
Cockpit fuse box

Diagnose
interface
FS50
FS51
FS38
FS24
7.5A
30A
30A
5A
PCANH PCANL
6 I01 14 I01
7 1D 1 1E
7 I1D 1 I1E
0.5 RW
2.5 BlR
2.5 R
1 UI3 2 UI3
1 IU3 2 IU3
Parking brake system - Parking brake system
I53 I53 I53 I53 I53

IGN
Motor- Motor+ Motor- Motor+ EPB indicator light
I53 I53 I53 I53 I53 I53 I53 I53 I53 I53 I53 I53 I53
Instrument
I07
2.5 WBr
cluster
2.5 WR
2.5 W
2.5 G
2.5 B
2.5 B
0.5 WG
0.5 WR
0.5 YW
0.5 YG
0.5 YR
0.5 W
0.5 R
2 IB3 1 IB3 2 IG3 1 IG3
2 BI3 1 BI3 2 GI3 1 GI3
0.5 Bl
Circuit diagram
2.5 WBr
2.5 WR
I56 I56 I56 I56 I56 I56 I56 I56 I56 I56
2.5 W
2.5 G
To background
light system
0.5 B
8
G13 G13 G13
52-6
Terminal definition
The terminal definitions are detailed in the circuit diagram catalogue. For any question, please refer
to the circuit diagram catalogue.
Fault diagnosis
Part name Part function Common part fault Vehicle fault phenomenon
Electronic parking Apply the parking

Damaged Parking unable to realize
brake switch brake
Apply the parking

EPB control unit Damaged Parking unable to realize
brake
Apply the parking

EPB motor Damaged Parking unable to realize
brake
Read and clear the fault codes
1. Use diagnostic apparatus to read fault code(DTC)

(a). Connect LIFAN V30 diagnostic tester to the diagnostic
interface.
(b). Select Version 6.5 or above, select “xuanlang” model,
select “Chassis Control”, and enter “EPB”.
(c). Read or clear DTC. 52
Tips:
• If the fault code can not be cleared up, this
means the fault has not been troubleshooter.
Troubleshoot the fault according to the fault
code prompts
• See list of failure codes for DTC list of EPB.
LFWX-6470-52005
DTC list
S/N DTC (ISO 15031-6) Fault definition
Switch power line - short to the ground or open

1 C113014
circuit
2 C113312 Switch on test - short to power
3 C113386 Switch on test - reactive signal
4 C113314 Switch on test - short to the ground or open circuit
5 C113412 Switch release test - short to power
6 C113486 Switch release test - reactive signal
Switch release test - short to the ground or open

7 C113414
circuit
8 C11352A Switch seizing - switch cannot be pulled up
9 C11362A Switch release seizing - release switch seizure
10 C110017 Voltage high - ECU voltage high
11 C110016 Voltage low - ECU voltage low
12 C110116 IGN wire disconnected
13 C11A071 Actuator seizing
14 U007388 CAN Bus off
15 U010087 Loss communication with EMS
16 U010187 Loss communication with TCU
17 U014087 Loss communication with BCM
18 U015287 Loss communication with MG2
19 U040186 Receiving invalid data from EMS
20 U041186 Receiving invalid data from MG
21 U012100 Lose communication with ESP
22 U040386 Receiving invalid data from ESP
23 U040286 Receiving invalid data from TCU
24 U042286 Receiving invalid data from BCM
25 C116009 ECU hardware
26 C110060 Power restart
27 C057498 PCB Board temperature sensor failure
28 C11B013 Left motor open circuit or fault
29 C11B113 Right motor open circuit or fault
30 C11B272 Left motor-driven MOSFET (relay) failure
31 C11B372 Right motor-driven MOSFET (relay) failure
32 C11B41D Left motor overcurrent

S/N DTC (ISO 15031-6) Fault definition
33 C11B51D Right motor overcurrent
34 C11B617 Left motor long time working
35 C11B717 Right motor long time working
36 C11B815 Left current testing circuit open circuit
37 C11B915 Right current testing circuit open circuit
38 C11BA29 Left current testing circuit signal abnormal
39 C11BB29 Right current testing circuit signal abnormal
40 C11BC00 Left EPB uninitialized or initialization failed
41 C11BD00 Right EPB uninitialized or initialization failed
42 C11BF04 EPB gradient sensor is abnormal
43 C11C000 EPB gradient sensor is not calibrated
52
Electronic parking brake switch

Removal
1. Remove the electronic parking brake switch.
(b). Remove the left lower cover plate of instrument
desk. (Reference: 85 – Removal of Instrument
Board and Auxiliary Instrument Board)
(c). Disconnect EPB switch connector clip.
LFWX-6470-52006
(d).Install EPB switch bolt and take down EPB brake

switch.
LFWX-6470-52007
Installation
1. Install the electronic parking brake switch.

(a). Install EPB switch and fasten bolt.
LFWX-6470-52006
(b).Connect EPB switch connector clip.

(c). Install the left lower cover plate of instrument
desk. (Reference: 85 – Instrument Board and
Auxiliary Instrument Board Installation)
(d).Connect the battery negative connector
52
LFWX-6470-52007
EPB control unit

Removal
1. Remove the EPB control unit.
(a). Remove driver seat. (Reference: 84-Removal of
Driver Seat)
(b). Remove EPB control unit bolt to take down the
EPB control unit.
LFWX-6470-52009
Installation
1. Install the EPB control unit.
(a). Install EPB control unit and fasten bolt.
(b). Remove driver seat.
(Reference: 84-Removal of Driver Seat)
LFWX-6470-52009
EPB motor
Removal
The removal and installation of left/right rear brake caliper EPB motor are practically the same. This
chapter only describes the removal and installation of rear left brake caliper EPB motor.
1. Remove the rear left brake caliper EPB motor.

(a). Use lifting machine to lift vehicle.
(b). Remove the left rear tyre of vehicle.(refer to 33
- wheel and tire, removal and installation of tire
side)
(c). Remove the brake calipers of left rear wheel.
(d). Remove EPB motor fixing bolt, and take down
EPB motor.
LFWX-6470-52008
Installation
1. Mount the EPB motor.
(a). Install EPB on the left rear brake calipers, install
fastening bolts and fasten them.
Torque: 20~30 N•M 52
(c). Install the brake calipers of left rear wheel.
(b). Install the left rear tyre of vehicle.(refer to 33 -
wheel and tire, removal and installation of tire
side)
(e). Lower vehicle.
LFWX-6470-52008
53A-a
ABS - ABS
ABS
ABS��1
Precautions�� 2
Hydraulic diagram�� 6
Initial inspection�� 7
Diagnosis��9
Diagnosis procedure�� 9
ABS diagnostic description�� 9
Read and clear the fault codes�� 9
Data stream�� 10
DTC list��11
ABS brake system��16
Wheel speed sensor��18
53
ABS - ABS 53A-1
ABS
Preparations
1. Special tools
Diagnosis
1 System failure diagnosis
equipment ABS
Maintenance data
Tire model 215/55 R17
Items N·m
Connecting bolt between ABS actuator and the

20~26
bracket
53A
53A-2 ABS - ABS
Precautions
1. After the vehicle is powered on or the engine is started, a short “Hum” sound will be
sent, which is the sound of ABS system self-test and is normal.
2. Before diagnosing ABS system, must ensure that the service brake system is operated
normally, without any fault.
3. When ABS system work properly, there should be a sound, mainly including:
• Sounds from motor, solenoid valve and return pump actions in ABS control unit.
• Sound from the brake pedal return.
• Crash sound between the suspension and the body due to the emergency braking.
4. The following two cases show that ABS system detects a fault:
(a) Turn on the ignition switch, complete the system self-test and maintain ABS/ESP warning
indicator in “On” position
(b) During driving, the warning indicator ABS should be on.
Warning
At this point, the driver may make the common brake, but the braking force should be
reduced as possible, to prevent the wheels from locking. After the alarm indicator is lit,
the vehicle should be driven immediately carefully to the authorized service station for
maintenance, in order to prevent the traffic accidents from more faults.
5. ABS system must be repaired by a technician who has been trained and has mastered
maintenance skills and can only be replaced with genuine parts.
6. When connecting ABS electronic control unit and wheel speed sensor wiring harness,
must pay attention to the followings:
(a). Before removing ABS electronic control unit and the wheel speed sensor wiring harness, place
the ignition switch in OFF position and disconnect the battery negative cable.
(b). Ensure that the connector is dry and clean, to prevent any foreign matter.
(c). Must install ABS wiring harness connector in place in the horizontal direction and the vertical
direction.
7. Connect ABS brake pipeline, and ensure its proper connection. ABS ECU can not
judge whether the brake line is correctly connected.The incorrect connection may
lead to serious accidents. Must connect the brake pipe according to the mark on ABS
assembly:
(a). MC1: the brake pipe 1 to connect the brake master cylinder.
(b). MC2: the brake pipe 1 to connect the brake master cylinder.
(c). FL: the brake pipe to connect the left front brake wheel cylinder.
(d). FR: the brake pipe to connect the right front brake wheel cylinder.
(e). RL: the brake pipe to connect the left rear brake wheel cylinder.
(f). RR: the brake pipe to connect the right rear brake wheel cylinder.
8. ABS control unit can only be replaced as a whole and can not be dismantled or partially
replaced/interchanged.Lifan Company does not provide separate spare parts and
does not provide the warranty for disassembled ABS control unit; Lifan Company
is not responsible for any adverse consequences caused by dismantling or partial
replacement/replacement of ABS control unit.After ABS system is repaired, it must be
tested, to ensure complete troubleshooting before delivery to the customer.
System description
1. Function
ABS (Anti-lock Braking System) can be used to prevent locking of the wheels during the
emergency braking, to maintain the stable vehicle braking and steering performances and
ensure the travel safety of the vehicle.
2. Composition
ABS consists of ABS control unit, pipes, speed sensor and other components.
ABS - ABS 53A-3
ABS: When the brake operation is performed at the speed of 15km/h above, the vehicle speed
sensor can detect the speed of each wheel hub, and then transfer the signals to ECU; when
the wheels are locked and the slipping rate is excessive, ECU can control the brake to reduce
the braking torque on a wheel or a number of wheels, to prevent the wheel locking and side
slipping.
Component drawing
4
5
2
53A
A BS
ABS right front wheel speed sensor ABS left rear wheel speed sensor
1 4
assembly assembly
ABS left front wheel speed sensor

2 5 ABS actuating mechanism
assembly
ABS right rear wheel speed sensor

3
assembly
IG1 B+ B+
Electrical control
Electrical control
AS 01
AS 25
30A
30A
FS38
5A
Ground PCANL PCANH PCANH PCANL I06 I14

7 1D 2 I19 1 I19 4 I19 3 I19 6 I01 14 I01 7 I41
7 I1D
34 IU1 21 IU1 20 IU1 1 IU2 26 IU1
34 UI1 21 UI1 20 UI1 1 UI2 26 UI1
33 IU1
33 UI1
0.50 WY
3.00 RG
0.5 RW
0.3 VW
0.5 GO
3.00 R
0.5 B
0.30 YB
0.30 Y
4 U14 11 U14 10 U14 7 U14 9 U14 25 U14 8 ; 17 ;
ABS - ABS
ABS controller power motor power solenoid valve Vehicle speed signal
'(9 +); supply power supply
24 U14 8 U14 1 U14 2 U14 19 U14 20 U14 5 U14 6 U14 22 U14 23 U14
0.50 BrB
0.50 WO
0.50 OB
0.50 GB
0.50 Br
0.50 YR
0.50 O
0.50 G
3.00 B
3.00 B
10 UI1 9 UI1 7 UI1 8 UI1
10 IU1 9 IU1 7 IU1 8 IU1
0.50 BrB
0.50 OB
0.50 Br
0.50 O
3 IB2 8 IB2 16 IG 10 IG
3 BI2 8 BI2 16 GI 10 GI
0.50 BrB
0.50 OB
0.50 Br
Circuit diagram
0.50 O
2 U16
U02 1 U16
U02 2 U10
U02 1 U10
U02 1 B6 2 B6 1 G4 2 G4
G22 G12 Left front wheel Right front wheel Left rear wheel Right rear wheel
speed sensor speed sensor speed sensor speed sensor
53A-4
ABS - ABS 53A-5
Terminal definition
U14 to the ABS assembly U06 to front right wheel speed sensor
17 18 19 20 21 22 23 24 25
1
10
2
11
3
12
4
13
5
14
6
15
7
16 16
8 9
2 1

Function Function
No. color No. color
1 0.5 /YR Left front wheel speed sensor+ Right front wheel speed sensor
1 0.5 /GB
signal -
2 0.5 /WO Left front wheel speed sensor-
Right front wheel speed sensor
3 NC NC 2 0.5/ G
signal +
4 0.5 /RW ABS controller power

U16 to left right wheel speed sensor
5 0.5 /O Left rear wheel speed sensor+
6 0.5 /OB Left rear wheel speed sensor-
7 0.5 /WY K wire
8 3.0 /B GND
9 3.0 /R Motor power 2 1

10 0.3 /YB PCANL
11 0.3 /Y PCANH
12 NC
13 NC Terminal Wire size/

No. color
Function 53A
14 NC
Left front wheel speed sensor
1 0.5 /WO
signal +
15 NC
2 0.5/ YR
16 NC signal -
Wheel speed signal

17 0.3 /VW
(except standard type)
18 0.5 /G O Brake switch (keep on)
19 0.5 /G Right front wheel speed sensor+
20 0.5 /GB Right front wheel speed sensor-
21 NC
22 0.5 /Br B Right rear wheel speed sensor -
23 0.5 /Br Right rear wheel speed sensor +
24 3.0 /B GND
25 3.0 /RG Solenoid valve power supply

53A-6 ABS - ABS
Hydraulic diagram
Lifan xuanlang anti-lock braking system adopts X type layout. ABS hydraulic regulator consists of 1
motor, 2 return pumps, 2 accumulators and 8 solenoid valves.
MC1 Brake master cylinder firist circuit RR Right rear wheel
MC2 Brake master cylinder second circuit FLEV Left front wheel oil inlet valve
M Motor FLAV Left front wheel oil outlet valve
RP1 Return pump 1 FREV Right front wheel oil inlet valve
RP2 Return pump 2 FRAV Right front wheel oil outlet valve
A1 Accumulator 1 RLEV Left rear wheel oil inlet valve
A2 Accumulator 2 RLAV Left rear wheel oil outlet valve
FL Left front wheel RREV Right rear wheel oil inlet valve
FR Right front wheel RRAV Right rear wheel oil outlet valve
RL Left rear wheel

ABS - ABS 53A-7

Common
Item Part function Vehicle fault phenomenon
part fault
Control the braking torque on each ABS system does not work
ABS/ESP Control unit Damaged
wheel and the indicator is abnormal
Control the braking torque on each ESP system does not work
Steering angle sensor Damaged
ABS system does not work

Wheel speed sensor Detect the speed of each wheel Damaged
and the indicator is abnormal
Measure the vehicle rotation

Body yaw rate sensor direction around the vertical Damaged ESP system does not work
ground axis
Transverse Detect the actual travel direction

Damaged ESP system does not work
acceleration sensor of the vehicle
Initial inspection
△ Tips:
Before ABS system diagnosis, first inspect the components that may lead to ABS system fault and
be easily accessible, the visual inspection and visual inspection steps can quickly identify the fault,
to eliminate the need for further diagnosis.
1. Be sure to install only the tires and wheels

with the recommended sizes on the vehicle.
The tread pattern and depth on the coaxial
tires must be the same.
Tire specifications: 215/55 R17
53A
LFWX-6470-53002
2. Inspect ABS hydraulic modulator, the brake pipe and the connector for leak.
3. Inspect ABS system fuse, to ensure the fuse cannot be burned and its model is correct.
There are 3 fuses on ABS system:
Pump motor slow blow fuse: 30A
Solenoid valve fuse: 30A
Electronic control unit fuse: 5A
4. Inspect the battery voltage, and inspect the battery terminals for corrosion or loosening.
The normal operating voltage range of ABS system is 9.3-16.8V.
5. Inspect ABS ground wiring for loosening and the grounding position for change.
53A-8 ABS - ABS
6. ABS grounding wire shall have good air tightness to prevent water and moisture
penetrating into ABS ECU by passing the pore passage in harness under the action of
capillary (siphon) effect, thus disabling the functions.
7. Perform appearance inspection and visual inspection of the following electrical
components:
(a). Whether ABS system wiring harnesses and connector is properly connected, and whether it is
pinched or cut.
(b). Whether the wiring harness arrangement is too close to high voltage or high current devices,
such as high-voltage supply or part, generator, motor, or stereo amplifier installed aftermarket.
Note:
High voltage or high current deputy may cause the induced noise in the circuit, to interfere
with the normal operation of the circuit.
(c). ABS components are very sensitive to the electromagnetic interference. If an intermittent fault
is suspected, inspect whether the anti-theft deputy, the lights or the mobile phone installed
after-sale is not properly installed.
8. ABS is an active safety system, its main function is to use the ground adhesive force as
maximum, to keep the vehicle steerability and driving stability. However, when the drive
speed exceeds the physical limit or high-speed driving on slippery surface, ABS cannot
completely prevent the slippage.
9. Excessive noise from ABS may be caused by the following reasons:
(a). ABS control unit and ABS control unit bracket fixing is loose.
(b). ABS control unit bracket and body fixing is loose.
(c). The plastic gasket on ABS control unit bracket is missed or damaged.
ABS - ABS 53A-9
Diagnosis
Diagnosis procedure
1. Read DTC
(a). There is DTC; go to Step 3
(b). No fault code, go to Step 4
2. Record the fault code, and then clear it.
3. Confirm and reproduce the fault: increase the vehicle to over 15 km/h, simulate the fault
status, and read the fault code again.
4. Rule out the fault without the fault code, and then go to Step 7.
5. Perform the troubleshooting based on the fault code table, and then go to Step 7.
6. Perform the troubleshooting based on the fault symptom table, and then go to Step 7.
7. Confirm that the fault has been ruled out and the system is returned to normal operation.
8. Diagnosis end.
ABS diagnostic description

The wheel speed signal collected via the wheel speed sensor is transmitted to ECU for the speed
calculation, and then calculate the vehicle deceleration and the wheel slipping rate. Based on the
calculated parameters, ABS controller can adjust the brake pressure during braking process via
the hydraulic control unit, to achieve the purpose of ABS. When the ignition switch is in ON position
at each time, ABS will perform the self-test; If there is any fault, ECU can automatically break ABS
function, and turn on ABS alarm indicator; at this time, the brake system operation will be same as
a brake system without ABS.

1. Use diagnostic apparatus to read fault code
(DTC)
(a). Connect LIFAN V30 diagnostic tester to the 53A
diagnostic interface.
(b). Select Version 6.4 or above, select “xuanlang”
model, select “Chassis Control”, and enter “ABS”.
Tips:
If the fault code can not be cleared up, this means
the fault has not been troubleshooter. Troubleshoot
the fault according to the fault code prompts, letting
the vehicle drive at a speed higher than 15km/h and
complete ABS dynamic self-testing, then conduct
again the clearing up of fault code
LFWX-6470-72006
53A-10 ABS - ABS
Data stream
Tips:
Using diagnostic apparatus to read data flow may make you be able to observe the working
conditions of relay, actuator and other components without needing to remove any parts. When
troubleshooting, first conduct the road test to read the data flow. This can significantly save the
diagnosis time.
Items Display Note
Hydraulic unit filling status Completed and normal -
FL wheel speed 0 Display FL wheel speed
FR wheel speed 0 Display FR wheel speed
RL wheel speed 0 Display RL wheel speed
RR wheel speed 0 Display RR wheel speed
Display current vehicle speed output to other

Speedometer 0
control unit
Display the operation status of FL oil-inlet

LF oil inlet solenoid valve Open/close
solenoid valve
Display the operation status of FL oil-outlet
LF oil outlet solenoid valve Open/close
solenoid valve
Display the operation status of FR oil-inlet

FR oil-inlet solenoid valve Open/close
solenoid valve
Display the operation status of FR oil-outlet

FR oil-outlet solenoid valve Open/close
solenoid valve
Display the operation status of RL oil-inlet

RL oil-inlet solenoid valve Open/close
solenoid valve
Display the operation status of RL oil-outlet

RL oil-outlet solenoid valve Open/close
solenoid valve
Display the operation status of RR oil-inlet
RR oil-inlet solenoid valve Open/close
solenoid valve
Display the operation status of RR oil-outlet

RR oil-outlet solenoid valve Open/close
solenoid valve
Relay status Open/close Display current ABS relay status
Pump motor status Open/close Display the current operation of pump
Display the input status of brake lamp switch

BLS(Brake Lamp Switch) status Open/close
signals
Display the voltage supplied to ABS Electronic

Storage battery Resistance 10~15V
control unit
ABS - ABS 53A-11
DTC list
DTC DTC description Fault location
1-1 No fault
2-1 Left front wheel oil inlet solenoid valve power-off fault
2-2 Left front wheel oil inlet solenoid valve power-on fault Left front wheel pressure
2-3 Left front wheel oil outlet solenoid valve power-off fault regulating valve
2-4 Left front wheel oil outlet solenoid valve power-on fault
3-1 Right front wheel oil intlet solenoid valve power-off fault
3-2 Right front wheel oil intlet solenoid valve power-on fault Right front wheel pressure
3-3 Right front wheel oil outlet solenoid valve power-off fault regulating valve
3-4 Right front wheel oil outlet solenoid valve power-on fault
4-1 Left rear wheel oil inlet solenoid valve power-off fault
4-2 Left rear wheel oil inlet solenoid valve power-on fault Left rear wheel pressure
4-3 Left rear wheel oil outlet solenoid valve power-off fault regulating valve
4-4 Left rear wheel oil outlet solenoid valve power-on fault
5-1 Right rear wheel oil inlet solenoid valve power-off fault
5-2 Right rear wheel oil outlet solenoid valve power-on fault Right rear wheel pressure
5-3 Right rear wheel oil outlet solenoid valve power-off fault regulating valve
5-4 Right rear wheel oil outlet solenoid valve power-on fault
1-2 System parameter matching error ECU
1-3 EEPROM error, the code does not match ECU 53A
1-4 ECU encryption bit calibration error EEPROM
1-5 Too low power supply voltage

Battery power supply
1-6 Too high power supply voltage
1-7 Too low ECU power supply voltage

ECU power
1-8 Too high ECU power supply voltage
1-9 ECU ignition switch power supply fault ECU power
1-A Motor ST fault Motor
1-E Too low ABS motor input voltage ABS motor
0-D Too big or too small ABS solenoid current ABS solenoid valve coil
8-1 Left front wheel speed sensor short circuit or open circuit Left front wheel speed sensor
9-1 Right front wheel speed sensor short circuit or open circuit Right front wheel speed sensor
A-1 Left rear wheel speed sensor short circuit or open circuit Left rear wheel speed sensor
53A-12 ABS - ABS
B-1 Right rear wheel speed sensor short circuit or open circuit Right rear wheel speed sensor
1-F Inconsistent speed signal
8-2 No left front wheel sensor signal

4 pieces of wheel speed sensor
9-2 No right front wheel sensor signal harness, connector, gear ring
and sensor assembly gap
A-2 No left rear wheel sensor signal
B-2 No right rear wheel sensor signal
8-3 Unstable left front wheel speed signal
9-3 Unstable right front wheel speed signal 4 pieces of wheel speed sensor
harness, connector, gear ring
A-3 Unstable left rear wheel speed signal and sensor assembly gap
B-3 Unstable right rear wheel speed signal

1. ABS fuse FS38 (blown)
2. ABS fault alarm indicator circuit Refer to Chapter 53 - Anti-block braking

ABS fault alarm
(short circuit or open circuit) system diagnosis, fault diagnosis
indicator can not be
(1. ABS fault alarm indicator can not be
turned on 3. Combination instrument (damage) turned on)
4. ABS control unit (damaged)
1. Check whether the fault code

output
2. ABS fault alarm indicator circuit Refer to Chapter 53 - Anti-block braking

ABS fault alarm
(short circuit) system diagnosis, fault diagnosis
indicator is turned
(2. ABS fault alarm indicator is turned
normally on 3. Check the instrument cluster normally on)
(damaged)
4. ABS control unit (damaged)
1. EBD fault alarm indicator circuit

(short circuit or open circuit)
2. Check the brake fluid (lack) Refer to Chapter 53 - Anti-block braking

EBD fault alarm
system diagnosis, fault diagnosis
indicator is turned 3. Check the instrument cluster (3. ABS fault alarm indicator is turned
normally on (damaged) normally on)
4. Check the ABS control unit
(damaged)
1. Read the fault code -

ABS system does not
action 2. Check the ABS control unit
Replacement
(damaged)
ABS - ABS 53A-13
Fault diagnosis
1. ABS fault alarm indicator can not be turned on
When performing the self-

Turn the power switch to “ON”
test of the combination
position, and observe whether Diagnosis is
instrument indicator, ABS Go to Step 1
the combination instrument finished
fault alarm indicator will no
indicator for self-test
be turned on
Check whether the engine Replace a fuse

compartment fuse box ABS with the same
The current in the power
control unit fuses FS01 and specification.
Go to Step 3 supply circuit is too big (short
FS02 are blown; in addition, if the fuse is
circuit or over load)
check the cab fuse box ABS blown again,
ECU fuse FS38 go to Step 2
Check ABS control unit power

supply circuit
Find out the
Disconnect the battery If the resistance is too short circuit
negative cable, and check small, the power circuit point, rule out
the resistance between ABS Go to Step 3 may be short circuit or the it and replace
control unit power wiring and combination instrument may a fuse with
the ground wiring be internal short circuit the same
specification
Check ABS control unit power

supply voltage
• Disconnect ABS control unit

connector U14 53A
Check the
• Turn the power switch to “ON” If the voltage is not within the
wiring from the
position, and check the voltage Go to Step 4 reasonable scope, the wiring
fuse to ABS/
between U14 4# terminal and harness may be open circuit
ESP ECU
the grounding wiring
Voltage: 9~13V
Check ABS control unit

grounding wiring
Repair
the wiring
Check the resistance between
harness from
8# and 24# terminals of ABS
The wiring may be short the engine
ECU connector U14 and the Go to Step 5
circuit compartment
grounding wiring
wiring U14 and
Resistance:<2Ω
the grounding
point G12
53A-14 ABS - ABS
Replace the combination

Replace the
instrument of same model
instrument The fault still exists Go to Step 6
and check whether the fault is
cluster
solved
Locate the
Replace the ABS control unit Replace the
causes from
of same model and check ABS actuator The fault still exists
other fault
whether the fault is solved assembly
phenomenon
2. ABS fault alarm indicator is turned normally on

ESP indicator lamp on Go to Step 1
indicator is turned on
Check ABS control unit PCAN

wiring harness
Check the wiring harness from

10# and 11# terminals of ABS
control unit connector U14 Repair
Go to Step 2
to the power supply or the corresponding
- Diagnosis
ground for short circuit, and The circuit has fault wiring harness,
instrument
check whether the terminals connector, or
check
are connected respectively terminal
with 14# and 6# terminals of
the diagnosis port I01
2 Check the diagnostic tester Normal Faulty Instruction
Connect the diagnosis Repair

instrument for fault diagnosis, according
Go to Step 3 There is DTC output
and check the fault code to the DTC
output prompt
Replace the instrument cluster Replace the

of same model and check instrument The fault still exists Go to Step 4
whether the fault is solved cluster
Locate the
causes from
other fault
phenomenon
ABS - ABS 53A-15
3. fault alarm indicator is turned normally on

EBD fault warning lamp on Go to Step 1
indicator is turned on
1 Check the diagnostic tester Normal Faulty Instruction
Connect the diagnosis Repair

instrument for fault diagnosis, according
Go to Step 2 There is DTC output
and check the fault code to the DTC
output prompt
Check whether the brake fluid Add the brake

Go to Step 3 Brake fluid is insufficient
is enough fluid
Check the braking liquid level

switch
Replace the
Check the brake liquid level The brake liquid level switch
Go to Step 4 brake liquid
switch for damage is damaged
level switch
Replace the instrument cluster Replace the

of same model and check instrument The fault still exists Go to Step 5
whether the fault is solved cluster
Locate the
causes from 53A
other fault
phenomenon
53A-16 ABS - ABS
ABS brake system

Replacement
1. Remove ABS control unit
(a). Switch the power supply to OFF, and disconnect
battery negative cable.
(b). Disconnect ABS control unit connector.
Tips:
Turn up the snap of the ABS control unit's harness
connector and pull off the connector.
LFWX-6470-53011
(c). Remove the brake pipe, and use plugs to block

the screw hole of the ABS assembly and the oil
hole of the brake line so as to avoid the invasion
of impurities.
LFWX-6470-53012
(d). Remove ABS control unit and the bracket fixing

bolts and remove ABS control unit.
LFWX-6470-53013
ABS - ABS 53A-17
2. Install ABS control unit

(a). Install the ABS control unit to the bracket, and
install and tighten the fixing nuts.
Torque: 22~28N•m
LFWX-6470-53013
(b). Install the brake pipe.

Tips:
Before the installation, remove the plugs on the
screw hole of the ABS control unit and the oil hole
of the brake pipe. Then, install the corresponding
pipe in the ABS control unit's hole.
LFWX-6470-53012
53A
(c). Install ABS control unit wiring harness.
(d). Install the negative battery terminal.
LFWX-6470-53011
53A-18 ABS - ABS
Wheel speed sensor

Replacement
1. Remove the front wheel speed sensor
(a) Remove the front wheel speed sensor mounting bolt and remove the front wheel speed sensor
(b) Remove the front fender (See Section 81 - Inside and outside fenders, Replacement)
(c) Disconnect the front wheel speed sensor connector and remove the wheel speed sensor
2. Remove the rear wheel speed sensor

(a). Remove rear tailgate of rear wheel mudguard.
(refer to 81 - interior trims and exterior trims, front/
rear wheel splash apron, tailboard, replacement)
(b). Disconnect the rear wheel speed sensor harness
connector.
LFWX-6470-53006
(c). Remove the rear wheel speed sensor harness

mounting bolt and remove the rear wheel speed
sensor harness.
LFWX-6470-53008
ABS - ABS 53A-19
3. Install the rear wheel speed sensor harness

(a). Install the rear wheel speed sensor harness to
the installation position and the harness fixing
bolt and then tighten the bolt.
Note:
Do not pull the wheel speed sensor wiring harness.
LFWX-6470-53008
(b). Connect the rear wheel speed sensor harness

connector.
Note:
Install the rear wiring harness, without distortion.
(c). Install tailgate of rear wheel mudguard. (refer to
81 - interior trims and exterior trims, front/rear
wheel splash apron, tailboard, replacement)
LFWX-6470-53006
53A
5. Install the front wheel speed sensor.

Note:
Before installation, clean the sensor mounting hole and the brake disc surface.
(a). Check the sensor mounting hole for any foreign bodies, and the brake disc surface for metal
debris or other foreign matters.
(b). Install front wheel speed sensor on installation site, then install and fasten the fixed bolt of front
wheel speed sensor.
Note:
(f). Connect the front wheel speed sensor harness connector.
(g). Install the front tailgate of front wheel mudguard. (refer to 81 - interior trims and exterior trims,
front/rear wheel splash apron, tailboard, replacement)
53A-20 ABS - ABS
53-a
ESP/ESC braking system - ESP/ESC braking system
ESP/ESC braking system

ESP��1
Precautions�� 2
17 New version ESC circuit diagram�� 5
Hydraulic diagram�� 8
Initial inspection�� 9
Diagnosis��10
Diagnosis procedure�� 10
ESP/ESC diagnostic description�� 10
Read and clear the fault codes��11
Data stream��11
ESP/ESC brake system��12
Wheel speed sensor��14
Steering wheel angle sensor��16
Replacement�� 16 53
Body yaw rate sensor��16
ESC DTC list�� 17
ESC DTC list�� 22
ESP/ESC braking system - ESP/ESC braking system 53B-1
ESP
Preparations
1. Special tools
Diagnosis
1 ABS System failure diagnosis
equipment
Maintenance data
215/55 R17
Tire model
Items N·m
Connecting bolt between ABS actuator and the

20~26
bracket
53B
53B-2 ESP/ESC braking system - ESP/ESC braking system
Precautions
1. After the vehicle is powered on or the engine is started, a short “Hum” sound will be
sent, which is the sound of ESP/ESC system self-test and is normal.
2. Before diagnosing ESP/ESC system, must ensure that the service brake system is
operated normally, without any fault.
3. When ESP/ESC system work properly, there should be a sound, mainly including:
Sounds from motor, solenoid valve and return pump actions in ESP/ESC control unit.
Sound from the brake pedal return.
Crash sound between the suspension and the body due to the emergency braking.
4 The following two cases show that ABS system detects a fault:
(a) Turn on the ignition switch, complete the system self-test and maintain ESP/ESC warning
indicator in “On” position
(b) During driving, the warning indicator ESP/ESC should be on.
Warning:
At this point, the driver may make the common brake, but the braking force should be reduced as possible,
to prevent the wheels from locking. After the alarm indicator is lit, the vehicle should be driven immediately
carefully to the authorized service station for maintenance, in order to prevent the traffic accidents from more
faults.
5. ESP/ESC system must be repaired by a technician who has been trained and has
mastered maintenance skills and can only be replaced with genuine parts.
6. When connecting ESP/ESC electronic control unit and wheel speed sensor wiring
harness, must pay attention to the followings:
(a). Before removing ESP/ESC electronic control unit and the wheel speed sensor wiring harness,
place the ignition switch in OFF position and disconnect the battery negative cable.
(b). Ensure that the connector is dry and clean, to prevent any foreign matter.
(c). Must install ESP/ESC wiring harness connector in place in the horizontal direction and the
vertical direction.
7. Connect ESP/ESC brake pipeline, and ensure its proper connection. ESP/ESC ECU can
not judge whether the brake line is correctly connected.The incorrect connection may
lead to serious accidents. Must connect the brake pipe according to the mark on ESP/
ESC assembly:
(a). MC1: the brake pipe 1 to connect the brake master cylinder.
(b). MC2: the brake pipe 1 to connect the brake master cylinder.
(c). FL: the brake pipe to connect the left front brake wheel cylinder.
(d). FR: the brake pipe to connect the right front brake wheel cylinder.
(e). RL: the brake pipe to connect the left rear brake wheel cylinder.
(f). RR: the brake pipe to connect the right rear brake wheel cylinder.
8. ESP/ESC control unit can only be replaced as a whole and can not be dismantled or
partially replaced/interchanged.Lifan Company does not provide separate spare parts
and does not provide the warranty for disassembled ESP/ESC control unit; Lifan
Company is not responsible for any adverse consequences caused by dismantling
or partial replacement/replacement of ESP/ESC control unit.After ESP/ESC system is
repaired, it must be tested, to ensure complete troubleshooting before delivery to the
customer.
System description
1. Function
ESP/ESC (Body Electronic Stability Protection System) can be used to prevent the vehicle
slipping due to understeering or wagging due to oversteering.
2. Composition
ESP/ESC consists of steering wheel angle sensor, wheel speed sensor, body yaw rate sensor
and other components.
ESP/ESC: The system is actually a traction control system; it can identify the driver steering
direction via the steering wheel angle sensor and wheel speed sensor, identify the vehicle
rotation angle around the vertical axis of the ground via the body yaw rate sensor and identify
the actual vehicle travel direction via the lateral acceleration sensor; based on the driver
steering intent and the actual vehicle operation, ESP/ESC can take the initiative to control the
wheels, to prevent the vehicle side slipping or wagging.
Component drawing
4
7 8
2 5 53B
ESC ESP
LFWX-6470-53010
ABS right front wheel speed sensor

1 5 Body yaw rate sensor
assembly
ABS left front wheel speed sensor

2 6 Steering wheel angle sensor
assembly
ABS right rear wheel speed sensor

3 7 ESC actuating mechanism
harness assembly
BS left rear wheel speed sensor

4 8 ESP actuating mechanism
harness assembly
ab central electrical control box
Engine compartment central electrical control box

IG1 B+ B+
AS 01
AS 25
25A
40A
FS38
5A
1 I51 4 I51
0.5 RW
7 1D 2 I19 1 I19 4 I19 3 I19 6 I01 14 I01

+96 +9)
7 I1D
2 I51 3 I51 5 I04 4 I04

21 IU1 20 IU1
0.5 RW
10 IU2 4 IU2 1 IU2
21 UI1 20 UI1
10 UI2 4 UI2 1 UI2
34 IU1
0.5 GrW
0.5 GrY
0.5 YBl
4.00 R
2.50 R
34 UI1
0.30 YB
0.30 Y
20 U14 33 U14 12 U14 4 U14 11 U14 10 U14 1 U14 25 U14
30 ; 2 ; 13 U14 38 U14 8 U14 19 U14 4 U14 16 U14 18 U14 31 U14 29 U14 17 U14
0.50 WO
0.50 BrB
0.50 OB
0.50 GB
0.50 YR
0.50 Br
0.3 VW
0.5 B
0.5 B
0.5 B
0.5 GO
0.50 O
0.50 G
2.50 B
4.00 B
10 UI1 9 UI1 7 UI1 8 UI1
10 IU1 9 IU1 7 IU1 8 IU1
26 UI1 33 UI1
0.50 BrB
0.50 OB
0.50 Br
0.50 O
26 IU1 33 IU1
3 IB2 8 IB2 16 IG 10 IG
3 BI2 8 BI2 16 GI 10 GI
Circuit diagram
0.50 BrB
0.50 OB
0.50 Br
0.50 O
2 U16
U02 1 U16
U02 2 U10
U02 1 U10
U02 1 B6 2 B6 1 G4 2 G4
I06 I14
6+69
G12
G21 G23 G22
53B-4
53B
53B-5
IG1 B+
control box
central electrical
Engine compartment
B+ B+
FS45
AS 01
AS 25
FS18
25A
40A
5A
10
6 I01 14 I01 2 I19 1 I19 3 I19 4 I19 17 1D 1 1C I51 3 I51 2 I51 5 I51 4 I51
+96 +9)
17 I1D 1 I1C
6 I04 7 I04 0.5 RBl

21 IU1 20 IU1
1 IU2 10 IU2 4 IU2
21 UI1 20 UI1
1 UI2 10 UI2 4 UI2
34 IU1
0.5 GrW
0.5 GrY
0.5 YBl
4.00 R
2.50 R
34 UI1
0.5 RW
0.30 YB
0.30 Y
17 New version ESC circuit diagram
12 U14 1 U14 25 U14 11 U14 10 U14 4 U14 20 U14 33 U14

30 ; 2 ; 13 U14 38 U14 8 U14 19 U14 4 U14 16 U14 18 U14 31 U14 29 U14 17 U14
0.50 WO
0.50 BrB
0.50 OB
0.50 GB
0.50 YR
0.50 Br
0.3 VW
0.5 B
0.5 B
0.5 B
0.5 GO
0.50 O
0.50 G
2.50 B
4.00 B
10 UI1 9 UI1 7 UI1 8 UI1
10 IU1 9 IU1 7 IU1 8 IU1
26 UI1 33 UI1
0.50 BrB
0.50 OB
0.50 Br
0.50 O
26 IU1 33 IU1
3 IB2 8 IB2 16 IG 10 IG
3 BI2 8 BI2 16 GI 10 GI
0.50 BrB
0.50 OB
0.50 Br
0.50 O
06
2 U1 2 06
1 U1 2 00
2 U1 2 00
1 U1 2 1 B6 2 B6 1 G4 2 G4
I06 I14
6+69
G12
G23 G22 G21
Terminal definition
U14 Connect to ESP / ESC controller assembly
12 11 10 9 8 7 6 5 4 3 2
13 1
24 23 22 21 20 19 18 17 16 15 14
38 25
37 36 35 34 33 32 31 30 29 28 27 26

Function Function
No. color No. color
1 4.0/R ESP pump motor + 29 NC
2 0.3/VW Wheel speed signal output 30 0.5/GB Right front wheel speed sensor-
3 NC Right rear wheel speed sensor

31 0.5/O
power supply
4 0.5/GB Right front wheel speed sensor+
32 NC
5 NC
33 0.5/GrY Yaw rate sensor signal -
6 NC
34 NC
7 NC
35 NC
8 0.5/WO Left front wheel speed sensor-
36 NC
9 NC
37 NC
10 NC
38 2.5/B Ground
11 NC
U06
12 0.5/YBl ESP switch signal to right front wheel speed sensor
13 4.0/B Ground
14 0.3/YB PCAN_L
15 NC
16 0.5/G Right front wheel speed sensor+
17 0.5/Br Right rear wheel speed sensor +

2 1
18 0.5/OB Left rear wheel speed sensor-
19 0.5/YR Left front wheel speed sensor+

20 0.5/Grw Yaw rate sensor signal + Terminal Wire size/
Function
No. color
21 NC
22 NC 1 0.5 /GB
signal +
23 NC
2 0.5/ G
signal -
24 NC
25 2.5/R ESP solenoid valve power supply
26 0.3/Y PCAN_H
27 4.0/R ESP pump motor +
28 0.3/VW Wheel speed signal output

U16 to left front wheel speed sensor I51 to the slew rate sensor
2 4
2 1
1 3

Function Function
No. color No. color
Left front wheel speed sensor 1 0.5/B Ground

1 0.5 /WO
signal +
2 0.5/GrW Sway rate sensor signal +
2 0.5/ YR 3 0.5/GrY Sway rate sensor -
signal -
4 0.5/RW ECU power supply
I19 to the angle sensor
1 2 3 4
Terminal Wire size/

Function
No. color
1 0.5/B Ground
2 0.5/WB Angle sensor B+ 53B

3 0.3/Y PCAN_H
4 0.3/YB PCAN_L
• Please check the circuit catalog for details.

• The definition of the terminals of the Xunlang 17 facelift model has been described in detail in
the circuit catalog. For details, please refer to the Xuanlang circuit catalog.
Hydraulic diagram
Lifan xuanlang anti-lock braking system adopts X type layout. ABS hydraulic regulator consists of 1
motor, 2 return pumps, 2 accumulators and 8 solenoid valves.
MC1 Brake master cylinder firist circuit RR Right rear wheel
MC2 Brake master cylinder second circuit FLEV Left front wheel oil inlet valve
M Motor FLAV Left front wheel oil outlet valve
RP1 Return pump 1 FREV Right front wheel oil inlet valve
RP2 Return pump 2 FRAV Right front wheel oil outlet valve
A1 Accumulator 1 RLEV Left rear wheel oil inlet valve
A2 Accumulator 2 RLAV Left rear wheel oil outlet valve
FL Left front wheel RREV Right rear wheel oil inlet valve
FR Right front wheel RRAV Right rear wheel oil outlet valve
RL Left rear wheel


Common
Item Part function Vehicle fault phenomenon
part fault
ESP/ESC Control Control the braking torque on ESP/ESC system does not work
Damaged
unit each wheel and the indicator is abnormal
Steering angle Control the braking torque on ESP/ESC system does not work
Damaged
sensor each wheel and the indicator is abnormal
Detect the speed of each ESP/ESC system does not work

Wheel speed sensor Damaged
Measure the vehicle rotation

Body yaw rate
direction around the vertical Damaged ESP/ESC system does not work
sensor
ground axis
Transverse Detect the actual travel

Damaged ESPESC system does not work
acceleration sensor direction of the vehicle
Initial inspection
Tips:
Before ESP/ESC system diagnosis, first inspect the components that may lead to ESP/ESC system
fault and be easily accessible, the visual inspection and visual inspection steps can quickly identify
the fault, to eliminate the need for further diagnosis.
1. Be sure to install only the tires and wheels

with the recommended sizes on the vehicle.
The tread pattern and depth on the coaxial
tires must be the same.
Tire specifications:215/55 R17 or 225/45 R18
53B
LFWX-6470-53002
2. Inspect ESP/ESC hydraulic modulator, the brake pipe and the connector for leak.
3. Inspect ESP/ESC system fuse, to ensure the fuse cannot be burned and its model is
correct. There are 3 fuses on ABS system:
Pump motor slow blow fuse: 10A
Solenoid valve fuse: 25A
Electronic control unit fuse: 5A
4. Inspect the battery voltage, and inspect the battery terminals for corrosion or loosening.
The normal operating voltage range of ESP/ESC system is 9.3-16.8V.
5. Inspect ESP/ESC ground wiring for loosening and the grounding position for change.
6. ESP/ESC gr ounding wire shall have good air tightness to prevent water and moisture
penetrating into ESP/ESC ECU by passing the pore passage in harness under the action of
capillary (siphon) effect, thus disabling the functions.
7. Perform appearance inspection and visual inspection of the following electrical
components:
(a). Whether ESP/ESC system wiring harnesses and connector is properly connected, and whether
it is pinched or cut.
(b). Whether the wiring harness arrangement is too close to high voltage or high current devices,
such as high-voltage supply or part, generator, motor, or stereo amplifier installed aftermarket.
Note:
High voltage or high current deputy may cause the induced noise in the circuit, to interfere
with the normal operation of the circuit.
(c). ESP/ESC components are very sensitive to the electromagnetic interference. If an intermittent
fault is suspected, inspect whether the anti-theft deputy, the lights or the mobile phone installed
after-sale is not properly installed.
8. ESP/ESC is an active safety system, its main function is to use the ground adhesive
force as maximum, to keep the vehicle steerability and driving stability. However, when
the drive speed exceeds the physical limit or high-speed driving on slippery surface,
ABS cannot completely prevent the slippage.
9. Excessive noise from ESP/ESC may be caused by the following reasons:
(a). ESP/ESC control unit and ESP/ESC control unit bracket fixing is loose.
(b). ESP/ESC control unit bracket and body fixing is loose.
(c). The plastic gasket on ESP/ESC control unit bracket is missed or damaged.
Diagnosis
Diagnosis procedure
1. Read DTC
2. Record the fault code, and then clear it.
3. Confirm and reproduce the fault: increase the vehicle to over 15 km/h, simulate the fault
status, and read the fault code again.
4. Rule out the fault without the fault code, and then go to Step 7.
5. Perform the troubleshooting based on the fault code table, and then go to Step 7.
6. Perform the troubleshooting based on the fault symptom table, and then go to Step 7.
7. Confirm that the fault has been ruled out and the system is returned to normal operation.
8. Diagnosis end.
ESP/ESC diagnostic description

The wheel speed signal collected via the wheel speed sensor and body yaw rate sensor is
transmitted to ECU for the speed calculation, and then calculate the vehicle deceleration and the
wheel slipping rate. Based on the calculated parameters, ESP/ESC controller can adjust the brake
pressure during braking process via the hydraulic control unit, to achieve the purpose of ESP/ESC.
When the ignition switch is in ON position at each time, ESP/ESC will perform the self-test; If there
is any fault, ECU can automatically break ESP/ESC function, and turn on ESP/ESC alarm indicator;
at this time, the brake system operation will be same as a brake system without ESP/ESC.

1. Use diagnostic apparatus to read fault
code(DTC)
(a). Connect LIFAN V30 diagnostic tester to the
diagnostic interface.
(b). Select Version 6.5 or above, select “xuanlang”
model, select “Chassis Control”, and enter “ABS”.
Tips:
If the fault code can not be cleared up, this means
the fault has not been troubleshooter. Troubleshoot
the fault according to the fault code prompts, letting
the vehicle drive at a speed higher than 15km/h
and complete ESP/ESC dynamic self-testing, then
conduct again the clearing up of fault code.
See the last pages of this chapter for DTC list of
ESP and ESC.
Data stream
Tips:
Using diagnostic apparatus to read data flow may make you be able to observe the working
conditions of relay, actuator and other components without needing to remove any parts. When
troubleshooting, first conduct the road test to read the data flow. This can significantly save the
diagnosis time.
Items Display Note
Hydraulic unit filling status Completed and normal -
FL wheel speed 0 Display FL wheel speed
FR wheel speed 0 Display FR wheel speed
RL wheel speed 0 Display RL wheel speed
RR wheel speed 0 Display RR wheel speed 53B

Speedometer 0 Display current vehicle speed output to other control unit
LF oil inlet solenoid valve Open/close Display the operation status of FL oil-inlet solenoid valve
LF oil outlet solenoid valve Open/close Display the operation status of FL oil-outlet solenoid valve
FR oil-inlet solenoid valve Open/close Display the operation status of FR oil-inlet solenoid valve
FR oil-outlet solenoid valve Open/close Display the operation status of FR oil-outlet solenoid valve
RL oil-inlet solenoid valve Open/close Display the operation status of RL oil-inlet solenoid valve
RL oil-outlet solenoid valve Open/close Display the operation status of RL oil-outlet solenoid valve
RR oil-inlet solenoid valve Open/close Display the operation status of RR oil-inlet solenoid valve
RR oil-outlet solenoid valve Open/close Display the operation status of RR oil-outlet solenoid valve
Relay status Open/close Display current ESP/ESC relay status
Pump motor status Open/close Display the current operation status of pump
BLS(Brake Lamp Switch)

Open/close Display the input status of brake lamp switch signals
status
Storage battery Resistance 10~15V Display the voltage supplied to ESP/ESC Electronic control unit
ESP/ESC brake system

Replacement
ESP / ESC control unit assembly and disassembly method is almost the same. Next ESP control
unit will be taken as an example for assembly and disassembly.
1. Remove ESP/ESC control unit

(a). With the power in OFF state, disconnect the
(b). Disconnect ESP/ESC control unit connector.
Tips:
• Turn up the snap of the ESP/ESC control
unit's harness connector and pull off the
connector.
• It is more convenient to remove the air filter
before removing it.
LFWX-6470-53003
(c). Remove the brake pipe, and use plugs to block

the screw hole of the ESP/ESC assembly and the
oil hole of the brake line so as to avoid the
invasion of impurities.
LFWX-6470-53004
(d). Remove ESP/ESC control unit and the bracket

fixing bolts and remove ESP/ESC control unit.
LFWX-6470-53005
2. Install ESP/ESC control unit

(a) Install the ESP/ESC control unit to the bracket,
and install and tighten the fixing nuts.
LFWX-6470-53005
(b). Install the brake pipe.

Tips:
Before the installation, remove the plugs on
the screw hole of the ESP/ESC control unit and
the oil hole of the brake pipe. Then, install the
corresponding pipe in the ESP control unit's hole.
LFWX-6470-53004
53B
(c). Install ESP /ESC control unit wiring harness.
(d). Install the negative battery terminal.
LFWX-6470-53003
Wheel speed sensor

Replacement
1. Remove the front wheel speed sensor
(a) Remove the front wheel speed sensor mounting bolt and remove the front wheel speed
sensor
(b) Remove the front fender (See Section 81 - Inside and outside fenders, Replacement)
(c) Disconnect the front wheel speed sensor connector and remove the wheel speed sensor
2. Remove the rear wheel speed sensor

(a). Disconnect the connector clip of rear wheel
speed sensor harness, and remove rear wheels.
LFWX-6470-53006
(b). Remove the rear wheel speed sensor harness

mounting bolt and remove the rear wheel speed
sensor harness.
LFWX-6470-53008
3. Install the rear wheel speed sensor harness

(a). Install the rear wheel speed sensor harness to
the installation position and the harness fixing
bolt and then tighten the bolt.
Warning:
Do not pull the wheel speed sensor wiring harness.
LFWX-6470-53008
(b). Connect the rear wheel speed sensor harness

connector.
Warning:
(c). Install tailgate of rear wheel mudguard. (refer to
81 - interior trims and exterior trims, front/rear
wheel splash apron, tailboard, replacement)
LFWX-6470-53006
53B
5. Install the front wheel speed sensor.

Warning:
Before installation, clean the sensor mounting hole and the brake disc surface.
(a). Check the sensor mounting hole for any foreign bodies, and the brake disc surface for metal
debris or other foreign matters.
(b). Install front wheel speed sensor on installation site, then install and fasten the fixed bolt of front
wheel speed sensor.
Warning:
(f). Connect the front wheel speed sensor harness connector.
(g). Install the front tailgate of front wheel mudguard. (refer to 81 - interior trims and exterior trims,
front/rear wheel splash apron, tailboard, replacement)
Steering wheel angle sensor

Replacement
1. Remove the steering wheel angle sensor
(b). Remove direction pipe column shield assembly.
(c). Remove the clock spring assembly .
(d). Disconnect the connection of the steering wheel
angle sensor from the clock spring and remove
the steering wheel angle sensor.
2. Install the steering-wheel angle sensor
(a) Install the steering wheel angle sensor onto the
clock spring and ensure it is seated properly.
(b) Install the clock spring assembly
(c). Install direction pipe column shield assembly.
(d). Connect the negative battery cable and check
ESP /ESC system for normal operation.
LFWX-6470-53007
Body yaw rate sensor

Replacement
1. Remove the body yaw rate sensor
(b). Remove the sub dashboard assembly (see
Section 85 - Dashboard and sub dashboard, Sub
dashboard, Replacement)
(c) Disconnect the body yaw rate sensor wiring
harness connector.
(d). Remove the body yaw rate sensor fixing bolt and
nut, and remove the body yaw rate sensor.
2. Install the body yaw rate sensor
(a) Install the body yaw rate sensor onto the
mounting position and install and tighten the
fixing bolt and screw.
(b) Connect the body yaw rate sensor wiring harness
LFWX-6470-53009 connector to ensure it is seated properly.
(c) Install the sub dashboard assembly (see
Section 85-Dashboard and sub dashboard, Sub
dashboard, Replacement)
(d). Connect the negative battery cable and check
ESP system for normal operation.
ESC DTC list

DTC DTC(Hex) DTC Description ABS/ESP Notice
B911917 Ox911717 ECU Voltage supply:high voltage A/E
B911716 Ox911716 ECU Voltage supply:low voltage A/E
ECU error(hardware,Micro-controller
C100004 Ox500004 A/E
error)
C101008 Ox501008 ECU error(general softwareproblem) A/E
ABS/ESC implausible control(control

C006B06 Ox406B06 A/E
time too long,etc)
Wheel-speed sensor,front
C003108 Ox403108 left:(signal failure)out of A/E
range,lost,noise,Intermittent
Wheel-speed sensor,front left:Signal

C003200 Ox403200 Line short to GND/OPEN;Supply A/E
Line open
Wheel-speed sensor,front left:Supply

C00A000 Ox40A000 A/E
LINE short to GND

C00A100 Ox40A100 A/E 53B
Line short to UBATT
under(no exact
Wheel-speed sensor,front left:general
C00A900 Ox40A900 A/E failurereason
error
detecable)
C003408 Ox403408 right:(signal failure)out of A/E
range,loet,noise,Intermittent
C003500 Ox403500 A/E
right:Signal Line short to GND/Open;
C00A200 Ox40A200 A/E
right:Signal Line short to UBATT
C00A300 Ox40A300 A/E
right:Signal line short to UBATT
under(no exact
C00AA00 Ox40AA00 A/E failurereason
right:general error
detectable)
Wheel-speed sensor,rear
range,loet,noise,Interittent
Wheel-speed sensor,rear left:signal

C003800 Ox403800 line short to GND/OPEN;Supply line A/E
open
Wheel-speed sensor,rear left:Supply

C00A400 Ox40A400 A/E
line short to GND
Wheel-speed sensor,rear left:Signal

C00A500 Ox40A500 A/E
line short to UBATT
Wheel-speed sensor,rear left:general

C00AB00 Ox40AB00 A/E
error
C003A08 Ox403A08 right:(Signal failure) out of A/E
range,lost,noise,Intermittent
under(no exact
C003B00 Ox403B00 A/E failurereason
right:Supply line short to GND
detectable)
C00A600 Ox40A600 A/E
right:Supply line short to GND
Wheel-speed sensor,rear right:Signal

C00A700 Ox40A700 A/E
line short to UBATT
undef(no exact
C00AC00 Ox40AC00 A/E failurereason
right:General error
detectable)
Wheel-speed sensor generic

C109904 Ox509904 error(sensor swap,multiple sensors A/E
error)
C004460 Ox404460 Pressure sensor fault(Signal) E
C004510 Ox404510 Pressure sensor fault(line) E

C004008 Ox404008 BLS fault:Plausibility E
Lateral acceleration sensor:signal

C006108 Ox406108 E
fault
Longitudinal acceleration
C006208 Ox406208 E
sensor:signal fault
C006308 Ox406308 YAW Rate sensor:signal fault E
YRS sensor cluster fauit(Hardware

C019604 Ox419604 failure,Temperature,range,internal E
fault)
YRS sensor cluster not calibrated

C00A800 0x40A800 E
or calibration failed )
U000500 0xC00500 CAN Bus overvoltage A/E
U000700 0xC00700 CAN Bus under voltage A/E
C100104 0x500104 CAN hardware error A/E
53B
U007300 0xC07300 CAN Bus Off error A/E
U100104 0xD00104 CAN Error Passive A/E
U010004 0xC10004 CAN timeout EMS E
CAN data corrupt / signal invalid

U010008 0xC10008 E
EMS
Optional: ESC
C106600 0x506600 SAS Calibration Error E projects only,
recommended
SAS signal layer

C046008 Ox446008 SAS fault (Signal) E algorithm/logic
error
U012604 OxC12604 CAN timeout SAS E
CAN data corrupt

U012608 OxC12608 SAS(DLC,CRA,alive counter E
error,etc)
Optional:Only
U010104 OxC10104 CAN timeout TCU E applicable for non-
MT project variants
Optional:Only
U010108 OxC10108 CAN data corrupt/signal invaid TCU E applicable for non-
MT project variants
C001004 Ox401004 valve fault,inlet valve FL A/E
C001104 Ox401104 valve fault,OUTlet valve FL A/E
C001404 Ox401404 valve fault,inlet valve FR A/E
C001504 Ox401504 valve fault,outlet valve FR A/E
C001804 Ox401804 valve fault,inlet valve RL A/E
C001904 Ox401904 valve fault,outlet valve RL A/E
C001C04 Ox401C04 valve fault,inlet valve RR A/E
C001D04 Ox401D04 valve fault,outlet valve RR A/E
C000104 Ox400104 Valve fault,USV1 E

C000304 Ox400304 Valve fault,HSV1 E
C109504 Ox509504 Valve relay error A/E
General Valve fault

C007208 Ox407208 （overheatprotection,signal A/E
invalid,hardware fault
C002004 Ox402004 Motor fault A/E
C104C04 Ox504C04 PATA switch falure E
C121208 Ox521208 Variant Coding Error E Optional
Optional:HHC
project only;only
Reverse Gear Switch applicable if
C108C08 OxC508C08 E
Signalpermanent High/Low Reverse Gear 53B
Switch signal is
sent
Lost Communication With YawRate External YRS

U012308 OxC12308 E
Sensor Module sensor cluster of
Invalid Data Received From YawRate External YRS

U051308 OxC51308 E
Sensor Module sensor cluster of
Option:External
External YRS sensor cluster of lateral
C006102 Ox406102 E YRS sensor cluster
acceleration sensor:signal fault
uesd
External YRS sensor cluster Option:External

C006202 Ox406202 of Longitudinal acceleratio E YRS sensor cluster
sensor:signal fault uesd
Option:External
External YRS sensor cluster of Yaw
C006302 Ox406302 E YRS sensor cluster
Rate SENSOR:signal fault
uesd
OPTIONAL:only
U010087 OxC10087 Lost Communication with EMS E EMS is node is
available
OPTIONAL:only
U010187 OxC10187 Lost Communication with BCM E TCU is node is
available
OPTIONAL:only
U014004 OxC14008 Lost Communication with BCM E BCM is node is
available
CAN data corrupt OPTIONAL:only

U014008 OxC14008 BCM(DLC,CRC,alive counter E BCM is node is
error,etc) available
ESC DTC list
C190004 0x590004 ECU Voltage supply:high voltage
A/E
C190104 Ox590104 ECU Voltage suppiy:low voltage
ECU error(hardware,Micro-controller
C100004 Ox500004
error)
A/E
C101008 Ox501008 ECU error(general software problem)
ABS/ESP implausible cotrol (control

C006B06 Ox406B06 A/E
time too long,etc.)
range,lost,noise,intermittent
Wheel-speed sensor,front left:(signal
C003200 Ox403200 line short to GND/OPEN;supply line
open)
A/E
Wheel speed sensor,front left:Signal
C00A000 Ox40A000
line short to GND
C00A100 Ox40A100
line short to UBATT
under(no exact failure
A/E
Wheel-speed sensor,front lefe:general reason detectable)
C00A900 Ox40A900
error
C003408 Ox403408 right:(signal failure)out of A/E
Wheel-speed sensor,front right:Signal

C003500 Ox403500 line short to GND/OPEN;Supply line A/E
open
Wheel-speed sensor,front right:Supply

C00A200 Ox40A200 A/E
line short to GND
Wheel-speed sensor,front right:Signal

C00A300 Ox40A300
line short to UBATT
Wheel-speed sensor,front right:general under(no exact failure

C00AA00 Ox40AA00 A/E
erro reason detectable)
C003708 OX403708 left:(signal failure)out of A/E
Wheel-speed sensor,rear left:Signal

C003800 Ox403800 line short to GND/Open;Supply line A/E
open
Wheel-speed sensor,rear left:Supply

C00A400 Ox40A400 A/E
line short to GND
Wheel-speed sensor,rear left:SIgnal

C00A500 Ox40A500 A/E 53B
line short to UBATT
Wheel-speed sensor,rear left:general under(no exact failure

C00AB00 Ox40AB00 A/E
error reason detectable)
C003A08 Ox403A08 right:(signal failure)out of A/E
Wheel-speed sensor,rear right:Supply

C00A600 Ox40A600 A/E
line short to GND
C00A700 Ox40A700 A/E
right:right:Supply line short to UBATT
Wheel-speed sensor,rear right:General under(no exact failure

C00AC00 Ox40AC00 A/E
error reason detectable)
Wheel-speed sensor,generic
C109904 Ox509904 error(sensor swap,multiple sensors A/E
error)
C004460 Ox404460 Pressure sensor fault (Signal) E
C004510 Ox404510 Pressure sensor fault (line) E
C004008 Ox404008 BLS fault:Plausibility E
C006108 Ox406108 Lateral acceleration sensor:signal fault E
Longitudinal acceleration sensor:signal

C006208 Ox406208 E
fault
C006308 Ox406308 Yaw Rate Sensor:signal fault E
YRS sensor cluster fault(Hardware fail

C019604 Ox419604 E
ure,Temperature,range,internal fault)
YRS sensor cluster not calibrated or

C00A800 Ox40A800 E
calibration failed
U000500 OxC00500 CAN Bus overvoltage A/E
U000700 OxC00700 CAN Bus under voltage A/E
C100104 Ox500104 CAN Bus hardware error A/E
U000104 OxC00104 CAN Bus Off error A/E
U100104 OxD00104 CAN Error Passive A/E

U010004 OxC10004 Lost Communication with EMS1 E
U030104 OxC30104 LOST Communication with EMS2 E
CAN data corrupt

U010008 OxC10008 EMS((DLC,CRC,Alive counter error)/ E
signal invalid EMS
C106600 Ox506600 SAS Calibration ERROR E
C046008 Ox446008 SAS fault (Signal) E
U012604 OxC12604 Lost Communication with SAS E
CAN data corrupt SAS(DLC,CRC,alive

U012608 OxC12608 E
counter error)
U010104 OxC10104 Lost Communication with TCU1 E
U030204 OxC30204 Lost Communication with TCU2 E

53B
CAN DATA CORRUPT
U010108 OxC10108 TCU(DLC,CRC,Alive counter error)/ E
signal invalid TCU
C001004 Ox401004 valve fault,inlet valve FL A/E
C001104 Ox401104 valve fault,outlet valve FL A/E
C001404 Ox401404 valve fault,inlet valve FR A/E
C001504 Ox401504 valve fault,outlet valve FR A/E

C001804 Ox401804 valve fault,inlet valve RL A/E
C001904 Ox401904 valve fault,outlet valve RL A/E
C001C04 Ox401C04 valve fault,inlet valve RR A/E
C001D04 Ox401D04 valve fault,outlet valve RR A/E
C109504 Ox509504 Valve relay error A/E
C002004 Ox402004 Return pumo fault A/E
General Valve fault

C007208 Ox407208 (overheat protection,signal A/E
invalid,hardware fault)
C104C04 Ox504C04 PATA switch failure E
C121208 Ox521208 Variant Coding Eerror E
Reverse Gear Switch signal permanent

C108C08 Ox508C08 E
High/low
Lost Communication With Yaw Rate

U012308 OxC12308 E
Sensor Module
Invalid Data Received From Yaw Rate

U051308 OxC51308 E
Sensor Module
External YRS sensor cluster of Lateral

C006102 Ox406102 E
acceleration sensor:signal fault
External YRS sensor cluster of

C006202 Ox406202 Longitudinal acceleration sensor:signal E
fault
External YRS sensor cluster of

C006302 Ox406302 Longitudinal acceleration sensor:signal E
fault
Lost Communication with Instrument

U015504 OxC15504 E
Cluster
invalid Data Received from Instrument

U042308 OxC42308 E
Cluster(DLC,CRC,alive counter error)
Not applicable for

U014004 OxC14004 Lost Communication with BCM E CP08(530)_ESP9
and x60_RC_ESP
Not applicable for

CAN data corrupt
U014008 OxC14008 E CP08(530)_ESP9
BCM(DLC,CRC,alivecounter error
and x60_RC_ESP
53B
Applicable to x80
C115000 Ox515000 Brake Disc Overheat E
ESP project.
Engine anti-theft system - Engine anti-theft system 54A-a
Ignition switch
Engine anti-theft system��1
System description��2 54A
System components�� 2
Fault phenomenon�� 5
DTC�� 7
Attached Drawing�� 8
Ignition switch assembly��8
Replacement�� 8
54A-b Engine anti-theft system - Engine anti-theft system
Engine anti-theft system - Engine anti-theft system 54A-1
Engine anti-theft system

Preparations
1. Special tools
54A
Read immobilizer
Diagnosis
1 DTC and data
equipment
flow etc.
Measure the
Digital universal
1 voltage and
meter
resistance
Conductor
2 Testing circuit
assembly
54A-2 Engine anti-theft system - Engine anti-theft system
System description
Auto electronic anti-theft system is a kind of world-class new auto anti-theft system. It is generally
known as Immobilizer in the industry. This system uses RFID wireless identification technology
and radio-frequency signal for transmission, calculation and validation. Compared with traditional
after-sales anti-theft system and AlarmSystem, electronic anti-theft system features the following
advantages:
● Auto electronic anti-theft system is intended for engine anti-theft purposes. It integrates key,
electronic anti-theft device and engine control unit into systematic anti-theft system through
proven anti-theft strategy, so as to greatly improve overall safety of auto anti-theft system;
● Auto electronic anti-theft system has better system security by adopting multi-layer password
validation for key, electronic anti-theft system and engine control unit;
● Electronic anti-theft system uses touch method without movable parts;
● It does not produce any sound and light pollution and it will not function by mistake;
● It is easy to operate without additional operation. You cannot even feel system existence during
normal use;
● You cannot start the engine by cross-connecting wires.
Tips:
The electronic anti-theft system of this model is integrated on body controller to realize anti-
theft function.
System components
Electronic anti-theft system of xuanlang ignition switch model is composed by a body control, a
anti-theft read/write identification coil and two remote keys with in-built anti-theft chip. Anti-theft
read/write identification coil is mounted on ignition lock core head and is connected to body control
through body wiring. Anti-theft chip is moutned inside plastic housing of remote key.
Connection between the electronic anti-theft system and the car is shown as below:
EOL
Remote control key Anti-theft controller CAN Diagnostic device /
(security cylinder) VIN code matching equipment
Standard code
Password
ID code
Password
,002
CAN
IC Instrument
ID
EMS
Front body controller:

Front body controller is integrated with anti-theft controller composed by micro-processor and
external elements to realize communication between anti-theft chip and engine ECU. When ignition
switch is ON, if remote key (anti-theft chip) and engine ECU are successfully identified within
specified time, engine ECU will release engine and the car can be started. Otherwise, the engine
cannot be started and anti-theft indicator will flash for prompting.
Communication with engine ECU:

Body controller is connected to engine ECU through body wiring and it will follow communication
protocol of engine ECU.
Component drawing
1-2 54A
1
3
5 4
1 Ignition switch components 4 Left front door lock cylinder
1-2 Security read-write recognition coil 5 Right front door lock cylinder
3 Folding key
Circuit diagram
2.0 R
0.5 R
I48 3 1 2 5 4 6
B1 ACC IG1 B2 IG2 ST
OFF
,9
'
ACC
ON
ST
0.3 BG
0.3 (?
0.3 BBl
16 1F
16 I1F 18 IU1
18 UI1
0.3 BR
15 1F
8.00 R
15 I1F
,9
5 1F
'
5 I1F
9(
'
9(
9(
'
'
K09 start relay

FS11
10A
1 /-
1 /-
1 ')
0.85 RW
20 W
To ACC output To IG2 output To IG1 output
8
15.00 R
8
7 UE1
0.85 R
'
B+ 1 E17
'
9(
9(
7 EU1
0.3 B
B+
0.5 B
1 E9
7 UE1
6 1F
0.5 V
7 EU1 /
3 E9
6 I1F
To instrument cluster
2 E9
16.00 B
G
G01 G22
G G11
G
Terminal definition
I48 to ignition coil D I49 to the anti-theft read/write identification coil
3 2 1 54A
4 3 2 1
6 5 4

Function Function
No. color No. color
1 0.3/BR ACC 1 0.3/R LED power supply B +
2 0.3/BG IG1 2 0.3/B LED ground
3 0.5/R AM1 3 0.3/GrY IMMO antenna A terminal
4 0.3/BBl IG2 4 0.3/GrBl IMMO antenna B terminal
5 0.5/R AM2
6 0.3/BY ST
Fault diagnosis
Fault phenomenon
User level (common troubleshooting methods in case that anti-theft device has the following
problems during use):
Fault phenomenon Inspection Processing
With the power in OFF 1. Check the output status

state, the instrument of terminals 3 and 11 of 1. Send it to the maintenance center
cluster immobilizer diagnostic interface I01 when for repair if these phenomena exist
indicator lamp is always the front body controller is in for a long time.
on operation.
1. Read DTC with the diagnostic 1. Disconnect the immobilizer

With the power in ON tester; connecting wire and connect it again
state, the instrument 2. Check the system harness and 2. Disconnect the battery negative
cluster immobilizer connectors for firm connection; cable, connect it after 10min and
indicator lamp blinks and 3. Check whether the electrical turn on the ignition switch to start.
the vehicle cannot start. system electrical interference 3. Send it to the maintenance center if
exceeds the limit the fault still exists.
1. Read DTC with the diagnostic

With the power in ON tester;
state, the instrument 2. Check the system harness and 1. Send it to the maintenance center
cluster immobilizer connectors for firm connection; for repair if these phenomena exist
indicator lamp blinks and 3. Check whether the electrical for a long time.
the vehicle can start. system electrical interference
exceeds the limit
With the power in ON

state, the instrument
1. Send it to the maintenance center
cluster immobilizer Check whether the external
for repair if these phenomena exist
indicator lamp is always connection is normal
for a long time.
on and the vehicle can
start.
In case that the car has some problem, maintenance people suspect it is caused by front
body controller. To validate this suspicision, operator can adopt the following methods and
steps for troubleshooting:
1. Remove the front body controller of failed vehicle. Check if power and grounding legs of front
body controller have short circuit. If so, replace it with new front body controller (go to Step 3);
if not, continue to Step 2.
2. Mount this front body controller on another faultless vehicle and check if it would cause failure
to the second vehicle. If so, it means that this front body controller has problems (go to Step 3);
if not, it means that the front body controller itself has no problem (go to Step 4).
3. Mount and fit new front body controller on failed vehicle and check if its anti-theft function can
work properly. If so, the problem is resolved (we can conclude that the front body controller has
problem). If the problem still exists, go to Step 4.
4. Check outside working conditions for failed vehicle, such as power supply, ground, CAN
connection, CAN line voltage, LIN connection, LIN line voltage, LED damage, LED connection,
insert contact, interference level of other electrical systems, working temperature and humidity.
Below are the possible faults and corresponding solutions:
1. Check whether the power is

1. Change battery and re-connect
normal
Diagnostic tester and inserts.
2. Check whether the connectors
2. Check if BCAN has short
immobilizer cannot are securely connected
circuit for ground in case of
communicate 3. Check whether there is voltage
low electric level; otherwise,
between the diagnostic
change front body controller.
interface I01 terminal 3 and 11
With the ignition in ON state, 1. Check battery voltage which

1. The battery voltage is too low; shall be higher than 9V;
the instrument cluster indicator
2. The authentication fails; 2. Use diagnostic unit to read
lamp blinks quickly all the time fault code and make analysis;

1. Perform inspection and
tester;
Instrument cluster indicator maintenance based on fault
2. Check the system harness and code;
lamp occasionally blinks with connectors for firm connection;
2. Fix connection and change
the vehicle running 3. Check whether the electrical inserts;
system electrical interference
3. Check if grounding is right;
exceeds the limit
With the ignition in ON state, 1. When front body controller is 1. Use oscilloscope for inspection.
under working state, check If there is no square wave
the instrument cluster indicator
output state of 3# and 11# signal output, change front
lamp is always on. terminals of diagnosis port I01. body controller.
DTC
Front body controller has self diagnosis function. Diagnostic unit candiagnostic unit read fault
codes accordingly. Fault codes can be divided into two categories, that is, one with history and one
without. Fault code without history will not be saved in front body controller and it will not appear if
there is such fault during next ignition. Fault code with history once generated will not be wiped out
automatically; it can only be wiped out by diagnostic unit. For the fault causes and corresponding
solutions, refer to below table.
54A
Fault
Fault cause Possible troubleshooting method Notes
code
1. Check whether the immobilizer coil is securely installed; if

loose, tighten it;
2. Check the coil connector plug and contact pin for
deformation or damage;
KL30 voltage 3. Check the coil 1 and 2 jack for open circuit with the
B119016
low universal meter; replace the coil if damaged;
4. Check whether the battery is too low; if not, check the
circuit conditions;
5. If transponder is damaged, change it;
6. Use diagnostic unit for learning again.
1. Check the generator output current;

KL30 voltage
B119017 2. Get rid of voltage impact of starting voltage on anti-theft
high
controller.
1. Disconnect wiring and controller and check if connecting

wiring of 1# insert of anti-theft device has low electric
level. If so, resolve the problem;
Short circuit 2. Check whether the immobilizer coil is securely installed; if
B120011 of IMMO coil loose, tighten it;
for ground 3. Check the coil connector plug and contact pin for
deformation or damage;
4. Check the coil 1 and 2 jack for open circuit with the
universal meter; replace the coil if damaged;
1. Check the CAN-line for short to ground or open circuit;
2. Check whether the contact of 3-pin connector is normal;
3. Shift power state to “ON/IGON” and use multi-meter to
check if 3# insert has high electric level. If it has low level,
U107388 CAN drop
check if it is in good contact with ECM insert and resolve
the problem;
4. Replace the immobilizer controller;
5. Replace ECM
1. Check the CAN-line for short to ground or open circuit;

2. Check whether the contact of 3-pin connector is normal;
3. Shift power state to “ON” and use multi-meter to check if
3# insert of diagnosis terminal has high electric level. If it
U10198F CAN failure
has low level, check if it is in good contact with ECM insert
and resolve the problem;
4. Replace the immobilizer controller;
5. Replace ECM
Instrument inserts are loose or instrument is damaged.

U116087 ICM drop Check the instrument combination;
Replace it and learn it again.
Fault
code
Check the CAN Network

EMS
1. Re-fit ECM;
U116787 validation
2. Replace the ECM and match;
error
3. Replace the immobilizer controller and match
Attached Drawing
FB101 (constant power) FB105

FB313 (IG power) CAN_L
FB301 (IG power)

FB104
Front body controller
CAN_H
Instrument Diagnostic
Engine ECU
FB110 cluster apparatus
FB112
FB113
+ - FB326
Remote controller
Battery
4 3 3 . 9 2 MHz
Remote control
receiving circuit
BAT
Locking
PJF7992
Unlocking
FB118
Trunk
FB119
LFWX-6470-54006
Ignition switch assembly

Replacement
1. Remove the ignition switch components
(a). Regulate steering column regulating mechanism,
and regulate the steering column to appropriate
position.
(b). Remove steering wheel (Refer to 61 – Hydraulic
Steering System-Steering wheel, Replacement).
LFWX-6470-54002
(c). Remove the fastening screw of upper and lower

aprons of steering column, and remove upper
and lower aprons of steering column.
54A
LFWX-6470-54003
(d). Disconnect connector clips of ignition switch,

anti-theft read-write recognition coil and key
plugging remind switch.
LFWX-6470-54008
(c). Remove ignition switch mounting bolt, and take

down the ignition switch component.
LFWX-6470-54004
2. Install ignition switch assembly

(a). Install ignition switch on installation site, and
install ignition switch mounting bolt.
LFWX-6470-54004
(b). Connect connector clips of ignition switch, anti-

theft read-write recognition coil and key plugging
remind switch.
LFWX-6470-54008
(c). Install upper and lower shields of steering column

on their installation sites, and install their
fastening screws and fasten them.
LFWX-6470-54003
(d). Install the steering wheel. (Refer to 61 –

Hydraulic Steering System-Steering wheel,
Replacement).
(e). Regulate steering column regulating mechanism,
and regulate the steering column to appropriate
position.
54A
LFWX-6470-54002
Engine anti-theft system - Engine anti-theft system 54B-a
Engine anti-theft system (One-touch start)

Engine anti-theft system��1
Precautions�� 1 54B
Check the system��11
PEPS DTC list�� 14
Attached Drawing�� 16
One-touch start switch��17
PEPS module��18
Electronic steering shaft lock��20
Interior low frequency
magnetic field aerial��22
54B-b Engine anti-theft system - Engine anti-theft system
Engine anti-theft system - Engine anti-theft system 54B-1
Engine anti-theft system

Preparations
1. Special tools
54B
Read immobilizer
Diagnosis
1 DTC and data
equipment
flow etc.
Measure the
Digital universal
1 voltage and
meter
resistance
Conductor
2 Testing circuit
assembly
Maintenance data
Items N·m
PEPS fastening bolt 8~12
Low frequency magnetic antenna fastening bolt/nut 10~12
Precautions
(a). Before start stop engine system is maintained, vehicle power supply must be turned off, and
battery negative cable should be disconnected.
(a). After re-install the battery and before starting the engine, must wait at least 10s.
54B-2 Engine anti-theft system - Engine anti-theft system
System description
Auto electronic anti-theft system is a kind of world-class new auto anti-theft system. It is generally
known as Immobilizer in the industry. This system uses RFID wireless identification technology
and radio-frequency signal for transmission, calculation and validation. Compared with traditional
after-sales anti-theft system and AlarmSystem, electronic anti-theft system features the following
advantages:
● Auto electronic anti-theft system is intended for engine anti-theft purposes. It integrates key,
electronic anti-theft device and engine control unit into systematic anti-theft system through
proven anti-theft strategy, so as to greatly improve overall safety of auto anti-theft system;
● Auto electronic anti-theft system has better system security by adopting multi-layer password
validation for key, electronic anti-theft system and engine control unit;
● Electronic anti-theft system uses touch method without movable parts;
● It does not produce any sound and light pollution and it will not function by mistake;
● It is easy to operate without additional operation. You cannot even feel system existence during
normal use;
● You cannot start the engine by cross-connecting wires.
System description
1. Function
One key start system can provide convenience for on/off-vehicle of driver and passengers and
vehicle start.
2. Composition
Electronic anti-theft system of xuanlang one-touch model is composed by one PEPS controller,
one engine ECU, electronic steering shaft lock, IMMO and two smart keys.
3. PEPS
PEPS controller is integrated with anti-theft controller which is formed by micro-processor and
external elements to realize communication with smart key and engine ECU. When power
state is in IG ON state, if smart key and engine ECU is successfully identified within specified
time, engine ECU will release engine and the car can be started; otherwise, the engine cannot
be started and anti-theft indicator will flash for prompting.
4. Communication with engine ECU:
PEPS controller is connected to engine ECU through body wiring and it will follow
communication protocol of engine ECU.
5. Principle
One key start system is an intelligent entry and start system; when the antenna in the vehicle
detects the smart key, the control unit in the vehicle will activate the power supply system. After
the starting conditions are met, PEPS controller will unlock the electronic steering shaft lock and
communicate with PEPS controller for jointly control of the engine start.
54B
Start button valid
Power supply status or Check the power

supply status
Power supply status IG ON
Speed ≠ 0
Check the engine status Check the speed
Speed = 0
E ngi ne s peed = 0
Check PS key
certification result
Engine speed ≠ 0 Invalid
Valid
failure
Check whether Not detected IMMO
the key is in the vehicle certification End
Pass
Send ESCL unlock
command
Judge ESCL status

ESCL is not unlocked (waiting time)
MT: The clutch pedal is not depressed ESCL is unlocked

AT: The brake pedal is not depressed
or not on P/N position
Power supply MT: Check the clutch pedal signal

AT: Check the brake pedal & gear position signal
switching
MT: Depress the clutch pedal

AT: Depress the brake pedal & P/N position
Ig2 and ACC are disconnected;

EMS initialization
IG1 and ST are connected
EMS initialization
is completed
CAN bus sends a random data RX
PEPS
EMS calculation
Pass F =G ( sk , RX)
EMS Calculation
F =G ( sk , RX)
The data result returned

from CAN bus is F EMS determined
F is consistent
PEPS
CAN bus sends the engine status message

Is EMS engine started?
Certification failure or timeout

Check the certification result
and wait for the start-up
success message Start failure or
Certification timeout
success and
start-up success
The power supply
is switched to IG ON The power supply is
position switched to the initial status
End
Component drawing
1 1 2
4
6
7 5 3
1
LFWX-6470-54002
Interior low frequency magnetic field

1 5 Intelligent key
aerial
2 Hatch signal switch 6 Electronic steering shaft lock (ESCL)
Trunk low frequency magnetic field

3 7 PEPS controller assembly
aerial
4 Front left door handle aerial

54B
54B-5
keyless entry/one-button start (PEPS) I

B+
FS16
15A
PEPS system
7 1F
7 I1F
Engine anti-theft system - Engine anti-theft system
3 I15 9 I15 17 I15 16 I15 13 I15 12 I15 15 I15 14 I15 19 I15 18 I15 20 I15 10 I15 10 I12 9 I12 5 I14 11 I14 7 I14 8 I14 9 I14 6 I14 15 I12 14 I12 7 I12
0.30 BlW
0.30 BlR
0.30 BlB
0.30 GrW
0.30 WY
0.30 GrBl
0.30 GrG
0.30 YG
0.30 GrO
0.30 GY
0.30 GrB
0.30 GrY
0.30 Gr
0.30 BrV
0.3 GrBr
0.30 GW
0.30 GW
0.30 WG
0.30 WV
0.30 WR
0.30 GBl
0.30 GBr
0.30 GO
2 I20 4 I20 5 I20
21 ID 14 ID 4 ID 3 ID 10 IB1 9 IB1 16 IB1 17 IB1
LIN Unlocking Locking
feedback enabled
21 DI 14 DI 4 DI 3 DI 10 BI1 9 BI1 16 BI1 17 BI1
ESCL lock
6 BV 5 BV
6 VB 5 VB Motor power
supply enabled GND Live, 12V
0 30 WY
0 30 Gr
0 30 GY
0 30 YG
1 I20 6 I20 3 I20
0.50 RY
0.50 BW
0.50 B
Circuit diagram
1 I23 2 I23 3 I23 4 I23 5 I23 6 I23 7 I23 8 I23 15 I09 14 I09 13 I09
IM IM Sta Sta LE Gr Am Sta
MOa M Oa rt b rt b Dp ee b er sw rt bu
2 1 2 1 2 1 2 1 nten nten
utto
ns
utto
ng
ow
er
n la
mp lam itch tto
na na sup p 1 n
3 D2 D2 4 1 D2 D2 2 e- e+ wit
ch
2
rou
nd ply
wir
2 1 e
One-touch start switch FBCM
Front left door handle aerial Vehicle inside Vehicle inside Vehicle inside Rear bumper
front antennae middle antennae rear antennae antennae G26
keyless entry/one-button start (PEPS) II

B+
FS09
20A
PEPS system
Speed Hatch inching P/N gear signal
BCANH BCANL signal switch GND GND detection LIMPHOME
16 I12 17 I12 3 I14 11 I12 24 I12 20 I14 4 I14 10 I13 13 I13 12 I13 15 I13 14 I13 17 I13 16 I13 19 I13 18 I13 10 I14 14 I14
0.30 WB
0.30 W
18 IU1 0.3 W
0.30 GrR
0.30 YW
0.30 VW
0.30 YBl
0.30 VW
0.30 YG
0.30 YR
0.30 YV
0.30 YB
0.30 Br
0.30 Y
0.50 O
0.50 B
1.25 B
18 UI1
19 IU1
0.30 BY
2.0 R
19 UI1
2 5
Start relay
0.3 W
K09
9 IG 15 IG IU2 6 IU2 2 IB1 1 IB1 3 IU2 4 1 3
21 IB1 5 IU2
21 BI1 9 GI 15 GI 5 UI2 6 UI2 2 BI1 1 BI1 3 UI2 4 UI2
0.30 B
2.0 W
33 IU1 7 BL2
33 UI1 7 LB2
To engine
ECU pin 60
3 I01 11 I01 1 L10
1 I03

UE1 15
EU1 15
switch
2 1 2 1 1 2 1
2.0 BY
2 L10
2 I03
Rear right tire Front left tire Rear left tire Front right tire To engine starter
17 U14 pressure pressure pressure pressure
17 I09 antennae antennae antennae antennae
ABS FBCM
54B-6
G34 G26 G24 G11
54B
54B-7
keyless entr y/one-button start(PEPS) III

B+ B+
ab central electrical
control box
SB08
SB09
30A
30A
2 5 2 5 2 5
Electrical control
Electrical control
ACC relay
IG2 relay
FS15
Ig1 relay
FS39
FS29
FS37
FS40
FS28
FS35
FS26
FS46
FS38
FS42
10A
10A
15A
10A
10A
10A
10A
15A
5A
5A
5A
1 3 1 3 1 3
6 1E 6 1B 10 1F 16 1F 11 1D 15 1F 10 1E 5 1F 16 1D 1 1D 3 1D 4 1B 5 1D 14 1D 7 1D 13 1D 12 1D
6 I1E 6 I1B 10 I1F 16 I1F 11 I1D 15 I1F 10 I1E 5 I1F 16 I1D On-board MP5 ACC Front/rear A/C Engine ECM Clearstory switch ABS ESP ECU airbag TCU
power panel Generator Instrument ESP steering
0.3 OBl
0.3 BBl
0.5 RG
0.3 BG
0.5 BR
0.3 OB
excitation cluster pin A16 angle sensor
0.3 O
Brake switch Diagnosis port pin 8 ESP yaw sensor

signal Make-up mirror lamp
4 I05
Clutch switch
3 I05
0.5 GO
1.25 B
0.85 R
0.5 R
1 I14 8 I12 4 I12 23 I12 20 I12 22 I12 19 I12 21 I12 18 I12

Host power Host power Clutch signal ACC relay drive ACC relay Ig2 relay Ig2 relay Ig1 relay Ig1 relay
feedback drive feedback drive feedback
18 I09
Ig1 relay drive
G23
Terminal definition
I12 to PEPS1 I13 to PEPS2
12 11 10 9 8 1
7 6 5 4 3 2
10 9 8 7 6 5 4 3 2 1
23 22 21 20 19 18 17 16 15 14
24 13
20 19 18 17 16 15 14 13 12 11

Function Function
No. color No. color
1 NC 1 NC
2 NC
2 NC
3 NC
3 NC
4 NC
4 0.5/GO Brake signal
5 NC
5 NC
6 NC
6 0.3/WG Start button signal
7 NC
7 0.3/BlR ESCL lock enabled
8 NC
8 0.85/R Host power B+
9 NC
9 0.3/GW IMMO antennae -
10 0.5/Br LIMPHOME
10 0.3/WR IMMO antennae +
11 NC
11 0.3/VW Trunk micro-switch signal
12 NC 12 0.3/YW
antennae +
13 NC
13 0.3/YV
14 0.3/BlB MQT ESCL unlocking feedback antennae -
15 0.3/BlW LIN bus Front left TPMS low frequency

14 0.3/YB
antennae +
16 0.3/W CAN_H
Front left TPMS low frequency
15 0.3/YG
17 0.3/WB CAN_L antennae -
18 0.3/OB IGN1 relay feedback Rear left TPMS low frequency

16 0.3/YR
antennae +
19 0.5/OBl IGN2 relay feedback
Rear left TPMS low frequency
17 0.3/GrR
20 0.3/O ACC relay feedback antennae -
21 0.3/BG IGN1 relay drive Front right TPMS low frequency

18 0.3/YBl
antennae +
22 0.3/BBl IGN2 relay drive
Front right TPMS low frequency
19 0.3/Y
23 0.3/BR ACC relay drive antennae -
24 1.25/B Ground 20 NC
I14 to PEPS3 I15 to PEPS4
10 9 8 7 6 5 4 3 2 1
10 9 8 7 6 5 4 3 2 1
11 12 13 14 15 16 17 18 19 20
54B
20 19 18 17 16 15 14 13 12 11

Function Function
No. color No. color
1 0.5/R Host power B+ 1 NC
2 NC
2 NC
3 0.3/VW Wheel speed signal acquisition
3 0.3/YG Front left door pull ground
4 0.5/O Gear P/N signal
4 NC
5 0.3/GBl Start button signal
5 NC
6 NC
6 NC
7 0.3/GW One-touch start switch LED power
7 NC
One-touch start switch green LED
8 0.3/WV
lamp control 8 NC
One-touch start switch amber Front left door pull inching
9 0.3/GO 9 0.3/GY
LED lamp control switch signal detection
10 0.3/BY ST relay drive Trunk low frequency antennae
10 0.3/BrV
+
11 0.3/GBr One-touch start button ground
11 NC
12 NC
12 0.3/GrW
13 NC antennae 1 +
14 0.3/W ST relay feedback Vehicle inside low frequency

13 0.5/GrG
antennae 1 -
15 NC
14 0.3/GrO
16 NC antennae 3 +
17 NC Vehicle inside low frequency

15 0.3/GrB
antennae 3 -
18 NC
Front left door pull low
19 NC 16 0.3/WY
frequency antennae+
20 0.5/B Ground Front left door pull low

17 0.3/Gr
frequency antennae-
20 NC
18 0.3/GrBl
antennae 2 +

19 0.3/GrY
antennae 2 -
Trunk low frequency

20 0.3/GrBr
antennae-
20 NC
I28 to the central antenna I38 to the front antenna in the car
2 1
1 2

Function Function
No. color No. color
Vehicle inside low frequency Vehicle inside low frequency

1 0.5/GrBl 1 0.3/GrG
antennae 2 - antennae 1 -
Vehicle inside low frequency Vehicle inside low frequency

2 0.5/GrY 2 0.3/GrW
antennae 2 + antennae 1 +
B3 to the internal rear antenna V3 to the trunk box antenna
2 1
2 1

Function Function
No. color No. color
1 0.3/GrO Vehicle inside antennae + 1 0.3/GrO Vehicle inside antennae +
2 0.3/GrB Vehicle inside antennae - 2 0.3/GrB Vehicle inside antennae -
L10 to the back door signal switch I20 to ESCL lock
3 6
1 2 2 5
1 4

Function Function
No. color No. color
Trunk low frequency antennae 1 0.5/BW Motor IG power

1 0.3/BrV
positive output
2 0.3/BlW LIN
Trunk low frequency antennae
2 0.3/GrBr 3 0.5/RY ESCL lock B +
negative output
4 0.3/BlB Unlocking signal
5 0.3/BlR Locking signal
6 0.5/B Ground
I23 to one-touch start switch D2 to the front door handle micro switch
1 2
1 2
3 4
3 4 5 6 7 8
54B

Function Function
No. color No. color
1 0.3/WR IMMO antennae - Front left door pull low frequency

1 0.3/Gr
antennae-
2 0.3/GW IMMO antennae +
Front left door pull low frequency
3 0.3/GBl Start button switch 1 2 0.3/WY
antennae+
4 0.3/GBr Start button ground wire Front left door pull button switch
3 0.3/YG
output
5 0.3/GW LED power supply
Front left door pull button switch
6 0.3/WV Green lamp power 4 0.3/GY
input
8 0.3/WG Start button switch 2
•17 There is a difference in the power supply of key entry/One-key start (PEPS) system between
original model and facelift of Xuanlang Model. For details, please refer to the Xunlang circuit
catalog.
General inspection
Check the system
(a). Check the system for evident mechanical or electrical damage and repair them if required.
(b). Check the system fasteners (such as bolts or nuts) for loosening; if any, retighten it.
(a). Check whether the system harness connector is installed reliable; if not, install it again.
3. Check the fuse
(a). Check the electronic shaft steering lock fuse FS16 on for blowing; if any, replace it with the
same specification.
 Tips:
The electronic shaft steering lock fuse is located in the fuse box in the centrol control box of engine
compartment.
(b). Check the fuses FS15, FS39 and FS16 on PEPS power supply for blowing; if any, replace it
with the same specification.
 Tips:
The PEPS power supply fuse is located in the fuse box in the centrol control box of engine
compartment.
(c). Check the starter fuse FS09 for blowing; if any, replace it with the same specification.
 Tips:
The starter fuse is located in the fuse box in the engine compartment.
(d). Check ACC relay K18, IG1 relay K20 and IG2
relay K19 in the fuse box in the centrol control of
engine compartment.
5 3 (e). Check the starter relay K09 in the fuse box in the
engine compartment.
1  Tips:
+ Remove the starter relay K09, connect the power
- supply as shown, and use a digital multimeter at ohm
position to measure the conduction between the relay
terminals 3 and 5; if not, replace the relay with the
2 same specifications.
LFWX-6470-54003
Fault diagnosis
User level (common troubleshooting methods in case that PEPS controller has the following
problems during use):
1. Check whether the one-touch 1. Send it to the maintenance

With the power in OFF state,
start switch is normal center for repair if these
the start switch indicator lamp
2. Check if terminals 6 and 7 are phenomena exist for a long
is always on
shorted to the power supply time.
1. Check whether the one-touch

start switch is normal 1. Disconnect the PEPs controller
cable and reconnect it
2. Check if terminals 6 and 7 are
With the power in ON/IGON 2. Disconnect the battery negative
shorted to the power supply
state, the start switch indicator cable, connect it after 10min
lamp blinks and the vehicle 3. Check if there is not enough and turn on the ignition switch to
vehicle power.
cannot start. start.
4. Check if the low-frequency
3. Send it to the maintenance
magnetic field antenna in the
center if the fault still exists.
car is working properly
1. Check whether the one-touch

start switch is normal
2. Check if one-key start switch
With the power in ON/IGON harness connector is in good 1. Send it to the maintenance
state, the start switch indicator condition. center for repair if these
lamp blinks and the vehicle phenomena exist for a long
can start. time.
car is damaged.
4. Check the charge of smart key
In case that the car has some problem, maintenance people suspect it is caused by PEPS
controller. To validate this suspicision, operator can adopt the following methods and steps
for troubleshooting:
1. Remove the PEPS controller of failed vehicle. Check if power and grounding legs of PEPS
controller have short circuit. If so, replace it with new PEPS controller (go to Step 3); if not,
continue to Step 2.
2. Install this PEPS controller on another faultless vehicle and check if it would cause failure to
the second vehicle. If so, it means that this PEPS controller has problems (go to Step 3); if not, 54B
it means that the PEPS controller itself has no problem (go to Step 4).
3. Install and fit new PEPS controller on failed vehicle and check if its anti-theft function can
work properly. If so, the problem is resolved (we can conclude that the PEPS controller has
problem). If the problem still exists, go to Step 4.
4. Check outside working conditions for failed vehicle, such as power supply, ground, CAN
connection, CAN line voltage, LIN connection, LIN line voltage, LED damage, LED connection,
insert contact, interference level of other electrical systems, working temperature and humidity.
Below are the possible faults and corresponding solutions:
1. Check whether the power is

normal Change battery and re-connect
2. Check whether the connectors inserts.
Diagnostic tester and immobilizer are securely connected Check if BCAN has short circuit
cannot communicate 3. Check whether there for ground in case of low electric
is voltage between the level; otherwise, change PEPS
diagnostic interface I01 controller.
terminal 3 and 11
Check battery voltage which shall

With the ignition in ON/IG ON
1. The battery voltage is too low; be higher than 9V;
state, the immobilizer indicator
2. The authentication fails; Use diagnostic unit to read fault
lamp blinks quickly all the time
code and make analysis;

tester;
2. Check the system harness
and connectors for firm
Perform inspection and
connection;
maintenance based on fault
Immobilizer indicator lamp 3. Check whether the electrical code;
occasionally blinks with the system electrical interference
Fix connection and change
vehicle running exceeds the limit
inserts;
4. Check if the smart key battery
Check if grounding is right;
is depleted.
car is connected properly.
PEPS DTC list

DTC DTC description
B170146 PIN not written
B170246 No ESK code generated
B170346 Smart key not learn
B170446 ESCL not learn
B170542 EEPROM operation error
B171013 Inside antenna 1 short to power or open circuit
B171011 Inside antenna 1 short to ground
B171313 Trunk antennae short to power or open circuit
B171311 Trunk antennae short to ground
B171413 Front left door antennae short to power or open circuit
B171411 Front left door antennae short to ground
B171513 Front right door antennae short to power or open circuit (preserved)
B171511 Front right door antennae short to ground (preserved)
B172096 Low frequency antennae drive IC circuit fault
B173012 Start switch green indicating lamp short to power
B173112 Start switch amber indicator lamp short to power
B174013 Escl lock enables short or open circuit to ground
B174012 Escl lock enables short circuit to ground
B175013 ACC relay short-circuited or open to ground
B175012 ACC relay to ground power supply
B175096 ACC relay internal failure
B176013 IGN1 relay short-circuited or open to ground
B176012 IGN1 relay to ground power supply
B176096 IGN1 relay internal failure

DTC DTC description
B177013 IGN2 relay short-circuited or open to ground
B177012 IGN2 relay to ground power supply
B177096 IGN2 relay internal failure

54B
B178096 PEPS relay drive failure
B179061 ESCL module authentication failure
B179096 ESCL module internal failure
B179071 ESCL module blocking failure
B119216 Battery voltage low
B119217 Battery voltage high
U170087 FBCM_4D4 message missing
U171087 FBCM_2A2 message missing
U172087 FBCM_140 message missing
U173087 FBCM_344 message missing
U174087 IC_210 message missing
U175087 EMS_094 message missing
U176087 EMS_28A message missing
U179087 TCU_097 message missing
U180087 ABS_068 message missing
U181087 EPB_179 message missing
U182087 RBCM_2A4 message missing
U183087 CAN Bus Off
U184083 LIN message check and error
U184087 LIN message missing

PEPS controller has self diagnosis function. diagnostic unit can read fault codes accordingly. Fault
codes can be divided into two categories, that is, one with history and one without. Fault code
without history will not be saved in PEPS controller and it will not appear if there is such fault during
next ignition. Fault code with history once generated will not be wiped out automatically; it can only
be wiped out by diagnostic unit.
For the fault causes and corresponding solutions, refer to below table.
Fault
code
1. Check whether the immobilizer coil is securely

installed; if loose, tighten it;
2. Check the coil connector plug and contact pin
for deformation or damage;
3. Check the coil 1 and 2 jack for open circuit
B119216 KL30 voltage low
with the universal meter; replace the coil if
damaged;
4. Check whether the battery is too low; if not,
check the circuit conditions;
5. If transponder is damaged, change it;
1. Check the generator output current;

B119217 KL30 voltage high 2. Get rid of voltage impact of starting voltage on
anti-theft controller.
Key anti-theft
functionis not 1. Key fitting is not successful.
written in.
Attached Drawing
IMMO coil
Gateway
One-touch start switch instrument cluster
PEPS
Intelligent key
EMS
LFWX-6470-54015
One-touch start switch

Replacement
1. Remove the one key start switch
(a). Remove the one key start panel. (refer to Chapter
85-Subpanel and dashboard-one key start panel,
replacement) 54B
(b). Remove start stop engine system button
connector.
LFWX-6470-54004
(b). Press down the buckle and take out the start stop
engine system button according to arrow
direction.
LFWX-6470-54005
2. Install the one-touch start switch

(a). Install start stop engine system button on its
installation site according to arrow direction.
LFWX-6470-54006
(b). Install the one-key start switch connector.

(c). Remove the one key start panel. (refer to Chapter
85-Subpanel and dashboard-one key start panel,
replacement)
LFWX-6470-54004
PEPS module
Replacement
1. Remove the PEPS module.
(a). Remove the instrument upper panel. (refer to
Chapter 85- Dashboard/console instrument upper
panel, replacement)
(b). Disconnect the PEPS module harness connectors
LFWX-6470-54007
(c). Remove the PEPS module fixed bolt, then take

out PEPS module.
LFWX-6470-54008
2. Install the PEPS module.

(a). Install PEPS module on installation site, install
PEPS module fixing bolt and fasten it.
54B
LFWX-6470-54008
(b). Connect the PEPS module harness connectors.

(c). Install the instrument upper panel. (refer to
Chapter 85- Dashboard/console instrument upper
panel, replacement)
LFWX-6470-54007
Electronic steering shaft lock

Replacement
1. Remove the electronic steering shaft lock
(a). Remove the steering wheel. (refer to 61 - hydraulic steering system, steering wheel,
replacement)
(b). Remove the instrument desk lower plate. (refer to 85 - dashboard/subpanel system)
(c). Remove the steering shaft shield fixing screw and take down the steering shaft lower shield
and instrument decorative cover. (Refer to 85 - Dashboard/Auxiliary Dashboard System
Steering Shaft Guard, Replacement)
(d). Remove the clock spring and steering angle sensor. (refer to 74 - driver's information system,
clock spring, replacement)
(e). Remove the cluster switch. (refer to 74 - driver's information system, cluster switch,
replacement)
(f). Remove the upper steering shaft. (refer to Chapter 61 - Hydraulic steering system - steering
shaft, replacement)
(g). Disconnect the electronic steering shaft lock

connector.
LFWX-6470-54012
(h). Drill a hole on the electronic steering shaft lock

fastening bolt.
(i). Use the reverse thread bolt tap to remove the
electronic steering shaft lock clamp fastening
bolt, and remove the electronic steering shaft
lock.
 Tips:
The electronic steering shaft lock fastening bolt is
a special bolt, and must replace the removed bolt
with a new one.
LFWX-6470-54013
2. Mount the electronic steering shaft lock

(a). Install electronic steering shaft lock on installation
site, install its fixing bolt and fasten it until bolt
sleeve is broken.
54B
LFWX-6470-54013
(b). Connect electronic steering shaft lock connector

clip.
Note:
When tightening the electronic steering shaft
lock fastening bolt, must prevent that the bolt is
broken suddenly, which may result in injuries of
maintenance personnel.
(c). Install the upper steering shaft. (refer to Chapter
61 - Hydraulic steering system - steering shaft,
replacement)
(d). Install the cluster switch. (refer to 74 - driver's
information system, cluster switch, replacement)
(e). Install the clock spring and steering angle sensor.
(refer to 74 - driver's information system, clock
spring, replacement)
LFWX-6470-54012 (f). Remove the steering shaft shield fixing screw
and take down the steering shaft lower shield
and instrument decorative cover.(Refer to 85 -
Dashboard/Auxiliary Dashboard System Steering
Shaft Guard, Replacement)
(g). Install the instrument desk lower plate. (refer to
85 - dashboard/subpanel system)
(h). Remove the steering wheel. (refer to 61 -
hydraulic steering system, steering wheel,
replacement)
Interior low frequency magnetic field aerial

Replacement
Tips:
The replacement methods of all antennas are basically the same, and only the dashboard antenna
is exampled in this section.
1 2
5
4
1 Vehicle inside front antennae 4 Vehicle inside rear antennae
2 Vehicle inside middle antennae 5 Trunk antenna
3 Front left door handle antennae

1. Remove the interior low frequency magnetic

field aerial
(a). Remove the subpanel. (refer to 85 - dashboard/
Subpanel-subpanel, replacement)
(b). Disconnect the interior low-frequency magnetic
field antenna wiring harness connector.
54B
LFWX-6470-54010
(b). Remove the low-frequency magnetic field

antenna fixing bolts, and remove the interior low-
frequency magnetic field antenna.
Torque:10 ~ 12 N•m
LFWX-6470-54010
2. Install the interior low frequency magnetic

field aerial
(b). Install internal low frequency magnetic field
antenna on its installation site, and install and
Torque:10 ~ 12 N•m
LFWX-6470-54010
(b). Connect the interior low-frequency magnetic field

antenna wiring harness connector
(c). Install the subpanel. (refer to 85 - dashboard/
Subpanel-subpanel, replacement)
LFWX-6470-54010
54B
Hydraulic steering mechanism - Hydraulic steering mechanism
61-a
Steering mechanism
Hydraulic steering mechanism 1
Preparations …………………… 1
Maintenance data ……………… 1
System description …………… 2
Precautions …………………… 3
Component drawing …………… 4
General Inspection……………… 5
System Inspection …………… 5
Check the steering fluid ……… 5
Check the steering wheel …… 7
Check the steering tie rod …… 8
Check the steering gear ……… 9
Fault diagnosis …………………12
Steering fluid ……………………16
Discharge ………………………16
Filling ……………………………16
Exhaust …………………………17
Power steering oil can …………17
Replacement ……………………17
Steering wheel …………………18
Adjustment ……………………18
Steering……………………………20
Power steering pump …………26 62
Steering gear ……………………29
Steering oil pipe …………………40
61-b Hydraulic steering mechanism - Hydraulic steering mechanism
61-1
Hydraulic steering mechanism

Preparations
S/N Tool External view NOTE NOTE
Left-hand rotation Remove the ignition

1
screw tap switch special bolt
Remove the
2 lier combination switch
fastening clamp
Measure the steering

3 Dial indicator
shaft clearance
Maintenance data
62
Steering wheel free stroke ±10°
Temperature of steering fluid -30℃ ~120℃
Specification ATF220
Steering fluid 1100±50ml (mount the steering oil tank mark for
Filling capacity
filling)

Items N·m
Steering wheel retaining nut 80~105
Steering shaft lower section and steering shaft and
20~26
steering gear lock bolt
61-2 Hydraulic steering mechanism - Hydraulic steering mechanism
Steering shaft upper section and upper steering

20~26
gear lock bolt
Upper steering shaft mounting bracket fixing nut 20~26
Steering gear tie rod slotted nut 60
Steering shaft upper seal cover assembly fixing nut 6~12
Steering shaft lower seal cover assembly fixing nut 6~12
Steering oil can inlet and outlet pipe fixing bolt 6~12/20~26
Steering gear oil inlet and outlet pipe fixing bolt 6~12
Steering gear fixing bolt and nut 200~220
Steering oil pump fixing bolt 55~65
System description
1. Function
The hydraulic steering system allows the following functions:
• Reduce the steering force applied to the steering wheel, especially when there is significant
steering resistance during in-situ steering and low-speed large-angle steering.
• Increase the sensitivity of steering.
• Reduce the impact of ground backlash on the steering wheel.
• In case of a tire blasting, it can better prevent a sudden turn of the wheel, thus improving driving
safety.
2. Composition
The hydraulic steering system consists of the hydraulic steering gear, power steering oil pump,
power steering oil can, steering oil pipe and power assisted steering control valve etc. The
hydraulic steering gear is the executing part for the steering system hydraulic boosting; the oil
pump and engine are connected to supply the hydraulic power for the system; the steering oil can
is designed to store, cool and filtrate the oil.
3. Principle
The pinion-rack motion steering gear consists of the control valve, mechanical steering gear and
power steering oil pump.
The control valve is the high sensitivity rotary spool valve with advanced structure; the mechanical
steering gear is pinion-rack type.
(a). Control valve
1: Valve element
2: Torsion bar
3: Valve body
A: The passage of the oil pump output pipe
B, C: power passage to the left and right cavity 道
D: Connect to the oil return passage to the oil tank
The control valve right 1 valve spool, 2 torsion bar
and 2 valve block form the NO type rotary spool valve.
Through the prepared gap between the 1 valve spool
and 3 valve block, the hydraulic oil can enter the left
and right chamber.
LFWX-6470-61001
(b). Mechanical steering part

The mechanical steering section is pinion-rack type and consists of the gear shaft, rack-piston
assembly and steering tie rod.
(c). Operating principle
61-3
• Centre position
During the linear driving (the steering wheel not operated), the steering oil pump supplies the
hydraulic oil to enter from the oil inlet A. The oil passes through the prepared gap of the rotary
spool valve and flows back to the oil can from the oil return port D since the rotary spool valve does
not move at this point. Then the two working chambers will not generate the boosting since the oil
pressure is the same.
• Steering process
When the steering wheel is rotated, the gap of valve slot between the valve block 3 and valve spool
will change and consequently generate the oil pressure difference between the hydraulic oil flowing
to two working chambers. The oil pressure difference acts on the piston to push it to overcome
the steering boosting force and generate displacement, which in turn drives the steering tie rod
assembly to move and realize the power assisted steering.
Return process:
After the steering finishes, the effort applied to the steering wheel will disappear. Since the elastic
force of torsion bar 2 forces the valve spool 1 to return to the equilibrium position relative to valve
block 3, the oil pressure difference of two oil chambers of the steering gear will disappear. Then the
vehicle will restore the linear driving state under the function of the front wheel auto aligning torque.
Precautions
1. Precautions before maintenance
(a). In case of finding abnormal clearance, jamming and front sway, analyze problems and find
out the failure part, and repair it.
(b). When the steering system is checked, vehicle should be driven on flat and dry road.
2. Precautions for maintenance.
(a). During maintenance, in case of finding bearing is blocked and loose, it should be changed.
(b). During maintenance process, in case of finding lock bolt or nut has more than 3 damaged
threads, replace the lock bolt or nut.
(c). Do not weld spare parts of hydraulic steering gear and system rods in any way.
(d). After steering gear is installed, comprehensively check steering portability and flexibility.
When steering wheel is rotated, it can be rotated easily without loosening, and the maximum
angle of front wheel should be measured.
(e). After steering system is maintained, timely make up steering fluid and exhaust hydraulic
system air, and see exhaust method in (61 – Hydraulic Steering System, Steering Fluid,
Replacement)
(f). Bolt of each component of steering system must be fixed according to regulated torque.
(g). After hydraulic steering gear and other steering mechanism are maintained, check wheel
alignment.
3. Other considerations
(a). After a new hydraulic steering gear runs for 2500km, hydraulic oil should be changed; and
meanwhile filter screen in oil can should be cleaned; when the hydraulic steering gear runs
every two years or 50000km, hydraulic oil should be changed and oil can should be cleaned. 62
(b). Monthly check whether hydraulic oil is reduced or not, and whether oil is bad and impurities
are more or not; in case of finding unfavorable conditions, timely add or change hydraulic oil.
(c). When feeding hydraulic oil, brand of new hydraulic oil should keep consistent with that of
original hydraulic oil of power steering system, and misuse of hydraulic oil will lead to damage
and leakage of hose and sealing element, and hydraulic oil of different brands can not be
mixed.
(d). When vehicle is running, in case of finding abnormal steering sound, suddenly heavier
steering and blocked steering, you need to immediately stop your vehicle to make
maintenance, find out and eliminate failures.
(e). Check tyres and keep their pressures to conform to regulations.。
(f). Carefully check whether steering system parts are normally impacted or not, and timely
change damaged parts or defective spare parts.
(g). The steering wheel staying at the steering limit position should not exceed 3s; otherwise the
steering oil pump will be damaged.
(h). When steering wheel is locked, do not move your vehicle to prevent damage of steering
system spare parts.
(i). Protect pipeline from collision and damage in use; the tightness of each section should be
appropriate, and the pipeline should have no dead bend.
Component drawing
23-1
23
24
19
23-2
12
22
12-1 11
18 22 10
12-2 14
13
20 11
6-1
19 21
6-2 11
6
7 8 9
5 16
1-3
1-4
4 15
18 18
18
17
1-2 1
2
1-1
3
1 Steering gear assembly 12 Lower steering shaft upper section

1-1 Left steering tie rod 12-1 Crossing joint components
Lower steering shaft upper section
1-2 Right steering tie rod 12-2
assembly
1-3 Long oil tube 13 Hexagon flange bolt
1-4 Short oil tube 14 Upper steering shaft assembly
Hexagon and plain washer
2 15 Hexagon flange nut
subassembly
3 Hexagon flange nut 16 Hexagon flange nut
4 Hexagon slotted thin nut 17 Steering gear oil inlet and outlet pipe
5 Split pin 18 Hexagon flange bolt
Steering shaft lower seal cover
6 19 Steel strip elastic hoop
assembly
Steering shaft lower seal cover press
6-1 20 Power steering oil pump assembly
plate
61-5
6-2 Steering shaft lower seal cover 21 Steering oil can inlet and outlet pipe
7 Hexagon flange nut 22 Hexagon flange bolt
Steering shaft upper seal cover
8 23 Steering oil can assembly
assembly
9 Plastic cover type nut 23-1 Steering oil can cap
10 Lower segment lower steering shaft 23-2 Steering oil can body
11 24 Power steering oil can clip
General Inspection
System Inspection
1. Check the system operation
(a). Start the engine, rotate the steering wheel, check whether the steering wheel is heavy to be
operated or not, if yes, make maintenance according to the following diagnosis contents.
(b). Make road test, check whether the steering wheel is shaking or not when vehicle is running,
if yes, maintain according to the following contents.
(c). Start the engine, rotate the steering wheel, check whether the steering wheel is heavy to be
operated or not, if yes, make maintenance according to the following diagnosis contents.
2. Check for system leakage
(a). Check whether the system has obvious oil leakage or not, if yes, maintain it.
(a). Check whether the system has obvious collision deformation marks or not, if yes, maintain it.
(b). Check whether system fasteners (e.g. bolt and nut) are loose or not, if yes re-fasten them.
Check the steering fluid

1. Check the height of steering liquid level
(a). Stop the vehicle on a level rod.
(b). Stop the engine, and check liquid level in power
steering oil can; if liquid level is lower than
“MIN”, add steering fluid.
Note:
• “MAX” and “MIN” are the highest and lowest scale
lines of the steering fluid when the engine is in cold
state.
62
LFWX-6470-61004
(c). Keep engine run at idle speed, check the oil

level in power steering oil can, and make mark.
(d). Stop the engine, re-measure liquid level in
power steering oil can after several minutes,
and make mark.
(e). Measure increment of liquid level. (Height
difference of two measurement results)
Max fluid level positive error: 5mm
Engine
idle
speed Engine
stalling

LFWX-6470-61004
2. Exhaust the power steering system

(a). Check the oil level.
Normal Abnormal
(b). Jack and support the front of the vehicle.
(c). Turn the steering wheel.
△ Tips:
When the engine is shutdown, gently turn the steering
wheel from the locking position at one side to the
o locking position on other side, and repeat the
operation several times.
(d). Lower the vehicle, start the engine, and operate
it at idle speed a few minutes.
(e). Turn the steering wheel.
△ Tips:
Operate the engine at idle speed, turn the steering
wheel to the left or right limit positions and hold it
2~3s, and turn it to the limit position on opposite side
LFWX-6470-61006 and hold it 2~3 s. Repeat the operation several times.
(f). Shut down the engine.
(g). Check the oil for bubbles or white impurities.
If air bubbles or impurities are not completely
drained, repeat the above steps.
(h). Check the liquid level.
3. Check the steering fluid pressure
(a). Disconnect oil pipe on the power steering pump assembly, and install steering hydraulic
pressure inspection tools.
Note:
Ensure the oil manometer valve opens.
(b). Exhaust air in power steering system. (Refer to 61 - hydraulic steering system, steering fluid,
bleeding)
(c). Start engine and make it run at idle speed.
(d). Rotate steering wheel from the limit position on one side to the other side for several times,
so as to improve steering fluid temperature.
Normal operating temperature: -30℃ ~ 120℃
Note:
The steering wheel staying at the steering limit position should not exceed 3s; otherwise
the steering oil pump will be damaged.
(e). Maintain the idling state of engine, close tool valve, observe pressure gauge reading and
make record.
Minimum oil pressure: 6400kPa
△ Tips:
If the oil pressure is too low, it indicates the power steering oil pump assembly is damaged and
should be replaced.
61-7
Note:
The tool valve off time should not exceed 3s; otherwise the oil temperature will be too high
and the power steering oil pump assembly will be damaged.
(f). Keep the idling state of engine, and totally open tool valve.
(g). Maintain engine speed within 1000~3000r/min range, and measure oil pressure of engine
when it runs at the speed of 1000r/min and 3000r/min respectively.
Oil pressure difference: 490kPa
Note:
Do not rotate the steering wheel.
△ Tips:
• If the oil pressure difference is too significant and the flow control valve of power steering pump
assembly is damaged, you need to repair it or replace the power steering pump assembly.
• If there is clogging or leaking in the hydraulic system of the power steering system, rinse the
hydraulic pipe or replace relevant parts.
(h). Keep the idling state of engine, and totally open tool valve. Turn the steering wheel to the left
or right limit position and measure oil pressure value.
Minimum oil pressure: 6400kPa
△ Tips:
• If the oil pressure is too low, there is leaking or damage inside the power steering, and you need
to replace the power steering pump assembly.
• If there is leaking in the hydraulic system of the power steering system, repair the hydraulic pipe
or replace relevant parts.
Note:
The steering wheel staying at the steering limit position should not exceed 3s; otherwise
the steering oil pump will be damaged.
(i). Remove detection tools, and install power steering system.
(j). Exhaust air in hydraulic steering system. (Refer to 61 - hydraulic steering system, steering
fluid, bleeding)
Check the steering wheel

1. Check the steering wheel operating effort
Note:
Do this on the genuine tire under the standard tire
pressure.
(a). Drive the vehicle on a flat and clean road.
(b). Keep front wheels on straight driving position,
and connect the spring-loaded thrust meter on
the wheel flange of the steering wheel. 62
(c). Start the engine and run it idling.
(d). When spring-loaded thrust meter is pulled until
front wheels start rotating, reading of spring-
loaded thrust meter should be recorded.
Steering effort: less than 40N
△ Tips:
Check the following parts if the steering effort is too
LFWX-6470-61007 high:
• The steering gear assembly turns towards the tie
rod
• Steering shaft
• Gear rack guide mechanism adjustment
• Steering pump
1. Check the steering wheel free stroke

(a) Place the front wheels in the straight travel
position.
(b) Stop the front wheels, and turn the steering
wheel to the left and right to measure the free
a stroke of the steering wheel.
Steering wheel free stroke: less than 10°
△ Tips:
If the steering wheel free stroke exceeds the specified
range, check the hydraulic steering gear, steering
shaft and tyre pressure.
LFWX-6470-61005
Check the steering tie rod

1. Check the steering tie rod fixing device and
the dust cover
(a). Remove front wheels.
(b). Shake the arrowhead position of steering tie rod
by hand, and check whether it has clearance or
not.
LFWX-6470-61008
(c). Check the steering rod ball head dust cover as

the position indicated by the arrow for damage;
if any, replace the ball head.
LFWX-6470-61009
61-9
(d). Check whether arrow-pointed position of

steering gear dust cover is damaged or not, if
yes, change the steering gear dust cover.
(e). Reinstall front wheels.
LFWX-6470-61010
2. Check the steering tie rod ball
(a). Use bench clamp to fix tie rod joint.
(b). Install steering linkage nut on ball head bolt.
(c). Forth and back swing ball head bolts for at least
5 times.
(d). Use torque wrench to continuously rotate nut
and read out torque.
Rotary torque: 1.5~3.0N·m
Note:
Replace the tie rod assembly if the rotating torque
is out of the specified range.
△ Tips:
The inspection of the left/right steering gear tie rod
ball head is the same.
LFWX-6470-61011
Check the steering gear

1. Check the working condition of steering
shaft
62
(a). Check the installation of the steering gear
assembly and the steering shaft.
• Check the up and down, left and right and axial
movements of the steering wheel for clearance.
• Check whether the steering assembly fastening
nuts and bolts are loosened.
LFWX-6470-61012
2. Check the upper steering shaft assembly

(a) Fix the upper steering column and shake the upper steering shaft, to check the upper
steering shaft bearing for clearance; if any, replace the upper steering shaft assembly.
(b). Fix upper steering column; rotate the inner shaft of steering column; check whether the inner
shaft is jammed or not, if yes, change upper steering shaft assembly.
3. Check the lower steering shaft assembly
(a). Hold the both ends of the knuckle and carry out
the reverse rotation, to check the steering shaft
knuckle for loosening; if any, replace it.
LFWX-6470-61013
61-11
Fault diagnosis
1. Front wheel (alignment incorrect)
2. Steering gear fixing bolt (loos)
3. Steering tie rod (excessive gap of ball
head) Refer to 61 - hydraulic steering
Steering wheel jittering system diagnosis, fault diagnosis (3.
4. Swing arm ball pin(excessive gap) Steering wheel jittering)
5. Front shock absorber upper support
(abrasion)
6. Steering gear (fault)
1. Steering gear fixing bolt (loos)
2. Steering tie rod (loos)
3. Steering tie rod (excessive gap of ball Refer to 61 - hydraulic steering
Excessive steering head) system diagnosis, fault diagnosis (3.
wheel free gap
4. Steering shaft (fault) Excessive steering wheel free gap)
5. Front wheel bearing (worn or loose)
1. Steering fluid (too less)
2. Driving belt (too loose)
3. Front wheel (alignment incorrect)
Refer to 61 - hydraulic steering
4. Swing arm ball pin(abrasion)
system diagnosis, fault diagnosis (3.
Heavy steering 5. Front shock absorber upper support Heavy steering)
(abrasion)
6. Steering shaft (fault)
7. Power steering oil pump (fault)
8. Steering gear(fault)
1. Steering fluid (too less)
2. Steering fluid (air admission)
3. Driving belt (too loose) 62
4. Steering gear fixing bolt (loos) Refer to 61 - hydraulic steering
Steering abnormal noise system diagnosis, fault diagnosis (4.
5. Steering tie rod (loos) steering abnormal noise)
6. Steering shaft (fault)
7. Power steering oil pump (fault)
Fault diagnosis
1. Heavy steering
Check the whether the system
steering is heavy (refer to 61 - Diagnosis is
Heavy steering Go to Step 1
hydraulic steering system, general finished
inspection, inspection of system)
Check the steering wheel operating
effort
Check the whether the steering
wheel operating effort is too high
Diagnosis is Steering effort too
(refer to 61 - hydraulic steering Go to Step 2
finished high
system, general inspection,
inspection of steering wheel)
2 Check the steering fluid Normal Faulty Instruction
Check the working conditions of the
steering fluid (Refer to 61 - hydraulic
Go to Step 4 Steering fluid too less Go to Step 3
steering system, general inspection,
inspection of steering fluid)
Check the steering system for oil
leak
Check the steering system for oil Repair the system oil leak
leak (Refer to 61 - hydraulic steering and fill the steering fluid (refer
Go to Step 4 Oil leak in the system
system, general inspection, inspec- to 61 - hydraulic steering
tion of system) system, steering fluid, filling)
4 Check the driving belt Normal Faulty Instruction

Check the working conditions of the Pre-load or replace the
Go to Step 5 Driving belt too loose
driving belt driving belt
5 Check the front wheel Normal Faulty Instruction
Perform the front wheel ali-
Check the front wheel alignment
Front wheel align- gnment (Refer to 33 - wheel
(Refer to 33 - wheel and tire, wheel Go to Step 6
ment incorrect and tire, wheel alignment,
alignment, testing)
adjustment)
Check the swing arm ball pin as-
sembly
Check the working conditions of the Replace the front vibration
swing arm ball pin assembly (Refer absorber and upper
Abrasion of swing
to front suspension, general inspec- Go to Step 7 support (refer to 31 - front
arm ball pin
tion, inspection of swing arm ball pin suspension front vibration
assembly) absorber, service)
7 Check the front vibration absorber Normal Faulty Instruction
Check the working conditions of Replace the front vibration
the front vibration absorber (Refer Front vibration ab- absorber and upper
to 31-front suspension, general Go to Step 8 sorber upper support support (refer to 31 - front
inspection, inspection of front vibra- abrasion suspension front vibration
tion absorber) absorber, service)
8 Check the upper steering shaft Normal Faulty Instruction
Check the working conditions of the
Replace the upper steering
upper steering shaft (Refer to 61 -
Steering column shaft (refer to 61 - hydraulic
hydraulic steering system, general Go to Step 9
inside shaft seizing steering system, steering
inspection, inspection of steering
shaft, replacement)
shaft)
9 Check the lower steering shaft Normal Faulty Instruction
61-13

Check the working conditions of Replace the lower
Severe abrasion of
the lower steering shaft (Refer to steering shaft (refer to
lower steering shaft
61 - hydraulic steering system, Go to Step 10 61 - hydraulic steering
universal joints at both
general inspection, inspection of system, steering shaft,
ends
steering shaft) replacement)
10 Check power steering oil pump Normal Faulty Instruction
Check the working conditions Replace the lower
of the power steering oil pump steering shaft (refer to
Steering hydraulic
(Refer to 61 - hydraulic steer- Go to Step 11 61 - hydraulic steering
pressure too low
ing system, general inspection, system, power steering
inspection of steering fluid) oil pump, replacement)
Replace the steering gear of Locate the causes from
same model and check whether Diagnosis is finished The fault still exists other fault phenome-
the fault is solved non
2. Steering wheel jittering

Carry out the road test and
check the steering wheel for
Diagnosis is Steering wheel
dither (refer to 61 - hydraulic Go to Step 1
finished jittering
steering system, general
1 Check the front wheel Normal Faulty Instruction
Perform the front wheel
Check the front wheel alignment
Front wheel alignment (Refer to 33
(Refer to 33 - wheel and tire, Go to Step 2
alignment incorrect - wheel and tire, wheel
wheel alignment, testing)
alignment, adjustment)
2 Check the steering gear Normal Faulty Instruction
Check the fixing conditions of
the steering gear (refer to 61
Steering gear fixing
- hydraulic steering system, Go to Step 3 Tighten again
bolt looseness
general inspection, inspection of
system)
3 Check the steering tie rod Normal Faulty Instruction
Check the working conditions Replace the steering tie
of steering tie rod (Refer to 61 Excessive gap of rod ball head (Refer to 61 -
- hydraulic steering system, Go to Step 4 steering tie rod ball hydraulic steering system, 62
general inspection, inspection of head steering gear with tie rod
steering tie rod) assembly, replacement)
Check the swing arm ball pin as-
sembly
Check the working conditions of
Replace the swing arm
the swing arm ball pin assem-
Excessive gap of ball pin (refer to 31 - front
bly (Refer to front suspension, Go to Step 5
swing arm ball pin suspension swing arm ball
pin, service)
swing arm ball pin assembly)
Check the front vibration absor-
ber
Check the working conditions Replace the front vibration
of the front vibration absorber Front vibration ab- absorber upper support
(Refer to 31-front suspension, Go to Step 6 sorber upper support (refer to 31 - front suspen-
general inspection, inspection of abrasion sion front vibration absorb-
front vibration absorber) er, service)

Replace the steering gear Locate the causes
of same model and check Diagnosis is finished The fault still exists from other fault
whether the fault is solved phenomenon
3. Excessive steering wheel free stroke

Check the whether the steering
wheel free stroke is excessive
Excessive steering
(refer to 61 - hydraulic steering Diagnosis is finished Go to Step 1
wheel free stroke
system, general inspection,
inspection of steering wheel)
the steering gear (Refer to 61
Steering gear fixing
- hydraulic steering system, Go to Step 2 Tighten again
bolt looseness
system)
Check the working conditions
of steering tie rod (Refer to 61 Excessive gap of
- hydraulic steering system, Go to Step 3 steering tie rod ball Tighten again
general inspection, inspection of head
steering tie rod)
Replace the steering
Check the working conditions tie rod ball head (Refer
of steering tie rod (Refer to 61 Excessive gap of to 61 - hydraulic
- hydraulic steering system, Go to Step 4 steering tie rod ball steering system,
general inspection, inspection of head steering gear with
steering tie rod) tie rod assembly,
replacement)
Check the working conditions of Replace the upper
the upper steering shaft (refer to steering shaft (refer to
Inside steering shaft
61 - hydraulic steering system, Go to Step 5 61 - hydraulic steering
bearing damage
general inspection, inspection of system, steering shaft,
steering shaft) replacement)
5 Check the hub bearing Normal Faulty Instruction
Replace the hub
Check the hub bearing wearing
Front wheel hub bearing (refer to 31
conditions (refer to 31 - front
Go to Step 6 bearing wear or - front suspension
suspension, general inspection,
looseness system, hub bearing,
inspection of hub bearing)
replacement)
Replace the steering gear of Locate the causes
same model and check whether Diagnosis is finished The fault still exists from other fault
the fault is solved phenomenon
4. Steering abnormal noise

61-15

Check the steering system for
abnormal noise (refer to 61 - Abnormal noise upon
Diagnosis is finished Go to Step 1
hydraulic steering system, general steerin
the steering fluid (Refer to 61 -
hydraulic steering system, general Go to Step 3 Steering fluid too less Go to Step 2
fluid)
Check the steering system for oil
leak
Repair the system
Check the steering system for oil leak and fill the
oil leak (Refer to 61 - hydraulic steering fluid (Refer to
Go to Step 3 Oil leak in the system
steering system, general inspection, 61 - hydraulic steering
inspection of system) system, steering fluid,
filling)
System bleeding
the steering fluid (Refer to 61 -
(refer to 61 - hydraulic
hydraulic steering system, general Go to Step 4 Air in steering fluid
steering system,
steering fluid, bleeding)
fluid)
4 Check the driving belt Normal Faulty Instruction
Check the working conditions of the Pre-load or replace the
Go to Step 5 Driving belt too loose
driving belt driving belt
the steering gear (Refer to 61 - Steering gear fixing
Go to Step 6 Tighten again
hydraulic steering system, general bolt looseness
Check the working conditions
of steering tie rod (Refer to 61 -
Steering tie rod
hydraulic steering system, general Go to Step 7 Tighten again
looseness
inspection, inspection of steering tie
rod)
62
Check the working conditions of the Replace the upper
·The steering shaft
upper steering shaft (Refer to 61 - steering shaft (refer to
bearing is damaged.
hydraulic steering system, general Go to Step 8 61 - hydraulic steering
·The inner steering
inspection, inspection of steering system, steering shaft,
shaft is loose
shaft) replacement)
8 Check the lower steering shaft Normal Faulty Instruction
Check the working conditions of the Replace the lower
Looseness of lower
lower steering shaft (Refer to 61 - steering shaft (refer to
steering shaft
hydraulic steering system, general Go to Step 9 61 - hydraulic steering
universal joints at both
inspection, inspection of steering system, steering shaft,
ends
shaft) replacement)
9 Check the power steering oil pump Normal Faulty Instruction
Replace the power

steering oil pump
the power steering oil pump (Refer
Steering hydraulic (refer to 61 - hydraulic
to 61 - hydraulic steering system, Go to Step 10
pressure too low steering system,
steering oil pump,
steering fluid)
replacement)

Inspection by
replacement
Replace the steering
Locate the causes
gear of same model and Diagnosis is
The fault still exists from other fault
check whether the fault is finished
phenomenon
solved
Steering fluid
Discharge
1. Discharge the steering fluid
(a). Use jack to jack up the front portion of the
vehicle, and make sure wheels can freely rotate.
(b). Remove low pressure oil pipe clamp of steering
gear, disconnect the low pressure oil pipe and
drain steering fluid.
△ Tips:
• When the steering fluid is discharged, use the oil
collector to collect the discharged steering fluid.
• After the steering fluid is discharged, mount the
steering low pressure tubing and secure it with the
clamp.
• Turn on the power steering oil cover to facilitate the
discharge of the steering fluid.
(c). Start the engine and run it idling.
(d). Rotate steering wheel from the limit position on
LFWX-6470-61014 one side to the other side for several times, and
make sure steering fluid in hydraulic steering
system is totally drained.
Note:
• The steering wheel is in the limit position for no more
than 3s.
• If your skin is in contact with the steering fluid, it
should be cleaned in time.
(e). Stop the engine.
Filling
1. Fill the steering fluid
(a). Open engine compartment cover。
(b). Unscrew power steering oil can cover, and feed
steering fluid.
Specification: ATF220
Filling volume: according to the reference line
on the steering fluid pot
(c). Exhaust air of steering system.
Note:
When filling the steering fluid, ensure the fluid level is
within the required range.
(d). Install power steering oil can cover.
LFWX-6470-61015
61-17
Exhaust
1. Hydraulic steering system exhaust
(a). Check steering fluid level.
(b). Use jack to jack up the front portion of the vehicle, and make sure wheels can freely rotate.
(c). Rotate steering wheel from the limit position on one side to the other side for several times.
Note:
The steering wheel should not stay at the limit position more than 3s
(d). Lower vehicle, start engine and keep it run at idle
speed for several minutes.
Normal Abnormal (e). Continuously rotate the steering wheel.
△ Tips:
Run the engine idling, rotate the steering wheel to the
limit position of one side and then to the limit position of
opposite side. Repeat this operation for several times.
Note:
The steering wheel should not stay at the limit
position more than 3s
(f). Check whether there are bubbles in steering fluid
or not, if yes, repeat exhaust steps and check
whether there is leakage of steering fluid or not.
(g). Check whether there are bubbles in steering fluid
or not, if yes, repeat exhaust steps and check
LFWX-6470-61006
whether there is leakage of steering fluid or not.
(h). Check liquid level and add steering fluid.
Power steering oil can

Replacement
1. Remove the power steering oil pot
(a). Open engine compartment cover。
(b). Drain the steering fluid.(Refer to 61 - hydraulic steering system, steering fluid, draining)
(c). Remove low pressure oil return pipe ① clamp
and withdraw low pressure oil return pipe ① .
(d). Remove clamp of steering oil pump oil inlet pipe
3 ③ , and pull out steering oil pump oil inlet pipe ③ .
(e). Unplug power steering oil can ② in upward
1 direction.
62
LFWX-6470-61016
2. Mount the power steering oil tank

(a). Install power steering oil can ② on oil can
support.
3 (b). Install low pressure oil return pipe ① and clamp
on power steering oil can ② .
1 (c). Install air inlet pipe ③ and clamp of steering oil
pump on power steering oil can ② .
(d). Fill steering fluid. (Refer to 61 - hydraulic steering
system, steering fluid, filling)
(e). Exhaust air in hydraulic steering system. (Refer
2 to 61 - hydraulic steering system, steering fluid,
bleeding)
LFWX-6470-61016
Steering wheel
Adjustment
1. Adjust the steering wheel
(a). Regulate steering column regulating mechanism;
after regulating steering wheel to appropriate
position, regulate steering column regulating
mechanism to its locking position.
Note:
• Do not adjust the steering wheel while driving;
otherwise any lost of control of the steering
operation may result in accidents and even
serious casualties.
• Ensure that the steering wheel is firmly locked
after adjustment; otherwise, the steering
wheel may suddenly be shifted, resulting in an
accident, and even serious casualties.
• Do not adjust the steering wheel toward
directly to your face; otherwise, the airbag will
LFWX-6470-61017 not provide effective protection in case of an
accident. After adjustment, the steering wheel
should be toward the driver's chest.
61-19
Replacement
1. Remove the steering wheel.
(a). Remove the driver airbag. (Refer to 72 - Safety Protection Device Driver Airbag,
Replacement)
(b). Remove steering wheel fixing nut.
(c). Use steering wheel puller to remove steering
wheel.
Torque: 80~105N·m
△ Tips:
Before pulling out the steering wheel, make the
assembly mark on the steering shaft and steering
wheel to ensure the parts can be assembled to their
original positions.
LFWX-6470-61018
2. Install the steering wheel.
(a). Install steering wheel on installation site, install
steering wheel retaining nut and fasten it.
Torque: 80~105N·m
(b). Install the driver airbag.(Refer to 72 - Safety
Protection Device Driver Airbag, Replacement)
LFWX-6470-61018
62
Steering
Replacement
1. Remove the steering shaft
(a). Remove the steering wheel.refer to 61 - hydraulic steering system, steering wheel,
replacement)
(b). Remove the lower left dashboard guard panel. (Refer to chapter 85 Instrument Board and
Auxiliary Instrument Board – Left Lower Apron of Instrument Board, Replacement)
(c). Remove the steering shaft shield fixing screw
and take down the steering shaft lower shield and
instrument decorative cover.
(d). Remove the clock spring and steering angle
sensor. (Refer to 74 – Safety Protection Device,
Clock Spring, Replacement)
LFWX-6470-61018
(e). Disconnect combination switch connector clip.
LFWX-6470-61020
61-21
(f). Remove combination switch and take it out.
LFWX-6470-61021
(g). Disconnect the electronic steering shaft lock
connector.
LFWX-6470-61022
(h). Remove the mounting and retaining nuts of upper
steering shaft as well as the fixing bolt of steering
shaft, and break steering shaft assembly from its
installation site.
62
LFWX-6470-61023
(i). Remove the upper section lock bolt of steering

shaft, and take out the upper steering shaft
assembly.
LFWX-6470-61024
(j). Remove the plastic cap type nut for fixing sealing
cover component on steering shaft, and take out
sealing cover component on steering shaft.
LFWX-6470-61025
(k). Remove the retaining nut of steering-shaft lower
sealing cover component, and take out the
steering-shaft lower sealing cover component.
LFWX-6470-61026
61-23
(l). Remove lower section lock bolt of steering shaft,

and take out the lower section component of the
lower steering shaft.
(m). Remove electronic steering shaft lock. (Refer to
54B - engine immobilizer (one-touch start) system
electronic steering shaft lock, replacement)
LFWX-6470-61027
2. Install the steering shaft.

(a). Install electronic steering shaft lock on upper steering shaft. (Refer to 54B - engine
immobilizer (one-touch start) system electronic steering shaft lock, replacement)
(b). Install the lower section of steering shaft on its
installation site, and install the lower section lock
bolt of steering shaft and fasten it.
Torque: 20~26 N·m
LFWX-6470-61027
(c). Install steering-shaft lower sealing cover
component on its installation site, and install its
retaining nut and fasten it. 62
Torque: 16~20 N·m
LFWX-6470-61026
(d). Install steering-shaft upper sealing cover

component on its installation site, and install its
retaining plastic nut and fasten it.
Torque: 16~20 N·m
LFWX-6470-61025
(e). Install upper steering shaft assembly on lower
steering shaft assembly, and install and fasten
upper section locking bolt of upper steering shaft.
Torque: 20~26 N·m
LFWX-6470-61024
(f). Install upper steering shaft on its installation site,

install retaining nut and bolt of upper steering
shaft mounting bracket and fasten them.
Torque: 20~26 N·m
LFWX-6470-61023
61-25
(g). Connect electronic steering shaft lock connector

clip.
LFWX-6470-61022
(h). Connect combination switch connector clip.
LFWX-6470-61020
(i). Put combination switch on its installation site and
install it.
62
LFWX-6470-61021
(j). Install clock spring and direction-angle sensor. (Refer to 74 – Safety Protection Device, Clock
Spring, Replacement)
(k). Install steering shaft lower apron and instrument

decoration cover on their installation sites, and
install steering cover fixing bolt and fasten it.
LFWX-6470-61018
(l). Install the left lower apron of instrument board. (Refer to chapter 85 Instrument Board and
Auxiliary Instrument Board – Left Lower Apron of Instrument Board, Replacement)
(m). Install steering wheel. (refer to 61 - hydraulic steering system, steering wheel, replacement)
Power steering pump

Replacement
1. Remove the power steering pump assembly
(a). Lift the vehicle.
(b). Drain the steering fluid. (Refer to 61 - Hydraulic Steering System Steering Fluid, Emissions)
(c). se wrench to clockwise screw up tensioning
wheel, and remove and take down the power
steering pump belt.
LFWX-6470-61030
61-27
(d). Remove the power steering pump pipe clamp,

and disconnect the power steering pump inlet
pipe.
LFWX-6470-61029
(e). Remove the high pressure oil pipe joint bolt, then
disconnect high pressure oil pipe.
LFWX-6470-61031
(f). Remove the fixing bolt of power steering pump
and engine, and take out the power steering
pump.(fix the bolt in the position as shown by the
arrowhead)
Torque: 55~65 N•m
62
LFWX-6470-61032
2. Mount the power steering pump

(a). Install the power steering pump on engine, then
install and fasten power steering pump fixing
bolt.(fix the bolt in the position as shown by the
arrowhead)
Torque: 55~65 N•m
LFWX-6470-61032
(b). Install pressure supply pipe on its installation site,
install pressure supply pipe joint bolt and fasten
it.
LFWX-6470-61031
(c). Install power steering pump oil inlet pipe on its
installation site, and install power steering pump
oil pipe clamp.
LFWX-6470-61029
61-29
(d). Use wrench to clockwise rotate tensioning wheel,

and install power steering pump belt.
LFWX-6470-61030
(e). Feed steering fluid and exhaust gas. (Refer to 61 – Hydraulic Steering System, Steering
Fluid, Filling)
(f). Lift the vehicle.
Steering gear
Replacement
1. Remove the steering gear with tie rod assembly
(a). Jack up vehicle and remove front wheels.
(b). Drain the steering fluid.(Refer to 61 - hydraulic steering system, steering fluid, draining)
(c). Remove high pressure pipe joint bolt, and
disconnect the high pressure pipe.
62
LFWX-6470-61031
(d). Remove the fixing bolt of oil inlet and outlet pipe
component bracket of steering gear.。
LFWX-6470-61038
(e). Use oil pipe wrench to remove nuts of oil inlet
and outlet pipes of steering gear, and take out oil
inlet and outlet pipes of steering gear.
LFWX-6470-61039
(f). Remove lower section lock bolt of steering shaft,
and take out the lower section component of the
lower steering shaft.
LFWX-6470-61027
61-31
(g). Remove the cotter pin for mounting the steering

tie rod.
LFWX-6470-61033
(h). Remove the slotted nut of steering tie rod.
LFWX-6470-61034
(i). Use ball head stripper to remove steering tie rod

ball head.
62
LFWX-6470-61034
(j). Remove the fixing bolt and nut of steering gear

and tie rod assembly.
LFWX-6470-61035
(k). Release the fixing bolt of engine mounting.
(l). Take out steering gear and tie rod assembly from
one side of wheel.
LFWX-6470-61037
2. Disassemble the steering gear assembly
(a). Use oil pipe wrench to remove oil pipe nuts of
short oil pipe and long oil pipe on steering gear,
and take out the long oil pipe and the short oil
pipe.
LFWX-6470-61040
61-33
b). Make the assembly mark at the end of the

steering gear ball bar, loosen the locking nut, and
remove the hydraulic steering gear ball bar.
LFWX-6470-61041
(c). Remove the steering gear dust cover clamp on
both side,then take down steering gear dust
cover.
LFWX-6470-61042
(d). Pry up steering gear pull rod lock-up plate, fix

steering gear and remove steering gear pull rod.
△ Tips:
Mark the left/right rack to facilitate the future
installation.
62
LFWX-6470-61043
(e). Release nut of rack guide spring.
LFWX-6470-61044
(f). Remove guide spring cover and take out guide

spring and guide block.
LFWX-6470-61045
3. Assemble the steering gear assembly
(a). Install rack guide block and guide spring on
installation site, install rack guide spring cover
and pre-tighten it.
LFWX-6470-61045
61-35
(b). Fasten the lock nut of rack guide spring cover.
LFWX-6470-61044
(c). Fix the steering gear, install steering gear pull rod
on installation site according to disassembling
mark, and install steering gear pull rod lock-up
plate.
LFWX-6470-61043
(d). Install dust covers and clamps on two sides of
the steering gear, and use special tools to fasten
the clamp.
△ Tips:
The steering gear clamp cannot be reused. It must be
replaced if removed. 62
LFWX-6470-61042
(e). Install steering gear ball head pull rod on its

installation site according to mark made in
disassembly, and install and fasten locking nut.
Torque: 45 N·m
LFWX-6470-61041
(f). Install steering gear oil inlet and outlet pipe on
installation site, and use oil pipe wrench to fasten
the nuts of oil inlet and outlet pipes.
Torque: 23~27 N·m
LFWX-6470-61039
(l). Install the fixing bolt of steering gear detection oil
pipe component support and fasten it.
Torque: 6~12 N·m
LFWX-6470-61038
61-37
(m). Install long/short oil pipe on steering gear on its

installation site, use oil pipe wrench to tighten the
nuts on two ends of the long/short oil pipe.
Torque: 23~27 N·m
LFWX-6470-61040
4. Mount the steering gear with the tie rod
assembly
(a). Install bogie and tie rod assembly on front-front
auxiliary frame from one side of wheel; install the
lower section of lower steering shaft on tie rod
according to disassembly mark, and install and
fasten lock screw.
Torque: 20~26 N·m
LFWX-6470-61027
(b). Install steering gear fixing bolt and nut, and
fasten them.
Torque: 200~220 N·N
62
LFWX-6470-61035
(c). Install steering linkage ball head on steering

knuckle, and install and fasten slotted nut of
steering tie rod.
Torque: 60 N·m
LFWX-6470-61034
(d). Install steering tie rod and install cotter pin.
LFWX-6470-61033
(e). Install high pressure oil pipe on steering pump,
and install and fasten high pressure oil pipe joint
bolts.
LFWX-6470-61031
61-39
(f). Install low pressure pipe and clamp of steering

gear.
LFWX-6470-61031
(g). Install engine mounting fixing bolt and pre-fasten
it.
Torque: 85~105 N·m
LFWX-6470-61037
(h). Fill the steering fluid.(Refer to 61 - hydraulic steering system, steering fluid, filling)
(i). Exhaust air in hydraulic steering system. (Refer to 61 - Hydraulic Steering System, Steering
Fluid, Exhaust)
(j). Install front wheels and adjust toe-in valve (Refer to 33 – Wheels and Tyres, Four-wheel
Alignment, Adjustment)
62
5. Verify
(a). Check steering effort of steering wheel. (Refer to 61- Hydraulic Steering System – General
Inspection – Check Steering Wheel)
△ Tips:
If the steering wheel rotating effort is too high, adjust the tightness of steering gear rack guide
spring cover.
Steering oil pipe

Replacement
1. Remove the steering oil tank inlet/outlet pipe
(a). Discharge the steering fluid.(Refer to 61 - hydraulic steering system, steering fluid, draining)
(b). Remove clamping stirrups on two ends of the oil
inlet and outlet pipes of steering oil can.
LFWX-6470-61046
(c). Remove the low pressure pipe clamp, and
disconnect the low pressure pipe.
LFWX-6470-61014
61-41
(d). Remove the clamping stirrup of power steering

pump oil inlet pipe, and take out the power
steering pump oil inlet pipe.
LFWX-6470-61029
(d). Remove the fixing bolt of fixing support of oil inlet
and outlet pipes of steering oil can, and take out
the oil inlet and outlet pipes of steering oil can.
LFWX-6470-61047
2. Mount the steering oil tank inlet/outlet pipe
(a). Install oil inlet and outlet pipes of steering oil can
on their installation sites, and install and fasten
fixing bolt of steering oil can fixing support.
Torque: 6~12 N·m
Torque: 20~26 N·m (Oil tank inlet pipe) 62
LFWX-6470-61047
(d). Install power steering pump oil inlet pipe on its

installation site, and install power steering pump
oil pipe clamp.
LFWX-6470-61029
(c). Install low pressure pipeline on its installation

site, and install its clamping stirrup.
LFWX-6470-61014
(b). Install oil inlet and outlet pipes of steering oil can
on steering oil can, and install oil inlet and outlet
pipes clamping stirrup of steering oil can.
(c). Fill steering fluid. (Refer to 61 – Steering System,
Steering Fluid, Filling)
LFWX-6470-61046
61-43
62
Safety Protection Device - Safety Protection Device
72-a
Safety Protection Device

Air bag ………………………………1 Testing ………………………… 45
Preparations ………………………1 Replacement …………………… 45
Maintenance data …………………2 Airbag DTC ……………………… 47
Precautions ………………………2 DTC list ………………………… 47
Distribution plan …………………4
Component drawing ………………5
Circuit drawing ……………………7
Terminal definition ………………9
On-vehicle inspection ………… 12
Pre-inspection ………………… 15
Airbag ECU ……………………… 16
Side collision sensor…………… 18
Driver airbag …………………… 19
Discard ………………………… 21
Co-driver airbag ………………… 25
72
Discard ………………………… 29
Clock spring …………………… 29
Side safety air curtain ………… 32
Installation ……………………… 33
Seat belts ………………………… 34
Front row seat belt ……………… 37
Testing ………………………… 37
Center row seat belt …………… 42
Testing ………………………… 42
Rear row seat belt ……………… 45
72-b Safety Protection Device - Safety Protection Device
72-1
Air bag
Preparations
1. Special tools
S/N Tool External view No. Description
Special tool for

1 Firing the airbag
airbag firing
Diagnosis Fault diagnose of

2 equipment airbag system
72
Digital universal Measure the voltage

1 meter and resistance
To remove and install

2 Screw driver the screw and pry the
snap ring etc.
3 Wiring group Testing circuit

72-2 Safety Protection Device - Safety Protection Device
Maintenance data
Items N.m
Retaining bolts of airbag ECU 6~12
Retaining bolts of co-driver's airbag 6~12
Precautions
Warning:
1. For airbag system, correct working procedure must be followed, otherwise the airbag may
deploy suddenly, cause serious injury. Meanwhile, any incorrect action on airbag system can
cause malfunction of the system.
2. Be sure the ignition switch is at OFF position, both negative and positive terminal are
disconnected for 90s before any action. The safeguard systems are equipped with failsafe
power, if any actions are taken in 90s after terminals of battery disconnect, the airbag may
deploy suddenly.
3. The airbag assembly must not be exposed in hot atmosphere or flame.
Note:
1. As it is difficult to detect fault in airbag system, the diagnose trouble code (DTC) should
be used as an important source of information for troubleshooting. Examine DTC before
disconnect the battery in troubleshooting of the airbag system.
2. Even after a minor crash without deployment of airbag, the airbag module assembly and
airbag electronic control unit (SRS ECU) should be inspected as well.
3. If there is possibility to compact the airbag electronic control unit (SRS ECU) in repair, the
SRS ECU connector must be disconnected before any action.
4. Parts of airbag system from other vehicle should never be used. Always replace with new
parts.
5. Horn airbag module assembly must not be disassembled.
6. If the airbag module assembly fall onto ground, or there is crack, dent or other defection,
always replace with a new one.
7. Always detect fault in system circuit by using a digital multimeter with high impedance.
8. Precautions in Description Tag on airbag system parts must be observed in repair.
9. Memories of electronic clock and audio system are cleared after cable of battery
disconnected. Record all necessary data before repair. Reset electronic clock and audio
system after repair. Standby power supply other than the vehicle must not be used to keep
data memory. The standby power supply will power airbag system, so that the airbag may
deploy suddenly in repair.
10. Encryption should be conducted for airbag electronic control unit (SRS ECU) before any
repair of airbag or other components of the vehicle. Decrypt the airbag electronic control unit
(SRS ECU) after repair.
11. It is forbidden to dismantle or repair driver and co-driver’s airbag module and airbag
electronic control unit (SRS ECU) assembly for reusing or other purpose.
12. The airbag ECU, airbag module and clockspring should be removed and stored properly
before varnish baking to avoid any adverse influence of high temperature (above 93℃ ).
13. Connectors of airbag electronic control unit (SRS ECU) assembly, clockspring to airbag
electronic control unit (SRS ECU) assembly, clockspring to driver’s airbag module and co-
driver’s airbag module to airbag electronic control unit (SRS ECU) assembly are equipped
with a failsafe mechanism preventing accidental deployment of airbag. All requirements must
be followed in repair of airbag system to avoid injury for sudden deployment and other parts.
72-3
14. The airbag module must be installed immediately after taken out of shipping carrier in repair
of airbag system. If there is any suspending of work, airbag module must be put back into the
shipping carrier. Never store airbag module in areas without tenter. Removed airbag should
be placed with deployed side facing up.
15. When repair finished, it is required to check electric circuit before connection. The airbag can
only be connected with electric circuit that is confirmed in good condition.
16. There should be no person in vehicle when connecting power supply to airbag system.
17. Check for proper function of SRS warning indicator after repair of airbag system.
18. The airbag must be replaced when the service lifetime (see Operation Manual for details) is
expired.
72
Distribution plan
6
1
2
3
LFWX-6470-12001
Driver cabin center controller box
1 4 Clock spring
(fuse)
2 SRS malfunction indicator 5 Airbag ECU
3 Driver's airbag module assembly 6 Co-driver's airbag module assembly
72-5
Component drawing
2
1
3 6
6
5
LFWX-6470-72069
1 Driver's airbag assembly 4 Left safety air curtain assembly

Hexagon head cross slot bolt, spring
2 Co-driver's airbag assembly 5 washer and plain washer assembly
72
parts
3 6 Right safety air curtain assembly
2
2
4
3
1
LFWX-6470-72070
1 Airbag ECU 4 施咒弹簧

2 Hexagon flange bolt 5 Side collision sensor
72
72-7
Airbag system (2017 model, comfortable version)

Left air curtain Right air curtain
Diagnostic
interface
Airbag controller
Circuit drawing
Left pre-warning Right pre-warning Driver's side Co-driver's side Left collision Right collision
type belt type belt Driver's airbag airbag airbag sensor sensor
17
IG1
SR05
10 A
13 1D
13 I1D PCANH PCANL
1 S4 2 S4 1 S11 2 S11 6 I01 14 I01
0.5 RW
4 IS1
0.3 Br
0.3 R
0.3 Bl
0.3 Y
4 SI1
5 S1 22 S1 23 S1 24 S1 25 S1 15 S1 40 S1
1 S1 2 S1 3 I37 4 S1 10 S1 11 S1 14 S1 13 S1 16 S1 17 I37 18 S1 19 S1 45 S1 20 S1 46 S1 21 S1 6 S1
0.3 OBl
0.3 GrB
0.3 GrW
0.3 BrB
0.3 BrW
0.3 WBr
0.3 PW
0.3 WG
0.3 GB
0.3 PB
0.3 GW
0.3 OB
0.3 O
0.3 Bl
0.5 B
7
4 S03 3 S03
1 S5 2 S5 1 S10 2 S10 1 S07
2 2 S02 1 S7 2 S7 1 S8 2 S8 1 S8 2 S8 1 S8 2 S8
G13
72-8
72-9
Terminal definition
S1 Connect airbag ECU
Terminal No. Wire size/color Fuction Terminal No. Wire size/color Fuction
1 NC 26 NC NC
2 NC 27 NC NC
3 NC 28 NC NC
4 NC 29 NC NC
5 0.3/RW IG+ 30 NC NC
6 0.3/B Grounding 31 NC NC
7 NC NC 32 NC NC
8 NC NC 33 NC NC
9 NC NC 34 NC NC
Driver airbag
10 0.3/Bl 35 NC NC
drive low end
Driver airbag
11 0.3/Br 36 NC NC
drive high end
12 NC 37 NC NC
Assistant driver 72
13 0.5/Gr airbag drive 38 NC NC
high end
Assistant driver
14 0.5/W airbag drive low 39 NC NC
end
15 0.3/Y PCANH 40 0.3/YB PCANL
16 NC NC 41 NC NC
17 NC NC 42 NC NC
18 NC NC 43 NC NC
19 NC NC 44 NC NC
20 NC NC 45 NC NC
21 NC NC 46 NC NC
22 NC NC 47 NC NC
23 NC NC 48 NC NC
24 NC NC 49 NC NC
25 NC NC 50 NC NC
S2 Connect to PAB airbag module
Terminal Wire size/

Fuction
No. color
Assistant driver airbag drive
1 0.5/W
low end
Assistant driver airbag drive
2 0.5/Gr
high end
S3 Connect to the clock spring
Terminal Wire size/

Fuction
No. color
1 0.3/Bl Driver airbag drive low end
2 0.3/Br Driver airbag drive high end
3 NC
4 NC
S4 Connect to the car body gruonding
Terminal Wire size/

Fuction
No. color
1 0.3/B To bodywork ground
·Refer to the circuit catalog for details on the
customization of the facelift.
72-11
System description
1. Operation principle of airbag
In a frontal collision, impact signal generated by the crash sensor is sent to airbag ECU and
analyzed there. If the ECU determines that firing requirement is met, an ignition pulse will be sent
to fire the ignition tube in airbag module, which in turn ignites the inflammation chemical inside the
module to generate massive gas to inflate the bladder ins a very short time. Expanded bladder can
burst through the trim cover to protect driver and co-driver from impact caused by crash, resulting
in reduced injury to them.
2. Operation principle of airbag clock spring
Mounting shell of the clocksping is on the steering column. Upper circle of the spring is inserted in
the steering wheel. Spiral cable is installed between the upper circle and mounting shell. The upper
circle of clockspring turns along with the steering wheel. This takes the output end of the cable
to move. This movement makes the cable spiral to wind or release, do not twine on the column
meanwhile has electric connectivity. The clockspring is a bridge for power supply from the vehicle
body to function part on the steering wheel.
3. Component of the system
XUANLANG series vehicles employ the electronic double airbag system and 6-airbag system. In
the steering wheel central decorative cover and dashboard in the front of the front seat, one airbag
and one 6-airbag system is provided. In addition, the driver's side and front seat side airbag and air
curtain are provided.
The airbag system consists of driver’s airbag module, co-driver’s airbag module, clockspring,
electronic control unit of airbag, airbag harness and warning labels.
72
1. Check driver’s airbag (no crash)
(a). Check the system with the diagnostic tester
(refer to Chapter 72 Safety protection device -
fault diagnosis, pre-inspection).
(b). Check the driver's airbag surface, notch at
the gap and fine crack for damage or evident
discoloration.
LFWX-6470-72002
2. Check driver’s airbag module (without

deployment after crash)
(b). Check the driver's airbag surface, notch at
the gap and fine crack for damage or evident
discoloration.
(c). Check the airbag harness for scuffing and
connector for damage or break.
(d). Check for deformation of steering wheel.
LFWX-6470-72003
Note:
There should be no interference between driver’s airbag and steering wheel. Even gap
should be around the new airbag when installed on the steering wheel.
Warning:
The correct procedure should be followed to install the driver's airbag.
3. Check driver’s airbag module (deployed
after crash)
(b). Remove driver’s airbag and steering wheel
from the vehicle. (Refer to 61 - steering system,
steering wheel, replacement)
(c). Check for any damage of clock spring and
harness.
LFWX-6470-72004
72-13
4. Check co-driver’s airbag (no crash)

(a). Check the system with the diagnostic tester (refer to Chapter 72 Safety protection device -
(b). Visually inspect the surface of the disassembled driver airbag; if it has boss or cracks, change
the driver airbag.
5. Check driver’s airbag (without deployment after crash)
(b). Visually inspect the surface of the disassembled co-driver airbag; if it has boss or cracks,
change the driver airbag.
(c). Check the airbag harness for scuffing and connector for damage or break.
(d). Check for damage in instrument panel stiffener.
Note:
Do not repair damaged instrument panel and the stiffener. They should be changed.
6. Check driver’s airbag module (deployed after crash)
(b). Remove the co-driver’s airbag module assembly.
(c). Check for any damage in parts and harness around the co-driver’s airbag module.
Note:
Do not repair damaged instrument panel and the stiffener or any parts and harness of the
airbag module. They should be changed.
7. Check the front seat side airbag module (without deployment after crash)
(b). Check whether airbag wiring harness is scratched or not and whether connector is damaged
or broken or not.
(c). Check the seat for damage.
Note:
If the seat is damaged, replace it directly and do not repair.
8. Check the front seat side airbag module (deployed after crash)
fault diagnosis, pre-inspection). 72
(b). Carefully check whether spare parts and wiring harness near the passenger side curtain
airbag module are damaged or not.
(c). Check the seat for damage.
Note:
If the seat airbag module harness and connector are damaged, replace them directly and do
not repair.
9. Check the side air curtain (without crash)
(b). Visually inspect the surface of curtain airbag disassembled; if the side curtain airbag is loose
and the fixing sleeve is damaged, change the side curtain airbag.
10. Check the side air curtain (without deployment after crash)
(b). Visually inspect the surface of side curtain airbag disassembled; if the side curtain airbag is
loose and the fixing sleeve is damaged, change the side curtain airbag.
(b). Check whether side curtain airbag is scratched or not and whether connector is damaged or
broken or not.
11. Check the side air curtain (deployed after crash)
(b). Carefully check whether spare parts and wiring harness near the side curtain airbag module
are damaged or not.
Note:
If the side safety air curtain module accessories and harness are damaged, replace them
directly and do not repair.
12. Inspect eh airbag ECU (without crash)
13. Inspect eh airbag ECU (without deployment after crash)
14. Inspect eh airbag ECU (deployed after crash)
15. Check airbag harness and connector (no crash)
16. Check airbag harness and connector (after crash)
(b). Check for any break, crack and fragmentation or the airbag harness.
(c). Check for any damaged connector on airbag harness.
72-15
Fault diagnosis
Pre-inspection
1. Inspect the self-check system
(a). Power state: “ON/IG ON”.
(b). Inspect airbag warning indicator on cluster.
Standard:
The airbag warning indicator turns off in 5-6s
after ignition. If the airbag warning indicator
illuminates continuously, electric circuit fault
exists in the system. Read the DTC by using a
scan tool and repair as required.
Note:
Once power at “ON/IG ON” state, airbag ECU
tests parts in the system.
LFWX-6470-72005
2. Read and eliminate the DTC

(a). Connect V30 diagnostic tester to the diagnostic
interface.
(b). On screen of scan tool, read DTC in “Body
Electronics - Airbag System”.
(c). According to screen information, refer to DTC
List to diagnose. (See Section 72 - Diagnose of
Safeguard Devices, Diagnose Trouble Code)
(d). After repair, clear the DTC.
72
LFWX-6470-72006
Airbag ECU
Replacement
1. Remove the airbag ECU
(a). Turn off the ignition switch and disconnect the
battery negative cable
△ Tips:
After disconnecting the battery negative cable, wait for
90s at least before the subsequent operation.
(b). Re m o v e th e a u x i l i a r y F a s c i a Co n s o l e
assembly (See Section 85: Fascia Console
and Auxiliary Fascia Console - Auxiliary
Fascia Console, Change)
LFWX-6470-72007
(c). Disconnect airbag ECU connector.

Warning:
Before working on the airbag system, carefully
read Chapter 72 Safety protection device - airbag,
precautions.
LFWX-6470-72008
(e). Remove retaining bolts of airbag ECU.

(f). Remove airbag ECU.
LFWX-6470-72009
72-17
2. Install the airbag ECU.

(a). Place the ECU at correct position for installation
on floor.
△ Tips:
Make sure there is no foreign matters on mounting
surface of the ECU. Be sure to place the ECU smooth
and steady. Connecting port of the ECU should face
right, mounting holes (3) on ECU should align with
holes on support.
Note:
Handle the airbag ECU gently and avoid falling. If
the airbag ECU falls from higher position, change
it. Never install damaged airbag ECU in vehicle.
LFWX-6470-72010
(b). Install retaining bolts of airbag ECU.

Torque: 6~12N•m
LFWX-6470-72009
72
(c). Connect airbag ECU connectors.
△ Tips:
All connectors should be fixed securely with no
damage on harness.
LFWX-6470-72008
(d). Install auxiliary fascia console (See Section 85:

Fascia Console and Auxiliary Fascia Console -
Auxiliary Fascia Console, Change)
(e). Connect the battery negative cable
LFWX-6470-72007
Side collision sensor

Replacement
1. Remove the side impact sensor
(a). Remove the B pillar lower panel. (refer to 81 -
interior trims and exterior trims, B pillar lower
panel, replacement)
(b). Disconnect the side impact sensor connector.
(c). Remove the fixing bolt of side impact sensor
and take out the side impact sensor.
/):;
2. Mount the side impact sensor
(c). Put side impact sensor on its installation site,
and install and fasten its fixing bolt.
(b). Connect the connector clip of side impact
sensor.
(c). Install the B pillar lower panel. (refer to 81 -
interior trims and exterior trims, B pillar lower
panel, replacement)
/):;
72-19
Driver airbag
Replacement
1. Remove the driver's airbag
(a). Turn off the ignition switch and disconnect the battery negative cable.
△ Tips:
After disconnecting the battery negative cable, wait for 90s at least before the subsequent
operation.
Warning:
Before working on the airbag system, carefully read Chapter 72 Safety protection device -
airbag, precautions.
(b). Put airbag withdrawal tool (screwdriver
with 4-6mm width) in driver SRS assembly
disassembly holes (3) and push the fixing clip.
LFWX-6470-72013
(c). Push up driver’s airbag module.

△ Tips:
Push the driver’s airbag module slowly, prevent any
damage on airbag harness and horn switch harness. 72
LFWX-6470-72011
(d). Disconnect driver’s airbag connector.

(e). Disconnect horn switch connector.
Note:
Apply no stress on harness, otherwise it can be
pulled to breaking.
LFWX-6470-72012
(f). Remove driver airbag module assembly and

put aside securely.
Note:
It is very dangerous to put airbag module facing
LFWX-6470-72014 down. Burst bladder can make the module
bouncing, which may cause serious injury.
Position the module facing up.
LFWX-6470-72015
3. Install the driver airbag module.

(a). Take a new co-driver airbag module assembly.
Note:
The new airbag module may abruptly be triggered
and expand to cause the person injury in the case
of improper handling. Therefore, maintain the
airbag front section facing your body front when
handling the airbag to reduce the possible injury.
72-21
(b). Connect the driver's airbag module connector.

(c). Connect horn switch connector.
LFWX-6470-72016
(d). Install the driver's airbag module.

△ Tips:
Make sure the airbag seating properly. After
installation, check to confirm even match between
airbag and reception on steering wheel and repeat
installation as required.
(d). Connect positive and negative battery cables.
4. Connect the battery negative cable
5. Inspect driver's airbag module
6. Check airbag malfunction indicator
LFWX-6470-72002 72
Discard
△ Tips:
When dispose vehicle or airbag module, the discarded airbag should be fired, this can eliminate
any risk of burning in certain circumstances. Follow procedure to fire the discarded airbag. In case
of failure in firing discarded airbag, contact authorized service station of Lifan.
Warning:
• Never dispose driver’s airbag module not fired.
• It is advisable to fire airbag in places away from community or outdoor, because firing
operation may cause loud sound of bursting.
• The special tool for firing from Lifan should be used to fire discarded airbag. Operate this
in a place far from the electrical interference.
• Any operation of firing should be conducted 10m away from airbag in firing operation.
• The airbag will be hot after fired. Wait for at least 30min before touching.
• Safety gloves and goggle should be worn to handle fired airbag.
• Do not spill water on fired airbag.
• Clean your hand after operation.
1. Preparation
(a). Prepare the special tool for airbag firing
(b). Prepare a battery as power supply to fire airbag.
(c). Prepare a discarded wheel with rim and
some discarded wheel without rim, and some
cardboard boxes and weights.
LFWX-6470-72017
(d). Prepare some discarded vehicle harness.

△ Tips:
Diameter of the harness conductor should be more
than 1.3mm, which means 1.25mm2 cross section
area of harness.
Warning:
The harnesses are used to tie the airbag in firing
operation. Thicker or thinner harness may break
when the airbag burst. It is very dangerous.
Reliable binding harness or equivalent must be
used.
(e). Choose a suitable open area.
LFWX-6470-72018
2. Inspect performance of special firing tool for

airbag
Red (a). Connect the special tool to battery.
△ Tips:
Black Hold red clip of the special tool onto positive post of
the battery, while black one onto negative. The yellow
connector is for airbag module. Leave it alone in this
step.
Yellow
LFWX-6470-72019
72-23
(b). Push activation button of the special firing tool

for airbag. Confirm illumination of LED.
Red Warning:
If the LED does not light, the special should not
Black be used because of fault.
(c). Disconnect the special tool from battery.
Yellow
LFWX-6470-72020
3. Fix the driver’s airbag module.

(a). Connect lead to driver’s airbag module.
72
LFWX-6470-72021
(b). Bind driver’s airbag onto wheels prepared.

△ Tips:
Expansion of driver’s airbag can damage wheel,
thus discarded wheels should be used.
Warning:
• Make sure the airbag is bond tightly with
harness or equivalent. It is very dangerous if
the harnesses are break when the airbag bursts
during firing.
• Make sure to bind the driver’s airbag facing
up. If the metal side of airbag faces up, it can
cut the harness during burst of airbag, which
can cause risk of flying airbag. This is very
dangerous.
LFWX-6470-72022
4. Connect the special tool for airbag firing

(a). Connect lead of driver’s airbag to yellow
connector of the special tool.
Red
△ Tips:
Black
Leave the secondary latch of the cascade lock
unengaged to avoid damage to connector and
harness of the special tool. Make sure binding
harness are loose than that of outside. The cascade
lock and loose binding harness prevents excessive
Yellow shock in burst of airbag, to protect harness of the
special tool.
(b). Move the special tool for airbag firing 10m away
from airbag bond on wheel.
LFWX-6470-72023
5. Cover the bond airbag module.
(a). Cover the bond airbag module with cardboard
box or discarded wheels.
• Cover with cardboard box:
Cover the airbag module bond to wheel with a
cardboard box bigger then wheel, put 190N weight on
the box. As shown in the Figure.
LFWX-6470-72024
• Cover with wheels:
Cover the airbag module bond to wheel with at least
three discarded wheel (without rim). As shown in the
Figure.
LFWX-6470-72025
72-25
6. Fire the airbag module

(a). Connect red and black clips of the special tool
Red to positive and negative post of the battery
respectively.
Black (b). Confirm there is no person or animal 10m
around bond airbag.
(c). Push button to fire the airbag.
LFWX-6470-72026
7. Dispose driver's airbag module

(a). Remove driver’s airbag from the wheel rim.
(b). Put airbag into a plastic bag and tie the opening,
then dispose the airbag as a discarded vehicle
part.
Warning:
• The airbag will be hot after fired. Wait for at
least 30min before touching.
• Safety gloves and goggle should be worn to
handle fired airbag.
72
LFWX-6470-72027
Co-driver airbag
Replacement
1. Remove the co-driver airbag
(a). Turn off the ignition switch and disconnect the
battery negative cable
△ Tips:
After disconnecting the battery negative cable, wait for
90s at least before the subsequent operation.
(b). Remove the glovebox (See Section 85: Fascia
Console and Auxiliary Fascia Console -
Glovebox, Replacement)
LFWX-6470-72028
(c). Disconnect co-driver’s airbag connector

Warning:
Before working on the airbag system, carefully
read Chapter 72 Safety protection device - airbag,
precautions.
(d). Remove the fascia console assembly (See
Section 85:Fascia Console and Auxiliary Fascia
Console - Fascia Console, Change)
LFWX-6470-72029
(e). Remove retaining bolts of co-driver's airbag.
LFWX-6470-72030
(f). Pry up clip that attach co-driver’s airbag
module to fascia, remove the co-driver’s
airbag module assembly.
Warning:
Never dismantle co-driver’s airbag module.
LFWX-6470-72031
72-27
(g). Remove co-driver's airbag module assembly

and put aside safely.
Note:
It is very dangerous to put airbag module facing
down. Burst bladder can make the module
bouncing, which may cause serious injury.
Position the module facing up.
LFWX-6470-72032
2. Install co-driver's airbag module assembly

(a). Take a new co-driver airbag module assembly.
Note:
The new airbag module may abruptly be triggered
and expand to cause the person injury in the case
of improper handling. Therefore, maintain the
airbag front section facing your body front when
handling the airbag to reduce the possible injury.
72
LFWX-6470-72033
(b). Install new co-driver airbag module assembly on

fascia console.
LFWX-6470-72031
(c). Install the fascia console assembly(See Section

85: Fascia Console and Auxiliary Fascia
Console - Auxiliary Fascia Console, Change)
Note:
Check for well seating after installation.
(d). Connect the co-driver's airbag connector.
Note:
Do not pull the airbag harness forcedly.
LFWX-6470-72029`
(e). Install assistant airbag fixing bolt on instrument
desk pipe beam assembly.
Torque:6~12N•m
LFWX-6470-72030
(f). Install the glovebox (See Section 85: Fascia

Console and Auxiliary Fascia Console - Auxiliary
Fascia Console, Change)
(g). Connect the battery negative cable
(h). Check the front seat airbag module.
(i). Check the airbag MIL.
LFWX-6470-72028
72-29
Discard
△ Tips:
When dispose vehicle or airbag module, the discarded airbag should be fired, this can eliminate
any risk of burning in certain circumstances. Follow procedure to fire the discarded airbag. In case
of failure in firing discarded airbag, contact service department of Lifan authorized dealer.
Warning:
• Never dispose co-driver’s airbag module not fired.
• It is advisable to fire airbag in places away from community or outdoor, because firing
operation may cause loud sound of bursting.
• The special tool for firing from Lifan should be used to fire discarded airbag. Operate this
in a place far from the electrical interference.
• Any operation of firing should be conducted 10m away from airbag in firing operation.
• The airbag will be hot after fired. Wait for at least 30min before touching.
• Safety gloves and goggle should be worn to handle fired airbag.
△ Tips:
Dispose the co-driver’s airbag in same way of driver’s airbag (See Section 72: Safeguard
Devices - Driver’s Airbag, Disposal).
Clock spring
Replacement
1. 拆卸时钟弹簧
(a). Turn off the ignition switch and disconnect the battery negative cable.
△ Tips:
After disconnecting the battery negative cable, wait for 90s at least before the subsequent
operation.
(b). Set the wheels of the vehicle straight forward.
(c). Remove driver’s airbag module (See Section 72: Safeguard Devices - Driver’s Airbag,
Change). 72
Warning:
Before working on the airbag system, carefully read Chapter 72 Safety protection device -
airbag, precautions.
(d). Remove the steering wheel (refer to 61 -
replacement)
LFWX-6470-72034
(e). Remove steering column cover. (refer to 61

- hydraulic steering system, steering wheel,
replacement)
LFWX-6470-72035
(f). Pry up the catch of the clockspring.

△ Tips:
Mark the clockspring or fix it with adhesive tape for
reusing.
LFWX-6470-72036
(g). Remove the clockspring, disconnect clockspring
connector.
Note:
Do not pull the airbag harness forcedly.
LFWX-6470-72004
72-31
2. Install the clock spring

(a). Confirm that the front wheels of the vehicle are
in the straight ahead position.
(b). Connect clockspring connector.
LFWX-6470-72004
(c). Install catch, and fix the clock spring with it.
LFWX-6470-72036 72
(d). Install steering column cover (refer to 61 -
replacement)
LFWX-6470-72035
(e). Install steering wheel. (refer to 61 - hydraulic

steering system, steering wheel, replacement)
(f). Install driver’s airbag module (See Section 72:
Safeguard Devices - Driver’s Airbag, Change)
(h). Check the front seat airbag module.
(i). Check the airbag MIL.
LFWX-6470-72034
Side safety air curtain

Replacement
1. Remove the side air curtain
(a). Remove roof.
(refer to: 81 - interior trims and exterior trims: roof,
replacement)
(b). Turn off the ignition switch and disconnect the
△ Tips:
After disconnecting the battery negative cable,
wait for 90s at least before the subsequent
operation.
(c). Disconnect curtain air bag connector clip.
LFWX-6470-72066
(d). Remove side curtain air bag fixing bolt.
LFWX-6470-72067
72-33
(e). Remove fixing bolt of side curtain airbag, and

take down the side curtain airbag.
LFWX-6470-72068
Installation
1. Install the side air curtain
(a). Install side curtain air bag and fasten bolt.
Torque:
LFWX-6470-72067 72
(b). Install side curtain air bag fixing bolt.

Torque:
LFWX-6470-72067
(c). Connect side curtain airbag connector clip.

(d). Install roof
(refer to: 81 - interior trims and exterior trims: roof,
replacement)
(e) Connect the battery negative cable.
LFWX-6470-72066
Seat belts
Preparations
S/N Tool External view No Description

1
To remove and install

2 Screw driver the screw and pry the
snap ring etc.
Speed wrench
For tightening or
3 and long/short
release the bolts
extension rod
72-35
Maintenance data
Items N·m
Front seatbelt retractor retaining bolt 50±5
Bolts for front seat belt upper mounting plate 50±5
Front seatbelt upper anchor bolt 50±5
Front seatbelt buckle retaining bolts 50±5
Middle seatbelt retractor retaining bolt 50±5
Middle seatbelt upper anchor bolt 50±5
Middle seatbelt upper anchor bolt 50±5
Middle seatbelt buckle retaining bolts 50±5
Rear seatbelt retractor retaining bolt 50±5
Bolts for rear seat belt upper mounting plat 50±5
Bolts for rear seat belt lower mounting plat 50±5
Rear seatbelt double end buckle retaining bolts 50±5
Precautions
1. Change seatbelt with worn or split webbing and dysfunctional buckle.
2. After collision evolving tension on seatbelt, change the seatbelt, even there is no damage
found on it.
3. It is forbidden to insert anything into the buckle. Never modify or remove the seatbelt.
4. Mild detergent should be used to clean dirty seatbelt. Corrosive detergent, dye and dry
cleaning agent may impair strength of seatbelt seriously.
5. If the webbing of seatbelt is worn, split or floppy due to chemical or sunshine, it must be
changed.
6. If metal joint of seatbelt deformed, distorted or rusted, it must be changed.
7. Performance requirement of the retractor: rewind freely in installed orientation.
72
8. Performance requirement of the adjuster: easy adjustment, hold webbing of seatbelt tightly
and reliable.
9. Performance requirement of the buckle lock: obvious feeling of insertion and release, no self
release. The system should not be failure.
Component drawing
1
1
2
2
3
4 11
8
9 10
14
7
15 12 13
13
LFWX-6470-72037
Front seat belt height adjustment Middle seatbelt buckle assembly -

1 9
device Center
2 Front left seatbelt buckle lock 10 Middle seatbelt buckle assembly - RH
Middle seatbelt retractor assembly -
3 Front seatbelt retractor assembly - LH 11
LH
4 Driver's belt retractor assembly 12 Rear seatbelt retractor assembly - LH
Front seatbelt retractor assembly -
5 13 Rear seatbelt buckle assembly
RH
Rear seatbelt retractor assembly -
6 Front seat belt retractor shield 14
RH
Middle seatbelt retractor assembly -
7 15 Middle seatbelt buckle assembly - LH
LH
Center row middle belt retractor
8
assembly
6-seat version is not equipped with item 8 and 9

72-37
Fault diagnosis
Recommended
Phenomena Questionable part
Measures
Seatbelt can not be extracted 1. Belt retractor assembly (damaged) Replacement
Seatbelt can not be retracted 1. Belt retractor assembly (damaged) Replacement
Seatbelt can not be buckled 1. Belt lock catch (damaged) Replacement
Buckled seatbelt can not be released 1. Belt lock catch (damaged) Replacement
The seatbelt can not stretch quickly with
1. Belt retractor assembly (damaged) Replacement
certain length extracted
1. Fuse (blown) Replacement
2. Instrument cluster (damaged) Replacement
Driver’s seatbelt warning indicator is 3. Driver’s seatbelt buckle (internal
inoperative Replacement
damage)
4. Harness (open circuit or short circuit)
harness or connector
Front row seat belt

Testing
1. Test the seatbelt retractor
(a). The seatbelt can be easily extracted with
constant force.
Note:
If the seatbelt cannot be extracted with constant force, 72
it must be changed.
(b). Sudden force on seatbelt should make it locked
immediately. Do not pull it further in this case.
Note:
If the seatbelt cannot be locked in this case, it must be
changed.
LFWX-6470-72038
2. Check the seatbelt latch

(a). Insert the seatbelt into buckle.
△ Tips:
The lock catch insertion and unlocking should be easy
and reliable; the surface should be smooth without
sharp edges. If the seatbelt can not engage into the
buckle easily, change the buckle and repeat test.
LFWX-6470-72040
(b). Pull the safety belt hard to check whether it is
locked or not.
Note:
If the belt disengages the lock catch while not
unfastened, the belt lock catch must be replaced.
LFWX-6470-72041
(c). The seatbelt should disengage from buckle

when button is pushed down.
Note:
If the seatbelt can not disengage easily from buckle,
change the buckle to eliminte potential danger.
LFWX-6470-72042
72-39
1. Remove front seat belt retractor assembly

(a). Remove front row seat. (refer to 84 - seat - front row seat, replacement)
(b). Remove front/rear door sill cover. (refer to 81 - interior trims and exterior trims - doorsill panel,
removal)
(c). Remove B pillar lower cover. (refer to 81 - interior trims and exterior trims, lower panel,
replacement)
(d). Open front carpet.
(e). Take down left middle foam of carpet.
(f). Up slide upper decoration leather sheath of
safety belt along safety belt.
LFWX-6470-72043
(g). Remove fixing bolts on the lower fixing points of
front safety belt.
Torque: 50±5 N.m
72
LFWX-6470-72045
(h). Remove fixing bolt of front safety belt retractor

and take out the retractor.
Torque: 50±5 N.m
LFWX-6470-72046
(i). Remove B column upper apron. (See Chapter

81 Interior & Exterior – B Column Upper Apron,
Replacement).
(j). Remove retaining nut on fixing point of front
seat belt retractor assembly.
(k). Remove front seatbelt retractor assembly.
LFWX-6470-72047
(l). If height regulator is deformed or damaged,

change it.
LFWX-6470-72065
2. Install front seat belt retractor assembly

(a). Install retaining nut on fixing point of front seat
belt retractor assembly.
Torque: 50±5 N.m
LFWX-6470-72047
72-41
(b). Install front seat belt retractor fixing bolt.

Torque: 50±5 N.m
Note: for the small bolts in the figure, the torque
is 6 ~ 12N.m
(c). Install B pillar upper cover. (See Chapter 81
Interior & Exterior – B Column Upper Apron,
Replacement).
LFWX-6470-72046
(d). Install fixing bolts on the lower fixing points of

front safety belt.
Torque: 50±5 N.m
72
LFWX-6470-72045
(e). Install safety belt decoration leather sheath.

△ Tips:
After installation of seatbelt, check tightening torque
and condition of seatbelt carefully to eliminate
possible injury in emergent cases.
LFWX-6470-72043
(f). Install left middle foam of carpet.

(g). Install front carpet.
(h). Install B pillar lower cover. (refer to 81 - interior trims and exterior trims, lower panel,
replacement)
(i). Install front/rear door sill cover. (refer to 81 - interior trims and exterior trims - doorsill panel,
removal)
(j). Install front row seat. (refer to 84 - seat - front row seat, replacement)
3. Remove front seatbelt buckle
(a). Disconnect front seatbelt buckle connector.
(b). Remove retaining bolt of front seatbelt buckle.
(c). Remove front seatbelt buckle.
4. Install front seatbelt buckle
(a). Install front seatbelt buckle.
(c). Install retaining bolts of front seatbelt buckle and tighten.
Torque: 50±5N.m
(c). Install front seatbelt buckle connector.
Center row seat belt

Testing
△ Tips:
Middle seatbelt retractor and buckle should be tested in same way as front seatbelt. Refer to test
procedure of front seatbelt.
Replacement
△ Tips:
The center row double seat middle belt retractor cannot be removed. To replace this retractor, the
seat must be replaced.
1. Remove middle seat belt retractor assembly
(a). Remove rear door sill cover.
72-43
(b). Remove bolts for connecting lower fixing points

of left and right safety belts with floor.
Torque: 50±5 N.m
LFWX-6470-72051
(c). Remove C pillar lower cover assembly. (refer to

81 - interior trims and exterior trims - side wall
trim assembly, replacement)
LFWX-6470-75022 72
(d). Remove C pillar upper cover assembly. (refer to
81 - interior trims and exterior trims - side wall
trim assembly, replacement)
LFWX-6470-75048
(e). Remove bolts of middle left and right safety

belts on upper fixing points.
Torque: 50±5 N.m
LFWX-6470-72049
(f). Remove connecting bolts of left and right

retractors of middle seat belts and car body, and
take down the retractors.
Torque: 50±5 N.m
LFWX-6470-72053
2. Remove the seat belt latch outside the

middle row double seats
(a). Remove fixing bolt for connecting lock catch and
seat.
(b). Take out the shackle assembly.
Torque: 50±5 N.m
LFWX-6470-72058
72-45
3. Remove the middle row seat belt buckle

(a). Remove the fixing bolt of middle individual seat
belt lock and seat, and take down the lock.
Torque: 50±5 N.m
△ Tips:
Since the seat is removed in advance, the center row
single seat lock catch can be removed with ease.
To remove the center row single seat lock catch
without removing the seat, slide the center row double
seat to the foremost position and the single seat to the
rearmost position to provide the sufficient space for
the removal of center row single seat belt lock catch.
LFWX-6470-72059
2. Mount the middle row belt retractor assembly

Note:
Alway tighten retaining bolts of seatbelt to torque specified. Uniform fine thread is used for
both seatbelt retaining bolts and nuts. Never use bolts with different grade of thread or with
metric thread together.
Rear row seat belt

Testing
△ Tips:
Rear seatbelt retractor and buckle should be tested in same way as front seatbelt. Refer to test
procedure of front seatbelt.
Replacement 72
1. Remove rear seat belt retractor assembly
(a). Remove rear seat belt decorating plate.
LFWX-6470-72060
(b). Remove bolts for connecting safety belts on the

lower fixing points of the rear safety belt with car
body.
Torque: 50±5 N.m
LFWX-6470-72061
(c). Remove bolts for connecting safety belts on the

upper fixing points of the rear safety belt with
car body.
Torque: 50±5 N.m
LFWX-6470-72062
(d). Remove C pillar lower cover. (see Chapter 81 –
Interior & Exterior – Side Wall Decorating Plate,
Replacement)
LFWX-6470-72063
72-47
(e). Remove connecting bolts of rear seat belt

retractor and car body side wall, and take down
the retractor.
Torque: 50±5 N.m
LFWX-6470-72064
2. Install front seat belt retractor

Airbag DTC
DTC list
Faultdescription DTC Diagnostic meter display
Driver's seat front drive configuration
B100224 Driver's seat front drive configuration error
error
Passenger front drive configuration
B100324 Passenger front drive configuration error
error
Driver's seat rear drive configuration
B100424 Driver's seat rear drive configuration error
error
Passenger rear drive configuration
B100524 Passenger rear drive configuration error
error 72
Driver's seat rear sensor fault B100496 Driver's seat rear sensor fault
Passenger seat rear sensor fault B100596 Passenger seat rear sensor fault
Driver's seat rear drive short to ground B100411 Driver's seat rear drive short to ground
Driver's seat rear drive short to power B100412 Driver's seat rear drive short to power
Passenger seat rear drive short to
B100511 Passenger seat rear drive short to ground
ground
Passenger seat rear drive short to
B100512 Passenger seat rear drive short to power
power
ECU internal error B100049 ECU internal error
Front airbag record collision B105000 Front airbag record collision
Driver's side airbag records collision B105100 Driver's side airbag records collision
Passenger side airbag records
B105200 Passenger side airbag records collision
collision
Collision output circuit short to ground B103414 Collision output circuit short to ground
Collision output circuit short to power B103412 Collision output circuit short to power
Driver's seat belt buckle switch open Driver's seat belt buckle switch open
B102012
circuit/short to power circuit/short to power
Driver's seat belt buckle switch short Driver's seat belt buckle switch short to
B102011
to ground ground
Faultdescription DTC Diagnostic meter display

Passenger seat belt buckle switch open Passenger seat belt buckle switch open
B102112
circuit/short to power circuit/short to power
Passenger seat belt buckle switch short Passenger seat belt buckle switch short
B102111
to ground to ground
Passenger airbag deactivation switch Passenger airbag deactivation switch
B102212
open circuit/short to power open circuit/short to power
Passenger airbag deactivation switch Passenger airbag deactivation switch
B102211
short to ground short to ground
Vehicle configuration error B100100 Vehicle configuration error
CAN bus off line U007300 CAN bus off line
IC node off line U015500 IC node off line
ABS node off line U012100 ABS node off line
Driver's seat belt state definition defect B102013 Driver's seat belt state definition defect
Passenger seat belt state definition
B102113 Passenger seat belt state definition defect
defect
Driver's seat monitoring sensor short to Driver's seat monitoring sensor short to
B102312
power power
Driver's seat monitoring sensor short to Driver's seat monitoring sensor short to
B102311
ground ground
Driver's seat position undefined B102313 Driver's seat position undefined
Passenger seat monitoring sensor short Passenger seat monitoring sensor short
B102512
to power to power
Passenger seat monitoring sensor short Passenger seat monitoring sensor short
B102511
to ground to ground
Passenger seat position undefined B102513 Passenger seat position undefined
Collision output circuit 2 short to ground B103411 Collision output circuit 2 short to ground
Collision output circuit 2 short to power B103412 Collision output circuit 2 short to power
PADS DTC undefined B102213 PADS DTC undefined
Only record belt data after the collision B105300 Only record belt data after the collision
Watchdog resetting continuously B105600 Watchdog resetting continuously
Belt protection enabled 6 times Belt protection enabled 6 times
B105400
continuously continuously
Only record preloader data after the Only record preloader data after the
B105700
collision collision
Preloader protection enabled 6 times Preloader protection enabled 6 times
B105800
continuously continuously
72-49
72
Stereo set delight system - Stereo set delight system
73-a
Stereo set delight system

Stereo set delight system ………1
GPS player system ………………4
360 ° all-round vision system …5
Terminal definition …………… 10
Entire audio system not work … 11
Individual speaker not work … 12
Radio/MP5 player component
drawing …………………………… 13
Radio/GPS player component
drawing …………………………… 14
Radio/ MP5 player ……………… 15
Replacement …………………… 15 73
Front/rear door speaker ……… 17
Testing ………………………… 17
Antenna…………………………… 19
Testing ………………………… 19
360 ° all-round vision system 24
73-b Stereo set delight system - Stereo set delight system
73-1
Stereo set delight system

Preparations
Measure the
Digital universal
1 voltage and
meter
resistance
Install/remove
2 Screw driver screws, pry up
panels
73
3 Wiring group Testing circuit
73-2 Stereo set delight system - Stereo set delight system
Precautions
△ Tips:
Radio wave received by the antenna
1. Coverage zone
Coverage range of AM broadcast is significantly large than that of FM broadcast system. High
resolution AM broadcast can be received in areas where there is no FM signal. Beside smaller
reception area, there always is squelch and other noise in stereo FM signal in some location.
2. Reception problem
Besides squelch, the interference, multiplex transmission and attenuation exists too. This is due to
problem of radio wave itself, that is irrelevant to electrical noise.
(a). Interference
Besides squelch, the AM broadcast receives other type of noise, especially at night. This is due to
reflection of AM radio wave by the Ionosphere. The reflected wave interferes with that the antenna
received directly from the same signal source. This is known as Interference.
(b). Multiplex transmission
The radio reflected by obstacles is known as multiplex transmission. High building or mountain
may reflect radio signal transmitted by emitting antenna of broadcast, this may interfere with other
signals, causing multiplex transmission.
(c). Attenuation
The FM wave is more likely be reflected by high buildings or mountain due to its higher frequency
than AM wave. For this reason, always the FM is likely to disappear gradually, or can not be
received due to blockage of vehicle by obstacles. This is known as attenuation.
3. Information of AM/FM broadcast channel will be eliminated when negative cable of battery
disconnected. Before disconnect negative cable of battery, you can record channel
informations for resetting after the cable would be connected.
4. Make sure the ground cable is fixed securely after removal and installation of the antenna
assembly.
△ Tips:
Poor ground link of antenna may cause noise in broadcast signal reception. A new antenna can not
even correct this problem
5. Don’t touch paper basin of the speaker.
73-3
Component drawing
13 1
2
1 14 10
2
3
12 6
15
11
4
6
5
6 15 7
8
2
7
6
9
LFWX-6470-73001 73
1 Tweeter assembly 9 Rear view camera assembly

Cross recessed pan head self-tapping
2 10 Radio antenna feeding wire assembly
screw
Entertainment system control panel
3 Radio/GPS player assembly 11
assembly
4 Feeding wire of data port 12 Radio/GPS player wire
5 13 Vehicle inside monitoring camera system
screw –C type
Cross recess big half round self-tapping
6 Front speaker 14
screw
7 Snap button 15 Cross recessed pan head screw
8 Radio antenna assembly 16 Data port
GPS player system
4
6
1
11
7 12
12
11
10
10
1 GPS player assembly 7 Feeding wire of data port

2 8 Data port
screw
GPS player assembly mounting
3 9 Front speaker
bracket
Cross recess big half round self-
4 10 Center speaker
tapping screw
GPS player assembly mounting Cross recessed pan head self-tapping
5 11
bracket cover screw –C type
6 GPS antenna assembly 12 Snap button
73-5
360 ° all-round vision system
4
2 5
1 3
6
73
All-round vision front camera

1 5 All-round vision left camera assembly
assembly
2 6 All-round vision rear camera assembly
screw
All-round vision system controller
3 7 All-round vision right camera assembly
assembly
4 Hexagon flange nut
Multimedia system
Cab central electrical control box
Reverse camera Diagnostic

interface
Automobile data recorder
Video signal Signal GND Power ground Power supply
ACC power
supply
Multimedia system
Backlight power
output Backlight Left front Left front Right front Right front Left rear Left rear Right rear Right rear Steering Steering
power input speaker+ speaker- speaker+ speaker- speaker+ speaker- speaker+ speaker- wheel signal 1 wheel signal 2
Clock spring
Circuit drawing
To RBCM B10
pin 12
Horn relay To backlight Instrument cluster
control line system screen switch
signal
To
backlight
system
Left front Left tweeter Right front Right tweeter Left rear Right rear
speaker speaker loudspeaker loudspeaker
73-6
73
73-7
id 图和 pdf
图不一样
(17)

ACC B+
BCANL BCANH BCANH BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL
4 L4 5 L4 2 L4 3 L4 6 L4 1 L4 3 I01 11 I01 9 R7 4 R7 6 R7 10 R7 8 R7 2 R7 5 R7 3 R7 1 R7
FS21
FS29
10A
10A
0.5 BW
0.5 RBl
0.5 RW
0.5 BW
0.5 RBl
0.5 Bl
0.5 BW
0.5 RBl
3 LB2 8 LB2 3 LB2 2 LB2

3 LB2 8 LB2 3 LB2 8 LB2
3 1D 12 1F
3 BL2 8 BL2 3 BL2 2 BL2 3 BL2 8 BL2 3 BL2 8 BL2
3 I1D 12 I1F
0.5 BW
0.5 RBl
0.5 B/G
0.5 RW
0.5 B/Y
0.5 W
0.5 Bl
0.5 Bl
0.5 G
0.5 O
0.5 R
0.5 B
0.5 Y
0.30 WB
0.30 W
1.25 VW
10 BI2 5 BI2 4 BI2 9 BI2 10 BI2 5 BI2 4 RI2 3 RI2 2 RI2 1 RI2 10 RI2 9 RI2 8 RI2 7 RI2 6 RI2
0.5 VY
10 IB2 5 IB2 4 IB2 9 IB2 10 IB2 5 IB2 4 IR2 3 IR2 2 IR2 1 IR2 10 IR2 9 IR2 8 IR2 7 IR2 6 IR2
0.5 BW
0.5 RBl
0.5 RW
0.5 B/G
0.5 B/Y
0.5 Bl
0.5 W
0.5 Bl
0.5 G
0.5 O
0.5 R
0.5 B
0.5 Y
4 I17 7 I17 9 I16 10 I16 5 I16 6 I16 1 I16 3 I16 12 I16 13 I16 14 I16 15 I16 16 I16 17 I16 18 I16 19 I16 20 I16
ACC B+ RVC_CVBS- RVC_POWER- AUDIO_GND AUDIO_IN ACC UART-RX VIDIO_GND GND UART-TX VIDEO_IN POWER+12V
RVC_CVBS+ RVC_POWER+

+ - + - + - + - 1 2
REVERSE
11 I16 3 I17 6 I17 13 I17 14 I17 11 I17 12 I17 15 I17 16 I17 9 I17 10 I17 8 I17 1 I17 2 I17
0.50 O/B
0.50 W/B
0.50 Bl/W
0.50 V/B
0.50 Y/B
0.50 R/W
0.50 W/Y
0.50 W
0.30 Bl
0. 5 B
0.50 O
0.50 V
0.50 Y
2 IB2
2 BI2
23 ID1 22 ID1 13 IK1 12 IK1 20 IB1 13 IB1 2 IG1 3 IG2
23 DI1 22 DI1 13 KI1 12 KI1 20 BI1 13 BI1 2 GI1 3 GI2 7 I18 5 I18
0.85 B

11 I18 I18 9 10I18 8 I18
2 BM 1 BM 2 GN 1 GN
0.50 W/B
0.50 W/B
0.50 O/B
0.50 O/B
0.50 P/W
0.50 W
0.50 W
0.50 O
0.50 O
2 MB 1 MB 2 NG 1 NG
0.50 B
0.3 Bl
0.3 w

RBCM B10 12

1 D9 2 D9 1 I02 2 I02 1 K6 2 K6 1 I45 2 I45 1 M2 2 M2 1 N2 2 N2
G28 G28 G21

()
id 图和 pdf
图不一样

ACC B+
BCANH BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL BCANL
360 3 I01 11 I01 9 R7 4 R7 6 R7 10 R7 8 R7 2 R7 5 R7 3 R7 1 R7
FS37
FS41
10A
10A
17 I54 18 I54 10 I54 9 I54

3 1D 12 1F
3 I1D 12 I1F
0.5 B/G
0.5 B/Y
0.5 W
0.5 Bl
0.5 G
0.5 O
0.5 R
0.5 B
0.5 Y
0.30 WB
0.30 W
1.25 VW
0.5 BrW
0.5 BW
4 RI2 3 RI2 2 RI2 1 RI2 10 RI2 9 RI2 8 RI2 7 RI2 6 RI2

0.5 VY
0.5 Br
0.5 W
4 IR2 3 IR2 2 IR2 1 IR2 10 IR2 9 IR2 8 IR2 7 IR2 6 IR2
0.5 B/G
0.5 B/Y
0.5 W
0.5 Bl
0.5 G
0.5 O
0.5 R
0.5 B
0.5 Y
4 I17 7 I17 10 I16 9 I16 8 I16 7 I16 1 I16 3 I16 12 I16 13 I16 14 I16 15 I16 16 I16 17 I16 18 I16 19 I16 20 I16
ACC B+ AUDIO_GND AUDIO_IN ACC UART-RX VIDIO_GND GND UART-TX VIDEO_IN POWER+12V

+ - + - + - + - 1 2
REVERSE
11 I16 3 I17 6 I17 13 I17 14 I17 11 I17 12 I17 15 I17 16 I17 9 I17 10 I17 8 I17 1 I17 2 I17
0.50 O/B
0.50 W/B
0.50 Bl/W
0.50 V/B
0.50 Y/B
0.50 R/W
0.50 W/Y
0.50 W
0.30 Bl
0. 5 B
0.50 O
0.50 V
0.50 Y
2 IB2
2 BI2
23 ID1 22 ID1 13 IK1 12 IK1 20 IB1 13 IB1 2 IG1 3 IG2
23 DI1 22 DI1 13 KI1 12 KI1 20 BI1 13 BI1 2 GI1 3 GI2 7 I18 5 I18
0.85 B

11 I18 I18 9 10I18 8 I18
2 BM 1 BM 2 GN 1 GN
0.50 W/B
0.50 W/B
0.50 O/B
0.50 O/B
0.50 P/W
0.50 W
0.50 W
0.50 O
0.50 O
2 MB 1 MB 2 NG 1 NG
0.50 B
0.3 Bl
0.3 w

RBCM B10 12

1 D9 2 D9 1 I02 2 I02 1 K6 2 K6 1 I45 2 I45 1 M2 2 M2 1 N2 2 N2
G28 G28 G21

73-8
73
73-9
360()
B+ B+

FS18
FS42
RBCM MP5

10A
5A
BCANH BCANL

12 B10 15 I16 14 I16 10 I16 9 I16 3 I01 11 I01
1 1C 1 1D
1 I1C 1 I1D
0.5 BW
0.5 YG
0.5 RY
0.5 BlW
0.5 RBl
0.5 VW
0.5 WB
0.5 RG
0.5 W
0.5 W
39 I54 40 I54 25 I54 26 I54 23 I54 24 I54 17 I54 18 I54 36 I54 35 I54
DVD- DVD+
360
+ + + +
1 I54 2 I54 3 I54 4 I54 5 I54 6 I54 7 I54 8 I54 9 I54 10 I54 11 I54 12 I54 29 I54 30 I54 13 I54 14 I54 15 I54 16 I54 31 I54 32 I54 38 I54
0.5 GW
0.5 GBl
0.5 GR
0.5 GY
IB2 IB2 IB2 IB2
0.5 GrW
10 5 9 4
0.5 GrBl
0.5 BrBl
0.5 GrR
0.5 GrB
0.5 BrR
0.5 BrB
0.5 YW
0.5 PBl
0.5 YBl
0.5 BrW
0.5 YR
0.5 PB
0.5 PY
0.5 YB
0.5 PW
0.5 B
10 BI2 5 BI2 9 BI2 4 BI2
0.5 GW
0.5 GBl
0.5 GR
0.5 GY
11 IU1 12 IU1 13 IU1 14 IU1 10 ID2 5 ID2 9 ID2 4 ID2 8 ID2 3 ID2 10 IK2 5 IK2 9 IK2 4 IK2 8 IK2 3 IK2
11 UI1 12 UI1 13 UI1 14 UI1 10 ID2 5 ID2 9 ID2 4 ID2 8 ID2 3 ID2 10 IK2 5 IK2 9 IK2 4 IK2 8 IK2 3 IK2
4 BL2 9 BL2 3 BL2 8 BL2
4 LB2 9 LB2 3 LB2 8 LB2
0.5 BrBl
0.5 BrR
0.5 BrB
0.5 YW
0.5 PBl
0.5 YBl
0.5 GrW
0.5 BrW
0.5 GrBl
0.5 YR
0.5 PY
0.5 PB
0.5 YB
0.5 GrR
0.5 GrB
0.5 GW
0.5 GBl
0.5 PW
0.5 GR
0.5 GY
id 图和 pdf
4 U33 3 U33 1 U33 2 U33 4 L4 3 L4 1 L4 2 L4 4 D10 3 D10 1 D10 2 D10 6 D10 5 D10 4 K7 3 K7 1 K7 2 K7 6 K7 5 K7
图不一样

+ +
G13
Terminal definition I17 MP5 assembly 2
I16 MP5 assembly 1
Terminal Wire size/

Fuction
No. color
Terminal Wire size/ 1 0.5/WY Steering wheel signal 1
Fuction
No. color
2 0.5/RW
1 NC
3 0.5/B Lamp control signal -
2 NC
4 0.5/VY ACC
3 NC
5 NC
4 NC
6 0.3/Bl Lamp control signal +
5 0.5/RW RVC_POWER+
7 1.25/VW B+
6 0.5/Bl RVC_POWER-
8 0.85/B Grounding
7 NC
9 0.5/V Right rear speaker (+)
8 NC
10 0.5/VB Right rear speaker (-)
9 0.5/RBl RVC_CVBS+
11 0.5/O Right front speaker (+)
10 0.5/BW RVC_CVBS-
12 0.5/OB Right front speaker (-)
11 0.5/BlW REVERSE
13 0.5/W Left front speaker (+)
Driving audio signal screen
12 0.5/BG 14 0.5/WB Left front speaker (-)
ground
13 0.5/Y Driving audio signal 15 0.5/Y Left rear speaker (+)
Driving recorder ACC 16 0.5/YB Left rear speaker (-)
14 0.5/R
signal
Driving recorder
15 0.5/Bl
communication receiving
Driving video signal screen
16 0.5/BY
ground
Driving video power
17 0.5/B
ground
Driving recorder
18 0.5/G
communication sending
19 0.5/W Driving video signal
20 0.5/O Driving video power +
I47 Connect to the active antenna
Terminal Wire size/

Fuction
No. color
1 0.5/VW Active antennae power
73-11
Fault diagnosis
Fuse (blown) Replacement
Harness (open circuit or short Repair or replace the harness or
Entire audio system not work
circuit) connector
Radio (damaged) Replacement
Harness (open circuit or short Repair or replace the harness or
circuit) connector
malfunction of individul speaker
Speaker (damaged) Replacement
Radio (damaged) Replacement
Change the environment or replace
Aerial receiving failure
the aerial assembly
Check connection of harness
Loose harness connector
Radio on, poor quality connector
Check and repeat installation of the
Speaker incorrectly installed
speaker
Radio damage Replacement
Repair or replace the harness or
Poor connection of speaker wiring
Low volume under all mode connector
Change the environment or replace 73
Antenna Receiver
Received no broadcast the aerial assembly
Entire audio system not work

Steps Diagnosis Yes No
Check the system
• Be sure the power supply system is OK.
1 Go to Step 2
• When the power supply at ACC position, check for normal
oepration of audio system.
Check the fuse
2 • Remove the instument panel, open the fuse block cover. Go to Step 5 Go to Step 3
• check audio system fuse FS21, FS29.Is anyone blown?
Check the power circuit for open circuit or short circuit
Repair or
• Turn on the radio player.
3 replace the Go to Step 4
• Measure voltage between terminal 4/7 of I17 and ground with
radio
digital multimeter. Is there the battery voltage?
Check the harness
4 Go to Step 6
• Repair harness with fault or change as required.
Replace fuse
5 • Before replacement of blown fuse, any fault in the circuit should Go to Step 6
be eliminated, and then replace with 10A fuse.
6 Check whether the fault is solved and finish the diagnosis.
Individual speaker not work

Inspect the system (taking the LF door speaker as example)
1 • Ensure the power supply system is normal. Go to Step 2
• Turn on the player. Does speaker operate normally?
Check for open circuit
• Check for continuity between terminal 1 of D9 and terminal 13 of
2 Go to Step 3 Go to Step 5
I17, and that between terminal 2 of D9 and terminal 14 of I17 with
a multimeter that set in Ohm position.
Check the lines for short circuit
3 • Check for continuity between terminal 1 and 2 of D9 with a Go to Step 5 Go to Step 4
multimeter that set in Ohm position.
Inspect the speaker
• Remove front left door cover and disconnect front left door
Repair or
speaker connector.
4 replace the Go to Step 6
• Connect battery between two terminals of front left door speaker
radio
for a very short time and then disconnect. Dose the speaker
sound?
Check the harness
5 Go to Step 7
• Repair or replace the faulty harness.
Change the speaker
6 Go to Step 7
• Refer repair procedure in Service Manual to change speaker.
△ Tips:
Referring to Operation Manual of Lifan Xuanlang, inspect function of on board radio/CD player,
meanwhile check for any abnormality of sound emitted by the speaker, to determine cause of fault
primarily and eliminate possibility of misoperation
73-13
Radio/MP5 player component drawing
LFWX-6470-73002
73
1 Home 7 Setting
2 Android mobile connection 8 Volume/power
3 Upward selection/skip backward 9 Apple mobile telephone SIRI function
4 Downward selection / skip forward 10 Answer the call
5 Mode 11 Break talk
6 Radio 12 Touch display
Radio/GPS player component drawing
1 Main menu 7 Navigation key

2 Android mobile connection 8 Volume/power
3 Upward selection/skip backward 9 Setting key
4 Downward selection / skip forward 10 Answer the call
5 Mode 11 Break talk
6 Radio 12 Touch display
73-15
Radio/ MP5 player

Replacement
Description:
The method to replace MP5 and GPS player assembly is the same. Now we take MP5 player
replacement as an example.
1. Preparation before change
(a). Record channel setting of the radio/player.
Note:
The flat blade screw driver wound by adhesive tape must not be used. It can damage the
dashboard panel.
2. Remove the radio/MP5 player
(a). Remove MP5 decorating cover plate, center air
output and MP5 button panel. Slowly turn over
and take down the decorating cover plate after
disconnecting connectors between panel and
MP5.
△ Tips:
Pry MP5 decoration cover plate open with the slotted
head screwdriver covered by the tape to prevent
damaging any component
LFWX-6470-73003
73
(b). Remove the fastening screw for connecting
radio//MP5 player and instrument board, slowly
turn out, and take out the player after disconnect
the back connector of the player.
Note:
The radio/P5 player is test by qualified specialist.
No other ones may disassemble it.
△ Tips:
Damaged radio/MP5 player can be determined
indirectly through replacing the suspected one with a
functional one.
LFWX-6470-73017
3. Install the radio/MP5 player

(a). Connect radio/digital player connector and
antenna connector, position the radio/digital
player body.
Note:
Connect the connector; a "click" sound issued
indicates that it is connected in place.
(b). Install 4 screws of radio/MP5 player body and
tighten.
△ Tips:
Route the harness smoothly to prevent pinching
during installation.
LFWX-6470-73017
(c). Connect the connector between MP5 button

panel and MP5 player, and install radio/MP5
player decorating cover plate.
△ Tips:
Put on the radio/MP5 player panel and push it with
your hands until seat properly. Hard items should not
be used to knock the panel.
(d). After installation of radio/MP5 player, install
central control switch and glove box in turn.
LFWX-6470-73003
73-17
Front/rear door speaker

△ Tips:
Test and replacement of rear door speaker should be conduct in same way of the front door
speaker. Please refer to procedure of front door speaker test and replacement.
Testing
1. Test of components
(a). Check for continuity between terminals 1 and
2 of the speaker by using multimeter.If not,
change the speaker.
LFWX-6470-73004
(b). Or connect battery between two terminals of

front/rear door speaker.
Status: humming
Note:
The battery must not be connected between
terminals of horn for any longer time. If it is not 73
the case above, change the component.
LFWX-6470-73005
Replacement
1. Disconnect the battery negative cable
2. Remove door inner cover assembly. (See
81 – Interior & Exterior, Door inner trim,
Replacement)
3. Remove the door speaker.
(a). Release door speaker connector.
LFWX-6470-73006
(b). Remove 3 self-tapping screws of door speaker.

(c). Remove the door speaker.
Note:
Don’t touch paper basin of the speaker with your
hand.
LFWX-6470-73007
4. Mount the door speaker

(a). Install door speaker on installation site.
(b). Install 3 self-tapping screws of door speaker and
fasten them.
LFWX-6470-73007
73-19
(c). Reconnect door speaker connector.

Note:
5. Install door inner cover assembly.
6. Connect the battery negative cable
7. Turn on audio system, check function for
door speaker
LFWX-6470-73006
Antenna
Testing
1. Test the antenna
(a). Disconnect power line of antenna, measure
resistance between power line and ground of
the antenna by using a digital multimeter set on
200Ω position.
Resistance value: infinity
73
LFWX-6470-73008
(b). Measure resistance between antenna connector
terminal and ground of the by using a digital
multimeter set on 200Ω position.
Resistance value: zero
△ Tips:
If it is not case above, the power line or antenna may
be short circuit. Change the power line or antenna
assembly.
Note:
• Only measurement in which probe of digital
multimeter contact metal part of the antenna
terminal is valid.
• This is a schematic diagram. In practice, one end
should be treated as ground side, while measure
LFWX-6470-73009 continuity between the other end and ground.
Replacement
1. Disconnect the battery negative cable
2. Remove the radio/MP5 player
3. Remove the antenna assembly
(a). Disconnect antenna feeder connector (the
last disassembly step of MP5 is to disconnect
antenna feeder and MP5).
(b). Remove right A column upper apron.
(c). Remove the fascia console assembly (See
Section 81: Fascia Console and Auxiliary Fascia
Console - Auxiliary Fascia Console, Change).
LFWX-6470-73010
(d). Take off clips that fixing antenna power line on
right A-pillar.
LFWX-6470-73011
(e). Remove ceiling trim

cover (See Section
81: Internal & External
Trim - Hand Rail and
Ceiling, Change).
(f). Remove clips that
fixing antenna power
line on ceiling.
LFWX-6470-73012
73-21
(g). R e m o v e
retaining
screws of
the antenna
assembly.
LFWX-6470-73013
(h). Remove antenna assembly and the power line.
73
LFWX-6470-73015
4. Install the antenna assembly

(a). Position antenna properly.
(b). C o n n e c t
a n t e n n a
power line
and antenna
connector,
install retaining
screw and
tighten. Install
the antenna
assembly on
roof.
LFWX-6470-73013
(c). R o u t t h e
antenna power
line smoothly,
attach the fixing
clips on roof.
(e). I n s t a ll c e il i n g
trim cover
(See Section
81: Internal &
E x t e r n a l Tr i m
- Hand Rail
and Ceiling,
Change).
LFWX-6470-73012
(e). Attach fixing clips of power line on A-pillar.
LFWX-6470-73011
73-23
(f). Install the fascia console assembly (See

Section 81: Fascia Console and Auxiliary Fascia
Console - Auxiliary Fascia Console, Change).
(g). Install right A-pillar trim panel.
LFWX-6470-73010
(h). Install antenna connector on radio/MP5 player.

5. Install the radio/digital player body
6. Connect negative cable of battery, turn on
the audio system to test function.
73
LFWX-6470-73014
360 ° all-round vision system

Replacement
1. Remove surround view video camera
component
(a). Remove front bumper. (See Section 81 - Internal
& External Trim - Front Bumper, Change)
(b). Disconnect the connector clip of front surround
view video camera.
LFWX-6470-73020
(c). Remove fastening screw of front surround view

video camera, and take out the front surround
view video camera.
LFWX-6470-73021
2. Remove left/right all-round vision camera

component
(a). The replacement of left/right all-round vision
camera is almost the same. Here is the example
of left camera.
(b). Remove left front door inner trim. (refer to 81 -
interior trims and exterior trims, front left door
panel, replacement)
(c). Disconnect the connector clip of the left
surround view video camera component and left
outer rearview mirror.
(d). Remove the left outside rear-view mirror. (See
83 – Power Window, Rear-view Mirror, Sunroof
System, Rear-view Mirror, Replacement)
(e). Take down surround view video camera.
LFWX-6470-73022
73-25
3. Remove rear surround view video camera

component
(a). Remove rear license plate assembly. (refer to
81 - interior trims and exterior trims, rear license
plate assembly, replacement)
(b). Disconnect the connector clip of rear surround
view video camera component.
(d). Take out rear surround view video camera
component.
LFWX-6470-73023
4. Remove rear surround view video camera

component
(a). Remove main body assembly on instrument
panel. (refer to 83 - dashboard and auxiliary
instrument system, dashboard upper body
(b). Disconnect the connector clip of surround view
system controller.
(c). Inspect the retaining nut of surround view
system controller, and take out the surround
view system controller.
73
LFWX-6470-73024
5. Install rear surround view video camera

component
(a). Install surround view system controller on
installation site, and install and fasten its
retaining nut.
(b). Connect the connector clip of surround view
system controller.
(c). Install main body assembly on instrument board.
(refer to 83 - dashboard and auxiliary instrument
system, dashboard upper body assembly,
replacement)
LFWX-6470-73024
6. Install rear surround view video camera

component
(a). Install rear surround view video camera on
installation site, and connect its connector clip.
(b). Install rear license plate assembly. (refer to 81
- interior trims and exterior trims, rear license
plate assembly, replacement)
LFWX-6470-73023
7. Install left/right all-round vision camera

component
(a). The replacement of left/right all-round vision
camera is almost the same. Here is the example
of left camera.
(b). Install left surround view video camera
component on installation site, as well as left
outer rearview mirror. See (83 – Power Window,
Rearview Mirror and Sunroof System)
(c). Connect the connector clip of left outside rear-
view mirror and left surround view video camera
component.
(d). Install left front door inner trim. (refer to 81 -
interior trims and exterior trims, front left door
panel, replacement)
LFWX-6470-73022
8. Mount the front view camera

(a). Install front surround view video camera on
bolt.
(b). Install front bumper. (See Section 81 - Internal &
External Trim - Front Bumper, Change)
LFWX-6470-73021
Driver information system - Driver information system 74-a
Driver information system

Driver information system ………1
NOTE ………………………………2
Terminal definition ………………7
Instrument cluster ……………… 16
Combination switch …………… 19
74
74-b Driver information system - Driver information system
Driver information system - Driver information system 74-1
Driver information system

Preparations

1
For screw and panel

2 Short screw driver
removal 74
Conductor
3 Testing circuit
assembly
74-2 Driver information system - Driver information system
NOTE
4
4
4
2
1
120
！
0
LFWX-6470-74001
S/N Symbol Name NOTE
Arrow on instrument panel (in green) and left steering

1 Left steering indicator
lamp will flash when left steering indicator turns on.
This indicator shows status of vehicle low beam

lamp. This indicator lights when low beam turns on,
3 Low beam light indicator indicating that the vehicle is in low beam operating
status. Once the low beam turn off, the indicator turns
off.
This indicator shows status of vehicle high beam. This
High beam light indicator lights when high beam turns on, indicating
4
indicator that the vehicle is in high beam operating status.
Once the high beam turns off, the indicator turns off.
This indicator shows operation status of rear fog

5 Rear fog light indicator lamp. It lights once the rear fog lamp turns on. Once
the the rear fog lamp turns off, this indicator turns off.
This indicator shows status of vehicle lamplet. This

indicator lights when lamplet turns on, indicating that
6 main lighting switch
the vehicle is in lamplet operating status. Once the
lamplet turns off, the indicator turns off.
Arrow on instrument panel (in green) and right

7 Right steering indicator steering lamp will flash when right steering indicator
turns on.
This indicates illuminates when ignition at “ON/IG

Engine OBD system
8 ON” position. With engine started, it turns off. If not,
fault indicator
emission control system of engine is defective.
Unbuckled driver’s If the driver’s seatbelt is not buckled when ignition

9 seatbelt warning at “ON/IG ON” position, the warning indicator
indicator illuminates.
Front row occupant belt If the co-driver’s seatbelt is not buckled when
10 unfastening warning ignition at ON position, the warning indicator
lamp illuminates.
Charging system This indicator turns off with engine started. If not, the
11
warning light battery or charging system is defective.
This indicator shows operation status of ABS. With

ignition at “ON/IG ON” position, the ABS indicator
Anti-lock brake system
13 illuminates for several seconds during self-check
warning indicator
of vehicle, then turns off. If this indicator illuminates
continuously, the ABS is defective.
This indicator shows operation status of airbag. With
ignition at “ON/IG ON” position, the airbag warning
14 Airbag warning indicator indicator illuminates for several second during self-
check of vehicle and then turns off. If not, the airbag
is defective.
This indicator shows fuel level of vehicle. With ignition 74
at “ON/IG ON” position, the fuel warning indicator
15 Fuel warning indicator illuminates for several second during self-check
of vehicle and then turns off. If this indicator still
illuminates with engine started, fuel is short in vehicle.
This indicator illuminates when any single door open,

16 Door Open Indicator
and turns off when all doors are closed.
This indicator shows engine coolant temperature.

With ignition at “ON/IG ON” position, this indicator
illuminates for several second during self-check of
Coolant temperature
17 vehicle, then turns off. If the coolant temperature
warning indicator
warning indicator always illuminates, temperature of
engine coolant is above threshold value, stop driving
the vehicle immediately as possible.
With ignition switch at “ON/IG ON” position, this
indicator illuminates for 3-4 seconds for system self-
Brake system warning check, and then turns off if no fault detected. If the
19
indicator indicator does not turn off after self-check, or turns on
during driving, the brake system is defective or brake
fluid level is low.
Over speed (above The indicator illuminates when vehicle speed exceed
20 120km/h) warning 120km/h to arouse attention of the driver. Once speed
indicator is below 120km/h, the indicator turns off.

Vehicle repair warning indicator illuminates during self-check and then turns
21
lamp off. If it keep illuminating, the electronic engine control
system is defective.
This indicator shows status of park brake. It is
normally extinguished. Once the park brake applied,
Park brake warning
22 the indicator turns on automatically. Once the park
indicator
brake released, the indicator turns off automatically. If
not, repair as required.

indicator illuminates during self-check and turns
Oil pressure warning off once engine started. If this indicator illuminates
23
indicator continuously, engine oil pressure is lower than
specification. Turn off engine and have the vehicle
repaired by Lifan authorized service station.
Flashing of ESP (Vehicle Stability Control system)
ON indicator shows that the ESP is operating. If this
24 ESP operation indicator
indicator illuminates during driving, the ESP system is
defective.
Flashing of ESP (Vehicle Stability Control system)

25 ESP OFF indicator
OFF indicator show that the ESP is off.
If there is consecutively three times of lock/unlock,

ESCL malfunction
26 the controller emits alert and the ESCL malfunction
warning indicator
warning indicator illuminates, till the alert disappear.
If this indicator illuminates during driving, power

Electric power steering
27 steering system is defective. Contact Lifan authorized
system indicator
service station for repair.
In case of failure, the PEPS (keyless entry system)

PEPS malfunction
28 controller emits alert and the PEPS malfunction
warning indicator
warning indicator illuminates, till the alert disappear.
The tire pressure warning indicator illuminates when

Tire pressure warning
29 one or more tire(s) pressure low or there is air leaking
indicator
during driving.
Hazard warning When hazard warning indicator switch is pushed, all

30
indicators steering lamp and indicators flash.
Front fog lamp

31 Turn on front fog lamp to light the front fog lamp.
indicators
Anti-theft Alarm With the immobilizer active, the immobilizer LED lamp
32
Indicator will blink slowly and the engine cannot start.
PEPS malfunction During the vehicle running, the indicator lamp will be
33
indicator (if equipped) on and the EPB fault will occur.
△ Tips:
• The seatbelt indicator is set on display.
• When inspect the cluster, primary check can be conduct referring description above.
Component drawing
74
LFWX-6470-74002
Dashboard switch assembly 8 Combination switch assembly

1
Dashboard switch assembly 9 Hexagon flange nut
2 10 Hexagon flange nut
screw – c type
3 Start button assembly 11 Driver cabin center controller box
4 Onboard power port Quick fuse
5 Data Interface Quick fuse
6 Instrument panel Quick fuse
11-1
7 Quick fuse
screw – c type
Combination switch assembly Quick fuse
8
Combination switch assembly
Component drawing
1 3
1 Electrical park brake witch 4 Combination switch assembly

2 5 Driver cabin center controller box
screw
3 Dashboard switch assembly
Terminal definition
I07 Connect to the combination instrument
I23 to one-touch start switch assembly
Terminal Wire size/

No. color Fuction
No. color
1 0.3/WR IMMO antenna -
1 0.3/YB PCAN_L
2 0.3/GW IMMO antenna +
2 0.3/Y PCAN_H
3 0.3/GBI Start the button switch 1
3 0.3/GBl Parking signal
4 0.3/GBR Start button ground wire
4 NC
5 0.3/GW LED power supply
5 NC
6 0.3/WV Green lamp power
6 0.3/GR Fuel signal
7 0.3/BBl Fuel signal GND
8 0.3/WG Start the button switch 2
8 NC
I04 Connect to the instrument switch 9 NC

74
components 10 0.3/WR Charge indicator
11 0.3/WB BCAN_L
8 7 6 5 4 3 2 1 12 0.3/W BCAN_H
16 15 14 13 12 11 10 9 13 0.5/B GND
14 NC
Terminal Wire size/
Fuction
No. color 15 0.5/R B+
Instrument switch assembly 16 0.5/RY IG1
1 0.5/R
B+ Driver's belt unfastening
17 0.3 /GB
indicator lamp
2 NC
18 NC
3 NC
19 NC
4 0.5/B Signal GND
20 NC
5 NC
21 NC
6 0.5/B Grounding
22 NC
7 0.5/RG Hatch switch signal
23 NC
8 0.3/Bl Background light power
24 0.3/G Front fog light indicator
The power of the dipped
9 0.5/GY 25 NC
headlight
26 NC
10 0.5/GR Analogue alignment signal
27 NC
11 NC
28 0.3/Bl Oil pressure sensor
12 0.5/PBl PWM-OUT
Instrument cluster screen
13 NC 29 0.3/W
switch signal
14 NC 30 0.3/P Brake alarm
15 0.5/B Grounding Front seat belt unfastened
31 0.3/O
indicator lamp
16 NC
Front seat pressure sensor
32 0.3/BW
signal
I21 Connect to the combination switch
9 10 11 12 13 14 15 16
1 2 3 4 5 6 7 8
Terminal Wire size/

Fuction
No. color
1 NC
2 NC
3 NC
4 0.3/Bl Fog switch
5 0.3/YBr Turn lamp switch
6 NC
7 NC
8 NC
9 0.3/WG Dimming switch
10 0.3/Br Lamp switch
11 0.3/WR Analog switch ground
12 0.3/GR Wiper intermittent switch
13 0.3 /GB Rear wiper switch
14 0.3/GW Front wiper switch
15 NC
16 NC
I33 Connect to the car power supply -
Terminal Wire size/

Fuction
No. color
1 1.25/B Grounding
I33 Connect to the car power supply +
Terminal Wire size/

Fuction
No. color
1 1.25/WY ACC+
Circuit drawing
Reverse lamp on-board power
supply system

/
？？？？

ACC IG1 B+

B+
FS 35
FS 28
FS 24
7.5A
15A
10A
FS25
10A
1 1D 14 1D 1 1E
1 I1D 14 I1D 1 I1E

0.85 R
0.85 R
3 I06 1 I06 14 1C
14 I1C

0.5 R
4 I06 2 I06 1 I04
B+

1.25 WY
0.85 GO

0.5 Br
PWM -O UT
4 I04 6 I04 15 I04 7 I04 8 I04 9 I04 10 I04 12 I04
0.5 PBl
0.5 GY
0.5 GY
0.5 PBl
0.3 Bl
Power
I32 35 IU1
interface
35 UI1
3 IU1
27 IU1 26 IU1 3 IB1 0.3 Bl
2 I11
3 UI1
I33
0.5 B
27 UI1 26 UI1 3 BI1
0.5 B
0.5 B
FBCM
0.5 PBl
0.85 GY
0.5 GY
0.85 GY
0.5 GY
4 IB1 6 IG1
0.85 GO
8 U17 12 U17 9 U17 8 U8 12 U8 9 U8

0.5 GO
3 IU1 + + + +
4 BI1 6 GI1
0.5 Br

0.5 GO
- - - -

0.5 GO
3 UI1 1 U17 5 U17 1 U8 5 U8
14 U17 14 U8

16 ID1 6 BM1 15 IK1 6 GN1
0.5 BlO
4Rear
B8 left 7 U17 7 U8
20 UE1 19 UE1 combination 2 BL2 3 BG

8 I09 6 I17 9 I18 6 I24 1 I25 9 I34
16 DI1 6 MB1 15 KI1 6 NG1

20 EU1 19 EU1 lamp 2 LB2 3 GB FBCM
35 E01 Mp52 A
1 B8 ECU
0.5 BlR
0.5 WBl
0.5 GO
1.25 B
0.5 GO
0.85 B
0.85 B
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
69 E1 33 E1 1 L1 Rear
4 G5right
10 D7 2 K4 6 M4 2 K4 6 N4
High brake combination 1
light

lamp
EMS 2 L1 1 G5
G28 G38 G33 G32

G23 G11 G13 G13 G13 G13 G13
G28 G21 G27 G27 G22
74
Instrument cluster system

B+

B+ B+

FS 34
10A

FS 04
FS 06
10A
15A
IG1 B+
K06
FS 37
FS 20
15A
10A
FBCM

K04
14 1D 13 1F 18 I11
14 I1D 13 I1F
13 1C 12 1C
0.5 RY
0.5 R
0.5 WY
1.25 W
13 I1C 12 I1C
0.5 Y
0.5 BrR
1.25 G
1.25 G

ECU 44 ECU 9
16 I07 15 I07 24 I07
IG1 B+
Instrument cluster system

GND
17 I07 31 I07 32 I07 10 I07 3 I07 28 I07 29 I07 30 I07 12 I07 11 I07 2 I07 1 I07 13 I07 6 I07 7 I07 29 UI1
0.3 WR
0.3 GBl
0.5 BBl
0.5 GR
0.3 WB
29 UI1
0.3 YB
0.3 W
0.3 Bl
0.3 W
0.5 B
0.3 P
0.3 Y
1.25 W
22 IU1 23 IU1 24 IU1

0.3 BW
0.3 GB
0.3 O
22 UI1 23 UI1 24 UI1 24 IB1 23 IB1 6 IB1
24 BI1 23 BI1 6 BI1

0.3 WR
0.3 Bl
0.3 P
0.5 BBl
0.5 GR
1.25 W
22 UE 23 UE 1 U10
22 EU 23 EU

1 I29 1 I35 1 I36

2 U10 2 B2 3 B2 1 B2

4 B2
2 I29 2 I35 2 I36
0.50 YB
0.50 V
0.30 B
0.30 B
0.30 B
0.50 B
1.25 B
3 E9 I31 E10 8 I18 3 I01 12 I01 6 I01 14 I01

BCANH BCANL PCANH PCANL

G14 G21 G35

G22
Fault diagnosis
1. Fuse (blown) Replacement
Entire instrument not Repair or replace the harness or
work connector
Instrument background 1. Harness (open circuit or short circuit)
connector
lamp not light
connector
Fault of speedometer
2. Vehicle speed sensor (damaged) Replacement
connector
Fault of fuel meter
2. Fuel sender (damaged) Replacement
Parking brake indicator connector
lamp not on/on 2. Park brake witch (damaged) Replacement
Engine oil pressure 1. Harness (open circuit or short circuit)
connector
warning indicator lamp
2. Oil pressure warning switch (damaged) Replacement
not on/on
Lack of brake fluid, connector
inoperative indicator 2. Brake fluid level sensor Replacement
1. Low brake fluid level Add to correct level.
Lit braking indicator connector
3. Luggage compartment switch (damaged) Replacement
Driver’s seatbelt Repair or replace the harness or
warning indicator is connector
inoperative/always 2. Driver’s seatbelt switch (damaged) Replacement
illuminates 3. Instrument cluster (damaged) Replacement
Co-driver’s seat belt Repair or replace the harness or
warning indicator is connector
inoperative/always 2. Co-driver’s seatbelt switch signal Replacement
illuminates 3. Instrument cluster (damaged) Replacement
Entire instrument not work

Check the system
Go to Step
1 • Ensure the power supply system is normal.
2
• With ignition switch at ON position, inspect function of cluster.
Check the fuse
Go to Step Go to Step
2 • Open central control box in driver compartment.
8 3
• Check whether diagnostic interface fuse FS20 and FS37 are blown?
Check the power circuit for open circuit
• With ignition switch at OFF position.
• Disconnect cluster connector I07.
• Open central control box connector I1D and I1F in driver Go to Step Go to Step
3
compartment. 4 7
• Check for continuity between terminal 15 of I07 and terminal 13 of
I1F, and that between terminal 16 of I07 and terminal 14 of I1D with a
multimeter that set in Ohm position.
Check for short circuit between power line and ground
• isconnect the instrument cluster connector I07.
• Measure voltage between terminal 15 of I07 and ground with digital Go to Step Go to Step
4
multimeter set in V position. Is there the battery voltage? 5 7
• With ignition switch at ON position..
74
• Measure voltage between terminal 16 of I07 and ground with digital
multimeter set in V position. Is there the battery voltage?
Check the ground circuit for open circuit
5 • Disconnect the instrument cluster connector I07.
6 7
• Measure to determine whether there is continuity between terminal 13
of I07
Replace the instrument cluster
Go to Step
6 • Replace the instrument cluster according to the repair procedures in
9
the service manual.
Check the harness Go to Step
7
• Repair or replace the faulty harness. 9
Replace fuse
Go to Step
8 • Before replacement of blown fuse, any fault in the circuit should be
9
eliminated, and then replace with 10A, 15A fuse.
Instrument background lamp not light

Check the system
Go to Step
2
• Turn on lamplet, check for normal function of cluster backlight.
Check the power circuit for open circuit or short circuit

• Disconnect the cluster connector I21. Go to Step Go to Step
2
• Turn on the lamplet. 3 4
• Measure voltage between terminal 10 of I21 and ground with digital
multimeter set in V position. Is there the battery voltage?
Replace the combination switch. Go to Step
3
• Replace the combination switch. 5
4
Fuel gauge fault

Check the signal line for open circuit
• Disconnect instrument cluster connector I07 and fuel pump assembly
1 connector B2.
2 7
• Measure resistance between terminal 2 of connector B2 and terminal
6 of connector I07 with a multimeter that set in Ohm position.. Is it
less than 2Ω?
Check the signal line for short to ground
2 • Disconnect the fuel pump assembly connector B2
3 7
• Measure resistance between terminal 2 of B2 and ground. Is it higher
than 1MΩ?
• Disconnect the fuel pump assembly connector B2 and instrument
cluster connector I07. Go to Step Go to Step
3
• Measure resistance between terminal 3 of connector B2 and terminal 4 7
7 of connector I07 with a multimeter that set in Ohm position.. Is it
less than 2Ω?
Inspect fuel sender
• Disconnect the fuel pump assembly connector B2 Go to Step Go to Step
4
• Remove fuel sender. Measure resistance between terminal 1 5 6
of connector F04 and ground with a multimeter that set in Ohm
position.. Is it higher than 1MΩ?
Go to Step
8
the service manual.
Change the electric fuel pump
Go to Step
6 • Replace the electric fuel pump according to the repair procedures in
8
the service manual.
7
Parking brake indicator lamp not on/on

Check the system
Go to Step
2
• Does parking brake indicator lamp illuminates always or inoperative?
2 • Disconnect the park brake switch connector I31.
3 6
• Measure resistance between terminal 1 of I31 and ground with a
multimeter that set in Ohm position. Is it higher than 1MΩ?
• Disconnect the park brake switch connector I31 and instrument
3 cluster connector I07
4 6
• Measure resistance between terminal 1 of connector I31 and
terminal 3 of connector I07 with a multimeter that set in Ohm
position.. Is it less than 2Ω?
Inspect park brake switch
• Release the park brake.
• Measure resistance between terminal 1 of the park switch I31 and
ground with a multimeter that set in Ohm position. Is it higher than
4 1MΩ?
Go to Step Go to Step 74
5 7
• Apply park brake.
• Measure resistance between terminal 1 of the park switch I31 and
ground with a multimeter that set in Ohm position. Is it less than
2Ω?
Go to Step
8
the service manual.
6
Change the park brake switch
Go to Step
7 • Refer to repair procedure in Service Manual to change the park
8
brake switch.
Engine oil pressure warning indicator lamp not on/on

Check the system
• Ensure the power supply system is normal. Go to Step
1
• Does oil pressure warning indicator illuminates always or 2
inoperative?
2 • Disconnect oil pressure warning switch connector E10.
3 6
• Measure resistance between terminal 1 of E10 and ground with a

• Disconnect oil pressure sensor connector E10 and instrument cluster
3 connector I07.
4 6
• Measure resistance between terminal 1 of connector E80 and
Inspect oil pressure warning switch
• When engine oil pressure is low, measure resistance between
terminal 1 of the oil pressure sensor connector E10 and ground with
4 a multimeter that set in Ohm position. Is it less than 2Ω?
5 7
• When engine oil pressure is normal, measure resistance between
terminal 1 of oil pressure sensor connector E10 and ground with a
Go to Step
8
the service manual.
6
Change the oil pressure warning switch
Go to Step
7 • Replace the oil pressure warning switch according to the repair
8
procedures in the service manual.
Brake fault warning indicator lamp not on/on

Check the system
1
• Does brake fault warning indicator lamp illuminates always or 2
inoperative?
2 • Disconnect brake fluid sensor connector U10.
3 7
• Measure resistance between terminal 2 of U10 and ground with a
• Disconnect the brake fluid sensor connector U10 and the instrument
3 cluster connector I07.
4 7
• Measure resistance between terminal 2 of connector U10 and
4 • Disconnect the brake fluid level sensor connector U10.
5 7
• Measure resistance between terminal 1 of U10 and ground with a
multimeter that set in Ohm position. Is it less than 2Ω?
Inspect brake fluid level sensor

• When brake fluid level is low (below MIN mark on dipstick), measure
resistance between terminal 1 and 2 of brake fluid level sensor with a
multimeter that set in Ohm position.. Is it less than 2Ω? Go to Step Go to Step
5
• When brake fluid level is low (between MIN and MAX mark on 6 7
dipstick), measure resistance between terminal 1 and 2 of brake fluid
level sensor with a multimeter that set in Ohm position.. Is it higher
than 1MΩ?
Go to Step
9
the service manual.
7
Change the brake fluid level sensor
Go to Step
8 • Replace the brake fluid senso according to the repair procedures in
9
the service manual.
Driver's/ Co-driver‘s belt not fastened warning indicator lamp not on/on
Check the system 74
Go to Step
2
• Does driver’s seatbelt indicator illuminates always or inoperative?
• Disconnect driver’s seatbelt switch connector I29 and co-driver’s Go to Step Go to Step
2
seatbelt switch connector I35. 3 7
• Measure resistance between terminal 1 of I29/I35 and ground with a
3
seatbelt switch connector I35, multipurpose display connector I05. 4 7
• Measure resistance between terminal 1 of I29/I35 and terminal 17/31
of I07 with a multimeter that set in Ohm position.. Is it less than 2Ω?
4
seatbelt switch connector I35, multipurpose display connector I05. 5 7
• Measure resistance between terminal 2 of I29/I35 and ground with a
multimeter that set in Ohm position. Is it less than 2Ω?
Inspect driver’s seatbelt switch/ co-driver’s seatbelt switch

• Buckle the seatbelt.
• Measure resistance between terminal 1 and 2 driver’s seatbelt
switch/ co-driver’s seatbelt switch with a multimeter that set in Ohm
5 position.. Is it higher than 1MΩ?
6 7
• Release the seatbelt.
• Measure resistance between terminal 1 and 2 driver’s seatbelt
switch/ co-driver’s seatbelt switch with a multimeter that set in Ohm
Go to Step
9
the service manual.
7
Replace the driver’s seatbelt switch
Go to Step
8 • Replace the driver’s seatbelt switch according to the repair
9
procedures in the service manual.
Instrument cluster
Replacement
1. Remove the cluster
(a). Disconnect the battery negative.
(b). Remove steering wheel. (refer to 61 - steering
system, steering wheel, replacement)
(c). Remove two fastening screws on steering wheel
upper shield.
LFWX-6470-74003
(c). Use slot type screwdriver to pry up combination

instrument apron.
Note: cover the bit of slotted head screwdriver
with the tape to prevent damaging the instrument
desk and instrument cluster components.
LFWX-6470-74004
(d). Remove two self-tapping screws for connecting

combination instrument cowl component and
instrument.
(e). Use slot type screwdriver to pry up combination
instrument cowl component, and take down
upper shields of combination instrument cowl
and steering wheel.
Note: cover the bit of slotted head screwdriver
with the tape to prevent damaging the instrument
desk and instrument cluster components.
LFWX-6470-74005
(f). Remove four self-tapping screws for connecting

the combination instrument and instrument
desk.
74
LFWX-6470-74006
(g). Slowly take out combination instrument and turn
it over, disconnect wiring harness connector,
and take down combination instrument.
LFWX-6470-74007
2. Install the instrument cluster

(a). Connect cluster connectors.
Note:
LFWX-6470-74007
(b). Install the instrument cluster to proper position.

△ Tips:
Put harness at back of the cluster under console,
engage locating tongues into locating holes.
(c). Install retaining screw of the cluster.
LFWX-6470-74006
(d). Install combination instrument cowl and steering

wheel steering wheel upper shield on their
installation sites.
△ Tips:
Insert the instrument mask positioning tongue in the
locating hole.
(e). Install fastening screw of combination instrument
cowl components.
LFWX-6470-74005
(f). Install combination instrument apron on its

installation site.
△ Tips:
Insert the panel positioning tongue in the locating
hole.
LFWX-6470-74004
(g). Install two fastening screws on steering wheel

upper shield.
(h). Install steering wheel. (refer to 61 - steering
(i). Connect the battery negative.
74
LFWX-6470-74003
Combination switch
Replacement
1. Remove the combination switch
(a). Disconnect the battery negative.
(b). Remove steering wheel. (refer to 61 - steering
(c). Remove two fastening screws on the steering
wheel shield, and take down the steering wheel
shield.
LFWX-6470-74008
Central door lock and body immobilizer - Central door lock and body immobilizer 75-a
Central door lock and body immobilizer

Central door lock and body
immobilizer��1
System description��2 75
Circuit diagram��3
17 New version circuit diagram�7
Precautions��9
Check the system��9
1.Check system working conditions
��9
Check the front left door lock� 10
Diagnosis �� 11
Front body control module(FBCM)/
PEPS�� 15
Change�� 15
Front door signal switch�� 16
Change�� 16
Rear door signal switch�� 17
Change�� 17
Hatch inching switch�� 17
Change�� 17
Rear body control module (RBCM)
�� 18
Change�� 18
75-b Central door lock and body immobilizer - Central door lock and body immobilizer
Central door lock and body immobilizer - Central door lock and body immobilizer 75-1
Central door lock and body immobilizer

1. Special tools
Read immobilizer 75
Diagnosis
1 DTC and data
equipment
flow etc.
Measure the
Digital universal
1 voltage and
meter
resistance
Conductor
2 Testing circuit
assembly
75-2 Central door lock and body immobilizer - Central door lock and body immobilizer
System description
1. Function
Car central lock (abbreviation of “central control door lock”) is designed and installed
to improve convenience and safety during use of cars.
Anti-theft system is designed to give alarms when someone wants to forcibly open
car door or back door.
2. Composition
The central door lock mainly consists of the door lock, hatch lock and door control
module.
The bodywork immobilizer system mainly consists of the remote control/smart key,
front/rear BCM, door control module, PEPS control module, door signal switch and
hatch inching switch etc.
75
75-3
B B B B B B B
Central door lock and body immobilizer - Central door lock and body immobilizer
FS26
FS29
FS18
FS31
15A
10A
10A
20A
FS15
20A
FS43
FS13
10A
15A
0.85 GR
31 UI1 28 UI1
U4 2
13 1C 10 1F 7 1B 3 1B 14 1C 3 1D 31 IU1 28 IU1
0.3 RB
0.85 GY
10 R4
5
13 I1C 10 I1F 7 I1B 3 I1B 14 I1C 3 I1D 0

2 5
R4
R4
9 I04
4
1 8 U17 12 U17 9 U17 8 U8 12 U8 9 U8 U4 1

8
E8

10 I04
13 U17
U8
8-
1 R4
20 W
1 I50
3
13
1 1 U17 5 U17 6 U17 1 U8 5 U8 U8
R4
6
R4
I17
UI1 15 UI2 2
2 I50
0.85 RG
0.85 GY
2
1.25 R
3
MP5 2 15 EU1
2.0 RBl
3 I50 4 I50
15 UE1
1 R4 IU1 15 IU2 2
4 UI1
0.3 GrBl
0.3 GrY
19 UI1
R4
4 IU1
R4
0.85 BlW
0.85 BW
19 IU1
1 RI1
3
2
0.3 O
0.3 W
1 IR1
I11 18 I11 19 2 I09 1 I09 13 I11 1 I11 7 I09 1 I10 21 I09 22 I09 11 I11 12 I11
IMMO+ IMMO- B+ B B ACC
B+
12 I09 13 I09 7 I10 4 I10 14 I11 12 I10 15 I11 16 I10 11 I09 14 I09 15 I09 16 I09 17 I09 18 I09 2 I11 10 I09
0.5 PBl
7 ID1 8 IU1 6 IU1 17 ID1
I 5 IU1 I
6 IK1 10 IU1 7 IU1
7 DI1 8 UI1 6 UI1 17 DI1 5 UI1 6 KI1 10 UI1 7 UI1
8 I04
0.3 BrY
0.5 YW
0.5 BrW
0.5 RY
0.5 YG
0.5 RY

0.5 YG
0.5 RY
0.5 YG
0.3 WG
21 UE1
0.3 BrR
0.3 GBl
0.3 BG
6(
0.5 Br
0.5 RY
21 EU1
9 D7 10 U17 5 D8 14 U17
15 I27
I26 10 U8
1 U19 1 U5 14 U8
5 K5

16 I26
13 I26
E25 2
3 U17 6 D8 7 U17 7 U8
Circuit diagram
3 U8 6 K5
2 U19 2 U5
E25 1
1.25 B
1.25 B
0.5 B
-8
0.5 B
0.5 B
0.5 B
0.5 B
(
0.3 B
(
(
(
(
(
(
3 I10 3 I10 3 R3 3 I10 3 I10
PEPS
IGN1
G24 G24 G25 G26 G11 G23 G13 G27 G11 G13 G11 G11 G25 G11 G13
//
B B
FS10
FS34
10A
10A
?
2 5
25 IU1 2 5 2 5

6 D8
6 K5 25 UI1

0.85 G
1 3
1 3 1 3 0.5 GB
8 D8
8 K5
11 1C 12 1C
2 U20 2 U1
0.5 G
0.5 YB
0.5 YB
11 I1C 12 I1C
7 D8 7 K5
16 UI1 17 UI1
11 U17 11 U8
1 U20 1 U1 16 IU1 17 IU1
25 DI1 16 KI1 24 DI1 10 KI1
4 U17 U8
0.5 BrW
4
0.5 BrY
0.5 BrR
25 ID1 16 IK1 24 ID1 10 IK1

0.5 Y
0.5 YB
19 I11 20 I11 18 I11 16 I11 17 I11

,()3
BCANL BCANH
8 I10 24 I11 25 I114 4 I11 3 I11 14 I10 13 I10
I1 5 I10
I1 6 I10 22 I11 23 I11
I11 21 I11 5 I11 8 I11 7 I11 10 I11 9 I11 8 I09
8 5 I09 4 I09 3 I09 26 I11
1.25 GW
1.25 GY
0.5 YBl
0.5 BlY
0.3 GBl
0.5 BlR
0.3 Gr
0.3 G
0.85 B
0.85 B
0.85 B
0.3 O
0.3 P
0.5 B
0.5 B
1 IU1 2 IU1
1 UI1 2 UI1 2 I08 1 I08 15 IB1 7 IG1 8 IG1
I 14 IB1
0.3 WB
1.25 GW
0.3 W
1.25 GY
15 BI1 7 GI1 8 GI1 14 BI1
2 I08
3 I01 7 I01
0.3 WR
0.3 WG
0.3 YBr
0.5 RG
0.3 Bl
0.3 GBl
0.3 GW
0.3 GR
0.3 Gr
0.3 GB
0.3 Br
0.3 O
0.3 P
4 U13 LIN
7 I04
1 U13
0
3 U13
B1 B1 B1 B1
5 U13
0.5 B
1.25 B
0.5 B
0.5 B
14 I21 13 I21 12 I21 11 I21 10 I21 9 I21 5 I21 I21
G27 G23 G10 G
G21 G
G25 G14 G14 G14 G14
75-4
75
75-5
B B B B B
FS26
10A
20A
FS18
FS13
FS31
15A
20A
FS43
15A
-8
31 UI1 28 UI1
10 1F 7 1B 3 1B 14 1C 31 IU1 28 IU1 2 U4
0.3 RB
10 R4
0.85 GY
10 I1F 7 I1B 3 I1B 14 I1C

0
2 5
R4
R4
9 I04
8 U17 12 U17 9 U17 8 U8 12 U8 9 U8 1 U4
4
1
0.85 BlW
0.85 BW
10 I04
13 U17
13 U8
1 R4
8-
1 3 1 U17 5 U17 6 U17 1 U8 5 U8 6 U8

R4
UI1 UI2
R4
15 2

0.85 RG
2
1.25 R
3
2.0 RBl
IU1 15 IU2 2
1 R4 4 UI1
0.85 BW
0.85 BlW
(
4 IU1
R4
R4
1 RI1
2
5
1 IR1
2 I09 1 I09 13 I11 1 I11 21 I09 22 I09 11 I11 12 I11
B+ B B
B+
0.5 PBl
7 ID1 8 IU1 6 IU1 17 ID1 5 IU1 6 IK1 10 IU1 7 IU1
7 DI1 8 UI1 6 UI1 17 DI1 5 UI1 6 KI1 7 UI1
10 UI1
8 I04
0.3 BrY
0.5 YW
0.5 BrW
0.5 PBl
0.5 YG
0.5 RY
0.5 RY
0.5 RY

0.5 YG
0.5 YG
21 UE1
0.3 WG
0.3 BG
0.3 BrR
0.5 Br
0.3 GBl
0.3 RY
21 EU1
9 D7 10 U17 5 D8 15 I26
I27 1 U19 1 U5 14 U17 14 U8
10 U8 5 K5

16 I26
13 I26
E25 2
3 U17 6 D8 7 U17 7 U8
3 U8 6 K5
2 U19 2 U5
0.5 B
0.5 B
0.5 B
0.5 B
0.5 B
E25 1
0.5 GR
1.25 B
1.25 B
0.5 B
0.3 B
0.5 B
0.3 B
0.5 B
3 I10 3 I10 3 R3 3 I10 3 I10
0.5 B
0.5 B
IGN1
G24 G25 G26 G11 G23 G
G13 G
G27 G
G11 G
G13 G
G11 G11 G25
G G11 G13
//
B B
FS10
FS34
10A
10A
?
2 5
25 IU1 2 5 2 5

6 D8
6 K5 25 UI1

0.85 G
1 3
1 3 1 3 0.5 GB
8 D8
8 K5
11 1C 12 1C
2 U20 2 U1
0.5 G
0.5 YB
0.5 YB
11 I1C 12 I1C
7 D8 7 K5
16 UI1 17 UI1
11 U17 11 U8
1 U20 1 U1 16 IU1 17 IU1
25 DI1 16 KI1 24 DI1 10 KI1
4 U17 U8
0.5 BrW
4
0.5 BrY
0.5 BrR
25 ID1 16 IK1 24 ID1 10 IK1

0.5 Y
0.5 YB
19 I11 20 I11 18 I11 16 I11 17 I11

,()3
BCANL BCANH
8 I10 24 I11 25 I114 4 I11 3 I11 14 I10 13 I10
I1 5 I10
I1 6 I10 22 I11 23 I11
I11 21 I11 5 I11 8 I11 7 I11 10 I11 9 I11 8 I09
8 5 I09 4 I09 3 I09 26 I11
1.25 GW
1.25 GY
0.5 YBl
0.5 BlY
0.3 GBl
0.5 BlR
0.3 Gr
0.3 G
0.85 B
0.85 B
0.85 B
0.3 O
0.3 P
0.5 B
0.5 B
1 IU1 2 IU1
1 UI1 2 UI1 2 I08 1 I08 15 IB1 7 IG1 8 IG1
I 14 IB1
0.3 WB
1.25 GW
0.3 W
1.25 GY
15 BI1 7 GI1 8 GI1 14 BI1
2 I08
3 I01 7 I01
0.3 WR
0.3 WG
0.3 YBr
0.5 RG
0.3 Bl
0.3 GBl
0.3 GW
0.3 GR
0.3 Gr
0.3 GB
0.3 Br
0.3 O
0.3 P
4 U13 LIN
7 I04
1 U13
0
3 U13
B1 B1 B1 B1
5 U13
0.5 B
1.25 B
0.5 B
0.5 B
14 I21 13 I21 12 I21 11 I21 10 I21 9 I21 5 I21 I21
G27 G23 G10 G
G21 G
G25 G14 G14 G14 G14
75-6
75
75-7

B B B B B
FS26
10A
20A
FS18
FS13
FS31
15A
20A
FS43
15A
-8
31 UI1 28 UI1
10 1F 7 1B 3 1B 14 1C 31 IU1 28 IU1 2 U4
0.3 RB
10 R4
0.85 GY
10 I1F 7 I1B 3 I1B 14 I1C
0.85 BW
0
2 5
R4
R4
4 1B 9 I04
8 U17 12 U17 9 U17 8 U8 12 U8 9 U8 1 U4
4
1
4 I1B
10 I04
13 U17
13 U8
1 R4
8-
--
9 1E 6 1E 1 3 1 U17 5 U17 6 U17 1 U8 5 U8 6 U8

R4
UI1 UI2
R4
15 2

9 I1E 6 I1E
0.85 RG
2
1.25 R
3
(
2.0 RBl
IU1 15 IU2 2
1 R4 4 UI1
0.85 BlW
4 IU1
R4
R4
1 RI1
2
5
1 IR1
2 I09 1 I09 13 I11 1 I11 21 I09 22 I09 11 I11 12 I11
B+ B B
17 New version circuit diagram
B+
0.5 PBl
7 ID1 8 IU1 6 IU1 17 ID1 5 IU1 6 IK1 7 IU1
0.5 BrW
10 IU1
7 DI1 8 UI1 6 UI1 17 DI1 5 UI1 6 KI1 7 UI1
10 UI1
8 I04
0.3 BrY
0.5 YW
0.5 YG
1.25 B
1.25 B
0.5 RY
0.5 PBl
0.5 YG

0.5 YG
0.5 RY
0.5 RY
21 UE1
15 I26
I27
0.3 WG
0.3 BrR
0.3 GBl
0.3 BG
0.5 Br
21 EU1
9 D7
16 I26
13 I26
-( 10 U17 5 D8
1 U19 1 U5 14 U17 14 U8
10 U8 5 K5
E25 2
3 U17 6 D8 7 U17 7 U8
3 U8 6 K5
2 U19 2 U5
(
(
(
E25 1
0.5 B
0.5 B
0.5 B
0.3 B
0.5 B
0.3 B
0.5 GR
3 I10 3 I10 3 R3 3 I10 3 I10
IGN1
G24 G25 G26 G11 G23 G13
G G27
G G
G11 G13
G G
G11 G11 G25
G G11 G13
//
B B
FS10
10A
FS34
10A
8?
2 5
25 IU1 2 5 2 5

6 D8
6 K5 25 UI1

-
1 3
0
1 3 1 3 0.5 GB
8 D8
8 K5
0 1 13 1C 12 1C
2 U2
U 0 2 U1
-
14 13 I1C 12 I1C
0.5 YB
7 D8 7 K5
16 UI1 17 UI1
11 U17 11 U8
1 U20 1 U1 16 IU1 17 IU1
25 DI1 16 KI1 24 DI1 10 KI1
4 U17 4 U8
0.85 B
0.85 B
(X8
25 ID1 16 IK1 24 ID1 10 IK1
0.5 BrY
0.5 BrW
0.5 B
0.5 B
?
?(
19 I11 20 I11 18 I11 16 I11 17 I11

,()3
BCANL BCANH
8 I10 24 I11 25 I114 4 I11 3 I11 14 I10 13 I10
I1 5 I10
I1 6 I10 22 I11 23 I11 21 I11 5 I11 8 I11 7 I11 10 I11 9 I11 8 I09
8 5 I09 4 I09 3 I09 26 I11
1.25 GW
1.25 GY
0.5 YBl
0.5 BlY
0.3 GBl
0.5 BlR
0.3 Gr
0.3 O
0.3 P
0.85 B
0.5 RG
0.3 G
1 IU1 2 IU1
1 UI1 2 UI1 2 I08 1 I08
15 IB1 7 IG1 8 IG1
I 14 IB1
0.3 WB
1.25 GW
1.25 GY
0.3 W
2 I08
15 BI1 7 GI1 8 GI1 14 BI1
3 I01 7 I01
0.3 WR
0.3 WG
0.3 YBr
0.3 Bl
0.3 Gr
0.3 GBl
0.3 GR
0.3 GW
0.3 GB
0.3 Br
0.3 O
0.3 P
4 U13 2/4
0 7 I04
1 U13
3 U13
0.5 B
B1 B1 B1 B1
5 U13
(
6 I21 5 I21 2 I21 1 I21 8 I21a 6 I21a 3 I21a 1 I21a 7 I21a
G27 G23 G10 G21 G25 G14 G14 G14 G14
75-8
Maintenance data
Items N·m
Front/rear BCM assembly bolt/nut 6 ～ 12

75
PEPS Controller mounting nut 6 ～ 12
Precautions
(a). As long as power supply is under non-OFF state, it is forbidden to insert or connect
any components in the system (such as any battery cable or system part insert,
etc.), no matter whether engine is running or not.
(a). Before removing or Installing any electrical unit or when it is easy for tool or
equipment to get contact with exposed electrical terminals, disconnect cable on
negative terminal of battery to prevent damages to operators or vehicle.
(b). While disconnecting system inserts, do not pull wiring to avoid any damage.
General inspection
Check the system
1. Check system working conditions
(a). Check if key/central control switch can lock all doors. If not, refer to the following
diagnosis to perform maintenance.
(b). Check whether key/center control switch can be used to unlock four door locks
or not; whether back door can enter pre-unlocking state or not, if not, maintain
according to the following diagnosis contents.
required.
(b). Check if the system has obvious mark of deformation after collision. If so, perform
maintenance.
(a). Check whether the system harness connector is installed reliable; if not, install it
again.
4. Check the fuse
(a). Check whether front door controller fuse FS32 and rear door controller fuse FS33
are blown out or not, if yes, change the same specification of fuse.
△ Tips:
The above fuses are located in the cab fuse box.
Check the hatch inching switch

1. Check hatch micro-signal line
(a).Power state is “OFF”, and back door micro-
switch harness connector is disconnected.
(b). Use the make-break gear of digital
multimeter to detect whether No.1
terminal of back door micro-switch wiring
harness connector and NO.11 terminal
I12 connector are conducted or not, if
not, maintain related wiring harnesses
according to circuit diagram.
2. Check the working condition of back
L10 Connect to back door micro-switch door micro switch
(a). Power state is “OFF”, and back door micro-switch harness connector is
disconnected.
(b). Use the make-break gear of digital multimeter to detect whether No.1 terminal and
No.2 terminal of back door micro-switch are conducted or not; if they can not be
conducted after pressing micro-switch, change the back door micro-switch.
Check the hatch lock harness

1. Check the hatch lock harness
L6 (a). Power state is “OFF”, and back door lock
harness connector is disconnected.
(b). According to circuit diagram, check
whether No.2 terminal of connector clip
L6 is conducted or not; check whether
1 2 No.1 terminal of L6 and battery negative

pole are conducted or not, if not, maintain
related wiring harness according to circuit
diagram.
Check the front left door lock

1. Check locking signal wire of front left
*
door
(a). Switch the power supply to “OFF”, and
disconnect left front door lock actuator
and left front door window lift switch 1
connector.
5 4 3 2 1
10 9 8 7 6
(b). Use the make-break gear of digital

D3 multimeter to detect whether No.5 terminal
of door lock actuator D3 and No.3 terminal
of D6 are conducted or not, if not, maintain
related wiring harnesses according to
circuit diagram. 75
1 2 3 4 5 6
2. Check unlocking signal line of front left door

(a). Switch the power supply to “OFF”, and disconnect left front door lock actuator and
left front door window lift switch 1 connector.
(b). Use the make-break gear of digital multimeter to detect whether No.6 terminal of
door lock actuator D3 and No.2 terminal of window lift switch D6 are conducted or
not, if not, maintain related wiring harnesses according to circuit diagram.
Diagnosis

1. Harness (open circuit)
2. Front left door lock (fault) See 75-central control lock and
Key/central control lock switch body anti-theft fault diagnosis (key/
3. Front body controller (fault)
cannot lock all door locks. central control switch cannot lock
4. Front left door controller all door locks)
5. Key(fault)
The smart key/central lock switch 2. Front left door lock (fault) See 75-central control lock and
cannot unlock the door locks and
body anti-theft fault diagnosis (key/
the hatch cannot be unlocked in 3. Front body controller (fault)
central control switch cannot lock
advance; the remote control key
4. Front left door controller (fault) all door locks)
cannot unlock all doors
5. Key(fault)

1. Hatch cover lock (fault)

See 75-central control lock and
Hatch cannot be opened. 3. Hatch micro-switch (fault) body anti-theft fault diagnosis
(Hatch cannot be opened.)
4. Rear body controller (fault)
5. Fuse (blown)
Fault diagnosis
1. Key/central control lock switch cannot lock all door locks

Check if key/central control
lock can lock all door locks Go to Step 1/
Key/central control
(see 75-general inspection of Check whether the
Diagnosis is finished lock cannot lock all
central control door lock and immobilizer is under
door locks.
body anti-theft system, check normal operation
system).
Check if signal line of front
left door lock is connected Check the relevant
(see 75-general inspection of harness according
Go to Step 2 Unconnected
central control door lock and to the circuit
body anti-theft system, check diagram
front left door lock).
2 Check the front left door lock Normal Faulty Instruction
Check the front left door lock Replace the front
working conditions (refer to left door lock (refer
Chapter 75 - Central door lock Front left door lock t o C h a p t e r 8 2 -
Go to Step 3
and body immobilizer, general damaged Door and door lock,
inspection, inspection of front front door lock,
left door lock) replacement)
Check the front body controller
working conditions
Check working condition
of body controller (see
75-general inspection of Front body controller Replace the front
Go to Step 4
central control door lock and damaged body controller
body anti-theft system, check
BCM).
Reassemble the system and Locate the causes
check whether the fault is Diagnosis is finished The fault still exists from other fault
solved phenomenon
2. The key/central lock switch cannot unlock the door locks and the hatch cannot
be unlocked in advance;

Check whether the key/
central lock switch can unlock Key / central lock 75
all the 4 doors and whether switch can not
Go to Step 1/
the hatch can be unlocked unlock all the 4
Check whether the
in advance (refer to 75 - Diagnosis is finished doors and whether
immobilizer is under
central control door lock the hatch can not
normal operation
and bodywork immobilizer, be unlocked in
general inspection, inspection advance
of system)
Check if signal line of front
left door unlock is connected
Check the relevant
(see 75-general inspection of
Go to Step 2 Unconnected harness according to
central control door lock and
the circuit diagram
front left door lock).
Check the front left door lock
Replace the front left
working conditions (refer to
door lock (refer to
Chapter 75 - Central door lock Front left door lock
Go to Step 3 Chapter 82 - Door and
and body immobilizer, general damaged
door lock, front door
inspection, inspection of front
lock, replacement)
left door lock)
Check the front body
controller working conditions
Check working condition of
front body controller (see
75-general inspection of F r o n t b o d y Replace the front
Go to Step 4
central control door lock and controller damaged body controller
body controller).
Reassemble the system and Locate the causes
check whether the fault is Diagnosis is finished The fault still exists from other fault
solved phenomenon
3. Hatch cannot be opened


Press the smart key
unlocking key/remote control
key hatch unlocking key/
central control door lock
unlocking key and then
press the hatch inching Hatch cannot be
switch to check whether the opened.
hatch can open (refer to 75
- central control door lock
and bodywork immobilizer,
general inspection, inspection
of system)
Check inside manual open
hatch
Replace hatch lock
Check if inside manual open (see 82-door and
Go to Step 2 Cannot be opened.
hatch is working door lock, trunk lock,
replace)
Check hatch micro-switch
wiring
Check if hatch micro-switch
signal line is connected
Check the relevant
(see 78-general inspection
of central control lock and
the circuit diagram
hatch micro-switch)
Check the hatch inching
switch
Check working condition
Replace it (see
of hatch micro-switch (see
75-central control lock
75-general inspection of Micro-switch is
Go to Step 4 and body anti-theft
central control lock and body damaged
system, hatch micro-
anti-theft system, check trunk
switch, replacement)
micro-switch)
4 Check lock actuator wiring Normal Faulty Instruction
Check the relevant
Check if hatch lock actuator
wiring is connected.
the circuit diagram
Check if rear body controller
Check the relevant
power and ground is
Go to Step 6 Abnormal harness according to
connected with positive and
the circuit diagram
negative terminals of battery.
Replace it (see
Replace it with body 75-central control
controller of the same type Diagnosis is finished The fault still exists lock and body anti-
and check if fault is resolved. t h e f t c o n t r o l l e r,
replacement)
Front body control module(FBCM)/PEPS

Change
1. Remove FBCM/PEPS
(a). Remove the dashboard (See Section
85 - Dashboard and Sub-dashboard – 75
Dashboard, Replacement)
△ Tips:
The approximate position of the FBCM / PEPS is
indicated by a red circle in the figure.
The FBCM/PEPS is located on the mounting
bracket on the dashboard beam.
LFWX-6470-75010
(b). Remove two mounting bolts on FBCM/

PEPS mounting bracket.
LFWX-6470-75011
(c). Disconnect the connector of FBCM/PEPS,

and take down FBCM/PEPS and mounting
bracket.
LFWX-6470-54017
(d). Remove two fixing bolts of FBCM and

mounting bracket and take down FBCM.
LFWX-6470-75014
(e). Remove four fixing bolts of FBCM and

mounting bracket and take down FBCM.
LFWX-6470-75014
2. Install FBCM/PEPS
Install the parts and tighten them to the required torque.
Front door signal switch

Change
1. Remove front door signal switch
(a). Open the front door.
(b). Remove fixing bolt for front door signal switch.
(c). Disconnect front door signal switch inserts and
remove front door signal switch.
LFWX-6470-75016
2. Install front door signal switch

(a). Connect front door signal switch inserts.
(b). Install front door signal switch to right place and install and tighten fixing
bolts.
Rear door signal switch 75

Change
△ Tips:
It is basically the same to replace front and rear door signal switches, see 75-central
control door lock and body anti-theft system, front door signal switch, replacement.

Change
1. Remove hatch micro-switch
(a). Remove hatch trim board. (see 81-interior
& exterior trim - hatch trim board,
replacement).
LFWX-6470-75019
(b). Remove the four nuts for connecting the

rear license decorating plate and back
door outer plate. (See Chapter 81 Interior
& Exterior– Rear License Decorating Plate,
Replacement).
LFWX-6470-75018
(c). Slowly rotate rear license decorating plate,

disconnect back door micro-switch wiring
harness connector and rear license plate
lamp wiring harness connector, and take
down the rear license plate, micro-switch
LFWX-6470-75017 and license plate lamp component.
LFWX-6470-75020
(d). Remove two screws for connecting micro-

switch and rear license decorating plate
handle box.
LFWX-6470-75021
2. Remove hatch micro-switch

Rear body control module (RBCM)

Change
1. Remove RBCM
(a). Remove C column lower apron component.
(See Chapter 81 Interior & Exterior – Side
Wall Decorating Plate, Replacement)
LFWX-6470-75022
(b). Remove two fixing bolts for connecting

RBCM and left rear column reinforcement
support, and take down RBCM.
75
LFWX-6470-75023
LFWX-6470-75024
1. Install RBCM
Anti-collision Radar System
Anti-collision Radar System … 1
Component drawing (42 radar) 3
Component drawing (4/6 radar) 4
Reverse lamp switch (MT) …… 8
Anti-collision radar sensor …… 9
76
Anti-collision Radar System - Anti-collision Radar System 76-1
Anti-collision Radar System

Preparations
1. Recommend tool
No. Tool External view S/N Description

1
Remove screw and

mounting bracket of
2 Screw driver
anti-collision radar
sensor
76
Conductor
3 Testing circuit
assembly
76-2 Anti-collision Radar System - Anti-collision Radar System
Precautions
1. Detection function may be not abnormal under conditions below
(a). The anti-collision radar sensor is covered by mud or snow etc. (The detection function works
after cleaning).
(b). Frozen anti-collision radar sensor (The detection function works when temperature increased)
(c). Blocked anti-collision radar sensor.
(d). In cold weather and failure condition, the anti-collision radar sensor may fail to detect
obstacles.
2. Detection range is restricted by conditions below
(a). The anti-collision radar sensor is covered by mud or snow etc.
(b). Driving vehicle in extreme weather.
3. Detection error may arise in conditions below
(a). Driving on bumpy road, unpaved road or in higher grasses.
(b). Loud trumpet from vehicle nearby, motorcycle engine noise nearby, air braking noise from
high-duty vehicle nearby, or ultrasonic from other vehicle nearby.
(c). Heavy rain, water contact the sensor (spilled).
(d). Seriously tilting of vehicle body.
(e). Aftermarket fender or radio antenna fitted on vehicle.
(f). The anti-collision radar sensor is covered by mud or snow etc.
(g). Moving toward high curb or corner of extruding items.
4. The anti-collision radar sensor can not detect some kind of items
(a). Thin stuffs such as wire and rope.
(b). Material such as cotton and snow, which absorb ultrasonic.
(c). Items with sharp edge.
(d). Very small items.
(e). Hang up items.
5. Additional notes
(a). The anti-collision radar sensor cannot detect items directly under bumper. (The anti-collision
radar sensor may detect lower items and thin bars and then lost tracking.)
(b). Anti-collision radar sensor may not detect obstacle too close.
(c). If falling or rushed, the anti-collision radar sensor cannot detect any obstacles.
Component drawing (42 radar)
76
LFWX-6470-76001
1 Anti-collision radar sensor 3 Mounting bracket of radar (right)
2 Mounting bracket of radar (left)
Component drawing (4/6 radar)
LFWX-6470-76001
1 Anti-collision radar sensor
System description
1. General
Anti-collision radar sensor equipped on Lifan xuanlang vehicles is a vehicle detection system
simulating detection theory of the bat during flying. By using 2 or 4 ultrasonic anti-collision radar
sensors on rear of the vehicle and 2 on front of the vehicle, this system emit and receive signal,
and feedback data to controller which is integrated in frong/rear body controller. The controller
compare returning time to determine distance to the obstacle, then emit different audio or indicator
warning according the distance to alert the driver with distance from vehicle to the obstacle,
facilitate reversing and safety.
2. Function of component
Component Functions
Anti-collision radar sensor To detect distance between vehicle and obstacles
Buzzer Sound in light of distance to obstacles to alert driver
Sent signal of reversing to anti-collision radar control
Reverse switch
(integrated in frong/rear body controller)
3. Self-check of rear anti-collision radar controller

(a). With the power in ON state.
(b). In case of engaging the reverse gear, anticollision radar controller will make self-checking.
• If the anti-collision radar is functional, the reverse indicator and buzzer is OK, which may operate
for 0.6 to 1.0 second.
• If the anti-collision radar is not functional, the reverse indicator and buzzer is defective. 76
4. Detection range of rear anti-collision radar (rear radar on left and right sides)
(b). Put shift lever in R position; If distance A > 0.55m, no alert.
(c). If distance A is between 0.4m to 0.55m (inclusive), quick intermittent sound alert (4HZ)
(d). If distance A is less than 0.4m (inclusive), continuous sound alert.
(e). Close range blind zone: ≤ 0.2m.
5. Detection range of rear anti-collision radar (left, middle and right rear radar)
(b). Put shift lever in R position; If distance A > 1.2m, no alert.
(c). If distance A is between 0.8m to 1.2m (inclusive), intermittent sound alert (2HZ).
(d). If distance A is between 0.4m to 0.8m (inclusive), quick intermittent sound alert (4HZ)
(e). If distance A is less than 0.4m (inclusive), continuous sound alert.
(f). Close range blind zone: ≤ 0.2m.
6. Detection range of front anti-collision radar
(b). When the vehicle is driven ahead and its speed is less than 15km/h, detection distance A is
more than 0.55m, there is no warning tone.
(c). If distance A is between 0.4m to 0.55m (inclusive), quick intermittent sound alert (4HZ)
(d). If distance A is less than 0.4m (inclusive), continuous sound alert.
(f). Close range blind zone: ≤ 0.2m.
1. Precheck
(a). Put shift lever into R position with Power switch
at ON position, then apply part brake to assure
safety of the vehicle.
(b). Moving a cylindrical post (diameter: 60mm)
around the anti-collision radar sensor to
measure detection range of the reversing radar
sensor.
Warning:
• Be sure that nobody is behind the vehicle
before test the anti-collision radar.
• To prevent accidental damage to the vehicle, the
cylindrical post must not be replaced with wall
or other hard obstacles.
LFWX-6470-76002
(c). Status of test indicator and buzzer should be as
following when obstacle detected:
(rear radar on left and right sides)
• If distance A > 5.5m, no alert.
• If distance A is between 0.4m to 0.55m
(inclusive), quick intermittent sound alert (4HZ)
• If distance A is less than 0.4m (inclusive),
continuous sound alert.
• Close range blind zone: ≤0.2m.
LFWX-6470-76002
(left, middle and right rear radar)

• If distance A > 1.2m, no alert.
• If distance A is between 0.8m to 1.2m (inclusive), intermittent sound alert (2HZ).
• If distance A is between 0.4m to 0.8m (inclusive), quick intermittent sound alert (4HZ)
• If distance A is less than 0.2m (inclusive), continuous sound alert.
• Close range blind zone: ≤0.2m.
Fault diagnosis
1. Fuse (open) Replacement
2. Reverse gear switch (damaged) Replacement
Totally inoperative 3. A n t i - c o l l i s i o n r a d a r s e n s o r
system Replacement
(damaged)
4. Harness (open or short power
Repair or replace the harness or connector
supply circuit)
1. Reverse switch (damaged) Replacement
Functions with 2. Instrument cluster (damaged) Replacement
transmission in gears 3. C h e c k t h e c r a s h s e n s o r
other than Reverse Replacement
(damaged)
4. Check the circuit (short circuit) Repair or replace the harness or connector
1. A n t i - c o l l i s i o n r a d a r s e n s o r
Replacement
No system operation in (damaged)
reverse gear (Reverse 2. Instrument cluster (damaged) Replacement
lamp functions) 3. Harness (open circuit or short
Repair or replace the harness or connector 76
circuit)
Malfunction of buzzer 2. A n t i - c o l l i s i o n r a d a r s e n s o r
Replacement
(Reverse lamp (damaged)
functions) 3. Harness (open circuit or short
circuit)
Reverse lamp switch (MT)

Replacement
1. Remove the reverse lamp switch
△ Tips:
The reverse switch is on transmission.
(a). Disconnect the negative cable from the battery.
(b). Disconnect the connector from the reverse lamp
switch.
(c). Remove the reverse lamp switch.
△ Tips:
Reverse lamp switch 1 is clamped to the reverse lamp
line bracket 2.
1. Reverse lamp switch 2. Reverse lamp wire bracket assembly
LFWX-6470-76003
2. Install the reverse lamp switch
(a). Install the reverse lamp switch.
(b). Connect the connector from the reverse lamp
switch.
Note:
(c). Connect the battery negative cable.
1. Reverse lamp switch 2. Reverse lamp wire bracket assembly

LFWX-6470-76003
Anti-collision radar sensor

Replacement
△ Tips:
The removal and installation of the front and rear anti-collision radar is the same. Here is the
removal and installation of the rear anti-collision radar.
1. Remove the rear bumper
(a). Remove the fastening screw and lock for
connecting left and right mudguards, fenders
and tail bumper. (See Chapter 81 – Interior &
Exterior – Bumper, Replacement)
LFWX-6470-76004
(b). Remove fixing bolt on rear bumper.
(c). Slowly take down rear bumper; disconnect the
lamp connector and anticollision radar sensor 76
connector on the rear bumper and take down
the rear bumper.
LFWX-6470-76005
2. Remove the crash radar sensor
(a). Take down anticollision radar sensor from the
anticollision radar sensor support. (Press it out
from the outer side of rear protector to its inner
side)
LFWX-6470-76006
3. Mount the crash radar sensor

(a). Install anticollision radar sensor on the
anticollision radar sensor support of rear
bumper.
△ Tips:
After fixing, shake it gently to check whether the
installation is firm.
LFWX-6470-76006
4. Install the rear bumper

(a). Install bumper (see Chapter 81 Interior & Exterior – Rear Bumper, Replacement)
76
Lighting Systems - Lighting Systems
77-a
Lighting Systems
Lighting Systems …………………1
System description ………………3
Component drawing ……………4
Part function and fault ……………5
On-vehicle inspection ……………5
Diagnosis ……………………………6
Fault phenomenon table …………6
Fault diagnosis ……………………9
Front combination lamp ……… 44
Adjustment …………………… 44
Testing ………………………… 45
Daytime Running Light/Position
light ……………………………… 50
Replacement …………………… 50 77
Fog lamp ………………………… 51
Rear combination lamp ……… 52
Rear retro-reflector with fog lamp
assembly ………………………… 55
Front dome light ………………… 57
Rear dome light ………………… 58
High-mounted stop lamp …… 61
License plate lamp ……………… 62
Door light ………………………… 63
Make-up mirror Light…………… 63
Combination switch …………… 64
77-b Lighting Systems - Lighting Systems
77-1
Lighting Systems
Preparations
Digital universal
1 Measure the voltage or resistance
meter
Auxiliary measurement of voltage or

2 Wiring group
resistance
77
3 Screw driver For screw and panel removal
4 T-shaped rod Remove the bolt

77-2 Lighting Systems - Lighting Systems
Maintenance data
Bulb Color Power (W) QTY
High beam White 55 W 2
Low beam White 55 W 2
Front Combination lamp Front position light Red 0.5 W 2
Front turn signal Amber 21 W 2
Curve auxiliary lamp Amber 55 W 2
Stop lamp（LED） Red 18*0.2W/8*0.5W 2
Rear position light
Red 18*0.2W 4
Rear combination lamp （LED）
Rear turn signal Amber 21 W 2
Reverse lamp White 16 W 2
Daytime running light (LED) White 6*0.5W 2
License plate light（LED） White 3*0.5W 2
High-level stop lamp（LED） Red 8*0.5W 1
Side turn signal（LED） Amber 3*0.5W 2
Front fog light White 55 W 2
Rear fog light White 21 W 2
Trunk light Amber 5W 1
Door light Amber 5W 4
Glove box lamp Amber 1.2 W 1
Dressing lamp Amber 2*0.5W 1
Front dome light Amber 5W 1
Rear dome light Amber 5W 2

Item N•m
Front combination lamp the fixing bolts 8 ～ 12
Daytime running light assembly fixing bolt 5～6
Rear combination lamp I the fixing nuts 8 ～ 12
Rear combination lamp II fixing bolt and nut 8 ～ 12
Reverse lamp assembly fixing bolt 5～6
77-3
Precautions
1. In inspection by using battery, positive and negative probe should not close to each other,
otherwise may cause short circuit.
2. To measure the voltage in the circuit, the power state shoult be ON.
3. Always prepare a new bulb for replacement.
4. Always replace with new bulb of same rated power.
5. When replacing the light, if the light removed from the vehicle is stored for too long time, the
lightshade may be covered with dust and moisture, which may cause the poor lighting or
advance damage. Therefore, the light surface should be wiped with a cloth before installation.
6. The lamp holder must be fixed securely after bulb replacement. Clearance around the lamp
holder may cause lens unclear, water can also get into lamp cavity through the clearance.
System description
1. Function
The lighting system is one of the essential systems for the vehicle driving safety.
In order to ensure safe and reliable vehicle driving, the vehicle is equipped with a variety of lighting
and signal devices for road lighting, indication of vehicle width and location, vehicle inside lighting,
instrument indications, night maintenance and etc. In addition, under turning, braking, parking,
reversing and other conditions, it can issue a light or sound signal to alert pedestrians and other
vehicles.
2. Composition
The lighting system mainly consists of front combination lamp, rear combination lamp, front/rear
dome lights, trunk light, daytime running light, high-mounted stop lamp, reverse lamp, license plate
lamp, fog lamp and etc.
77
Component drawing
13
1 11 12 15
10-1
2 11-1
10-1 14 10-1
16
17 19
1-3
1-2
1-1
10-1 18
20 3
2 21 4
6
5-1
27 6
26
22 5
10-1
25 10
24 8
1-3 24-1 7
23-1
9
23 LFWX-6470-77001
Right front combination lamp

1 12 Right makeup light assembly
assembly
1-1 Bulb 13 Dome lamp assembly
1-2 Bulb 14 Cross recessed pan head screw
1-3 Bulb 15 Luggage compartment light assembly
2 16 Rear dome light assembly
3 17 High-position stop lamp assembly
screw
4 Right daytime running light assembly 18 Hexagon flange bolt
5 Right front fog light assembly 19 License plate lamp assembly
5-1 Bulb 20 Right rear door light assembly II
Cross recess big half round self-
6 21 Right rear door light assembly
tapping screw
7 Left front fog light assembly 22 Right rear fog lamp assembly
8 Left daytime running light assembly 23 Left rear fog lamp assembly
9 Left front combination lamp assembly 23-1 Bulb
10 Left/right front door light 24 Left rear door light assembly II
10-1 Bulb 25 Left rear door light assembly
77-5
11 Glove box lamp assembly 26 Hexagon flange nut

11-1 Bulb 27 Combination lamp positioning buckle

Vehicle fault
Part name Part function Common part fault
phenomenon
It is not turned on or
Dome lamp assembly /
turned off
Provide the lighting for the driver It is not turned on or
Makeup mirror light /
and the passengers turned off
Rear dome light It is not turned on or
/
assembly turned off
Provide the road lighting and the
Front/rear fog lamp It is not turned on or
signal to the rear vehicles in rain /
assembly turned off
and fog weather
Front combination lamp It is not turned on or
Provide the night road lighting /
assembly turned off
Rear combination lamp It is not turned on or
Lighting signal system /
assembly turned off
High-mounted stop lamp Lighting signal system /
turned off
Side turn signal Lighting signal system /
turned off
Daytime driving light Provide an eye-catching and safe It is not turned on or
/
assembly signal for daytime driving turned off
Provide the rear road lighting
and signal to other vehicles 77
and pedestrians for reversing It is not turned on or
Reverse lamp /
operation; indicate that the vehicle turned off
is reversing, and has lighting and
signalling functions
License plate lamp Provide the license plate lighting /
turned off
Trunk light It is not turned on or
For trunk and glove box lighting /
Glove box lamp turned off
1. Function inspection
(a). Park the vehicle on a safe place and apply the
parking brake.
Note:
When inspecting the lighting system, must ensure
that the battery voltage is not less than 12V.
(b). The power state should be ON.
(c). Turn on the light switches of the lighting system,
to inspect their functions.
Condition: All lights are switched on/off by their
switches.
△ Tips:
For specific switch and light usage and turning on/off
rules, see Lifan Xuanlang ehicle User Manual.
LFWX-6470-77002
2. Inspect fuses and relays in the engine

compartment central control box
K03
(a).Open the engine compartment cover.
FS03
K02
FS04
K04
FS05
(b). Open the engine compartment central control
FS06
FS08
K05
FS09
K07
K09
box cover.
FS10
FS07

FS11
K11
K06
15.0
30/2
R
(c). Inspect the fuses and relays corresponding to
FS02
85
K08
FS13
K13
K10
FS01
the lights of the lighting system.
Condition: The fuse should be continuity and the relay
should be operated properly.
△ Tips:
The engine compartment central control box includes
the following lighting system fuses: high beam and
low beam fuse FS13, corner lamp fuse FS10, high
beam and low beam relay K13, left corner lamp relay
K10, right corner lamp relay K11.
Note:
LFWX-6470-77003 The marks on the rear side of the engine
compartment central control box cover shall
prevail.
3. Inspect the fuses in the cab central control
box
(a). Remove the note box on lower left side of the
dashboard.
(B). Inspect the fuses corresponding to the lights.
Condition: the fuse should be continuity.
△ Tips:
The cab central control box includes the lighting
system related fuses: stop lamp fuse FS24, dome
lamp and glove box lamp fuse FS26, front fog lamp
FS39
FS43
FS22
FS19
FS47
FS41
FS24
FS15
FS30
FS46
FS28
FS29
FS42
FS40
FS37
FS35
FS38
fuse FS34, vanity mirror lamp FS37 and front fog lamp
K19
K18
K20
K14
relay K16 etc.

SB10
SB08
SB09
FS34
FS36
FS23
FS32
FS17
FS27
FS14
FS18
FS33
FS31
FS16
FS25
FS26
FS44
FS21
FS20
FS45
K15
K17
K16
LFWX-6470-77004
Diagnosis
1. Fuse (blown)
2. Relay (damaged)
The high/low beam See Section 77- Lighting System
3. Bulb (damaged)
on both sides are not -Diagnosis, Troubleshooting (1. The high/
operated 4. Wiring harness (fault) low beam on both sides are not operated)
5. L i g h t c o m b i n a t i o n s w i t c h
(damaged)
1. Bulb (damaged) See Section 77- Lighting System
The high/low beam on
-Diagnosis, Troubleshooting (2. The high/
one side is not operated 2. Wiring harness (fault)
low beam on one side is not operated)
77-7

1. Fuse (blown) See Section 77- Lighting System
The front turn signal and
-Diagnosis, Troubleshooting (3. The front
the side turn signal are 2. Wiring harness (fault)
turn signal and the side turn signal are not
not operated 3. FBCM(damaged) operated)
1. Wiring harness (fault) See Section 77- Lighting System
The rear turn signal is
2. Bulb (damaged) -Diagnosis, Troubleshooting (4. The rear
not operated
3. RBCM(fault) turn signal is not operated)
1. Fuse (blown)
2. Wiring harness (fault)
See Section 77- Lighting System
All turn signals are not 3. L i g h t c o m b i n a t i o n s w i t c h
-Diagnosis, Troubleshooting (5. All turn
operated (damaged)
signals are not operated)
4. FBCM(fault)
5. RBCM (fault)
The rear fog lamp on
-Diagnosis, Troubleshooting (6. The rear
one side is not operated 2. Lamp (damaged)
fog lamp on one side is not operated)
2. Bulb (damaged)
The rear fog lamps See Section 77- Lighting System
3. L i g h t c o m b i n a t i o n s w i t c h
on both sides are not -Diagnosis, Troubleshooting (7. The rear
(damaged)
operated fog lamps on both sides are not operated)
4. FBCM (fault)
5. RBCM (fault)
1. Wiring harness (fault) See Section 77- Lighting System 77
The stop lamp on one
-Diagnosis, Troubleshooting (8. The stop
side is not operated 2. Bulb (damaged) lamp on one side is not operated)
The stop lamps on both
-Diagnosis, Troubleshooting (9. The stop
sides are not operated 2. Bulb (damaged)
lamps on both sides are not operated)
The high-position stop
-Diagnosis, Troubleshooting (10. The high-
lamp is not operated 2. Bulb (damaged) position stop lamp is not operated)
1. Fuse (blown) See Section 77- Lighting System
All stop lamps are not
2. Wiring harness (fault) -Diagnosis, Troubleshooting (11. All stop
operated
3. Brake switch (damaged) lamps are not operated)
The reverse lamp on
-Diagnosis, Troubleshooting (12. The
one side is not operated 2. Bulb (damaged)
reverse lamp on one side is not operated)
The reverse lamps 2. Bulb (damaged) -Diagnosis, Troubleshooting (13. The
on both sides are not
3. Reversing switch (fault) reverse lamps on both sides are not
operated
operated)
4. RBCM(fault)

1. Fuse (blown)
The front dome light is
-Diagnosis, Troubleshooting (14. The front
not operated 3. Bulb (damaged) dome light is not operated)
4. Front roof light switch(damaged)
1. Fuse (blown)
The rear dome light is
-Diagnosis, Troubleshooting (15. The rear
not operated 3. Bulb (damaged) dome light is not operated)
4. Rear dome light switch (damage)
The luggage 1. Fuse (blown) See Section 77- Lighting System
compartment light is not 2. Wiring harness (fault) -Diagnosis, Troubleshooting (16. The
operated 3. Trunk cover lock (fault) luggage compartment light is not operated)
1. Fuse (blown)
The left front door lamp
3. Door control switch (damaged) -Diagnosis, Troubleshooting (17. The left
is not operated
4. Left front door controller (damage) front door lamp is not operated)
5. FBCM(fault)
1. Fuse (blown)
The right front door 3. Door control switch (damaged)
-Diagnosis, Troubleshooting (18. The right
lamp is not operated 4. R i g h t f r o n t d o o r c o n t r o l l e r front door lamp is not operated)
(damaged)
5. FBCM(fault)
1. Fuse (blown)
The left rear door lamp 3. Door control switch (damaged)
-Diagnosis, Troubleshooting (19. The left
is not operated 4. L e f t r e a r D o o r C o n t r o l l e r rear door lamp is not operated)
(damaged)
5. FBCM(fault)
1. Fuse (blown)
The right rear door lamp 3. Door control switch (damaged)
-Diagnosis, Troubleshooting (20. The right
is not operated 4. R i g h t r e a r D o o r C o n t r o l l e r rear door lamp is not operated)
(damaged)
5. FBCM(fault)
77-9
Fault diagnosis
1. The high/low beam lights on both sides are not operated
Steps Inspection contents Inspection result
The high/low
Inspect the high/low beam lights for Diagnosis is beam lights on
Go to Step 1
operation finished both sides are not
turned on
Inspect whether the high/low beam FS13 fuse is
light fuses are blown blown
2 Inspect FS13 wiring harness Normal Faulty Instruction
Repair the wiring
harness and replace
Inspect FS13 wiring harness for
Go to Step 3 Short circuit the fuse with the same
operation
size based on the circuit
drawing catalog
3 Check the relay Normal Faulty Instruction
Inspect the high/low beam light Replace the relay of the
Go to Step 4 Relay is damaged
relay K13 for damage same specification
Replace the same type of high/low
Diagnosis is The fault still
beam bulb, and inspect whether Go to Step 5
finished exists
the fault is eliminated 77
Inspect the continuity of the high/
low beam power wiring harness:
(a).With the power in OFF state,
and disconnect left/right front
combination light wiring harness
connector U17/U08.
(b).With the power in ON state,
Check the relevant
turn on the low beam, inspect the Go to Step 6
Unconnected harness according to
voltage between the terminal 12
the circuit diagram
of the left/right front combination
light wiring harness connector
and the body grounding wire with
the voltage position on a digital
multimeter; if the voltage is 0,
inspect the relevant wiring harness
based on the circuit diagram.

Inspect the continuity
of the high/low beam
grounding wire:
(a).With the power in
OFF state, and dis-
connect left/right front
combination light wiring
harness connector U17/
U08。
Check the relevant har-
(b).Inspect the continu-
Go to Step 7 Unconnected ness according to the
ity between the terminal
circuit diagram
5 of the front combina-
tion lamp wiring har-
ness connector and the
body ground with the
resistance position on
a digital multimeter; if
not, inspect the wiring
harness based on the
circuit diagram.
Inspect the high/low
beam light signal wir-
ing harness in the light
combination switch for
continuity:
OFF state, and discon-
nect combination switch
I21 and FBCM wiring
harness connector I11.
circuit diagram
1 of the combination
switch wiring harness
connector and the
terminal 9 of FBCM
wiring harness with the
circuit diagram.
77-11

Inspect the light com-
bination switch signal
grounding wire for conti-
nuity:
nect combination switch
I21 and FBCM wiring
harness connector I11.
(b). Inspect the continu- Check the relevant har-
ity between the terminal Go to Step 9 Unconnected ness according to the
11 of the combination circuit diagram
connector and the ter-
minal 5 of FBCM wiring
harness connector I33
with the resistance posi-
tion on a digital multi-
meter; if not, inspect the
wiring harness based
on the circuit diagram.
Inspect the light combi-
nation switch
Replace the combina-
Inspect the light combi- tion switch (see Section
Light combination switch
nation switch for opera- Go to Step 10 77- Lighting System -
damage
tion Combination Switch, 77
Replacement)
Reassemble the system
and check whether the Diagnosis is finished The fault still exists
fault is solved
2. The high/low beam lights on one side are not operated

The high/low beam
Inspect the high/low
Diagnosis is finished lights on one side are Go to Step 1
beam for operation
not turned on
Inspection by
replacement
Replace the same type
of high/low beam bulb,
Diagnosis is finished The fault still exists Go to Step 2
and inspect whether the
fault is eliminated

Inspect the continuity of
the high/low beam power
wiring harness:
(a).With the power in OFF
state, and disconnect left/
right front combination light
wiring harness connector
U17/U08。
(b).With the power in ON
state, turn on the high Check the relevant
beam, Inspect the voltage Go to Step 3 Unconnected harness according to the
between the terminal 12 circuit diagram
of the front combination
lamp wiring harness
connector and the body
grounding wire with the
voltage position on a digital
multimeter; if the voltage
is 0, inspect the relevant
wiring harness based on
the circuit diagram.
of the high/low beam
grounding wire:
right front combination light
U17/U08.
Check the relevant
(b).Inspect the continuity
Go to Step 4 Unconnected harness according to the
circuit diagram
the front combination lamp
and the body ground with
the resistance position on
a digital multimeter; if not,
inspect the wiring harness
based on the circuit
diagram.
Reassemble the system
fault is solved
3. The front turn signal and the side turn signal are not operated
The front turn signal and
Inspect the turn signal
Diagnosis is finished the side turn signal are Go to Step 1
for operation
not operated
Inspect whether the
turn signal fuse FS18 is Go to Step 3 FS18 fuse blown Go to Step 2
blown
2 Inspect FS18 circuit Normal Faulty Instruction
77-13

Repair the wiring harness
Inspect FS18 circuit for and replace the fuse with
Go to Step 3 Short circuit
operation the same size based on
the circuit drawing catalog
Inspect the front turn
signal power supply wiring
harness for continuity:
state, and disconnect front
harness connector.
state, turn on the turn
Check the relevant
light, Inspect the voltage Go to Step 4
Unconnected harness according to the
circuit diagram
the front combination light
and the body grounding
wire with the voltage
position on a digital
multimeter; if the voltage
is 0, inspect the relevant
front turn light grounding
wire: 77
state, and disconnect front
harness connector.
(b).Inspect the continuity Check the relevant
between the terminal 3 of Go to Step 5 Unconnected harness according to the
the front combination lamp circuit diagram
diagram.
Inspect the side turn signal
Check the relevant
power wire for continuity
(see xuanlang circuit
circuit diagram
diagram)
Inspect the side turn
Check the relevant
signal grounding wire for
continuity (see xuanlang
circuit diagram
circuit diagram)
Check the relevant
FBCM power wire (refer to
Xuanlang - Circuit Diagram
circuit diagram
Book)

Check the relevant
of FBCM grounding
wire (refer to Xuanlang
the circuit diagram
Circuit Diagram Book)
Inspection by
replacement
of FBCM and inspect Locate the causes from
whether the fault is other fault phenomenon
eliminated
4. The rear turn signals are not operated

Inspect the turn signal The rear turn signal is
for operation not operated
the rear turn signal light
power wire :
(a).With the power
in OFF state, and
disconnect left/right
harness connector B8/
G5。
(b).With the power in
ON state, turn on the Check the relevant
Go to Step 2
turn signals and inspect Unconnected harness according to
the voltage between the the circuit diagram
terminal 3 of the rear
harness connector B8/
G5 and the body ground
with the voltage position
on a digital multimeter ;
if the voltage is 0, repair
the relevant wiring
circuit diagram.
77-15

Inspect the rear turn
signal grounding wire for
continuity:
right combination light
B8/G5.
between the terminal Go to Step 3 Unconnected harness according to
1 of the left/right rear the circuit diagram
combination lamp wiring
harness connector and
the body ground with the
resistance position on a
digital multimeter; if not,
repair the wiring harness
diagram.
Check the relevant
RBCM grounding wire
(refer to Xuanlang Circuit
the circuit diagram
Diagram Book)
Inspect the continuity of 77
Check the relevant
RBCM grounding wire
the circuit diagram
Diagram Book)
Inspect BCAN-L and
BCAN-H wires
between RBCM and
Maintain the wire
FBCM wires and between
Go to Step 6 Unconnected between BCAN-L and
BCAN-L and BCAN-H
BCAN-H
wires (refer to Xuanlang
6 Read fault code Normal Faulty Instruction
Connect the diagnosis
There is a fault code
device to inspect whether Repair according to the
Go to Step 7 output about BCAN-L
there is any fault code DTC prompt
and BCAN-H wires
output
Inspection by
replacement
of rear combination lamp Diagnosis is
The fault still exists Go to Step 8
and inspect whether the finished
fault is eliminated
Inspection by
replacement
of RBCM and inspect Diagnosis is Locate the causes from
whether the fault is finished other fault phenomenon
eliminated
5. All turn signals are not operated

Inspect the turn signal for Diagnosis is All turn signals are
Go to Step 1
operation finished not operated
Inspect whether the turn

Go to Step 3 FS18 fuse blown Go to Step 2
signal fuse FS18 is blown
Repair the wiring
harness and replace
Inspect FS18 circuit for
operation
drawing catalog
Inspect the turn signal light
wiring harness in the light
combination switch for
continuity:
state, and disconnect
combination switch I21
and FBCM wiring harness
connector I11. Check the relevant
(b). Inspect the continuity Go to Step 4 Unconnected harness according to
between the terminal 10 of the circuit diagram
the combination switch wiring
harness connector I11 and
the terminal 5 of FBCM wiring
harness connector I21 with
Inspect the signal grounding
wire in the light combination
switch for continuity:
connector I11.
Check the relevant
(b). Inspect the continuity
the circuit diagram
the combination switch wiring
based o
77-17

Inspect the combination
lamp switch
Replace the
Inspect the light combination switch (see
combination switch for Go to Step 6 Section 77- Lighting
damage
operation System - Combination
Switch, Replacement)
Check the relevant
FBCM power wire (refer
to Xuanlang - Circuit
the circuit diagram
Diagram Book)
Check the relevant
FBCM grounding wire
(refer to X Xuanlang
the circuit diagram
Check the relevant
RBCM power wire (refer
to X Xuanlang Circuit
the circuit diagram
Diagram Book)
Check the relevant 77
of FBCM grounding
the circuit diagram
Inspection by
replacement
of FBCM and inspect
eliminated
Inspection by
replacement
of RBCM and inspect Locate the causes from
eliminated
w6. The rear fog lights on one side are not operated
Inspect the rear fog The rear fog lamp on
lamp for operation one side is not operated

the rear fog lamp power
wire:
nect the left/right rear
fog light wiring harness
connector V1/V5.
ON state, and open the Check the relevant har-
rear fog lamp. Go to Step 2 Unconnected ness according to the
(c).Use a digital univer- circuit diagram
sal meter resistance to
check if there is voltage
between the rear fog
lamp harness connector
terminal 2 and the body
ground, and repair the
related harness accord-
ing to the circuit manual
if the voltage is 0.
of the rear fog lamp
grounding wire:
(a).Disconnect the left/
right rear fog light wiring
harness connector V1/
V5.
Check the relevant
(b).Inspect the
continuity between the
the circuit diagram
terminal 1 of the rear
fog light wiring harness
grounding wire; if not,
maintain the relevant
Inspection by
replacement
of rear fog light bulb and Locate the causes from
inspect whether the fault other fault phenomenon
is eliminated
7. The rear fog lamps on both sides are not operated

The rear fog lamps
Inspect the rear fog
Diagnosis is finished on both sides are not Go to Step 1
lamp for operation
operated
77-19

Inspect the continuity of the
rear fog lamp power wire:
state, and disconnect the left/
right rear fog light wiring har-
ness connector V1/V5.
state, and open the rear fog Check the relevant har-
lamp. Go to Step 2 Unconnected ness according to the
(c).Use a digital universal me- circuit diagram
ter resistance to check if there
is voltage between the rear
fog lamp harness connec-
tor terminal 2 and the body
ground, and repair the related
harness according to the cir-
cuit manual if the voltage is 0.
rear fog lamp grounding wire:
(a).Disconnect the left/right
rear fog light wiring harness
connector V1/V5.
(b).Inspect the continu- Check the relevant har-
ity between the terminal 1 Go to Step 3 Unconnected ness according to the
of the rear fog light wiring circuit diagram
harness connector and the 77
body grounding wire; if not,
maintain the relevant wiring
harness based on the circuit
diagram.
Inspect the rear fog light signal
wire in the light combination
switch for continuity:
connector I11.
Check the relevant
between the terminal 4 of the
the circuit diagram
combination switch wiring
harness connector I11 with the
resistance position on a digital
multimeter; if not, inspect the
wiring harness based on the
circuit diagram.

Inspect the light
combination switch
signal grounding wire
for continuity:
(a).With the power
in OFF state, and
disconnect combination
switch I21 and FBCM
wiring harness
connector I11.
Check the relevant
the circuit diagram
11 of the combination
connector I21 and
the terminal 5 of
FBCM wiring harness
connector I11 with the
harness based o
Inspection by
replacement
of rear fog light bulb and
inspect whether the fault
is eliminated
Inspect the light
combination switch
Replace the
Inspect the light combination switch (see
combination switch for Go to Step 7 Section 77- Lighting
damage
operation System - Combination
Switch, Replacement)
Check the relevant
the circuit diagram
Diagram Book)
Check the relevant
of FBCM grounding
the circuit diagram
Check the relevant
to Xuanlang Circuit
the circuit diagram
Diagram Book)
77-21

of RBCM grounding
circuit diagram
Inspect BCAN-L and
BCAN-H wires
Inspect the continu-
ity between RBCM
and FBCM wires and Maintain the wire be-
between BCAN-L and Go to Step 12 nconnected tween BCAN-L and
BCAN-H wires (refer to BCAN-H
Xuanlang Circuit Dia-
gram Book)
device to inspect Repair according to the
Go to Step 13 output about BCAN-L
whether there is any DTC prompt
and BCAN-H wires
fault code output
Inspection by
replacement
of FBCM and inspect
eliminated
Inspection by
14 Normal Faulty Instruction 77
replacement
eliminated
8. The stop lamps on one side are not operated

Inspect the stop lamp The stop lamp on one
for operation side is not operated

the stop lamp power wire:
right rear combination
light wiring harness con-
nector B8/G5。
state, and depress the
brake pedal.
(c).Inspect the voltage
circuit diagram
of the stop lamp wiring
the body grounding with
the voltage position on a
digital multimeter; if the
voltage is 0, inspect the
the stop lamp grounding
wire:
nector B8/G5。
Check the relevant
(b).Inspect the continu-
ity between the terminal
the circuit diagram
1 of the front combina-
tion lamp wiring harness
ground with the resis-
tance position on a digital
multimeter; if not, inspect
the wiring harness based
Inspection by
replacement
of rear combination lamp
assembly and inspect Diagnosis is finished The fault still exists
eliminated
9. The stop lamps on both sides are not operated

Inspect the stop lamp The stop lamps on both
for operation sides are not operated
77-23

the stop lamp power wire:
nector B8/G5。
state, and depress the
brake pedal.
(c).Inspect the voltage
circuit diagram
of the stop lamp wiring
the body grounding with
the voltage position on a
the stop lamp grounding
wire:
right rear combination 77
light wiring harness
connector B8/G5.
Check the relevant
the circuit diagram
of the front combination
lamp wiring harness
ground with the resistance
multimeter; if not, inspect
Inspection by
replacement
of rear combination lamp
assembly and inspect Diagnosis is finished The fault still exists
eliminated
10. High-mounted stop lamp is not operated

Inspect the stop lamp The high-position stop
for operation lamp is not operated

Inspect the high-position
stop lamp power wire for
continuity:
state, and disconnect the
high-mounted stop wiring
harness connector L01。
state, depress the brake
pedal.
(c). Inspect the voltage be-
circuit diagram
tween the terminal 1 of the
high-mounted stop lamp
L01 and the body ground
on a digital multimeter, if
the voltage is 0, inspect
Inspect the high-mounted
stop lamp grounding wire
for continuity:
high-mounted stop wiring
harness connector L01.
(b). Inspect the continu-
ity between the terminal 2
of the high-position stop
circuit diagram
lamp wiring harness con-
nector L01 and the body
ground with the resistance
position on a digital mul-
timeter; if not, repair the
relevant wiring harness
based on the circuit dia-
gram.
Replace the same type of
high-position stop lamp Locate the causes from
and inspect whether the other fault phenomenon
fault is eliminated
11. All stop lamps are not operated

Inspect the stop lamp All stop lamps are not
for operation operated
Inspect whether the
fuse FS24 is blown
77-25

Repair the wiring
harness and replace
operation
drawing catalog
Inspect the brake
switch power wire for
continuity:
(a).With the power
in OFF state, and
disconnect brake switch
connector I06
ON state, and inspect
Check the relevant
the voltage between Go to Step 4
the terminals 1 and 3 of
the circuit diagram
the brake switch wiring
harness connector I06
and the body ground
on a digital multimeter; if
the voltage is 0, Repair
the relative wiring
circuit diagram.
4 Check the harness Normal Faulty Instruction 77
Inspect the grounding
point G2 amd G33 of
Check the relevant
the stop lamps on both
sides and the high-
the circuit diagram
mounted stop lamp for
poor contact
Inspection by
replacement
of brake switch, and Locate the causes from
inspect whether the fault other fault phenomenon
is eliminated
12. The reverse lamps on one side are not operated

Inspect the reverse The reverse lamp on
lamp for operation one side is not operated

reverse lamp power wire :
left/right combination tail
L3/L11.
state, and engage the re-
verse gear. Check the relevant
(c). Inspect the voltage be- Go to Step 2 Unconnected harness according to
tween the terminal 3 of the the circuit diagram
left/right combination lamp
and the body grounding
wire with the voltage posi-
tion on a digital multimeter;
if the voltage is 0, inspect
the relevant wiring harness
based on the circuit dia-
gram.
the reverse lamp grounding
wire:
state,and disconnect the
L3/L11.
between the terminal 1 of Go to Step 3 Unconnected harness according to
the left/right combination the circuit diagram
lamp wiring harness
connector L3/L11 and
diagram.
Locate the causes
of reverse lamp bulb, and
Diagnosis is finished The fault still exists from other fault
inspect whether the fault is
phenomenon
eliminated
13. The reverse lamps on both sides are not operated

The reverse lamps
Inspect the reverse
Diagnosis is finished on both sides are not Go to Step 1
lamp for operation
operated
77-27

circuit diagram
Diagram Book)
RBCM grounding wire
(refer to Xuanlang -
circuit diagram
Check the relevant
the circuit diagram
Diagram Book)
Check the relevant
RBCM grounding wire
the circuit diagram
of the reverse lamp
grounding wire:
(a).With the power
in OFF state,and 77
disconnect the left/right
combination tail lamp
harness connector L3/
L11。
ON state, and engage
the reverse gear. Check the relevant
(c). Inspect the voltage Go to Step 6 Unconnected harness according to
between the terminal the circuit diagram
3 of the left/right
combination lamp wiring
harness connector
L3/L11 and the body
grounding wire with the
voltage position on a
relevant wiring harness
diagram.

the reverse lamp grounding
wire:
lamp harness connector.
Check the relevant
the left/right combination
the circuit diagram
lamp wiring harness
connector L3/L11 and
diagram.
Check the relevant
Inspect the reversing switch
signal wire for continuity
the circuit diagram
Inspect the continuity of the Check the relevant
reversing switch grounding Go to Step 9 Unconnected harness according to
wire the circuit diagram
Inspect BCAN-L and
BCAN-H wires
between RBCM and FBCM
Maintain the wire
wires and between BCAN-L
Go to Step 10 Unconnected between BCAN-L and
and BCAN-H wires (refer to
BCAN-H
Xuanlang Circuit Diagram
Book)
Connect the diagnosis There is a fault
device to inspect whether code output about Repair according to the
Go to Step 11
there is any fault code BCAN-L and DTC prompt
output BCAN-H wires
of reverse lamp bulb, and
eliminated
of reversing switch, and
eliminated
RBCM and inspect whether Diagnosis is finished The fault still exists Go to Step 14
the fault is eliminated
77-29

Inspection by
replacement
eliminated
14. The front dome light is not operated

Inspect the front dome The front dome light is
light for operation not operated
Inspect whether the
fuse FS26 is blown
Repair the wiring
harness and replace
operation
drawing catalog
Inspect the front dome
light power wire for 77
continuity:
(a).With the power
in OFF state, and
disconnect front dome
connector R04.
ON state, inspect the
Check the relevant
continuity between Go to Step 4
the terminal 10 of the
the circuit diagram
front dome light wiring
harness connector
left R04 and the
a digital multimeter;
and repair the related
harness according to
the circuit manual if the
voltage is 0.

Inspect the front dome
light ground wire for
continuity:
nect front dome light
wiring harness connec-
tor R04.
(b). Inspect the continu- Check the relevant har-
ity between the termi- Go to Step 5 Unconnected ness according to the
nal 1 of the front dome circuit diagram
connector R04 and the
repair the relative wiring
circuit diagram.
Inspection by replace-
ment
of front dome light bulb,
fault is eliminated
ment
of front roof light switch Locate the causes from
and inspect whether the other fault phenomenon
fault is eliminated
15. The rear dome light is not operated

Inspect the rear dome The rear dome light is
light for operation not operated
Inspect whether the
FS26 and FS27 fuse
fuse FS26 and FS27 Go to Step 3 Go to Step 2
are blown
are blown
Inspect FS26 and FS27
circuit
Repair the wiring
harness and replace
circuit for operation
drawing catalog
77-31

rear dome light power wire:
state, and disconnect rear
dome light wiring harness
connector, left rear dome
light R6 and right rear dome
light R5.
(b).With the power in ON Check the relevant
state, inspect the continuity Go to Step 4 Unconnected harness according to
between the terminal 1 of the the circuit diagram
rear dome light wiring har-
ness connector left R6/ right
R5 and the body ground with
the resistance position on a
digital multimeter; and repair
the related harness accord-
ing to the circuit manual if
the voltage is 0.
Inspect the continuity of rear
roof light grounding wire:
state, and disconnect left R6/
right R5 of rear dome light
wiring harness connector.
(b). Inspect the continuity Check the relevant 77
between the terminal 3 of the Go to Step 5 Unconnected harness according to
rear roof light wiring harness the circuit diagram
connector left R6/ right R5
rear roof light switch and
eliminated
Locate the causes
rear roof light switch and
Diagnosis is finished The fault still exists from other fault
phenomenon
eliminated
16. The trunk light is not operated

Inspect the luggage The luggage
compartment light for Diagnosis is finished compartment light is Go to Step 1
operation not operated

Inspect whether the fuse Fuse FS27 and FS26
FS27 and FS26 are blown are blown
wiring harness
Repair the wiring
harness and replace
circuit for operation
drawing catalog
the trunk light power wire :
OFF state, disconnect the
trunk light wiring harness
connector G6.
ON state, inspect the
Check the relevant
continuity between the Go to Step 4
terminal 1 of the trunk light
the circuit diagram
G6 and the body ground
with the resistance
multimeter; and repair the
related harness according
to the circuit manual if the
voltage is 0.
Inspect the trunk signal
wire for continuity:
trunk light wiring harness
connector G6 and trunk
cover lock wiring harness
connector L07.
between the terminal 2 Check the relevant
of the trunk light wiring Go to Step 5 Unconnected harness according to
harness connector G06 the circuit diagram
and the terminal 2 of the
trunk cover lock wiring
harness connector L07
with the resistance
multimeter; if not, repair
the relevant harness
diagram.
77-33

Inspect the trunk cover
lock grounding wire for
continuity:
(a). Disconnect the
trunk cover lock wiring
harness connector L07.
(b). Inspect the continu-
ity between the terminal Check the relevant har-
1 of the trunk cover Go to Step 6 Unconnected ness according to the
lock wiring harness circuit diagram
connector L07 and the
digital multimeter; If not,
repair the relevant wir-
ing harness based on
Inspect the trunk cover
lock
Replacement (see
Section 82 - Door/
Inspect the trunk cover Trunk cover lock
Go to Step 7 Cab Door/Door Lock
lock for operation damage
– Trunk Cover Lock,
Replacement)
Reassemble the system 77
fault is solved
17. The left front door light is not operated

Inspect the left front The left front door lamp
door lamp for operation is not operated
Inspect whether the
fuse FS26 is blown
Repair the wiring
harness and replace
operation
drawing catalog

Inspect the left front door light
power wire for continuity:
(a). Disconnect the left front
door lamp wiring harness
connector D01.
(b). Inspect the voltage be-
left front door wiring harness
circuit diagram
connector D01 and the body
ground with the voltage posi-
tion on a digital multimeter;
If the voltage is 0, repair the
relative wiring harness based
Inspect the left front door
lamp control wiring harness
for continuity:
(a). Disconnect the left front
door lamp wiring harness
connector D01 and the left
front door controller wiring
harness connector D06.
(b). Inspect the continuity Check the relevant har-
between the terminal 2 of Go to Step 5 Unconnected ness according to the
the left front door lamp wiring circuit diagram
harness connector D01 and
the terminal 7 of the left front
door controller wiring harness
connector D06 with the re-
sistance position on a digital
multimeter; If not, repair the
relative wiring harness based
control switch signal line for
continuity:
(a). Disconnect the left
front door control switch
connectors B01 and I10.
Check the relevant
between the terminal 1 of the
left front door control switch
the circuit diagram
wiring harness connector B01
and the terminal 6 of FBCM
wiring harness connector I10
with the resistance position
on a digital multimeter; If not,
repair the relevant wiring
diagram.
77-35

the door control switch, and
eliminated
right front door controller Go to Step 8 Unconnected harness according to the
power wiring harness circuit diagram
Inspect the left front door Check the relevant
controller grounding wire Go to Step 9 Unconnected harness according to the
for continuity circuit diagram
controller
Replacement (see
Section 78 - Central
Inspect the left front door Front left door
Go to Step 10 Control Lock and Anti-
controller for operation controller damage
theft Device - Front Door
Controller, Replacement)
Check the relevant
circuit diagram
Book)
Inspect the continuity of 77
Check the relevant
FBCM grounding wire
(refer to Xuanlang - Circuit
circuit diagram
Diagram Book)
Inspect LIN communication
signal line
signal line between the left
Inspect LIN
front door controller and Go to Step 13 Unconnected
communication wire
FBCM for continuity (see
Xuanlang circuit diagram)
13 Read LIN fault code Normal Faulty Instruction
Go to Step 14 output about LIN
communication wire
output
FBCM and inspect whether Diagnosis is finished The fault still exists
18. The right front door lamp is not operated

Inspect the right front The right front door
door lamp for operation lamp is not operated

Inspect whether the
fuse FS26 is blown
Repair the wiring har-
ness and replace the
Go to Step 3 Short circuit fuse with the same size
operation
drawing catalog
of the right front light
power wire:
(a). Disconnect the right
front door light wiring
harness connector K01.
(b). Use a digital
universal meter
Check the relevant
resistance to check if
there is voltage between
the circuit diagram
the right front door light
harness connector
K01 terminal 1 and the
body ground, and repair
the related harness
according to the circuit
manual if the voltage is
0.
of the right front light
control grounding wire:
front door light and the
right front door light
control wiring harness
connector K04.
(b). Inspect the voltage
Check the relevant
of the right front door
the circuit diagram
connector K01 and the
terminal 3 of the right
front door controller
wiring harness
connector K03 with the
maintain the relevant
77-37

left front door control switch
signal grounding wire:
(a). Disconnect the right front
door light switch and FBCM
G01, I10.
the front right door control
circuit diagram
switch wiring harness con-
nector G01 and the terminal
5 of FBCM wiring harness
connector I10 with the resis-
tance position on a digital
multimeter; if not, inspect the
wiring harness based on the
circuit diagram.
eliminated
power wiring harness circuit diagram
77
grounding wire circuit diagram
Inspect the right front door
controller
Replacement (see
Inspect the right front door Front right door
controller for operation controller damage
theft Device - Front Door
Check the relevant
circuit diagram
Book)
Check the relevant
FBCM grounding wire
circuit diagram
Diagram Book)
signal line
signal line between the right
front door controller and Inspect LIN
FBCM for continuity (refer to communication wire
Book)

device to inspect Repair according to the
whether there is any DTC prompt
communication wire
fault code output
Inspection by
replacement
eliminated
19. The left rear door lamp is not operated

Inspect the left rear door The left rear door lamp
lamp for operation is not operated
Inspect whether the
fuse FS26 is blown
Repair the wiring
harness and replace
operation
drawing catalog
the left front door light
power wiring harness:
(a). Disconnect the left
rear door light wiring
harness connector M03.
(b). Use a digital
universal meter
Check the relevant
resistance to check if
there is voltage between
the circuit diagram
the left rear door light
harness connector
M03 terminal 1 and the
body ground, and repair
the related harness
manual if the voltage is
0.
77-39

left rear light control grounding
wire:
(a). Disconnect the left rear
door light and the left rear door
light control wiring harness
connector M04.
left rear door light wiring
circuit diagram
harness connector M03 and
the terminal 3 of the left front
door controller wiring harness
connector M04 with the re-
sistance position on a digital
multimeter; if not, maintain the
relevant wiring harness based
left rear door control switch
signal grounding wire:
(a). Disconnect the left rear
wiring harness connector B04
and I10.
tween the terminal 1 of the left
rear door light wiring har-
circuit diagram
ness connector B04 and the 77
terminal 14 of the left front
door controller wiring har-
ness connector I10 with the
resistance position on a digital
multimeter; if not, maintain the
relevant wiring harness based
eliminated
Inspect the continuity of the Check the relevant har-
left rear door controller power Go to Step 8 Unconnected ness according to the
wiring harness circuit diagram
left rear door controller groun- Go to Step 9 Unconnected harness according to the
ding wire circuit diagram
Inspect the left rear door
controller
Replacement (see Sec-
tion 78 - Central Control
Inspect the left rear door con- Rear left door control-
Go to Step 10 Lock and Anti-theft Device
troller for operation ler damage
- Rear Door Controller,
Replacement)

Check the relevant
the circuit diagram
Diagram Book)
FBCM grounding wire
circuit diagram
Inspect LIN communica-
tion signal line
tion signal line between
the left rear door con-
troller and FBCM for Go to Step 13 Unconnected
tion wire
continuity (refer to Xu-
anlang - Circuit Diagram
Book)
device to inspect wheth- Repair according to the
Go to Step 14 output about LIN com-
er there is any fault DTC prompt
munication wire
code output
ment
whether the fault is eli- other fault phenomenon
minated
20. The right rear door lamp is not operated

Inspect the right rear The right rear door lamp
door lamp for operation is not operated
Inspect whether the
fuse FS26 is blown
Repair the wiring

harness and replace
operation
drawing catalog
77-41

right front door light power
wiring harness:
(a). Disconnect the right rear
door light wiring harness
connector N03.
(b).Use a digital universal Check the relevant
meter resistance to check if Go to Step 4 Unconnected harness according to
there is voltage between the the circuit diagram
right rear door light harness
connector N03 terminal 1
and the body ground, and
repair the related harness
manual if the voltage is 0.
the right front control wiring
harness:
rear door light and the right
rear door light control wiring
harness connector N04.
(b). Inspect the voltage
between the terminal 2 of the Check the relevant
right rear door light wiring Go to Step 5 Unconnected harness according to
harness connector N03 and the circuit diagram 77
the terminal 3 of the right
front door controller wiring
harness connector N04 with
maintain the relevant wiring
diagram.
right front door control switch
signal wiring harness:
(a). Disconnect the right rear
G02, I10.
Check the relevant
the rear right door control
the circuit diagram
connector G02 and the
terminal 13 of FBCM wiring

the door control switch,
fault is eliminated
Inspect the continuity of Check the relevant har-
the right rear door control- Go to Step 8 Unconnected ness according to the
ler power wiring harness circuit diagram
Inspect the continuity of Check the relevant har-
the right rear door control- Go to Step 9 Unconnected ness according to the
ler grounding wire circuit diagram
Inspect the right rear door
controller
Replacement (see
Inspect the right rear door The right rear door
controller for operation control unit damage
theft Device - Rear Door
Check the relevant
circuit diagram
Book)
FBCM grounding wire
circuit diagram
Diagram Book)
signal line
Inspect LIN communicati-
on signal line between the
right rear door controller Inspect LIN communicati-
and FBCM for continuity on wire
Diagram Book)
communication wire
output
FBCM and inspect whether Diagnosis is finished The fault still exists
21. The daytime running lights on both sides are not operated
77-43
With the power in ON

state, turn on the daytime The daytime running
running light and inspect Diagnosis is finished lights on both ends Go to Step 1
the daytime running light are not be turned on
for normal operation.
• Turn off all electrical

loads
·Replace the fuse with
• Open the central
the same size
control box in the engine The daytime running
Go to Step 3 ·If the replaced fuse
compartment lamp fuse is blown
is blown again, go to
• Visually inspect the
Step 2
daytime running lamp fuse
F43 for fusing.
Inspect the power supply

2 circuit for daytime running Normal Faulty Instruction
lights
Carry out step-by-step
Disconnect the negative If the resistance
inspection to identify
battery cable and measure is too small, the
short-circuit point,
the resistance between Go to Step 3 power supply wiring
eliminate the fault, and
the daylight running lamp harness is short-
replace the fuse with
power line and the ground circuit 77
same size
3 Inspect bulb Normal Faulty Instruction

Inspect the bulb wiring
harness for loosening or
Replace the daytime
disconnection
Go to Step 5 Bulb damage running lamp
• Remove the bulb and
assembly
inspect the LED for
blowing.
Inspect the daytime run-
ning light circuit
• Disconnect the daytime
running lamp connectors
U19 and U05
• Turn on the daytime run- Repair the wiring har-
ning lights and measure The detected volt- ness between the ter-
the voltage between the Go to Step 6 age is out of the minal 2 of the daytime
terminal 2 of the left front reasonable range running light connector
daytime running lamp con- and BCM
nectors U19 and U05 and
the ground
Voltage: 9~13V
Locate the causes
Test whether the fault is
Diagnosis is finished The fault still exists from other fault phe-
excluded
nomenon
Front combination lamp

Adjustment
1. Preparations before adjustment
(a). Adjust the vehicle to the following status.
• There is no deformation around the front combination lamp.
• Park the vehicle on a level surface.
• The tire pressure is at the standard value. (See Section 33 - Wheels and Tires - Wheels and
Tires, On-board Inspection)
• The driver sits in the vehicle (or with the counterweight of about 73kg) and the vehicel is no-load.
△ Tips:
The no-load condition means that the fuel and engine coolant and lubricants are filled fully, and
spare tire, jack, attaching tools and foot pads are in the specified locations.
2. Inspect the lighting range of the front
combination lamp
△ Tips:
This standard is a Chinese law about adjustment of
the front combination lamp. For the adjustment of the
front combination lamp in other countries, please refer
to the local laws and regulations.
(a). E n s u r e t h a t t h e f r o n t c o m b i n a t i o n l a m p
distribution lens surface is 10m away from the
screen, and the screen is a curtain or a flat wall.
(b). Start the engine.
(c). Turn on the low beam of the front combination
lamp.
(d). Inspect whether the lighting range of the front
combination lamp can meet the requirements in
the diagram.
LFWX-6470-77005 △ Tips:
A and B are the front combination lamp positions; H
is the front combination lamp height; L1 and L2 is the
distances from the front combination lamp centers to
the vehicle center.
(e). If the requirements are not met, adjust the front
combination lamp.
3. Adjust the lighting range of the front
combination lamp
(a). Open the engine compartment cover.
(b). Turn the adjusting screw to adjust the lighting
range of the front combination lamp within the
standard range.
△ Tips:
The front combination lamp can be adjusted
horizontally with the front combination lamp axis
adjustment switch in the cab.
LFWX-6470-77006
77-45
Testing
1. Inspect the high beam light
(a). Inspect the continuity between the terminal 5 and
the terminal 12 of the left/right front combination
lamps with the resistance position on a digital
multimeter
If the above condition can not be achieved,
3 4 5 replace the high beam light.
1 2 6 7
2. Inspect the low beam light
8 9 13 14 (a). Inspect the continuity between the terminal 5 and
10 11 12 the terminal 12 of the left/right front combination
multimeter
replace the low beam light.
3. Inspect the front turn signal
LFWX-6470-77007 (a). Inspect the continuity between the terminal 3 and
the terminal 10 of the left/right front combination
multimeter
replace the front turn light.
Replacement
1. Remove the front combination lamp
assembly
(a). Turn off the power supply and all electric
appliances.
(b). Disconnect the battery negative cable.
77
(c). Remove front combination lamp assembly and
bracket. (Refer to Chapter 81 - Interior and
exterior trims, front bumper, replacement)
(d). Remove retaining bolts of front combination
lamp assembly.
△ Tips:
The procedures for replacement of the left and right
combination lamp are same.
LFWX-6470-77008
(e). Remove front combination lamp assembly,

disconnect front combination lamp connector.
(f). Take off the front combination lamp.
△ Tips:
Take off the lamp combination gently to expose the
connector, then hold the lamp combination steady
and release the connector. This avoids stress on wire
of the front combination lamp which may cause wire
damaged.
LFWX-6470-77009
2. Remove the high-beam and low-beam light

bulbs
(a). Take out the rubber covers of low-beam and
high-beam lights.
△ Tips:
• Turn off the ignition switch and all electrical switches
when replacing the light.
• The procedures for replacement of the low-
beam and high-beam light bulbs of left/right front
combination lamp are same.
LFWX-6470-77010
(b). Slightly rotate high beam light and dipped

headlight, and take out their bulbs.
LFWX-6470-77011
(c). Disconnect connector of high beam light and

dipped headlight, and change bulbs of high
beam light and dipped headlight.
LFWX-6470-77012
77-47
3. Install the bulbs of low-beam and high-beam

lights.
(d). Connect connector of low-beam and high-beam
lights.
LFWX-6470-77013
(e). Install the bulbs of low-beam and high-beam

lights.
△ Tips:
Align the bulb boss with the notch.
77
LFWX-6470-77011
(f). Install the rubber covers of low-beam and high-

beam lights.
LFWX-6470-77010
4. Remove the cornering light bulb

(a). Take out auxiliary lamp rubber boot of bend.
(b). When locking lever is pressed down, it is also
pushed outwards and bend auxiliary lamp bulb
is taken out.
△ Tips:
• Turn off the one-key start switch and all electrical
switches when replacing the light.
• Remove the rubber covers of cornering assist lights
and those of low-beam and high-beam lights with
the same steps.
• Replace the left and right front combination
cornering assist lights with the same steps.
LFWX-6470-77014
(c). Disconnect bulb connector clip, and directly take

out bend auxiliary lamp bulb and components
connected therewith.
LFWX-6470-77015
5. Mount the cornering assist light bulb

(a). Change a new bulb and connect the connector
clip.
LFWX-6470-77015
77-49
(b). Install bend auxiliary lamp bulb, and inwards

push the locking lever when it is pressed down.
(c). Install the rubber boot of bend auxiliary lamp.
△ Tips:
switches when replacing the lamp.
• Remove the rubber covers of cornering assist lights
and those of low-beam and high-beam lights with
the same steps.
• Replace the left and right front combination
cornering assist lights with the same steps.
LFWX-6470-77017
6. Remove the front turning light bulb

(a). Take out front turn light rubber boot.
(b). Anticlockwise rotate the front turn signal lamp
socket, and take out the front turn signal lamp
socket and bulb.
(c). Disconnect front turn signal lamp connector clip.
(d). Change front turn signal lamp bulb.
△ Tips:
switches when replacing the lamp.
• Remove the rubber covers of front turning light and 77
those of low-beam and high-beam lights with the
same steps
• Replace the left and right front combination light
bulbs with the same steps.
LFWX-6470-77018
7. Mount the front turning light bulb

(e). Connect front turn signal lamp connector clip.
(f). Clockwise rotate front turn signal lamp holder,
and install front turn signal lamp holder and
bulb.
(g). Install front turn signal lamp rubber cover.
LFWX-6470-77019
8. Mount the front combination light assembly

(g). Connect the front combination lamp connector.
(h). Install front combination lamp assembly, and install and fasten fixing bolt.
Torque: 8 ～ 12N·m
(i). Install front bumper support and bumper assembly. (See Section 81 – Interior and Exterior
Trims - Front Bumper, Replacement)
(j). Connect the battery negative cable.
(k). Turn front combination lamp to confirm its function.
Daytime Running Light/Position light

Replacement
1. Remove the daytime running light
(a). Remove front bumper, disconnect daytime
running light connector. (See Section 81 –
Interior and Exterior Trims - Front Bumper,
Replacement)
(b). Remove retaining screws of daytime running
light, take off the light assembly.
LFWX-6470-77020
2. Install daytime running light

(a). Install daytime running light, install retaining
screws and tighten.
Torque: 5 ～ 6N·m
(b). Connect daytime running light connector, install
front bumper. (See Section 81 – Interior and
Exterior Trims - Front Bumper, Replacement)
LFWX-6470-77020
77-51
Fog lamp
Replacement
1. Remove front fog lamp
(a). Remove front bumper, disconnect front fog
lamp connector. (See Section 81 – Interior and
Exterior Trims - Front Bumper, Replacement)
(b). Remove retaining screws of front fog lamp,
remove the lamp assembly.
LFWX-6470-77021
2. Remove the front fog light bulb

(a). Rotate the front fog lamp socket and take out
the front fog lamp bulb.
77
LFWX-6470-77077
3. Install the front fog light bulb

(a). Rotate the front fog lamp socket and install the
front fog lamp bulb.
LFWX-6470-77076
4. Install front fog lamp

(a). Install front fog lamp assembly, install retaining
screws and tighten.
Torque: 5 ～ 6N·m
(b). Connect front fog lam connector, install front
bumper. (See Section 81 – Interior and Exterior
Trims - Front Bumper, Replacement)
LFWX-6470-77021
Rear combination lamp

Replacement
1. Remove the rear combination lamp II
(a). Turn off switching power supply and all electric
appliances.
(c). Open the hatch.
(d). Remove rear back door board. (refer to Chapter
81 – Interior & Exterior- Back door inner guard,
replacement)
(e). Remove the rear combination light II fixing nut,
and remove the rear combination light II.
(f). Disconnect the rear combination light II
connector.
△ Tips:
rear combination lamp are same.
LFWX-6470-77022
2. Install the rear combination lampII

(g). Connect the rear combination light II connector.
(h). Install rear combination lamp II, and install
retaining nut and fasten it.
(i). Install rear back door board. (refer to Chapter
81 – Interior & Exterior- Back door inner guard,
replacement)
(j). Close the hatch.
(k). Connect the battery negative cable.
LFWX-6470-77022
77-53
3. Remove the rear combination light I.

(b). Open the hatch.
(c). Remove the rear combination light I fixing nut.
(d). Disconnect the rear combination light I
connector.
(e). Remove the rear combination light I
△ Tips:
rear combination lamp are same.
LFWX-6470-77023
4. Install the rear combination light I

(f). Install the rear combination light I connector.
(g). Install the rear combination light I, and install
and tighten the outer fixing bolt.
(h). Close the hatch.
(i). Connect the battery negative cable.
77
LFWX-6470-77023
5. Remove the steering lamp bulb.

(a). Disconnect the negative battery cable and
disconnect the rear combination light II wiring
harness connector.
(b). Turn rear steering lamp holder, then remove the
rear steering lamp.
Note:
The replacement procedures for left and right rear
turn signals are same.
LFWX-6470-77024
(c). Rotate counterclockwise to remove the rear turn

signal lamp.
LFWX-6470-77025
5. Install the rear turn signal lamp bulb.

(d). Rotate clockwise to install the rear turn signal
lamp.
LFWX-6470-77026
(e). Rotate clockwise to install the rear turn signal
holder and connect its wiring harness connector.
LFWX-6470-77024
77-55
Rear retro-reflector with fog lamp assembly

Replacement
1. Remove the rear reflector with fog lamp
disassembly
(b). Remove rear bumper assembly and support.
(refer to Chapter 81 – Interior & Exterior-rear
bumper, replacement)
(c). Disconnect the connector of rear reflex reflector
and fog lamp assembly.
(d). Remove fastening screw of rear reflex reflector
and fog lamp assembly.
△ Tips:
The replacement of the rear left/right retro-reflector
with fog lamp assembly is the same.
LFWX-6470-77027
2. Remove the rear fog light bulb

(a). Rotate the rear fog lamp socket and take out
rear fog lamp socket and bulb assembly.
77
LFWX-6470-77075
(b). Anticlockwise unscrew the rear fog lamp bulb.
LFWX-6470-77025
3. Install the rear fog light bulb

(a). Clockwise screw up the bulb of rear fog lamp.
LFWX-6470-77026
(b). Clockwise screw up rear fog lamp socket.
LFWX-6470-77075
4. Install the rear reflector with fog lamp

disassembly
(e). Install rear reflex reflector and fog lamp
assembly, and fasten its fastening screw.
(f). Connect wiring harness connector of rear reflex
reflector and fog lamp assembly, and connect
LFWX-6470-77027
77-57
Front dome light

Replacement
1. Remove the front dome light.
(a). Turn off the one-key start switch and all
electrical appliances.
(c). Use slot type screwdriver to pry up front dome
2 light assembly.
Note:
Cover the bit of slotted head screwdriver with the
tape to prevent scuffing the trims.
LFWX-6470-77028
(d). Disconnect front dome light connector, and take

down the front dome light assembly.
77
LFWX-6470-77029
2. Install front dome light assembly.

(e). Connect front dome light connector.
LFWX-6470-77029
(f). Install front dome light cover assembly.

(g). Connect the battery negative cable.
LFWX-6470-77028
Rear dome light

Replacement
1. Remove the rear dome light
(b). Use slot type screwdriver to pry down the middle
dome light assembly.
Note:
Wrap the head of the flat-blade screwdriver with a
tape, to avoid damage to the trims.。
LFWX-6470-77030
(c). Disconnect rear dome light connector.

(d). Take down the rear dome light.
LFWX-6470-77031
77-59
2. Install the rear dome light assembly.

(e). Install rear dome light and connect rear dome
light connector.
(f). Connect the battery negative cable.
LFWX-6470-77031
3. Remove the rear dome light bulb

(b). Use quincunx screwdriver to remove middle
dome light cover.
77
LFWX-6470-77032
(c). Remove the rear dome light bulb
LFWX-6470-77033
4. Install the rear dome light bulb

(d). Install the rear dome light bulb.
LFWX-6470-77033
(e). Install the rear dome light cover.

(f). Connect the battery negative cable.
LFWX-6470-77032
77-61
High-mounted stop lamp

Replacement
1. Remove the high-mounted stop lamp
assembly
(a). Turn off the one-key start switch and all
electrical appliances.
(c). Disconnect the high-mounted stop lamp
connector and remove the high-mounted stop
lamp.
LFWX-6470-77035
2. Install the high-mounted stop lamp assembly

(a). Connect the high-mounted stop lamp connector,
and install the high-mounted stop lamp onto the
bracket plate.
(b). Connect the battery negative cable.
77
LFWX-6470-77035
License plate lamp

Replacement
1. Remove the license plate lamp assembly.
(b). Remove the rear cab door trims.
(c). Push the license plate assembly outward, and
pry the license plate assembly with a flat-blade
screwdriver from the inside.
Note:
The flat blade screw driver wound by adhesive
tape must not be used. It can damage the
dashboard panel.
LFWX-6470-77036
(d). Disconnect the license plate lamp connector.

(e). Remove the license plate lamp assembly.
LFWX-6470-77037
2. Install the license plate lamp assembly

(a). Position license plate lamp assembly, connector license plate lamp connector.
Note:
Connect the connector; a "click" sound issued indicates that it is connected in place.
(b). Install the license plate lamp assembly.
(c). Install the rear cab door trims.
(d). Connect the battery negative cable.
77-63
Door light
Replacement
1. Remove the door light assembly.
(b). Pry the door light assembly with a flat-blade
screwdriver.
Note:
• Wrap the head of a flat-blade screwdriver with
a tape to avoid damage to the front door inner
guards.
• The procedures for replacement of the left and
right door lights are same.
(c). Disconnect the door light harness connector
(d). Remove the door light.
2. Install the door light assembly.
(a). Connect the connector and install the door light
assembly.
LFWX-6470-77038
Make-up mirror Light

Replacement
1. Remove the make-up mirror light assembly.
(b). Pry the make-up mirror light assembly with a 77
flat-blade screwdriver.
Note:
• Wrap the head of the flat-blade screwdriver with
a tape to avoid damage to the ceiling assembly.
(c). Disconnect the make-up mirror light connector.
(d). Remove the make-up mirror assembly.
2. Install the make-up mirror assembly
(a). Connect the connector and install the make-up
mirror light assembly.
LFWX-6470-77039
Combination switch
Replacement
1. Remove the combination switch assembly
(a). Remove the steering wheel assembly. (See
Section 61 - Electric Steering System - Steering
Wheel, Replacement)
(b). Remove the clock spring assembly. (See
Section 72 - Safety Protection Device - Clock
(c). Disconnect the combination switch connector.
(d). Loosen the combination switch clamp with the
pliers and remove the combination switch.
2. Install the combination switch assembly.
(a). Loosen the combination switch clamp with the
pliers and install the combination switch.
(b). Connect the combination switch connector.
(c). Remove the clock spring assembly. (See
Section 72 - Safety Protection Device - Clock
LFWX-6470-77040
(d). Remove the steering wheel assembly. (See
Section 61 - Electric Steering System - Steering
Wheel, Replacement)
Interior and exterior trims -Interior and exterior trims
81-a
Interior and exterior trims

Interior and exterior trims …… 1 Rear shelf curtain ……………… 47
System description …………… 1 Change ………………………… 47
Preparations …………………… 1 Trunk bottom protective covering
Maintenance data ……………… 2 ……………………………………… 48
Precautions …………………… 2 Change ………………………… 48
Sun visor ………………………… 3 Tool kit …………………………… 50
Change ………………………… 3 Change ………………………… 50
Front door sill panel …………… 6 Rear license plate trim board … 51
Change ………………………… 6 Change ………………………… 51
Middle row seat bracket panel 7 Exterior panel of back door …… 54
Change ………………………… 7 Change ………………………… 54 81
Rear door sill panel …………… 8 Spoiler …………………………… 55
Change ………………………… 8 Change ………………………… 55
Front step board ………………… 9 Rear bumper …………………… 56
Change ………………………… 9 Change ………………………… 56
A pillar guard panel …………… 10 Rear air outlet …………………… 60
Change ………………………… 10 Change ………………………… 60
B pillar guard panel …………… 12 Vent panel………………………… 61
Change ………………………… 12 Change ………………………… 61
C pillar guard panel …………… 15 Front bumper …………………… 64
Change ………………………… 15 Change ………………………… 64
Rear apron panel ……………… 20 Front/rear wheel splash apron
Change ………………………… 20 tailboard ………………………… 68
Rear back door panel ………… 22 Change ………………………… 68
Change ………………………… 22 Splash apron …………………… 69
Front door interior panel ……… 25 Change ………………………… 69
Change ………………………… 25 Engine lower panel …………… 70
Rear door interior panel ……… 31 Change ………………………… 70
Change ………………………… 31 Engine side guard plate ……… 71
Triangle decorative panel……… 37 Change ………………………… 71
Change ………………………… 37 Engine decorative cover and
Door safety pull ………………… 39 bracket …………………………… 72
change ………………………… 39 Change ………………………… 72
Roof ……………………………… 41 Engine hood insulating mat … 73
Change ………………………… 41 Change ………………………… 73
Carpet …………………………… 42 Radiator upper cross member trim
Change ………………………… 42 board ……………………………… 74
Carpet foam block ……………… 46 Change ………………………… 74
Change ………………………… 46 Electric maintenance cover plate
81-b Interior and exterior trims -Interior and exterior trims

……………………………………… 75
Change ………………………… 75
Fender/fender exterior trim board
……………………………………… 76
Change ………………………… 76
Fender inside lining assembly 78
Change ………………………… 78
Side wall trims…………………… 79
Change ………………………… 79
B pillar exterior trim board …… 80
Change ………………………… 80
Rear door C pillar exterior trim
board ……………………………… 81
Change ………………………… 81
Door frame molding …………… 82
Change ………………………… 82
Door corner decorations ……… 83
Change ………………………… 83
Door interior/ exterior weather bar
……………………………………… 84
Change ………………………… 84
Strip and sealing elements …… 86
Front seal strip of engine
compartment ……………………… 86
Rear seal of engine compartment
……………………………………… 87
Fender decoration …………… 88
Deflector. ……………………… 89
Door frame strip ……………… 90
Door strip ……………………… 91
Hatch frame strip ……………… 92
Filler cap ………………………… 93
Change ………………………… 93
Roof cover molding …………… 94
Change ………………………… 94
Floor lower panel ……………… 95
Change ………………………… 95
81-1

System description
1. Composition
The interior and exterior trims mainly includes the interior trim and exterior trim.
The interior trims mainly include: sun visor, front door sill panel, rear door sill panel, A pillar panel,
B pillar panel, C pillar panel, front door inner panel, rear apron board panel, rear door inner panel,
rear shelf curtain, roof pull, roof, carpet and spare tire cover plate etc.
The exterior trims mainly include: front bumper, rear bumper, side wall trims, door window film,
hatch exterior trim board, rear license plate decoration, engine decorative cover, radiator upper
cross member trim board, splash apron and mudguard, strip and sealing elements, logo.
Preparations
81
Remove bolt and

1 Screw driver
clamp
Cut glass sealing

2 Knife
apart
Interior and exterior Remove the interior/

3
trims pry plate exterior trims
4 Steel wire Remove windshield

81-2 Interior and exterior trims -Interior and exterior trims
Maintenance data
Items N.m
Fixing bolt for front-row safety belt 45 ～ 60
Fixing bolt for middle-row safety belt 45 ～ 60
Fixing bolt for rear-row safety belt 45 ～ 60
Fixing bolt for front bumper 6 ～ 12
Fixing bolt for rear bumper 6 ～ 12
Precautions
(a). Before maintenance, sleeve protective jackets on seat and steering wheel.
(b). No matter engine runs or not, any elements in system can not be connected when vehicle
power supply is connected, as follows:
Battery any cable and system connector lamp.
(a). Before removing or mounting any electric apparatus, and when tools or equipment are easy
to contact with exposed electrical terminals, battery negative cable must be first disconnected
to prevent personnel injury or vehicle damage.
(b). When connector clip of system components is disconnected, please do not pull the wiring
harness to prevent its damage.
(c). You are suggested to use special tools to remove interior and exterior system parts; in case
of no special tools, you can use slot type screwdriver.
Note:
Cover the bit of slotted head screwdriver with the tape to prevent scuffing the trims.
(d). When interior and exterior system parts are removed, if they can not be removed easily,
please do not take them down by force, and take them down after checking whether buckle
or screw is missed or not.
(a). Keep oil or chemicals away from interior and exterior components to prevent their corrosion.
81-3
Sun visor
Change
△ Tips:
It follows the same way to change left and right sun-visors, so we will take right sun-visor as an
example.
1. Remove sunvisor
(a). Turn down sun shield, remove the right sun
shield holder cover plate to take out the holder
cover plate.
81
LFWX-6470-81001
(b). Take down the sun shield from sun shield
fixing hook, remove the fastening screw of the
sun shield, and break the sun shield from the
installation site.
LFWX-6470-81002
(c). Disconnect the make-up mirror lamp switch

wiring harness connector clip and take down the
sun shield.
LFWX-6470-81130
(d). Remove the fastening screw of sun shield hook,
and take out the sun shield hook.
LFWX-6470-81003
2. Install sunvisor
(a). Install sun shield hook on its installation site,
and install and fasten its screw.
LFWX-6470-81003
81-5
(b). Put the sun shield near its installation site, and
connect make-up mirror lamp switch wiring
harness connector clip.
LFWX-6470-81130
(c). Install sun shield fastening screw and fasten it. 81
LFWX-6470-81002
(d). Put sun shield holder cover plate on its

installation site, and install it and close the sun
shield.
LFWX-6470-81001
Front door sill panel

Change
△ Tips:
It follows the same way to change left and right front sill apron, so we will take left front sill apron as
an example.
1. Remove front threshold board
(a). Use interior & exterior crow plates to pry out the
front sill apron and take out the front sill apron.
Note:
Pay attention to the buckle to prevent damaging
the front door sill panel while removing the panel.
LFWX-6470-81004
2. Mount the front threshold guard
(a). Install buckle on front sill metal plate.
(b). Install front sill apron on sill; during installation,
align the front sill apron with the buckle, install
front sill apron and make sure it is installed in
place.
Note:
Pay attention to the buckle position to prevent
damaging the panel while installing the front door
sill panel.
LFWX-6470-81004
81-7
Middle row seat bracket panel

Change
△ Tips:
It follows the same way to change left and right middle row seat bracket panel, so we will take left
middle row seat bracket panel as an example.
1. Remove middle seat bracket panel.
(a). Use interior & exterior crow plates to knock
out middle seat bracket apron and take out the
middle seat bracket apron.
Note:
the center row seat bracket panel while removing
the panel.
81
LFWX-6470-81005
2. Install middle seat bracket panel.
(a). Put middle seat bracket apron on its installation
site; and then align middle seat bracket buckle
with mounting hole and install the middle seat
bracket apron in place.
Note:
the center row seat bracket panel while installing
the panel.
LFWX-6470-81005
Rear door sill panel

Change
△ Tips:
It follows the same way to replace front left and right threshold board. Take front left threshold
board as an example.
1. Remove rear threshold board.
(a). Remove middle seat bracket apron (see 81-
Interior & Exterior, Middle Seat Bracket Apron,
Replacement)
(b). Use interior & exterior crow plates to knock out
rear sill buckle, and take out middle-row rear sill.
Note:
When removing rear threshold board, pay
attention to clamp position to avoid causing
damage to the board.
LFWX-6470-81006
2. Install rear skirt board.
(a). Install buckle on the rear sill apron.
(b). Put rear sill apron on the rear sill buckle; and
then align rear sill apron buckle with mounting
hole and install the rear sill apron in place.
(c). Install middle seat bracket apron. (see 81-
Interior & Exterior, Middle Seat Bracket Apron,
Replacement)
Note:
When installing rear threshold board, pay
LFWX-6470-81006
81-9
Front step board

Change
△ Tips:
It follows the same way to replace front left/right, rear left/right step board. Take front left step board
as an example.
1. Remove the front step board
(a). Use interior & exterior crow plates to knock out
front step plate buckle, and take out the front
step plate.
Note:
the panel while removing the front step panel.
81
LFWX-6470-81007
2. Install the front step board
(a). Install buckle on the front step board.
(b). Put rear sill apron on the front step board; and
then align front step board buckle with mounting
hole and install the front step board in place.
Note:
When installing front step board, pay attention to
clamp position to avoid causing damage to the
board.
LFWX-6470-81004
A pillar guard panel

Change
△ Tips:
It follows the same way to replace front left and right A pillar guard panel. Take front left A pillar
guard panel as an example.
1. Remove the A pillar lower guard panel.
(a). Remove the front door sill guard panel.(See Section 81 - Interior and Exterior Trims – Front
Door Still Guard Panel, Replacement)
(b). Remove the retaining nut of A column lower
apron.
(c). Use exterior and interior crow plates to knock
out A column lower apron buckle and take out A
column lower apron.
Note:
When removing the A pillar lower guard panel,
pay attention to clamp position to avoid causing
LFWX-6470-81009
2. Install the A pillar lower guard panel.
(a). Install buckle on A column lower apron.
(b). Put A column lower apron on its installation
site, align the A column lower apron buckle to
mounting hole, install A column lower apron, and
make sure A column lower apron is installed in
place.
(c). Install A column lower apron retaining nut and
fasten it.
(d). Install the front door sill guard panel (See
Section 81 - Interior and Exterior Trims – Front
Note:
When installing the A pillar lower guard panel,
LFWX-6470-81009
81-11
3. Remove the A pillar upper guard panel.

(a). Remove the front frame strip near the A pillar
upper panel.
Note:
When removing the A pillar upper guard panel,
LFWX-6470-81011
(b). Use interior & exterior crow plates to pry out 81
fixing clamp of A pillar upper guard panel and
take out A pillar upper guard panel.
Note:
When removing the A pillar upper guard panel,
LFWX-6470-81010
4. Install the A pillar upper guard panel.
(a). Install buckle on A column upper apron.
(b). Put A pillar upper guard panel on its installation
site, align the A pillar upper guard panel buckle
to mounting hole, and then install the A pillar
upper guard panel in place.
Note:
When installing the A pillar upper guard panel,
LFWX-6470-81010
(c). Install the front frame strip near the A pillar

upper panel.
Note:
When installing the A pillar upper guard panel,
LFWX-6470-81011
B pillar guard panel

Change
△ Tips:
The replacement of the left and right B pillar guard panel is the same. Here is the replacement of
the left B pillar guard panel.
1. Remove the B pillar lower guard panel.
(a). Remove the front door sill guard panel.(See
(b). Remove the rear door sill guard panel (See
Section 81 - Interior and Exterior Trims – Rear
(c). Install the front and rear door frame strip near
the B pillar lower panel.
Note:
When removing the B pillar lower guard panel,
LFWX-6470-81012
81-13
(d). Use interior & exterior crow plates to pry out B

pillar lower guard panel buckle and take out the
B pillar lower guard panel buckle.
Note:
When removing the B pillar lower guard panel,
LFWX-6470-81013
2. Install the B pillar lower guard panel. 81
(a). Install buckle on B column lower apron.
(b). Put B pillar lower guard panel on its installation
site, align the B pillar lower guard panel buckle
to mounting hole, and then install the B pillar
lower guard panel in place.
Note:
When installing the B pillar lower guard panel,
LFWX-6470-81013
(c). Install the front and rear door frame strip near
the B pillar lower panel.
(d). Install the front door sill guard panel. (See
(e). Install the rear door sill guard panel. (See
Note:
When installing the B pillar lower guard panel,
LFWX-6470-81013
3. Remove the B pillar upper guard panel.

(a). Remove the B pillar lower guard panel.(See
Section 81 - Interior and Exterior Trims - B-pillar
Guard Panel, Replacement)
(b). Install the fastening screw of B column upper
apron, use interior and exterior crow plates to
pry out B column upper apron buckle, and take
out the B column upper apron.
Note:
When removing the B pillar upper guard panel,
LFWX-6470-81014
(c). Remove driver belt lower bracket fixing bolt,
withdraw the safety belt from B column upper
apron, and take out B column upper apron.
Note:
When removing the B pillar upper guard panel,
LFWX-6470-81015
4. Install the B pillar upper guard panel.
(a). Thread the driver seat belt through B column
upper apron.
(b). Install driver belt lower bracket fixing bolt and
fasten it.
Torque:45 ～ 60N·m
Note:
• When installing the B pillar upper guard panel,
• Before mounting the front panel of B-pillar, pass
the front seat belt buckle through the B-pillar
front panel.
LFWX-6470-81015
81-15
(c). Install B pillar upper guard panel

(d). Put B pillar upper guard panel on its installation
site, align the B pillar upper guard panel buckle
to mounting hole, and then install the B pillar
upper guard panel in place.
(d). Install fastening screw of B column upper apron
and fasten it.
(f). Install the B pillar lower guard panel. (See
Section 81 - Interior and Exterior Trims - B-pillar
Note:
When installing the B pillar upper guard panel,
LFWX-6470-81014
81
C pillar guard panel
Change
△ Tips:
The replacement of the left and right C pillar guard panel is the same. Here is the replacement of
the rear left C pillar upper guard panel.
1. Remove the C pillar lower guard panel.
(a). Remove bottom surface cover of trunk;
remove rack curtain storage slot cover plate
on C column lower apron, and remove the
rack curtain and tool box (See 81 – Tool Box,
Changed)
(b). Remove rear door sill guard panel.(See Section
81 - Interior and Exterior Trims – Rear Door Still
(c). Remove the rear skirt panel panel. (See Section
81 - Interior and Exterior Trims – Rear Skirt
Board Guard Panel, Replacement)
(d). Remove rear door seal near C column lower
apron.
Note:
When removing the C pillar lower guard panel,
LFWX-6470-81017 pay attention to clamp position to avoid causing
(e). Remove C column lower apron bolt hole covers

1 and 2 and C column lower apron safety belt
decorating plate in turn.
Note:
LFWX-6470-81016
(f). Remove the fixing bolt of rear passenger seat
belt lower bracket so as to take safety belt out
of C column lower apron, and take out the C
column lower apron.
Note:
LFWX-6470-81018
(g). Remove the erection bolt and buckle of C
column lower apron, and use interior & exterior
crow plates to pry out C column lower apron
buckle and take out the column lower apron.
Note:
LFWX-6470-81019
81-17
2. Install the C pillar lower guard panel.

(a). Install C column lower apron clamp.
(b). Put C pillar lower guard panel on its installation
site, align the C pillar lower guard panel buckle
to mounting hole, and then install the C pillar
lower guard panel in place.
(c). Install the mounting and fixing bolt and snap
fastener of C column lower apron and fasten
them.
Note:
When installing the C pillar lower guard panel,
+
LFWX-6470-81019
(d). Thread rear passenger seat belt through B 81
column lower apron.
(e). Install fixing bolt of rear seat passenger belt
lower bracket, and fasten it.
Note:
When installing the C pillar guard panel, pay
LFWX-6470-81018
(f). When installing the C pillar lower guard panel,

Note:
LFWX-6470-81016
(g). Install rear door seal near C column lower

apron.
(h). Install the rear door sill guard panel. (See
(f). Install the rear skirt panel panel. (See Section
81 - Interior and Exterior Trims –Rear skirt panel
panel, Replacement)
Note:
LFWX-6470-81017
3. Remove the C pillar upper guard panel.
(a). Remove the C pillar upper guard panel. (See
Section 81 - Interior and Exterior Trims –C pillar
upper guard panel, Replacement)
(b). Remove guide ring fixing bolt on rear passenger
seat belt, and take out the guide ring of the rear
passenger seat belt.
Note:
When removing the C pillar upper guard panel,
LFWX-6470-81020
(c). Remove lower support fixing bolt of middle
passenger seat belt, so as to extract the safety
belt from C column upper apron, and take out
the C column upper apron.
Note:
LFWX-6470-81021
81-19
(c). Use interior & exterior crow plates to pry out C

pillar upper guard panel, and take out C pillar
upper guard panel.
Note:
LFWX-6470-81022
4. Install the C pillar upper guard panel. 81
(a). Thread the middle seat belt lower bracket
through C column upper apron, and install and
Note:
• Before mounting the front panel of C-pillar, pass
the front seat belt buckle through the C-pillar
front panel.
• Pay attention to the buckle position to prevent
damaging the panel while installing the C pillar
upper guard panel
LFWX-6470-81021
(b). Install C column upper apron buckle.
(c). Put C column upper apron on its installation
site, align the C column upper apron buckle to
mounting hole, install C column upper apron,
and make sure C column upper apron is
installed in place.
Note:
When installing the C pillar upper guard panel,
LFWX-6470-81022
(d). Install support fixing bolt on rear passenger seat

belt, and fasten it.
(e). Install the C pillar lower guard panel. (See
Section 81 - Interior and Exterior Trims –C pillar
guard panel, Replacement)
Note:
When removing the C pillar guard panel, pay
LFWX-6470-81020
Rear apron panel

Change
1. Remove rear skirt board.
(a). Remove rack curtain storage slot cover plate
on C column lower apron, and remove the rack
curtain and tool box.
Note:
When removing the rear apron panel, pay attention
to clamp position to avoid causing damage to the
board.
LFWX-6470-81023
81-21
(b). Remove the back door shackle cover plate.

Note:
board.
LFWX-6470-81024
(c). Use exterior and interior crow plates to pry out 81

rear skirtboard apron buckle and take out the
rear skirtboard apron.
Note:
board.
LFWX-6470-81026
2. Install rear skirt board.

(a). Install rear skirtboard apron buckle.
(b). Put rear skirtboard apron on its installation site,
align its buckle with the mounting hole, and
Note:
When installing the rear apron panel, pay attention
board.
LFWX-6470-81026
(c). Put back door shackle cover plate on its

installation site, and install it.
Note:
When installing the rear apron panel, pay attention
board.
LFWX-6470-81024
Rear back door panel

Change
1. Remove rear back door panel
(a). Remove the fixing bolt of back door lower trim
handle box to take it out.
LFWX-6470-81027
81-23
(b). Use interior & exterior crow plates to pry out

back door upper apron buckle and take out the
back door upper apron buckle.
Note:
+
When removing the rear back door panel, pay
LFWX-6470-81028
(c). Use exterior and interior crow plates to pry out 81
left and right apron buckles of back door, and
take out the left and right aprons of the back
door.
Note:
LFWX-6470-81029
(d). Use interior and exterior crow plates to pry up
the buckle of back door lower apron and take
out the back door lower apron.
Note:
+
+
LFWX-6470-81030
2. Install rear back door panel

(a). Put the back door lower trim on its installation
site, align its buckle to mounting hole, install the
back door lower trim and make sure the back
door lower trim is installed in place.
(b). Install the buckle of the back door lower apron.
+
Note:
+
When installing the rear back door panel, pay

LFWX-6470-81030
(c). Put rear back door left/right panel on its

installation site, align its buckle with the
mounting hole, and install it in place.
Note:
LFWX-6470-81029
(d). Put rear back door upper panel on its installation
site, align its buckle with the mounting hole, and
Note:
+

LFWX-6470-81028
81-25
(a). Put the back door lower trim handle box on

its installation site, and install and fasten its
fastening screw.
Note:
LFWX-6470-81027
81
Front door interior panel
Change
△ Tips:
It follows the same way to replace inside panel for front left and right door. Take inside panel for
front left door as an example.
1. Remove inside panel for front door
front door armrest switch assembly.
LFWX-6470-81033
(b). Disconnect the connector clip of front door

armrest switch, and take out the front door
armrest switch assembly.
LFWX-6470-81034
(c). Remove the fastening screw of front door inner
trim and front door metal plate.
LFWX-6470-81131
(d). Remove inner handle cover plate of door, and
take it out.
LFWX-6470-81031
81-27
(e). Remove fastening screw of inner handle of door.
LFWX-6470-81032
(f). Use interior & exterior crow plates to pry out 81
front door lamp.
LFWX-6470-81132
(g). Disconnect the front door lamp connector clip,
and take out the front door inner trim.
LFWX-6470-81038
(h). Remove the fixing clamp of front door inner trim,

and use exterior and interior crow plates to pry
out front door inner trim.
LFWX-6470-81039
2. Mount the front door guard
(a). Install inner apron buckle of front door on the
front door inner trim.
(b). Install inner apron buckle of front door on the
front door inner trim.
(c). Make front door inner trim close to door
installation site, and connect front door lamp
wiring harness connector clip.
LFWX-6470-81038
(d). Install front door lamp on front door inner trim.
LFWX-6470-81133
81-29
(e). Put the front door inner panel on its installation

site, align its buckle to mounting hole, install the
front door inner panel and make sure the front
door inner panel is installed in place.
LFWX-6470-81039
(f). Install the fastening screw of inner handle cover 81
plate of front door and fasten it.
LFWX-6470-81032
(g). Put inner handle cover plate of front door on its
LFWX-6470-81031
(h). Install the fastening screw of front door inner

trim and front door metal plate.
LFWX-6470-81131
(i). Install the front door armrest switch assembly
near its installation site and connect the
disassembling parts of the front door armrest
switch assembly.
LFWX-6470-81034
(j). Install front door armrest switch assembly.
LFWX-6470-81033
81-31
Rear door interior panel

Change
△ Tips:
It follows the same way to replace inside panel for rear left and right door. Take inside panel for rear
left door as an example.
1. Remove inside panel for rear door
rear door armrest switch assembly.
81
LFWX-6470-81041
(b). Disconnect the connector clip of rear door
armrest switch, and take out the rear door
armrest switch assembly.
LFWX-6470-81042
(c). Remove the fastening screw of rear door inner

trim and rear door metal plate
LFWX-6470-81134
(d). Remove inner handle cover plate of rear door.
LFWX-6470-81044
(e). Remove fastening screw of inner handle of rear
door.
LFWX-6470-81045
81-33
(f). Use interior & exterior crow plates to pry out

rear door quarter trim panel.
LFWX-6470-81135
(g). Use interior & exterior crow plates to pry out 81
rear door lamp.
LFWX-6470-81136
(h). Disconnect the rear door lamp connector clip,

and take out the rear door inner trim.
LFWX-6470-81038
(i). Use interior & exterior crow plates to pry out

rear door inner trim buckle.
LFWX-6470-81046
2. Install inside panel of rear door

(a). Install inner apron buckle of rear door on the
rear door inner trim.
(b). Install rear door lamp on rear door inner trim.
LFWX-6470-81137
(c). Make door inner trim close to door installation

site, and connect rear door lamp wiring harness
connector clip.
LFWX-6470-81038
81-35
(d). Install rear door inner trim on its installation site,

align rear door inner trim buckle with mounting
hole, install fastening screw of rear door inner
trim and rear door metal plates, and make sure
rear door inner trim is installed in place.
LFWX-6470-81046
(e). Install fastening screw of inner handle of rear 81

door.
LFWX-6470-81045
(f). Install inner handle cover plate of rear door.
LFWX-6470-81044
(g). Install rear door armrest switch on its installation

site, and connect rear door armrest switch
connector clip.
LFWX-6470-81042
(h). Install rear door armrest switch assembly.
LFWX-6470-81041
(i). Install quarter trim panel of rear door on its

installation site, and install the quarter trim panel
of rear door.
LFWX-6470-81135
81-37
Triangle decorative panel

Change
△ Tips:
The replacement of the left and right triangle decorative panel is the same. Here is the replacement
of the rear left door inner panel.
1. Remove the front triangle decorative panel
(a). Use interior & exterior crow plates to pry out
front door quarter trim panel component,
and take out front door quarter trim panel
component.
81
LFWX-6470-81037
2. Install front triangle decorative panel
(a). Put quarter trim panel on its installation site, and
install it.
LFWX-6470-81037
3. Remove rear triangle decorative panel

(a). Remove the fixing clamp of rear triangle
decorative panel, and take out the rear triangle
decorative panel.
LFWX-6470-81135
4. Install rear triangle decorative panel
(a). Put quarter trim panel on its installation site,
align the rear triangle decorative panel buckle to
mounting hole, and then install the quarter trim
panel in place.
LFWX-6470-81135
81-39
Door safety pull

change
△ Tips:
The replacement of the front and rear door safety pull is the same. Here is the replacement of front
right door safety pull.
1. Remove safety handle
(a). Turn over the door mounting handle.
(b). Remove the cover plate of door safety handle,
and take it out.
81
LFWX-6470-81048
(c). Pull out door safety handle.
LFWX-6470-81050
2. Install safety handle

(b). Put the safety handle on its installation site and
install it in place by fixing clamp.
LFWX-6470-81138
(c). Install door safety handle cover plate.
LFWX-6470-81048
81-41
Roof
Change
1. Remove roof
(a). Remove sunvisor (see81- interior/exterior trim-sunvisor, replacement).
(b). Remove the door safety handle.(see81- interior/exterior trim - door safety handle,
replacement).
(c). Remove front dome light.(See 77 -Lighting System - front dome light, Replacement）
(d). Disconnect make-up lamp wiring harness connector clip. (See 77 – Lighting System -Make-
up Lamp, Replacement)
(e). Disconnect rear dome light wiring harness connector clip. (See 77 -Lighting System - rear
dome light, Replacement）
(f). Remove A column upper board (see 81 interior/exterior trim-A column board, replacement).
(g). Remove B column upper board (see 81 interior/exterior trim-B column board, replacement).
(h). Remove C column board (see 81 interior/exterior trim-C column board, replacement).
(i). Remove the ceiling buckle and take the ceiling
out under the cooperation of many persons. 81
△ Tips:
This operation is difficult for one person to complete
and the assistance from another person is needed.
LFWX-6470-81051
(j). Remove ceiling air outlet.
LFWX-6470-81052
2. Install roof
(a). Put roof air outlet on its installation site and
install it on ceiling.
(b). Connect rear dome light wiring harness
connector.(see 77 lighting system-rear roof
lamp, replacement).
(c). Connect make-up mirror lamp wiring harness
connector clip. (See 77 – Lighting System-
Make-up, Replacement)
LFWX-6470-81052
(d). Install ceiling on its installation site, and install
ceiling buckle.
Note:
Before installing the roof fixing clip, ensure to
arrange and connect the dome lamp harness well
to prevent crushing the harness in the roof.
(e). Install sunvisor. (see 81 lighting system-
Sunvisor, replacement).
(f). Install front dome light. (see 77 lighting system-
front roof lamp, replacement).
(g). Install door safety handle.(see81- interior/
exterior trim - door safety handle, replacement).
(h). Install C column panel. (see 81 interior/exterior
trim-C column panel, replacement).
(i). Install B column upper panel (see 81 interior/
exterior trim-B column panel, replacement).
LFWX-6470-81051
(j). Install A column upper panel (see 81 interior/
exterior trim-A column panel, replacement).
Carpet
Change
1. Remove carpet
(a). Remove auxiliary instrument panel.(refer to Chapter 85 - Dashboard/console, console,
replacement)
(b). Remove front threshold panel (refer to Chapter 81 Interior and exterior trims - Front threshold
panel, replacement).
(c). Remove rear threshold panel（(refer to Chapter 81 Interior and exterior trims - Rear
threshold panel, replacement).
(d). Remove middle seat bracket apron (see 81- Interior & Exterior - Middle Seat Bracket Apron,
Replacement)
(e). Remove A column upper panel (see 81- interior/exterior trim-A column panel, replacement).
(f). Remove B column upper panel (see 81- interior/exterior trim-B column panel, replacement).
(g). Remove C column upper panel (see 81- interior/exterior trim-C column panel, replacement).
(h). Remove the front seats (see 84-Seat-Front seats, replacement).
(i). Remove the middle seat (see 84-Seat-Middle seat, replacement).
(j). Remove the rear seat (see 84-Seat-Rear seat, replacement).
81-43
(k). Remove the fixing bolt of lower support of

middle seat belt.
LFWX-6470-81021
(l). Remove the fixing bolt of support of middle-row 81
middle safety belt lock.
LFWX-6470-81054
(m). Remove car body wiring harness clamp on
carpet, and take out car body wiring harness
clamp.
(n). Remove middle internal low frequency magnetic
field antenna. (See 54B – Start Charging
System, Internal Low Frequency Magnetic Field
Antenna, Replacement)
LFWX-6470-81126
(o). Remove the buckle of boot carpet, and take out

the boot carpet.
LFWX-6470-81053
(p). Remove the fixing clamp of rear and front
carpets, and remove the rear carpet and the
front carpet successively.
LFWX-6470-81127
2. Install carpet
(a). Install rear carpet and front carpet on their
installation sites in turn, and install their buckles.
LFWX-6470-81127
81-45
(b). Install boot carpet on its installation site and

install boot carpet buckle.
LFWX-6470-81053
(c). Install middle internal low frequency magnetic 81

field antenna. (See 18- Start Charging System,
Internal Low Frequency Magnetic Field Antenna,
Replacement)
(d). Install body wiring harness clamp on carpet, and
clamp it.
LFWX-6470-81126
(e). Install fixing bolt of support of middle-row middle

seat belt lock and fasten it.
LFWX-6470-81054
(f). Install fixing bolt of middle seat belt lower

bracket and fasten it.
LFWX-6470-81021
(g). Install the rear seats (see 84-Seat-Rear seat, replacement).

(h). Install the middle seat (see 84-Seat-Middle seat, replacement).
(i). Install the frontseat (see 84-Seat-Front seats, replacement).
(j). Install C column upper panel (see 81- interior/exterior trim-C column panel, replacement).
(k). Install B column upper panel (see 81- interior/exterior trim-B column panel, replacement).
(l). Install A column upper panel (see 81- interior/exterior trim-C column panel, replacement).
(m). Install center row seat bracket panel (see 81- interior/exterior trim- Center row seat bracket
panel, replacement).
(n). Install rear threshold and rear skirt panel(see 81- interior/exterior trim-Rear threshold and
rear skirt panel, replacement).
(o). Install front threshold and rear skirt panel(see 81- interior/exterior trim- Front threshold and
rear skirt panel, replacement).
(p). Install auxiliary instrument panel. (see 84 - Dashboard/console, console, replacement)
Carpet foam block

Change
1. Remove the carpet foam block
(a). Remove carpet (see 81 - interior/exterior trim -
Carpet, replacement)
(a). Take out carpet footrest foam and each cushion.
LFWX-6470-81055
81-47
2. Install the carpet foam block

(a). Install take out carpet footrest foam and each
cushion.
(b). Install carpet（(see 81 - interior/exterior trim -
Carpet, replacement)
LFWX-6470-81055
81
Rear shelf curtain
Change
1. Remove rear shelf curtain
(a). Take out ① rack curtain from C column apron
3
and withdraw it according to arrow ② direction,

apply force on the rack curtain ③ according
to arrow direction, and take down ③ from C
1 column apron after spring compression, and
2 take out the rack curtain.
1
LFWX-6470-81056
2. Install shelf curtain

3
(a). Install shelf curtain ③ on C column apron,
extend it along arrow ② direction, and install
rack curtain ① on the left and right column C
aprons.
1
2
LFWX-6470-81057
Trunk bottom protective covering

Change
1. Remove bottom surface cover I of trunk.
(a). Fold rear seat.
(b). Fold bottom surface cover I of trunk.
LFWX-6470-81059
(c). Remove the butterfly type bolt of trunk bottom

surface cover I support, and take out the trunk
bottom surface cover I support I.
LFWX-6470-81058
81-49
2. Remove bottom surface cover II of trunk.

(a). Take out trunk bottom surface cover II.
LFWX-6470-81060
3. Install bottom surface cover I of trunk. 81
(a). Install trunk bottom surface cover I on its
installation site.
(b). Install butterfly type bolt.
LFWX-6470-81058
(c). Open the rear seat.
LFWX-6470-81063
4. Install bottom surface cover II of trunk.

(a). Install bottom surface cover II of trunk.
LFWX-6470-81060
Tool kit
Change
1. Remove the tool kit
(a). Remove bottom surface cover of trunk II (See81
- interior trims and exterior trims, trunk bottom
protective covering, replacement)
(b). Take out the rack curtain. (place the shelf curtain
in the tool kit if not in use)
(c). Take out the tool kit
LFWX-6470-81061
2. Install the tool kit
(a). Install the tool kit
(b). Install rack curtain.(place the shelf curtain in the
tool kit if not in use)
(c). Install bottom surface cover of trunk II (See81
- interior trims and exterior trims, trunk bottom
protective covering, replacement)
LFWX-6470-81061
81-51
Rear license plate trim board

Change
1. Remove rear license plate panel
(a). Remove the hatch inner panel.(See81 - interior
trims and exterior trims, hatch inner panel,
replacement)
(b). Remove the fixing bolt of rear license decorating
plate handle box.
81
LFWX-6470-81064
(c). Install the retaining nut of rear license decorating
plate
LFWX-6470-81065
(d). Disconnect wiring harness connector clips of

rear license plate lamp and trunk microswitch.
LFWX-6470-75020
(e). Take out rear license decorating plate.
LFWX-6470-75017
(f). Remove the fastening screw of trunk microswitch
and rear license plate lamp decorating plate,
and take out the trunk microswitch, as well as
rear license plate lamp and rear license plate
handle box.
LFWX-6470-81142
2. Install rear license plate panel

(a). Install trunk microswitch on handle box.
(b). Install license plate lamp on rear license
decorating plate. (See 77 – Lighting System
License Plate Lamp, Replacement)
(c). Install handle box on rear license decorating
plate.
LFWX-6470-81128
81-53
(d). Put rear license decorating plate near its

installation site.
LFWX-6470-75017
(e). Connect wiring harness connector clips of trunk
micro switch and license plate lamp. 81
LFWX-6470-75020
(f). Install the retaining nut of rear license decorating

plate and fasten it.
Torque:4 ～ 8N·m
LFWX-6470-81065
(g). Install the fastening screw of license plate

handle box and fasten it.
LFWX-6470-81064
Exterior panel of back door

Change
1. Remove exterior panel of back door
(a). Remove hatch inner panel, (See81 - interior
replacement)
(b). Remove rear License Decorating Plate (See
Chapter 81 Interior & Exterior– Rear License
Decorating Plate, Replacement).
(c). Remove the fastening screw and nut of back
door outer decorating plate.
LFWX-6470-81066
(d). Use interior & exterior crow plates to remove

buckle of hatch outer decorating plate, and take
out the back door outer decorating plate.
LFWX-6470-81067
81-55
2. Install exterior panel of back door

(a). Install buckle, reed and T-shaped bolt of hatch
outer decorating plate.
LFWX-6470-81067
(b). Install the hatch outer decorating plate on 81
its installation site, and install and fasten its
fastening screw and nut.
Torque:4 ～ 8N·m
(c). Install hatch inner panel.(See81 - interior
replacement)
LFWX-6470-81066
Spoiler
Change
1. Remove spoiler
(a). Remove hatch inner panel (See81 - interior
replacement)
(b). Remove high-mounted stop lamp.(See77
- lighting system, high-mounted stop lamp,
replacement)
(c). Remove the retaining nut of spoiler, and take
out the spoiler.
(d). Remove rear joint of rear window hose. (See
86 – Rear Windshield Sprayer of Wiper and
Washing System, Replacement)
LFWX-6470-81068
2. Install spoiler
(a). Install rear joint of rear window hose. (See 86 –
Rear Windshield Sprayer of Wiper and Washing
System, Replacement)
(c). Install spoiler on its installation site, and install
and fasten its retaining nut.
Torque:6 ～ 12N·m
(a). Install high-mounted stop lamp.(See77 - lighting
system, high-mounted stop lamp, replacement)
(d). Install back door inner trim.(See81 - interior
replacement)
LFWX-6470-81068
Rear bumper
Change
1. Remove the rear bumper
(a). Open hatchback.
(b). Remove rear bumper fixing bolt
LFWX-6470-81069
(c). Remove the fastening screw of fender and rear

bumper, and fasten it.
LFWX-6470-81071
81-57
(d). Disconnect rear fog lamp wiring harness

connector clip.(See77 - lighting system, rear fog
lamp, removal)
LFWX-6470-81143
(e). Disconnect anti collision radar wiring harness 81
connector clip.(See76 - anti-collision radar
system, anti-collision radar sensor, replacement)
LFWX-6470-81144
(f). Remove the rear bumper
LFWX-6470-81070
(g). Remove fixing bolt of rear bumper mounting

bracket, and take out rear bumper mounting
bracket.
LFWX-6470-81072
2. Install the rear bumper
(a). Install rear bumper mounting bracket on its
installation site, and install rear bumper fixing
bolt and fasten it.
Torque:6 ～ 12N·m
LFWX-6470-81072
(b). Install the rear bumper near the rear wall of car
body.
LFWX-6470-81147
81-59
(c). Connect rear fog lamp wiring harness connector

clip.(See77 - lighting system, rear fog lamp,
removal)
LFWX-6470-81143
(d). Connect anti collision radar wiring harness 81
connector clip.(See76 - anti-collision radar
system, anti-collision radar sensor, replacement)
LFWX-6470-81144
(e). Install rear bumper on its installation site, make
rear bumper clamp aligned with the installation
site, install rear bumper and make sure it is
installed in place.
(f). Install bumper fixing bolt and fasten it.
Torque:6 ～ 12N·m
LFWX-6470-81069
(g). Remove the fastening screw of fender and rear

bumper, and use interior crow plate to pry out
the rear bumper.
(h). Put down back door.
LFWX-6470-81071
Rear air outlet

Change
△ Tips:
The replacement of the rear left and right air exit is the same. Here is the replacement of the rear
left air exit.
1. Remove the rear air outlet
(a). Remove the A pillar guard panel.(See Section
81, Interior and Exterior Trims - C-pillar guard
panel, Replacement)
(b). Remove the rear bumper.(See Section 81,
Interior and Exterior Trims - Rear bumper,
Replacement)
(b). Use rear interior & exterior crow plates to pry
out rear exhaust port and take the rear exhaust
port out.
LFWX-6470-81073
81-61
2. Install the rear air outlet

(a). Put the rear air outlet on its installation site and
install it.
(b). Install the C pillar guard panel. (See Section 81,
Interior and Exterior Trims - C-pillar guard panel,
Replacement)
(c). Install the rear bumper.(See Section 81, Interior
and Exterior Trims - Rear bumper, Replacement)
LFWX-6470-81073
81
Vent panel
Change
1. Remove vent panel
(a). Use interior & exterior crow plates to remove the
decorating plates of ventilating cover plates on
two sides of the front windshield, and take out
the decorating plates of ventilating cover plates
on two sides.
(b). Remove wiper arm assembly. (See 86 – Wiper
and Washing System Wiper Arm Assembly,
Replacement)
(c). Remove rear seal of engine compartment.
（(See81 - interior trims and exterior trims, strip
and sealing elements, engine compartment rear
strip)
LFWX-6470-81111
(d). Use interior and exterior crow plates to remove

the fixing clamp of ventilating cover plate and
take out the ventilating cover plate.
LFWX-6470-81112
(e). Use interior & exterior crow plates to pry up the

fixing clamps of right air deflector and middle air
deflector of ventilating cover plate, and take out
the right air deflector and middle air deflector of
ventilating cover plate.
LFWX-6470-81113
(f). Remove ventilating cover plate sealing strip,

and take it out.
LFWX-6470-81114
(g). Remove the brake fluid filling cover plate and

take it out.
LFWX-6470-81115
81-63
2. Install vent panel

(a). Install ventilating cover plate adhesive tape on
the ventilating cover plate.
LFWX-6470-81114
(b). Install right and middle air deflectors of 81

ventilating cover plate on their installation sites.
LFWX-6470-81113
(c). Install ventilating cover plate on its installation
site, and install its fixing clamp.
LFWX-6470-81116
(d). Put brake fluid filling cover plate on its

LFWX-6470-81117
(e). Install rear seal strip of engine compartment.
(See81 - interior trims and exterior trims, strip
and sealing elements, engine compartment rear
strip)
(f). Install wiper arm assembly. (See 86 – Wiper and
Washing System
(g). Put left and right decorating plates of ventilating
cover plate on their installation sites, and install
them.
LFWX-6470-81111
Front bumper
Change
1. Remove the front bumper
(a). Remove radiator upper cross member trim
board (See81 - interior trims and exterior
trims, radiator upper cross member trim board,
replacewment)
(b). Remove front bumper fixing bolt
LFWX-6440-81074
81-65
(c). Remove the fastening screw of front bumper

support and front bumper, as well as fastening
screw and bolt of engine shield and front
bumper, and use interior and exterior crow
plates to pry out the front bumper.
LFWX-6440-81075
(d). Disconnect the connector clip of front fog lamp 81
harness (See77 - lighting system, front fog lamp,
replacement)
(e). Disconnect daytime driving lamp wiring harness
connector clip.(See77 - lighting system, daytime
running lamp, replacement)
LFWX-6440-81145
(f). Use interior & exterior crow plates to pry out
clamp of front bumper, and take out the front
bumper.
LFWX-6440-81077
(g). Remove fixing bolt of front bumper mounting

bracket, and take out front bumper mounting
bracket.
LFWX-6440-81078
2. Install the front bumper

(a). Install front bumper mounting bracket on its
installation site, and install front bumper fixing
bolt and fasten it.
Torque:6 ～ 12N·m
LFWX-6440-81078
(b). Connect front fog lamp wiring harness
connector.(See77 - lighting system, front fog
lamp, replacement)
(c). Connect daytime driving lamp wiring harness
connector clip.(See77 - lighting system, daytime
running lamp, replacement)
LFWX-6440-81145
81-67
(d). Install front bumper on its installation site, make

bumper clamp aligned with its installation site,
and install front bumper in place.
LFWX-6470-81079
(e). Install the fastening screw of front bumper

mounting bracket and front bumper. 81
LFWX-6470-81075
(f). Install the fastening screw, clamp and bolt of

engine shield and front bumper. (See 81 –
Interior & Exterior, Engine Shield, Replacement)
(g). Install front bumper fixing bolt and fasten it.
Torque:6 ～ 12N·m
(h). Install the radiator upper cross member trim
board.(See81 - interior trims and exterior
trims, radiator upper cross member trim board,
replacewment)
LFWX-6470-81074
Front/rear wheel splash apron tailboard

Change
△ Tips:
The replacement of the front left, rear left, front right and rear right splash apron tailboard is the
same. Here is the replacement of the front left and rear left wheel splash apron tailboard.
1. Remove the front plate of front wheel mud
guard
(a). Lift up the car body.
(b). Remove wheel.(see 33-wheel and tire assembly,
replacement)
(c). Remove the front mudguard.(See81 - interior
trims and exterior trims, front wheel splash
apron, replacement)
(d). Remove the fixing bolt of the front tailgate of
front wheel mudguard, and take out the front
tailgate of front wheel mudguard.
LFWX-6470-81081
2. Remove the rear plate of rear wheel mud

guard
(a). Remove the rear wheel(see 33-wheel and tire
(b). Remove the fixing bolt of rear plate of rear
wheel mud guard and take out the rear plate of
rear wheel mud guard.
LFWX-6470-81082
3. Install the rear plate of rear wheel mud guard
(a). Install tailgate of rear wheel mudguard on its
bolts.
Torque:6 ～ 12N·m
(b). Remove the rear wheel (see 33-wheel and tire
LFWX-6470-81082
81-69
4. Install the front plate of front wheel mud

guard
(a). Install the front tailgate of front wheel mudguard
on front mudguard, and install and fasten its
fixing bolt.
Torque:6 ～ 12N·m
(b). Install the front wheel mudguard.(See81 -
interior trims and exterior trims, front wheel
mudguard, replacement)
(c). Install the front wheels(see 33-wheel and tire
(d). Lower the bodywork.
LFWX-6470-81081
Splash apron
81
Change
△ Tips:
It follows the same way to replace front and rear mud strip. Take front mud strip as an example.
1. Remove front wheel mudguard
(a). Remove mud strip (see 33-wheel and tire
(b). Remove the front tailgate of front wheel
mudguard(See81 - interior trims and exterior
trims, front/rear wheel splash apron, tailboard,
replacement)
(c). Remove clamp, self-tapping screws and bolts in
the position as shown in the diagram.
(d). Remove the mudguard
LFWX-6470-81080
2. Install front wheel mudguard
(a). Install the front tailgate of front wheel mudguard
on the front wheel mudguard.(See81 - interior
trims and exterior trims, front/rear wheel splash
apron, tailboard, replacement)
(b). Put the mudguard on its installation site, and
install mudguard buckle, screw and bolt.
Torque:6 ～ 12N·m
(e). Install wheel. (see 33-wheel and tire assembly,
replacement)
LFWX-6470-81080
Engine lower panel

Change
1. Remove the engine lower panel
(a). Lift the bodywork.
(b). Remove connecting bolt of front bumper and
engine shield. (see 81-interior/exterior trim -
Front bumper, replacement)
(c). Remove the buckle, bolt and screws of the left
and right lower engine shields.
LFWX-6470-81083
2. Install the engine lower panel
(a). Install the left and right lower engine shields
on their installation sites, and install and fasten
their fixing bolt, buckle and screws.
Torque:6 ～ 12N·m
(b). Install the connecting bolt of front bumper and
engine shield. (See 81 – Interior & Exterior,
Front Bumper, Replacement)
(c). Lower the bodywork.
LFWX-6470-81083
81-71
Engine side guard plate

Change
△ Tips:
The replacement of left and right engine panel is almost the same. This section only describes the
replacement of the left panel.
1. Remove the engine left panel
(a). Lift the bodywork.
(b). Remove front wheels (see 33-wheel and tire
(c). Remove front bumper (see 81-interior/exterior
trim - Front bumper, replacement).
(d). Remove fixing clamp of left engine shield, and
take it out.
81
LFWX-6470-81084
2. Install left engine shield

(a). Install left engine shield on its installation site
and install its fixing clamp.
(b). Install front bumper (see 81-interior/exterior trim
- Front bumper, replacement).
(c). Install front wheels (see 33-wheel and tire
(d). Lower the bodywork.
LFWX-6470-81084
Engine decorative cover and bracket

Change
1. Remove the engine trim cover
(a). Open the engine compartment.
(b). Take out engine trim cover (remove four engine
trim cover nuts of 1.5T vehicle model)
LFWX-6470-81085
(c). Remove the fixing bolt of mounting bracket of

engine trim cover, and take out the mounting
bracket of the engine trim cover.
LFWX-6470-81087
2. Install engine trim cover
(a). Put the engine trim cover mounting bracket on
its installation site, and install and fasten the
fixing bolt of engine trim cover.
Torque:6 ～ 12N·m
LFWX-6470-81087
81-73
(b). Put the engine trim cover on its installation site,

and install it.
(c). Close the engine compartment.
LFWX-6470-81085
Engine hood insulating mat

Change 81
1. Remove engine hood insulating mat

engine cover insulation pad buckle and take out
engine cover insulation pad.
LFWX-6470-81086
2. Install engine hood insulating mat

(a). Install engine cover insulation pad on its
installation site, and install the engine cover
buckle.
(b). Close the engine compartment.
LFWX-6470-81086
Radiator upper cross member trim board

Change
1. Remove the radiator upper cross member
trim board.
(b). Remove upper cross beam decorating plate
buckle and fixing bolt of water tank, and take
out upper cross beam decorating plate of water
tank.
LFWX-6470-81088
2. Install the radiator upper cross member trim

board.
(a). Install upper cross beam decorating plate of
upper tank on its installation site, and install and
fasten its fixing clamp and fixing bolt.
Torque:6 ～ 12N·m
LFWX-6470-81088
81-75
Electric maintenance cover plate

Change
1. Remove electric maintenance cover plate
electric maintenance cover plate and take it out.
81
LFWX-6470-81089
2. Install electric maintenance cover plate
(a). Put electric maintenance cover plate on its
LFWX-6470-81089
Fender/fender exterior trim board

Change
△ Tips:
The left and right fender is the same. Here is replacement of the left fender .
1. Remove the fender exterior trim
(a). Remove the front wheel mudguard.
(see 81-interior/exterior trim - Mud guard,
replacement)
(b). Press wheel fender outer decorating plate clip
on the inner side of the wheel fender, and take
out the wheel fender outer decorating plate.
LFWX-6470-81090
2. Remove fender
(a). Remove front combination lamp(See77 - lighting system, front combination lamp,
replacement)
(b). Remove front wheel splash apron (See81 - interior trims and exterior trims, front wheel
splash apron, replacement)
(c). Remove fender trims (See81 - interior trims and exterior trims, fender trims, replacement)
(d). Remove side wall trims.( see 81 - interior trims and exterior trims, side wall trims,
replacement)
(e). Remove front bumper.(see 81-interior/exterior trim - Front bumper, replacement)
(f). Remove Tires (see 33-wheel and tire, replacement)
(g). Remove fender fixing bolt and take out wheel
fender.
LFWX-6470-81092
81-77
3. Install the fender exterior trim

(a). Put decoration parts on their installation site,
and directly press their clamps in wheel fender
by hand.
(b). Install the front wheel splash apron. (see
81-interior/exterior trim - Mud guard,
replacement)
LFWX-6470-81090
4. Install fender
(a). Install fender on its installation site, and install
and fasten its fixing bolt. 81
Torque:6 ～ 12N·m
(b). Install tyres.(see 33-wheel and tire,
replacement)
(c). Install side wall decoration parts. (See81 -
interior trims and exterior trims, side wall trims,
replacement)
(d). Install front wheel mudguard.(See81 - interior
trims and exterior trims, front wheel splash
apron, replacement)
(e). Install wheel fender decoration parts.( See81
- interior trims and exterior trims, fender trims,
replacement)
(f). Install front combination lamp (See 77 - lighting
LFWX-6470-81092 system, front combination lamp, replacement)
(g). Install the front bumper(see 81-interior/exterior
trim - Front bumper, replacement)
Fender inside lining assembly

Change
△ Tips:
The replacement of the left and right fender inside lining assembly is practically the same. Here is
the replacement of the left fender inside lining assembly.
1. Remove fender inside lining assembly
(a). Remove mudguard.(see 81-interior/exterior trim
- Mud guard, replacement)
(a). Remove the fixing clamp of wheel fender lining
component and take out the wheel fender lining
component.
LFWX-6470-81106
2. Install fender inside lining assembly
(a). Install wheel fender on its installation site, and
install the wheel fender buckle.
(b). Install mud strip(see 81-interior/exterior trim -
Mud guard, replacement)
LFWX-6470-81106
81-79
Side wall trims

Change
△ Tips:
The replacement of the left and right side wall trims is the same. Here is the replacement of the left
side wall trims.
1. Remove side wall decoration parts.
(a). Remove front snap fasteners of side wall
decoration parts.
81
LFWX-6470-81093
(b). Remove the blanking cap of side wall decoration

parts, as well as fastening screw and buckle of
side wall decoration parts; remove the rear snap
fastener of the side wall decoration parts, and
take out the side wall decoration parts.
LFWX-6470-81094
2. Install the side wall trims
(a). Put side wall decoration parts on their
installation site, align the buckle of the side wall
decoration parts to mounting hole, and install
side wall decoration parts to make sure they are
installed in place.
(b). Install and fasten the fastening screw of side
wall decoration parts; install side wall decoration
part buckle; and install side wall decoration part
blanking cap.
LFWX-6470-81094
(c). Install the front snap fastener of the side wall

decoration parts.
LFWX-6470-81093
B pillar exterior trim board

Change
△ Tips:
The replacement of the front left/right door and rear left/right door B pillar exterior trim board is the
same. Here is the replacement of front left door exterior trim board.
1. Remove the B pillar exterior trim board.
(a). Remove door frame trim strip. (See 81 – Interior
& Exterior, Door Frame Trim Strip, Replacement)
(b). Remove the door exterior weather bar. (See 81
- interior trims and exterior trims, door exterior
weather bar)
(c). Remove the fastening screw of B column outer
trim panel of front door, and take out B column
outer trim panel of front door.
Note:
After removing the door B pillar exterior trim
board, clear the 3M sealant on the pillar.
LFWX-6470-81095
2. Install B column outer trim panel of door
(a). Make first coat on the B column metal plate and
B column outer decorating plate of door, and
tear off 3M protection glue.
(b). Install B column outer trim panel of door on
its installation site, and install and fasten the
fastening screw of the column outer trim panel.
(c). Install door sealing rubber strip. (See 81 –
Interior & Exterior, Sealing Rubber Strip,
Replacement)
(d). Install the outer water draining device of door
(See 81 - interior trims and exterior trims, door
exterior weather bar)
LFWX-6470-81095
81-81
Rear door C pillar exterior trim board

Change
△ Tips:
The replacement of the left and right door C pillar exterior trim board is the same. Here is the
replacement if the rear left door C pillar exterior trim board.
1. Remove the C column outer trim panel of
rear door.
(a). Remove rear triangle decorative panel,.(refer
to 81 - interior trims and exterior trims, triangle
decorative panel, replacement)
(b). Remove the door exterior weather bar.(See 81
- interior trims and exterior trims, door exterior
weather bar)
(c). Remove the fastening screw of C column outer
trim panel of rear door.
81
LFWX-6470-81096
(d). Take out Column outer trim panel of rear door.
LFWX-6470-81097
1. Install C column outer trim panel
(a). Install C column outer trim panel on its
installation site.
LFWX-6470-81097
(b). Install the fastening screw of C column outer

trim panel of rear door and fasten it.
(c). Install the outer water draining device of door
(See 81 - interior trims and exterior trims, door
exterior weather bar)
(d). Install rear quarter trim panel.(See 81 - interior
trims and exterior trims, triangle decorative
panel, replacement)
LFWX-6470-81096
Door frame molding

Change
△ Tips:
The replacement of front left, front right, rear left and rear right door frame molding is practically the
same. Here is the replacement of the rear left door frame molding frame molding.
1. Remove door frame trim strip
(a). Remove the fastening screw of door frame trim
strip.
LFWX-6470-81098
(b). Take out door frame trim strip.
Note:
After removing the door frame molding, clear the
3M sealant and primary coat on the door frame.
LFWX-6470-81099
81-83
2. Install door frame trim strip

(a). Before mounting door frame trim strip, make
3M94# first coat on door frame.
(b). Install door frame trim strip on its installation
site.
LFWX-6470-81099
(a). Install and fasten fastening screw of door frame
trim strip.
81
LFWX-6470-81098
Door corner decorations

Change
△ Tips:
The replacement of front left, front right, rear left and rear right door corner frame is practically the
same. Here is the replacement of the rear left door corner frame.
1. Remove door corner window decoration
block
(a). Remove door corner window decoration block
and take it out.
LFWX-6470-81100
2. Install the door corner window decoration

block
(a). Put door corner window decoration block on its
installation site and install it.
LFWX-6470-81100
Door interior/ exterior weather bar

Change
△ Tips:
The replacement of front left, front right, rear left and rear right door interior/ exterior weather bar is
practically the same. Here is the replacement of the rear left door interior/exterior weather bar.
1. Remove the outer water draining device of
door
(a). Remove the fastening screw of outer water
draining device of door.
LFWX-6470-81101
(a). Take out outer water draining device of door.
LFWX-6470-81102
81-85
2. Remove the inner water draining device of

door
(a). Remove back door inner trim. (See 81 – Interior
& Exterior, Door inner trim, Replacement)
(b). Remove the inner water draining device of door
and take it out.
LFWX-6470-81103
(a). Put inner water draining device of door on its 81
installation site and install it.
(b). Install rear door inner trim. (See 81 – Interior &
Exterior, Door inner trim, Replacement)
LFWX-6470-81103
4. Install outer water draining device of door.
(a). Install the outer water draining device of door on
its installation site.
LFWX-6470-81102
(a). Install and fasten fixing screw of outer water

draining device of door.
LFWX-6470-81101
Strip and sealing elements

Front seal strip of engine compartment
1. Remove the front seal strip of engine
compartment
(b). Use interior & exterior crow plates to pry
out fixing clamp of front seal strip of engine
compartment and take out front seal strip of
engine compartment.
LFWX-6470-81105
81-87
2. Install front seal strip of engine compartment

(a). Put the front seal strip of engine compartment
on its installation site, and install its clamp.
LFWX-6470-81105
81
Rear seal of engine compartment
1. Remove rear seal of engine compartment.
(a). Remove rear seal clamp of engine compartment
and take out rear seal.
LFWX-6470-81105
2. Install rear seal of engine compartment

(a). Before installation, put rear seal strip of front
hatch cover on its installation site, and install it
LFWX-6470-81105
Fender decoration
△ Tips:
The replacement of the left and right fender trims is the same. Here is the replacement of the left
fender trims.
1. Remove fender panel
(a). Open engine compartment cover
(b). Remove rear seal of engine compartment.(see
81-interior/exterior trim - rear seal of engine
compartment, replacement).
(c). Remove buckle, screw and bolt of wheel fender
decoration parts, and take out the wheel fender
decoration parts.
LFWX-6470-81091
2. Install fender panel
(a). Install the wheel fender decoration parts on their
installation site, and install their buckles, screws
and bolts.
(b). Install rear seal strip of engine compartment.
(see 81-interior/exterior trim - rear seal strip of
engine compartment, replacement).
(c). Close engine compartment cover.
LFWX-6470-81091
81-89
Deflector.
△ Tips:
The replacement of the left and right splitter is practically the same. Here is the replacement of right
splitter.
1. Remove the deflector.
(a). Remove the front bumper(see 81-interior/
exterior trim -Bumper, replacement).
(a). Remove the buckle and fixing bolt of air
deflector to take out the deflector.
81
LFWX-6470-81107
2. Install the deflector
(a). Install deflector on its installation site, install and
fasten the buckle and bolt of the deflector.
(b). Install front bumper (see 81-interior/exterior trim
-Bumper, replacement).
LFWX-6470-81107
Door frame strip

△ Tips:
The replacement of front left, front right, rear left and rear right door frame strip is practically the
same. This section only describes the replacement of the front left door frame strip.
1. Remove left front door frame seal and take it
out.
(a). Remove left front sill apron. (see 81- Interior &
Exterior - Front Sill Apron, Replacement)
(b). Remove A column lower board.(see 81-interior/
exterior trim - A column board, replacement)
(c). Remove left front door frame seal and take it
out.
LFWX-6470-81108
2. Install left front door frame seal
(a). Install left front door frame seal on its installation
site, slightly knock the seal by rubber hammer
and make sure the left front door frame seal is
installed in place.
(b). Install A column lower board. (see 81-interior/
exterior trim - A column board, replacement)
(c). Install left front door sill panel.(see 81-interior/
exterior trim- front door sill panel, replacement)
Install left front door sill panel
LFWX-6470-81108
81-91
Door strip
△ Tips:
The replacement of front left, front right, rear left and rear right door frame strip is practically the
same. This section only describes the replacement of the front left door frame strip.
1. Remove door seal strip
(a). Remove the fastening screw of the left front
door frame trim strip.
(b). Remove door seal strip mounting buckle, and
take out the door seal strip.
81
LFWX-6470-81109
2. Install door seal strip
(a). Install door seal strip on installation site, make
seal strip embedded in door seal strip fixing slot.
(b). Fasten the fastening screw of left front door
frame trim strip.
LFWX-6470-81109
Hatch frame strip

1. Remove hatch frame strip
(a). Unscrew the fixing bolt of combination tail lamp.
LFWX-6470-81146
(b). Remove hatch frame strip, and take it out.
LFWX-6470-81110
2. Install hatch frame strip
(a). Install hatch frame strip on its installation site,
slightly knock it by rubber hammer, and make
sure it is installed in place.
LFWX-6470-81110
81-93
(c). Fasten the fixing bolt of combination tail lamp.
LFWX-6470-81146
Filler cap
81
Change
1. Remove filler cover
(a). Pull oil tank wire opener to open filler cover.
△ Tips:
Oil tank wire opener is located under driver seat.
LFWX-6470-81118
(b). Remove two fixing bolts of oil filler cap and take
down the oil filler cap.
LFWX-6470-81119
2. Install filler cover

(a). Put the oil filler cap on its installation site and
install its fixing bolt.
LFWX-6470-81119
(a). Close the filler cover
LFWX-6470-81120
Roof cover molding

Change
1. Remove roof cover molding
(a). Remove and take out roof cover molding.
Note:
After removing the roof cover molding, clear the
glass cement on the roof metal sheet.
LFWX-6470-81118
81-95
2. Installroof cover molding

(a). Put roof cover molding on its installation site and
install it.
Note:
Before installing the roof cover molding, apply the
special glass cement to the molding and metal
sheet mounting face in advance. After the primary
coat is dry, apply the glass cement of 3 - 5mm in
diameter to the roof cover molding.
LFWX-6470-81118
81
Floor lower panel
Change
1. Remove the front panel of rear floor
(a). Remove the retaining nut of front lower floor
apron to take out the front lower apron of rear
floor.
△ Tips:
The replacement of the rear floor front left and front
right lower panel is practically the same. Below shows
the replacement of front left lower panel.
LFWX-6470-81122
2. Remove the lower board of rear floor beam
(a). Remove the retaining nut and fixing bolt of floor
side beam lower apron to take out the floor side
beam lower apron.
△ Tips:
The replacement of the rear floor left and right beam
lower panel is practically the same. Below shows the
replacement of left beam lower panel.
LFWX-6470-81123
3. Remove the left lower apron of rear floor

spare tire box
(a). Remove the retaining nut and buckle of left
lower apron of rear floor spare tire box, and take
out the left lower apron of rear floor spare tire
box.
LFWX-6470-81124
6. Install left lower apron of rear floor spare tire
box
(a). Install left lower apron of rear floor spare tire box
on its installation site, install its fixing bolt & nut
and buckle, and fasten them.
LFWX-6470-81124
7. Install the lower board of rear floor beam
(a). Install lower apron of rear floor side beam on its
installation, and install and fasten its fixing bolt
and nut.
△ Tips:
The replacement of the rear floor left and right beam
lower panel is practically the same. Below shows the
replacement of left beam lower panel.
LFWX-6470-81123
81-97
8. Install the front lower board of rear floor

(a). Put rear floor lower apron on its installation site,
and then install and fasten its retaining nut.
△ Tips:
The replacement of the rear floor front left and front
right lower panel is practically the same. Below shows
the replacement of front left lower panel.
LFWX-6470-81122
81
81-99
81
Door and door lock - Door and door lock
82-a
Door and door lock

Door and door lock …………… 1
Door ……………………………… 2
Change ………………………… 3 82
Door hinge and stop …………… 6
Change ………………………… 6
Door lock catch ………………… 9
Change …………………………10
Front door lock ………………… 11
Change ………………………… 11
Rear door lock……………………16
Change …………………………16
Engine compartment cover ……20
Change …………………………20
Engine compartment cover lock22
Change …………………………22
Rear back door …………………23
Change …………………………23
Hatch lock ………………………25
Change …………………………25
82-b Door and door lock - Door and door lock
82-1
Door and door lock

Preparations
Quick wrench,
Remove and install
1 connecting rod and
the fixing bolt
socket
82
Remove and install
2 Screw driver
the fixing screw
Maintenance data
Item N•m
Fixing bolts for front/rear door upper/lower hinge 20 ～ 26
Fixing bolts for front/rear door limiting stopper 6 ～ 12、20 ～ 26
Fixing bolts for hatchback locker 6 ～ 12
Fixing bolts for front/rear window sliding rail 6 ～ 12
Fixing bolts for front compartment cover hinge 20 ～ 26
Fixing bolts for hatchback hinge 20 ～ 26
Fender fixing bolt 6 ～ 12
Precautions
1. Do not use sharp tools to remove interior/exterior parts to avoid causing damage to these
parts.
2. Before operation, turn off the ignition switch and apply the parking brake.
3. Do not pull wiring when disconnecting inserts to avoid causing damage to the wiring.
82-2 Door and door lock - Door and door lock
Fault diagnosis
1. L o c k l a t c h ( i n a p p r o p r i a t e
Adjust the lock latch
Specified sealing cannot be adjustment)
reached after closing the door 2. Door lock assembly (door lock
Replace the door lock
assembly is damaged).
1. I n s i d e o p e n i n g h a n d l e
Door cannot be locked/opened Replace inside opening handle.
(damaged)
from inside
2. Door lock assembly (damaged) Replace the door lock
Door cannot be locked/opened by 1. Lock barrel (damaged) Replace the lock barrel
key 2. Door lock assembly (damaged) Replace the door lock
The key cannot be rotated. 1. Lock barrel (damaged) Replace the lock barrel
Door
Adjustment
△ Tips:
It follows the same way to adjust each door. Take front left door as an example.
1. Adjust front left door
(a). Remove fender (see 81 interior/exterior trim,
fender, replacement).
(b). Unscrew fixing bolts connecting upper/lower
door hinges and vehicle body. Adjust front left
door.
(c). After adjustment, tighten fixing bolts connecting
upper/lower hinges on front left door and vehicle
body.
Torque: 23（20~26）N•m
(d). Unscrew fixing bolts connecting upper/lower
door hinges and front left door. Adjust front left
door.
(e). After adjustment, tighten fixing bolts connecting
upper/lower hinges on front left door and front
left door.
LFWX-6470-82001 Torque: 23（20~26）N•m
82-3
Change
1. Remove front door assembly
(a). Disconnect door wiring inserts.
(b). Remove fixing bolts for front fender.
82
LFWX-6470-82002
(c). Remove fixing bolts for body side limiting
stopper.
LFWX-6470-82003
(d). Use jack to support front door and remove fixing
bolts for door hinges.
Note:
Pay attention to safety when removing front
doors. It is better for two people work together.
LFWX-6470-82004
(e). Remove fixing bolts for lower door hinges.

(f). Remove front door assembly.
LFWX-6470-82005
2. Install front door assembly
(a). Place door to installing place with the aid of
assistant. Install and tighten fixing bolts for
upper door hinges.
Note:
• Apply sealing glue on hinge surface and apply
lubricating grease on rotating part.
• Check if door sealing is hardened. If so, it might
lead to serious water leaking. Replace it with
new sealing in this case.
LFWX-6470-82005
(b). Install and tighten fixing bolts on door hinges.
LFWX-6470-82004
82-5
(c). Install and tighten fixing bolts for door and body
side limiting stoppers.
LFWX-6470-82003 82
(d). Sort out door wiring and connect door wiring

inserts.
(e). Install front fender to its right place. Install and
tighten fixing bolts for fender.
LFWX-6470-82002
3. Adjust door lock pin position so that the door is in right place.
4. Close the door and adjust front door cushion so that door is in contact with body.
Note:
Do not pull the harness when disconnecting the connector so as to prevent damaging the
harness.
Door hinge and stop

Change
△ Tips:
It follows the same way to replace door hinge and limiting stopper. Take front left door as an
example. The detailed description will be available if different.
1. Remove front left door hinge
△ Tips:
It follows the same way to replace upper and lower
hinge. Take upper hinge as an example.
Note:
In order to avoid door re-positioning, please do
not remove two door hinges simultaneously.
Replace door hinge on by one.
(a). Remove fender.
(b). Remove fixing bolts for connecting upper hinge
of front left door and vehicle body.
LFWX-6470-82006
(c). Remove fixing bolts for connecting upper hinge
of front left door and front left door.
△ Tips:
During removing, mark on front left door hinge and
surface of front left door for subsequent installing.
(d). Remove front left door hinge.
LFWX-6470-82004
2. Install front left door hinge
(a). Install front left door hinge to its right place and
tighten fixing bolts for connecting front left door
hinge and front left door.
△ Tips:
When installing front left door hinge, align with the
mark made during removing.
LFWX-6470-82004
82-7
(b). Install and tighten fixing bolts for connecting

upper hinge of front left door and body.
(c). Install the fender.
LFWX-6470-82006 82
3. Remove front left door limiting stopper

(a). Remove front left door panel and waterproof
membrane.(see 81 interior/exterior trim-front
door panel, replacement).
(b). Remove fixing bolts for connecting front left door
limiting stopper and body.
LFWX-6470-82003
(c). Remove fixing bolts for connecting front left door
limiting stopper and front left door. Remove front
left door limiting stopper.
LFWX-6470-82007
4. Install front left door limiting stopper

(a). Install front left door limiting stopper to its right
place and tighten fixing bolts for connecting front
left door limiting stopper and front left door.
LFWX-6470-82007
(b). Install and tighten fixing bolts for connecting
front left door limiting stopper and body.
(c). Install inside panel of front left door and
waterproof membrane. (see 81 interior/exterior
trim-front door inside panel, replacement).
LFWX-6470-82003
82-9
Door lock catch

Adjustment
△ Tips:
It follows the same way to adjust each door lock. Take front left door as an example. The detailed
description will be available if different.
Note:
Before adjusting lock, properly position the door.
1. Adjust door lock
(a). Unscrew fixing bolts for door lock.
82
LFWX-6470-82008
(b). Use rubber mallet to knock door lock and adjust
it up/down or left/right as needed.
△ Tips:
Left/right adjustment is intended to change the gap
between door and body; up/down adjustment is to be
done in case the door cannot be locked.
(c). Tighten fixing bolts for door lock.
LFWX-6470-82009
Change
1. Remove door lock
(a). Remove fixing bolts for door lock.
(b). Remove door lock.
LFWX-6470-82008
2. Install door lock
(a). Install door lock to its right place.
(b). Pre-tighten fixing bolts for door lock.
(c). Adjust door lock to its right place.
(d). Tighten fixing bolts for door lock.
LFWX-6470-82008
82-11
Front door lock

Change
1. Remove front door lock(No need to remove
the outer handle)
(a). Lift glass up to the top.
(b). Remove front door panel (see 81 interior/
exterior trim-front door panel, replacement).
(c). Tear down waterproof membrane.
82
LFWX-6470-82010
(c). Remove fixing bolts for front window guide rail
and remove the rail.
(d). Disconnect door lock inserts.
(e). Disconnect the connection of lock body and
outer pull rod & lock cylinder pull rod of outer
handle.
Note:
Do not pull the harness when disconnecting the
connector so as to prevent damaging the harness.
LFWX-6470-82011
(f). Remove 1 fixing bolt of outer handle of front
door.
LFWX-6470-82038
(g). Take out handle cap and lock cylinder of front

door.
LFWX-6470-82012
(h). Take down outer handle of front door.
LFWX-6470-82013
(i). Remove 1 fixing bolt of outer handle of front
door.
LFWX-6470-82014
82-13
(j). Take down outer handle base of front door and

outer handle gasket of front door.
LFWX-6470-82015 82
(k). Remove fixing bolts for front door lock.
LFWX-6470-82016
(l). Remove door lock.
LFWX-6470-82017
2. Install front door lock

(a). Install front door lock to its right place.
(b). Install and tighten fixing bolts for front door lock.
LFWX-6470-82016
(c). Install outer handle base and outer handle
gasket on their installation sites.
(d). Install outer handle fastening screw and fasten
it.
LFWX-6470-82014
(e). Install outer handle of front door.
(f). Pull front outer door handle through mounting
hole and pull it forward to install it onto outer
handle seat.
LFWX-6470-82013
82-15
(g). Install outer handle cap and lock cylinder of front

door.
LFWX-6470-82012 82
(h). Install outer handle fastening screw and fasten

it. Install outer handle fastening screw and
fasten it.
(i). Install the lock body and outer pull rod & lock
cylinder pull rod of outer handle.
LFWX-6470-82011
(j). Install glass guide rail and fixing bolt.
LFWX-6470-82011
(k). Connect door lock inserts.

(l). Apply sealing glue and water-proof film.
(m). Install bracket and fixing bolts for glass control
panel.
(n). Install front door inside panel (see 81 interior/
exterior trim-front door panel, replacement).
LFWX-6470-82010
Rear door lock
Change
1. Remove the rear door lock (no need to
remove the outer handle)
(a). Remove rear door panel (see 81 interior/exterior
trim-rear door panel, replacement).
(b). Tear down the waterproof membrane.
LFWX-6470-82030
(c). Remove rear door glass guide rail fastening
screw, and remove glass guide rail.
(d). Disconnect the door lock connector.
Note:
Do not pull the harness when disconnecting the
connector so as to prevent damaging the harness.
LFWX-6470-82031
82-17
(e). Remove fixing bolts for rear door lock.
LFWX-6470-82032 82
(f). Remove door lock.
LFWX-6470-82033
(g). Remove one fixing bolt of outer handle of rear
door.
LFWX-6470-82034
(h). Take out outer handle cap of rear door.
LFWX-6470-82034
(i). Take down the outer handle of rear door.
LFWX-6470-82035
(j). Remove 1 fixing bolt of outer handle of rear
door.
LFWX-6470-82036
82-19
(k). Remove rear door handle and its gasket.
LFWX-6470-82037 82
2. Install rear door lock

Install them back in the sequence reverse to the removal sequence.
Engine compartment cover

Adjustment
(a). Open front hatch cover.
(b). Rotate 4 rubber bolts on front hatch cover and
adjust their positions upward/downward to
adjust front hatch cover.
LFWX-6470-82018
(c). Adjust fixing bolts for front hatch cover and front
hatch cover hinge to realize forward/backward
adjustment of front hatch cover.
(d). Close front hatch cover.
LFWX-6470-82019
Change
1. Remove front hatch cover
(a). Open front hatch cover and use supporting rod
to support front hatch cover.
(b). Hold the front compartment cover by hand.
(c). Remove the wiper nozzle water pipe.
(d). Remove fixing bolts for front hatch cover and its
hinge. Remove front hatch cover.
△ Tips:
LFWX-6470-82019
82-21
(e). Remove decoration parts of left and right wheel

fenders.
82
LFWX-6470-82021
(f). Remove fixing bolts for front hatch cover hinge
and remove front hatch cover hinge.
LFWX-6470-82022
2. Install front hatch cover
(a). Install front hatch cover hinge to its right place
and tighten fixing bolts.
LFWX-6470-82022
(b). Install the left and right wheel fender decoration

parts.
LFWX-6470-82021
(c). Install front compartment cover on its installation
site.
(d). Install and tighten fixing bolts for connecting
front hatch cover and its hinge.
(e). Install the wiper nozzle water pipe.
△ Tips:
(f). Close front hatch cover.
LFWX-6470-82019
Engine compartment cover lock

Change
1. Remove front hatch lock
(a). Remove the radiator upper cross member trim
board.
(b). Remove fixing bolts for front hatch lock.
(c). Disconnect front hatch lock wire from the lock.
(d). Remove front hatch lock.
LFWX-6470-82023
82-23
2. Install front hatch cover lock

(a). Install front hatch cover lock wire to the lock.
(b). Install front hatch cover lock to right place and
tighten fixing bolts.
(c). Install the radiator upper cross member trim
board.
LFWX-6470-82023 82
Rear back door
Change
1. Remove back door assembly
(a). Pull out corrugated pipe connecting back door
and body. Disconnect back door wiring inserts.
Note:
Pay attention to safety when removing back door.
It is better to have two people working together.
LFWX-6470-82024
(b). Remove fixing bolts for back door supporting
rod and back door.
Note:
When removing fixing bolts for back door
supporting rod, use strut to hoist back door to
appropriate height to support it reliably.
LFWX-6470-82025
(c). Remove fixing bolts for connecting back door

and hinge. Remove back door assembly.
△ Tips:
Here the roof should be lifted first so as to remove the
two bolts covered by the roof.
LFWX-6470-82029
2. Install back door assembly
(a). Place back door to installing position. Install and
tighten fixing bolts for connecting hinge.
△ Tips:
Restore the roof.
LFWX-6470-82029
(b). Install and tighten fixing bolts for back door and
its supporting bar.
LFWX-6470-82025
82-25
(c). Connect back door wiring inserts. Connect

corrugated pipe for connecting back door and
body.
LFWX-6470-82024 82
Hatch lock
Change
Note:
Do not repair it to calibrate deviation of door lock. Calibrate it by replacing it.
1. Remove back door lock
(a). Remove fixing bolts for back door panel.
(b). Remove back door panel.
Note:
When removing back door panel, pay attention to
clamp position to avoid causing damage to the
panel.
LFWX-6470-82026
(c).Remove fixing bolts for back door lock and
remove back door lock.
Note:
When removing back door lock, assistance is
needed to open back door to the place to facilitate
removing of lock.
LFWX-6470-82027
(d). Remove connection between back door lock

and its wiring.
LFWX-6470-82028
2. Install back door lock
(a). Connect back door and back door wiring.
LFWX-6470-82028
(b). Place back door lock to its installing place.
Install and tighten fixing bolts.
LFWX-6470-82027
82-27
(c). Install back door panel and its fixing bolt.
LFWX-6470-82026 82
Electric window and rearview mirror - Electric window and rearview mirror 83-a
Electric window and rearview mirro

Electric window and rearview
mirro ……………………………… 1
Component drawing (window) 3
Rear view component drawing 4
Skylight sunshade component 83
drawing ………………………… 5
Unlocking skylight component
drawing ………………………… 6
Circuit diagram ………………… 7
Basic examination ………………16
Systematic examination ………16
Fault phenomenon table ………17
Front windshield…………………26
Change …………………………26
Hatch glass ………………………32
Change …………………………32
Sunshade assembly (full-view
skylight) …………………………35
Change …………………………35
Openable skylight ………………41
Change …………………………41
Front door glazing window ……42
Change …………………………42
Rear door glazing window ……45
Change …………………………45
Front quarter window assembly45
Change …………………………45
Rear quarter window assembly 45
Change …………………………45
Interior rearview mirror…………45
Change …………………………46
Exterior mirror……………………47
Change …………………………47
83-b Electric window and rearview mirror - Electric window and rearview mirror
Electric window and rearview mirror - Electric window and rearview mirror 83-1
Electric window and rearview mirro

Preparations
Quick wrench,
1 connecting rod and Remove the fixed bolt and nut
socket
83
Remove the fixed screw and

2 Screw driver
buckle
Digital universal Measure the voltage or

3
meter resistance
Auxiliary measurement of
4 Wiring group
voltage or resistance
83-2 Electric window and rearview mirror - Electric window and rearview mirror
Maintenance data
Sunshade motor operating voltage range 9 ～ 16V
Standard operating voltage of sunshade motor 13.5V
Operating ambient temperature of sunshade motor -30 ～ 85℃
Items N.m
Fixed bolt of front glass guide rail 9
Glass assembly and glass lifter connecting bolt 9
Front glass lifter assembly fixed bolt 9
Rear glass lifter assembly fixed bolt 9
Fixed bolt of rear glass guide rail 9
Outside rearview mirror assembly fixed nut 9
Sunshade glass fixed bolt 4
Sunshade motor fixed bolt 2.6
Sunshade assembly mounting bolt 9
Precautions
1. If the circuit disassembly and maintenance are involved during maintenance, disconnect the
battery negative cable first.
2. If it is required to open the vehicle door to remove during maintenance, support the vehicle
door with a pole.
3. Avoid removing the trim panel and other venerable parts with sharp tools.
4. The sunshade motor must be initialized in case of maintenance, adjustment and replacement
of the mechanical parts or motor of the sunshade.
Component drawing (window)
12
9 11
6
8
10
83
4
2
7
1
3
LFWX-6470-83001
Front windscreen glass components Hex bolt spring washer with
1 7 head cross slot and flat washer
components
Front windscreen sealing

2 8 Left rear door glass sealing strip
components
Left side wall front quarter window

3 9 Right rear door glass sealing strip
assembly
Right side wall front quarter window Left side wall rear quarter window
4 10
assembly assembly
Right side wall rear quarter window

5 Front left door glass assembly 11
assembly
6 Front right door glass assembly 12 Back door glass assembly

Rear view component drawing
1-1
3-1
3
4 2 -1
3-2
2-2
LFWX-6470-83002
Inside rearview mirror assembly Outside rear-view mirror assembly

1 3
(RH)
1-1 Cross recessed pan head screw 3-1 Right rearview mirror lens
Outside rear-view mirror assembly

2 3-2 Right side turn lamp assembly
(LH)
2-1 Left rearview mirror lens 4 Hexagon flange nut
2-2 Left side turn lamp assembly

Skylight sunshade component drawing
10
9
1
6 83
2 5
3
7
4
8
8-1
LFWX-6470-83003
1 Sunroof glass components 7 Hexagon flange nut
2 Skylight glass strip assembly 8 Sunroof sunshade of assembly
Sunroof sunshade motor and

3 Right roof cover molding front end 8-1
controller components
4 Left roof cover molding front end 9 Left roof cover molding assembly
5 Left roof cover molding rear end 10 Right roof cover molding assembly
6 Right roof cover molding rear end

Unlocking skylight component drawing
11
4 3
6-3
5 6-2
2
7 10
6
6-1
12
9
13
1 6-2
2 6-3

3 7
4 8 Skylight front left drain pipe assembly
5 9 Skylight front right drain pipe assembly
6 Sunroof assembly 10 Skylight rear left drain pipe assembly
6-1 11 Skylight rear right drain pipe assembly

83
83-7
Ⅰ
B+ B+ B+ B+
Rear defroster relay
2 5
To background light system
FS 25
FS 32
10A
25A
FS 30
FS 17
Electric window and rearview mirror - Electric window and rearview mirror
10A
25A
3
2 1C 2 1B 9 1E 1 1B 9 1F
2 I1C 2 I1B 9 I1E 1 I1B 9 I1F
0.3 Bl
0.5 RBl
0.85 R
0.3 RB
5 D7 10 D7 5 D6
2.0 P
IG
12 ID 11 ID
12 DI 11 DI
14 I26 12 D7 8 D7 6 D7 1 D7 2 D7 11 D7 7 D7 9 D7 1 D5 5 D5 6 D5 4 D6 3 D6 2 D6 2 D5 3 D5 1 D6 6 D6 9 D6 10 D6 7 D6 4 D5
1.25 RB
B
0.3 RB
2.0 WR
0.5 OBl
0.5 OW
2.0 WB
0.5 WY
0.5 BlB
0.5 YW
0.5 OB
0.3 GB
0.5 OR
0.3 Gr
0.3 Br
0.5 Bl
0.3 G
0.5 R
0.3 P
1 D1
9 DI 8 ID 10 ID
9 ID 8 DI 10 DI
0.5 P
2.0 P
0.5 P
2 D1
6 ID 2 IK 9 IK 7 IK 8 IK 13 DI 20 DI
0.5 WY
0.5 BlB
0.3 B
0.5 R
0.5 B
6 DI 2 KI 9 KI 7 KI 8 KI 13 ID 20 ID
1 D8 2 D8 4 D8 3 I08 1 K5 3 K5 2 K5 4 K5 2 D3 1 D3 4 D3 5 D3 6 D3
5 D8 6 D8 8 D8 7 I08 5 K5 6 K5 8 K5 7 K5 3 D3
20 DI
0.5 OBl
1.25 B
0.5 OB
0.5 BlB
0.5 BlB
0.5 B
0.5 RY
0.5 YG
0.5 B
0.5 Y
0.5 Y
To rear defrosting system 20 ID

24 DI 25 DI 17 DI 10 KI 16 KI 6 KI 7 ID
24 ID 25 ID 17 ID 10 IK 16 IK 6 IK 7 DI
Circuit diagram
20 I11 19 I11 14 I11 15 I11 7 I10 1 D4 3 D4 5 I24 18 I24 3 I09

Unlocking signal Locking signal LIN-line
M
FBCM A FBCM
G23 G27 G23 G23
//Ⅱ

B+ B+ B+

FS 33
25A
FS 32
FS 25
25A
10A
FBCM
LIN 4 1C
3 I09
4 I1C
1 1B 9 1F
1 I1B 9 I1F
1.25 RY
0.85 R
4 IK 3 IK 14 IK 12 IB1 18 IB1 22 IB1 4 IG 11 IG 12 IG
4 KI 3 KI 14 KI 12 BI1 18 BI1 22 BI1 GI GI 12 GI
4 11
2.0 RB

8 BM 1 BM 5 BM 8 GN 1 GN 5 GN
8 MB 1 MB 5 MB 8 NG 1 NG 5 NG
0.3 RB
0.3 RY
0.3 G
0.3 G
2.0 RB
0.3 G
0.3 Bl
2.0 RY
2.0 RY
0.3 Bl
0.5 R
0.3 Bl
0.5 R
0.5 R
10 K4 1 K4 K4 4 K4
0.3 RY
2 10 M4 1 M4 2 M4 4 M4 10 N4 1 N4 2 N4 4 N4

3 K4 14 K4 12 K4 7 K4
0.5 OW 8 K4 6 K4 3 M4 14 M4 12 M4 7 M4 8 M4 6 M4 3 N4 14 N4 12 N4 7 N4 8 N4 6 N4
2.0 WR
2.0 WB
0.5 OW
2.0 WR
0.5 OR
0.3 GB
2.0 WB
0.5 OW
2.0 WR
0.5 OR
0.3 GB
2.0 WB
1 K1
0.5 OR
0.3 GB
1 M3 1 N3
2.0 B

2.0 B

2.0 B

2 K1 2 M3 2 N3
1 S3 2 S3 2 S2 1 S2 1 M1 2 M1 2 M5 1 M5 1 N1 2 N1 2 N5 1 N5
M M M M M M

G27 G36 G31
83-8
83
83-9
/

B+ IG1 B+
10A
FS44
FS34
25A
FS35
15A
9 1F 13 1D 11 1F
9 I1F 13 I1D 11 I1F
0.5 RG
0.5 RY
1.25 R
4 IR1 6 IR1
2 IR1 4 RI1 6 RI1
2 RI1
0.5 RY
1.25 R
0.5 RG 0.5 RG
3 R3 6 R3
1 R6 1 R5 10 R4
5 R3

R4
0.50 W

2

M
R4
10 R3

0.50 Y
6
3 R6 2 R6 3 R5 2 R5 1 R4 4 R4
1 R3 8 R3 10 R3 5 R3
BA05 0.5 W
BA10 0.5 Y
0.50 GGr
0.50 GGr
0.50 GGr

0.5 B
1.25 B
1 RI1
1 IR1
0.50 B
1.25 B
3 IR1 FBCM
I09 2
3 I1F
RI1
()
3 IR1
3 I1F
RI1
G
G24
G
G24
、()

B+ B+ B+ B+
FS34
10A
FS48
25A
FS44
25A
FS35
25A
BCM
10 1F 5 1E 10 1F 11 1F 3 I09
10 I1F 5 I1E 10 I1F 11 I1F
10 IR1 6 IR1 9 IR1
10 RI1 6 RI1 9 RI1
3 IR1
3 RI1 0.50 W
1.25 R
0.50 Y
0.50 RG
0.50 YW
1.25 WR
0.50 RY
0.50 YB
0.30 G
1 R04 19 R04 18 R04 9 R04 8 R04 3 R03 1 R03 4 R03
R04 5 2
R03 R03 8 R03 7 R03 9 R03 5 R03 2 R03
+ +
LIN
2 R01

1 R01
0.5 BlR

21 R04 17 R04 11 R04 6 R03
1 R6 1 R5 10 R03
1 R02

2 R02
0.50 GGr
3 R6 2 R6 3 R5 2 R5
21 I25
0.5 B
0.5 B
0.5 B
BCM
83-10
G24
G24
60()
BCM MP5
BCANH BCANL

B10 15 I16 14 I16 10 I16 9 I16 3 I01 11 I01
0.5 WB
0.5 RY
0.5 YG
0.5 BW
0.5 W
0.5 W
0.5 BlW
0.5 VW
54 26 I54 23 I54 24 I54 17 I54 18 I54 36 I54 35 I54
DVD- DVD+

+ +
54 10 I54 11 I54 12 I54 29 I54 30 I54 13 I54 14 I54 15 I54 16 I54 31 I54 32 I54 38 I54
0.5 B
0.5 PBl
0.5 YB
0.5 BrBl
0.5 BrW
0.5 PB
0.5 BrB
0.5 YW
0.5 PY
0.5 YR
0.5 BrR
0.5 YBl
ID2 5 ID2 9 ID2 4 ID2 8 ID2 3 ID2 10 IK2 5 IK2 9 IK2 4 IK2 8 IK2 3 IK2
ID2 5 ID2 9 ID2 4 ID2 8 ID2 3 ID2 10 IK2 5 IK2 9 IK2 4 IK2 8 IK2 3 IK2
0.5 PBl
0.5 PY
0.5 YB
0.5 BrBl
0.5 BrW
0.5 BrB
0.5 PB
0.5 YR
0.5 YW
0.5 BrR
0.5 YBl
83
D10 3 D10 1 D10 2 D10 6 D10 5 D10 4 K7 3 K7 1 K7 2 K7 6 K7 5 K7

+ +
G13
Terminal definition (full-view skylight) D5 Connect to the front left door power window
switch 2
(for details, Seecircuit diagram catalogue)
D4 Connect to the front door glass lift motor
6 5 4 3 2 1
14 13 12 11 10 9 8 7
Terminal Wire size /

Function
No. Color
Terminal Wire size / 1 1.25/B Ground
Function
No. Color 2 1.25/WR Electric window up input
Front left door electric 3 1.25/WB Electric window down input
1 1.25/WR
window motor up input
Central control, electric
Front left door electric 4 1.25/RB window switch down power
2 1.25/WB
window motor down input B+
5 0.5/OR Central control locking
D6 Connect to the front left door power window 6 0.5/OW Central control unlocking
switch 1
7 NC
8 NC
9 NC
5 4 3 2 1 10 NC
11 NC
10 9 8 7 6
12 NC
13 NC
14 NC

Function D8 Connect to the rear-view mirror
No. Color
Central control locking
1 0.5/OBl
signal
4 3 2 1
Central control unlocking
2 0.3/Br
state signal 8 7 6 5
Central control locking
3 0.3/Gr
state signal
4 0.3/P Door lock status signal
5 0.3/Bl Backlight power supply
Central control unlocking
6 0.3 /GB
signal
7 0.3 /GB Door light
8 NC
9 0.3/G LIN
Front left door electric
10 0.5/R window switch down power
B+
K4 Connect to the front right door power window Terminal Wire size /
switch No. Color
Function
Exterior rearview mirror

1 0.5/R
6 5 4 3 2 1 lens horizontal adjustment
2 0.5/WY
14 13 12 11 10 9 8 7
lens vertical adjustment
Exterior rearview mirror left
3 0.5/BlW
motor common terminal
Left exterior rearview
4 0.5/P
mirror heating
Terminal Wire size / Function
No. Color 5 0.5/YG Turn signal lamp +
Front right door electric 6 0.5/B Turn signal lamp -

1 0.5/R
window down power B+ Exterior rearview mirror 83
7 0.5/Y
2 0.3/Bl Background light power electric folding
3 0.3 /GB Door light Exterior rearview mirror

8 0.5/YB
electric resetting
4 0.3/G LIN-line
5 NC
D7 接电动外后视镜开关
6 1.25/B Ground
7 0.5/OW Central control unlocking
9 NC 6 5 4 3 2 1
12 11 10 9 8 7
Door lamp, central control
10 1.25/RB and glass lift motor
powerB+
11 NC
Terminal Wire size / Function
Front right door electric
12 1.25/WB No. Color
window motor down input
1 0.3/B Ground
13 NC
2 0.5/B Ground
Front right door electric
14 1.25/WR 3 NC
4 NC
K3 Connect to the front right window power 5 0.5/RBl B+
window motor Exterior rearview left/right
6 0.5/WY mirror up/down common
terminal
1
Exterior rearview right
7 0.5/Bl mirror left/right common
2 terminal
Exterior rearview left mirror
8 0.5/R
left/right common terminal
9 0.5/YW
folding output signal
11 0.5/BlB right motor common
terminal
Exterior rearview mirror left
12 0.5/BlW
motor common terminal
K5 Connect to the front right electric rear-view

mirror
1
2
4 3 2 1
8 7 6 5

Function
No. Color
1 0.5/Bl
Terminal Wire size / lens horizontal adjustment
Function
No. Color Exterior rearview mirror
2 0.5/WY
Front right door electric lens vertical adjustment
1 1.25/WR Exterior rearview mirror
Front right door electric 3 0.5/BlB right motor common
2 1.25/WB terminal
window motor down input
Right exterior rearview
4 0.5/P
mirror heating
N4 接右后窗玻璃升降开关 5 0.5/RY Turn signal lamp +
6 5 4 3 2 1 6 0.5/B Turn signal lamp -

14 13 12 11 10 9 8 7 7 0.5/Y
electric folding
8 0.5/YB
electric resetting
M4 Connect to the rear left power window motor
Function
No. Color
6 5 4 3 2 1
1 0.5/R B+
14 13 12 11 10 9 8 7
3 0.3 /GB Door light
4 0.3/G LIN-line
5 NC Terminal Wire size /
Function
No. Color
6 1.25/B Grounding 1 0.5/R B+
7 0.5/OW Central control unlocking 2 0.3/Bl Background light power
8 0.5/OR Central control locking 3 0.3 /GB Door light
9 NC 4 0.3/G LIN-line
10 1.25/RY Controller live 5 NC
11 NC 6 1.25/B Grounding
Electric window motor 7 0.5/OW Central control unlocking
12 1.25/WB
down input
13 NC
9 NC
Electric window motor up
14 1.25/WR 10 1.25/RY Controller live
input
11 NC
N1 Connect to the rear right power window Electric window motor
12 1.25/WB
motor down input
13 NC
14 1.25/WR
input
M1 Rear left door electric window down motor

Terminal Wire size
Function
6 5 4
No. / Color
3 2 1
14 13 12 11 10 9 8 7 Electric window motor up

1 1.25/WR
input
Electric window motor

2 1.25/WB
down input
Function
No. Color
1 1.25/WR
input
Electric window motor
2 1.25/WB
down input
83
Operable skylight harness pin definition

Harness connector A（HULIAN 3CD10FGY）
(Connected to ECU that controls glass)
Pin Pin definition Signal contents Triggering level
Glass close Active low
HULIAN 3TS11MW
Key switch ground
Glass open Active low

Harness connector B（HULIAN 3TS11MW）
Power + (Connected to body wiring harness)
Pin Pin definition Signal contents Triggering level
Ignition key signal Active high Glass close Active low
Power ground
Glass open Active low
Harness connector A（HULIAN 3CD10FGY） Power +
(Connected to ECU that controls the shutter) Vehicle key signal Active high
Pin Pin definition Signal contents Triggering level Power ground
Rolling blind close Active low Rolling blind close Active low
Rolling blind open Active low
Power +
Power ground
Rolling blind open Active low
Power +
Ignition key signal Active high

Power ground
The terminal definitions listed

Bodywork end here are model:
connector for the HULIAN
full-view skylight. For the operable skylight terminal
3TS11MW
definitions, refer to the circuit diagram catalogue.
Basic examination
Systematic examination
1. Check the working condition of power windows
(a). Keep the system power “ON”, turn each window switch up and down and check the
working condition of the power window, and get the window serviced according to the
following diagnoses if it fails to work.
2. Check the working condition of the sunshade
(a). Check the seal and corrosion damage of the sunshade.
(b). Open and close the sunshade to check its function.
(c). Clean the sunshade guide rail and lubricate it with grease if necessary.
(d). Check the working condition of the sunshade and pay attention to possible friction residue.
3. Check the fuse
(a). Check if the power window fuse FS25, FS32, FS33 are fused, if so, replace with fuses with
the same specification.
△ Tips:
The power window fuses are in the fuse box of the cab.
(b). Check if the sunshade motor fuse FS37, FS44 is fused, if so, replace with a fuse with the
same specification.
△ Tips:
The sunshade motor fuse is in the fuse box of the cab.
(c). Check if the BCM controller fuse FS43 is fused, if so, replace with a fuse with the same
specification.
△ Tips:
The sunshade motor fuse is in the fuse box of the cab.
4. Check the left front door glass lifter switch control line
(a). Keep the power “OFF” and disconnect the left front door controller harness connector D5.
(c). Use the digital universal meter resistance to check if each controller terminal and its
corresponding 12 terminal of the meter harness connector ID1 are conducted, and replace if
not.
5. Check the working condition of the right front door glass lifter
(a). Keep the power “OFF” and disconnect the right front door glass lifter harness connector.
(b). Use the digital universal meter resistance to check if the right front door glass lifter Terminal 1
and Terminal 2 are conducted, and replace if not.
6. Check the working condition of the left rear door glass lifter
(a). Keep the power “OFF” and disconnect the left rear door glass lifter harness connector.
(b). Use the digital universal meter resistance to check if the left rear door glass lifter Terminal 1
7. Check the working condition of the right rear door glass lifter
(a). Keep the power “OFF” and disconnect the right rear door glass lifter harness connector.
(b). Use the digital universal meter resistance to check if the right rear door glass lifter Terminal 1
8. Check the sunshade switch signal line
(a). Keep the power “OFF” and disconnect the sunshade module harness connector R3.
(b). Use the digital universal meter resistance to check if the sunshade module harness connector
R3 Terminal 1 and the body ground are conducted, and repair the related harness according
to the circuit manual if not.
9. Check the sunshade motor power line
(a). Bring the power to “OFF” state and disconnect the sunshade motor harness connector.
(b). Keep the power “ON” and use a digital universal meter resistance to check if there is
voltage between R3 terminal 6 and the body gound, and repair the related harness according
to the circuit manual if the voltage is 0.
(c). Keep the power “ON” and use a universal meter resistance to check if there is voltage
between R3 terminal 3 and the body gound, and repair the related harness according to the
circuit manual if the voltage is 0.
10. Check the sunshade motor ground wire
(a). Bring the power to OFF state and disconnect the sunshade module harness connector R3.
(b). Use the digital universal meter resistance to check if there is voltage between R3 terminal 1
and the body gound are conducted, and repair the related harness according to the circuit
manual if not.
(c). Use the digital universal meter resistance to check if sunshade motor harness connector
Terminal 8 and the body ground are conducted, and repair the related harness according to
the circuit manual if not.
10. Check the operation condition of sunroof
(a). Switch the system power supply to “ON”, press sunroof switch, and inspect its working
condition; if the sunroof can not work, it should be maintained according to the following
diagnosis contents. 83
(b). Bring the power to LOCK state and disconnect the sunroof harness connector.
(c). Use digital multimeter resistance gear to detect whether sunroof No.1 terminal and No.2
terminal are conducted or not, if not, change them.
Fault diagnosis
1 Fuse (damaged) Change
2. Power circuit (open circuit
No electric window or short circuit)
works
3. FBCM Change
4. Check LIN signal cable Repair or replace the harness or connector

1. Motor (damaged) Change
2. Harness (open circuit) Repair or replace the harness or connector
Front left door electric 3. Glass regulator (damaged
window not working Repair or replace
or seized)
4. Left front glass lifter switch
Change
(damage)
Front right door electric 3. Glass regulator (damaged
or seized)
4. Right front glass lifter switch
Change
(damage)
Rear left door electric 3. Glass regulator (damaged
or seized)
4. Left rear glass lifter switch
Change
(damage)

Rear right door electric 3. Glass regulator (damaged
or seized)
4. Right rear glass lifter switch
Change
(damage)
1. Fuse (damaged) Change
Both sides electric 2. Electric rearview mirror

Change
rearview mirror not switch (damaged)
working 3. Electric rearview mirror
power, grounding circuit Repair or replace the harness or connector
(open circuit or short circuit)
1. Electric rearview mirror
Change
Left rearview mirror not switch (damaged)
working 2. Circuit (open circuit or short
circuit)
Change
Right rearview mirror switch (damaged)
not working 2. Circuit (open circuit or short
circuit)
Change
switch (damaged)
Left rearview mirror
2. Motor (damaged) Replace the rearview mirror assembly
vertical motion disabled
3. Circuit (open circuit or short
circuit)
Change
switch (damaged)
Left rearview mirror
lateral motion disabled
circuit)
Change
switch (damaged)
Right rearview mirror
vertical motion disabled
circuit)
Change
switch (damaged)
Right rearview mirror
lateral motion disabled
circuit)
1. Fuse (blown) Change
2. Harness (short circuit or
The sunshade fails to Repair or replace the harness or connector
open circuit)
work
3. Sunshade switch (fault) Repair or replace
4. Sunshademotor (fault) Change
1. Fuse(blown) Change
2. Harness(short circuit or
Operable skylight out of Repair or replace the harness or connector
open circuit)
operation
3. Sunshadeswitch (fault) Repair or replace
4. Sunshade motor (fault) Change
No electric window works

Check each power window
• Turn the power to ON.
1 Go to Step 2
• Operate the power window switch to check if each power
window can rise and fall?
Check the power window fuse
• Remove the bill box at the instrument desk lower left side.
• Check if the power window fuse FS32, FS33 and FS25 are
fused?
Check the harness
• Disconnect the front left door glass regulator main switch
connector D05.
• Use the universal meter voltage to check if there is battery 83
voltage between Terminal 4 of D05 and the ground.
3 Go to Step 4
• Use the meter resistance to check if Terminal 1 of D05 and
the ground are conducted.
• Use the universal meter voltage to check if there is battery
voltage between terminal 2 and terminal 3 of D05 and the
ground.
Solve the detected faults and check whether the faults are
4
eliminated. Then the diagnosis is finished.
Front left door electric window not working
Check the left front power window
1 Go to Step 2
• Operate the left front door power window switch to check if
the left front door power window can rise and fall.
Check the left front door glass lifter motor
• Disconnect the front left door glass regulator motor connector
D04.
• Connect terminal 1 and 2 of the motor to the battery positive
and negative polarity to check whether the motor is under
normal operation.
Check the left front door glass lifter motor circuit
• Disconnect the front left door glass regulator motor connector
D04.
• Turn the front left door glass lift switch to UP gear.
• Check whether there is battery voltage between D04
3 connector terminal 1 and the ground with the universal meter Go to Step 4 Go to Step 5
voltage gear.
• Turn the front left door glass lift switch to DOWN gear.
• Check whether there is battery voltage between D04
connector terminal 2 and the ground with the universal meter
voltage gear.
Check the left front door power window glass lifter
• Remove the left front door power window glass lifter.
• Check if the left front door power window glass lifter is
4 damaged or blocked by foreign matters. Go to Step 6 Go to Step 5
• Use the digital universal meter resistance to check if the left
front door glas lifter Terminal 1 and Terminal 2 are conducted,
and replace if not.
Check the left front door glass lifter switch

connector D05.
• Check whether the front left door glass lift switch terminal 2
5 and terminal 1of D04 are conducted with the universal meter Go to Step 3 Go to Step 6
resistance gear.
• Check whether the front left door glass lift switch terminal 3
and terminal 2of D04 are conducted with the universal meter
resistance gear.
Check the left front door glass lifter switch circuit
connector D05.
• Check whether there is battery voltage on the front left door
6 glass regulator main switch terminal 2 with the universal Go to Step 7
meter voltage gear
• Check whether there is battery voltage on the front left door
glass regulator main switch terminal 3 with the universal
meter voltage gear
7
Front right door electric window not working
Check the right front power window
1 Go to Step 2
• Operate the right front door glass lifter switch to check if the
right front door power window can rise and fall.
Check the right front glass lifter motor.
• Disconnect the front right door glass regulator motor
connector K03.
normal operation.
Check the right front door glass lifter motor circuit
• Disconnect the front right door glass regulator motor
connector K03.
• Turn on the glass lifter switch Up shift.
3 • Check whether there is battery voltage between K03 terminal Go to Step 4 Go to Step 5
1 and the ground with the universal meter voltage gear.
• Turn on the glass lifter switch Down shift.
• Check whether there is battery voltage between K03 terminal
Check the right front door power window glass lifter
• Remove the right front door power window glass lifter.
• Check if the right front door power window glass lifter is
damaged or blocked by foreign matters.
Check the right front door glass lifter switch

connector K04.
• Check whether the front left door glass lift switch terminal
5 6 and terminal 14 are conducted with the universal meter Go to Step 3 Go to Step 6
resistance gear.
6 and terminal 12 are conducted with the universal meter
resistance gear.
6
Rear left door electric window not working 83
Check the left front power window
1 Go to Step 2
• Turn on the left rear door glass lifter switch to check if the left
rear power window can rise and fall.
Check the left rear glass lifter motor.
• Disconnect the left rear glass lifter motor M1.
2 • Connect terminal 1 and 2 of the motor to the battery positive Go to Step 3 Go to Step 6
normal operation.
Check the left rear door glass lifter motor circuit
• Disconnect the rear left door glass regulator switch connector
M01.
• Turn the rear left door glass lift switch to UP gear.
3 • Check whether there is battery voltage between M01 terminal Go to Step 4 Go to Step 5
• Turn the rear left door glass lift switch to DOWN gear.
• Check whether there is battery voltage between M01 terminal
Check the left rear door power window glass lifter
• Remove the left rear door power window glass lifter.
• Check if the left rear door power window glass lifter is
Check the left rear door glass lifter switch
connector M04.
• Check the left rear door glass lifter switch
resistance gear.
resistance gear.
6
Rear right door electric window not working
Check the right rear power window

1 Go to Step 2
• Operate the right rear door glass lifter switch to check if the
right front door power window can rise and fall.
Check the right rear glass lifter motor.
• Disconnect the rear right door glass regulator motor
connector N01.
normal operation.
Check the right rear door glass lifter motor circuit
• Disconnect the rear right door glass regulator main switch
connector N01.
• Turn the rear right door glass lift switch to UP gear.
3 • Check whether there is battery voltage between N01 terminal Go to Step 4 Go to Step 5
• Turn the rear right door glass lift switch to DOWN gear.
• Check whether there is battery voltage between N01 terminal
Check the right rear door power window glass lifter
• Remove the right rear door power window glass lifter.
• Check if the right rear door power window glass lifter is
Check the right rear door glass lifter switch
connector N04.
resistance gear.
resistance gear.
6
Both sides electric rearview mirror not working
Check power mirrors
1 Go to Step 2
• Turn on the power mirror switch to check if the left and right
mirror can move freely.
Check the power mirror fuse
2 • Remove the bill box at the instrument desk lower left side. Go to Step 4 Go to Step 3
• Check if the power mirror fuse FS30 are fused.
Check the power mirror supply circuit
• Disconnect the electric rearview mirror switch connector D7.
3 voltage between the connector D7 Terminal 1 and the Go to Step 4
ground?
• Use the universal meter resistance to check if the connector
D7 Terminal 2is conducted?
4
Left rearview mirror not working

Check the left electric rearview mirror
1 Go to Step 2
• Turn on the left power mirror control switch to check if the left
rearview mirror can move freely?
Check the left power mirror switch
• Disconnect the electric rearview mirror switch connector D7.
• Turn on the left electric rearview mirror control switch.
• Turn on the electric rearview mirror upward adjustment switch
and check whether the D7 connector terminal 6 and terminal
8 are conducted with the universal meter resistance gear.
and check whether the D7 connector terminal 6 and terminal 83
• Turn on the rear-view mirror folding switch and check if D7
connector terminal 9 and terminal 1 are connected with the
multi-meter in resistance grade.
Check the left power mirror motor circuit
• Disconnect the left electric rearview mirror motor connector
D8.
• Turn on the left electric rearview mirror control switch.
• Turn on the electric rearview mirror leftward adjustment
switch.
• Check whether there is battery voltage between the
connector D8 terminal 1 and the ground with the universal
meter voltage gear.
• Turn on the electric rearview mirror upward adjustment
switch.
3 Go to Step 4
meter voltage gear.
• Turn on the electric rear-view mirror fold/reset switch.
connector D8 terminal 7/8 and the ground with the universal
meter voltage gear.
• Turn on the heated rear-view mirror heating switch
meter voltage gear.
4
Right rearview mirror not working
Check the right electric rearview mirror
1 Go to Step 2
• Turn on the right power mirror control switch to check if the
right rearview mirror can move freely?
Check the right power mirror switch

• Disconnect the electric rearview mirror switch connectorD7.
• Turn on the right electric rearview mirror control switch.
and check whether the D7 connector terminal 1 and terminal
• Turn on the electric rearview mirror rightward adjustment
switch and check whether the D7 connector terminal 1 and
terminal 6 are conducted with the universal meter resistance
gear.
• Turn on the rear-view mirror folding switch and check if D7
connector terminal 9 and terminal 1 are connected with the
multi-meter in resistance grade.
meter voltage gear?
Check the right power mirror motor circuit
• Disconnect the right electric rearview mirror motor connector
K5.
• Turn on the right electric rearview mirror control switch.
• Turn on the electric rearview mirror left/right adjustment
switch.
connector K5 terminal 1 and the ground with the universal
meter voltage gear?
• Turn on the electric rearview mirror up/down adjustment
switch.
3 Go to Step 4
connector K5 terminal 2 and the ground with the universal
meter voltage gear?
• Turn on the heated rear-view mirror heating switch
connector K5 terminal4 and the ground with the universal
meter voltage gear?
• Turn on the electric rear-view mirror fold/reset switch.
connector K5 terminal 7/8 and the ground with the universal
meter voltage gear?
4
The power sunshade fails to work
Check the power sunshade
1 Go to Step 2
• Operate the power sunshade to check if the power sunroof is
open or close.
Check the power sunshade fuse
• Check if the power window fuse FS44, FS37 are fused.
Check if the power sunshade switch signal line is
conducted
• Disconnect the front roof lamp assembly connector R4.
3 • Use the universal meter voltage to check if there is battery Go to Step 4 Go to Step 7
voltage between the R04 connector Terminal 2, 6 and
ground?
Check of the power sunshade switch grounding wire

isconducted
4 • Disconnect the front roof lamp assembly connector R04. Go to Step 5 Go to Step 7
• Use the universal meter resistance to check if the R04
connector Terminal 1 and the ground are conducted?
Check the power sunshade switch
5 • Turn the sunshade switch to OPEN. Go to Step 6 Go to Step 7
connector Terminal 5 and ground 2 are conducted?
Check the sunshade controller circuit
• Disconnect the sunshade controller connector R02.
• Check whether there is battery voltage between the 83
connector R02 terminal 1, 8 the ground with the universal
meter voltage gear.
R02 Terminal 2 and terminal 3 is conducted?
Replace with a sunshade motor with the same specification and
7 Go to Step 8
check if the fault is eliminated?
8
Operable skylight out of operation
Check of the operable skylight

1 • Turn the power to ON. Go to Step 2
• Operate the sunroof to check if the sunroof is open or close.
Check the sunroof fuse

• Check if the sunroof fuse FS44, FS37 are fused.
Check if the sunroof switch signal line is conducted
voltage between the R4 connector Terminal 2, 6 and ground?
Check of the sunroof switch grounding wire isconducted
connector Terminal 1 and the ground are conducted?
Check the sunroof switch
5 • Turn the sunroof switch to OPEN. Go to Step 6 Go to Step 7
connector Terminal 5 and ground 2 are conducted?
Check the sunroof controller circuit

• Disconnect the sunroof controller connector R02.
connector R02 terminal 1 ,8 the ground with the universal
meter voltage gear.
R02 Terminal 2 and terminal 3 is conducted?
Replace with a sunroof motor with the same specification and
7 Go to Step 8
check if the fault is eliminated?
8
Front windshield
Change
1. Remove the front windscreen
(a). Clean the inside, outside and periphery of the windscreen.
(b). Remove the wiper assembly. (refer to Chapter 86 Wiper and washing system - replacement)
(c). Remove front wall ventilating cover plate and its decoration parts. (See Chapter 81 Interior &
Exterior, Ventilating Cover Plate, Replacement)
(d). Cover the car body around the glass with adhesive tape for the prevention of damage.
(e). Remove the dashboard. (See Chapter 85 Dashboard and auxiliary dashboard, replacement)
(f). Remove the interior mirror. (refer to Chapter 83

Window glass and rearview mirror, replacement)
(g). Remove the sun visor.(refer to Chapter
81 Interior and exterior trims - sun visor,
replacement)
LFWX-6470-83005
w
(h). Remove the drive recorder
83
LFWX-6470-83006
(i). Scrape the cement around the glass with the
windshield knife.
LFWX-6470-83007
△ Tips:
To scrape with steel wire as shown in the following
steps:
• Drill through the glue with an awl to let the steel
wire through.
LFWX-6470-83008
• Let the steel wire through the car body and the
glass from inside.
• Tie wood blocks or similar objects onto both sides
of the steel wire.
• Cover the defroster mouth.
Warning:
If broken glass falls on the defroster mouth, it may
be blown into the passenger compartment and
cause injury.
• Pull the steel wire to cut off the glue.
Note:
Try to use the steel wire close to the glass for the
prevention of damaging the car body.
△ Tips:
The numbers in the figure represents respectively: 1.
Steel wire; 2. Windscreen; 3. Adhesive tape; 4. Glue.
LFWX-6470-83009
(j). Remove the front windscreen from the vehicle

with a sucker with the help of an assistant.
LFWX-6470-83010
(k). Scrape the glue residue on the car side evenly

with a knife with the insertion depth of 1~2mm.
Note:
Clean the knife with alcohol or scrape the oil stain
on the knife with similar before using the knife.
△ Tips:
The numbers in the figure represents respectively:
1.Knife; 2.Glue; 3.Car body.
LFWX-6470-83011
2. Install the front windscreen

(a). Clean the glue residue on the body at the
connection with the windscreen with cleaning
solution.
(b). Completely clean the old glue contact, paint or
exposed metal. Paint primer on the paint surface
or exposed metal surface carefully, do not paint
it onto the glue residue surface.
Note:
• Be sure to operate correctly according to
the instruciton manual offered by the primer
manufacturer and dry it according to the
specified time.
• Do not contact the primer with the car body,
glass and the old glue surface. 83
△ Tips:
LFWX-6470-83012 The numbers in the figure represents respectively:
1. Primer; 2. Brush; 3.With primer; 4. Without primer;
5.Old glue.
(c). Make 3M94 first coat along glass edge, and
then install adhesive tape along glass edge after
10min.
△ Tips:
Front windscreen frame sealing strip assembly；2.Front
windscreen assembly
LFWX-6470-83013
(d). Paint enough primer along the glass adhesive
edge with a new brush.
Note:
• Ensure to observe the instructions of the
manufacturer to operate correctly and dry at the
required interval.
• Do not apply the primer to the finish coat.
• Do not touch the primer face.
The width “a” is about 20mm.
“b” is about 15mm. “c” is about 18mm.
△ Tips:
Insertion strip; 2. Division strip.
LFWX-6470-83014
(e). Coat glue on the front windscreen.

Note:
• Apply the sealant from the glass lower side.
• Take care and do not damage the primer.
1
• The downside glue height should be higher than
the other three sides: upside, right side and left
e 2
f
side. The width “e” is about 8mm. The height “f”
is about 6mm.
• Press the glass into the body after coating glue.
• Hold the glass with a rubber sucker after
coating glue.
• Fulfil steps (g)~(i) in 10min to guarantee the
glue has enough viscosity.
• The handling method and drying time must
follow the instructions supplied by the bonding
agent manufacturer.
LFWX-6470-83015
△ Tips:
The numbers in the figure represents respectively:
1.Glue; 2.Glass.
(f). Scrape the residual paper from the insertion
strip and division strip.
(g). Press the glass into the body with a rubber
sucker.
Note:
Be careful not to damage the glass surface or the
car body.
(h). Fix the top insertion strip.
LFWX-6470-83010
(i). Check if there is any leakage by spraying water

with a hose outside the window. Where the
water leak is detected, dry the glass in the air
and plug the leak point with the sealant. If the
water leak still occurs, remove the glass and
install it again in the above way.
Note:
• Before the glue is totally dry, a sudden close of
the door may make the galss to loose or fall off.
Therefore, make sure to close all door windows
and operate carefully for frequently close or open
of the door before the glue is totally dry.
• If the insertion strip cannot be fixed in place,
fasten it with adhesive tape until the glue is
completely stuck.
• Each glue has its special dry time. Be sure to
LFWX-6470-83016 refer to the instruction manual of the manufacturer
to know the dry time of glue and besure to obey
precautions before operation.
• It is prohibited to drive the car before the glue is
completely stuck so as to ensure a firm adhesion.
(j). Install the interior mirror. (refer to Chapter 83

Window glass and rearview mirror - interior/
exterior rearview mirror, replacement)
83
LFWX-6470-83005
(k). Install driving recorder.

(l). Install the sun visor. (refer to Chapter 81 Interior
and exterior trims - sun visor, replacement)
(m). Install the front pillar decoration parts.
(n). Install the dashboard. (See Chapter 85
Dashboard and auxiliary dashboard,
replacement)
(o). Install the front wall ventilating cover plate and
its decoration parts. (See81 - interior trims and
exterior trims - vent panel, replacement)
(p). Install the wiper assembly.(refer to Chapter 86
Wiper and washing system , replacement)
LFWX-6470-83006
Hatch glass
Change
1. Remove the back door glass assembly.
(a). Remove back door trim panel. (See Chapter 81
Interior & Exterior, Replacement)
(b). Remove the spoiler.
(c). Remove rear wiper assembly and motor
assembly.
LFWX-6470-83017
(d). Suck the back door glass with a glass sucker,

supporting by a person for the prevention of
drop during the removal.
(e). Drill through the glue with an awl to let the steel
wire through.
LFWX-6470-83018
(f). Cut off the glue around the glass with steel wire.
Note:
LFWX-6470-83019
(g). Scrape the glue residue on the car side evenly

with a knife
LFWX-6470-83020 83
2. Install the back door glass assembly

connection with the back door glass with a clean
cloth or cleaning solution.
Note:
Dry it for above 10min if cleaning solution is used.
LFWX-6470-83021
(b). Paint enough primer along the glass adhesive
Note:
required interval.
LFWX-6470-83012
(c). Coat sealant.

Note:
• Immediately press the glass intot he back door
mounting hole after coating glue.
• Hold the glass with a glass sucker after coating
glue.
• The handling method and drying time must
follow the instructions supplied by the bonding
agent manufacturer.
• Press the glass into the back door moungint
hole with a glass sucker, then strike the glass
evenly with a rubber hammer to fasten it.
• Be sure to refer to the instruction manual of the
LFWX-6470-83018
manufacturer to know the dry time of glue and
be sure to obey precautions before operation.
(d). Fill in the rubber pads evenly under the glass to
ensure balanced installation of the glass.
(e). Stick adhesive tape at four corners of the glass
to avoid glass loosening.
LFWX-6470-83022
(f). Check if there is any leakage by spraying water

with a hose outside the window after drying
the glue according to the time specified by the
manufacturer. Where the water leak is detected,
dry the glass in the air and plug the leak point
with the sealant. If the water leak still occurs,
remove the glass and install it again in the
above way.
LFWX-6470-83023
(g). Install the spoiler.

(h). Wiper assembly and motor assembly.
(i). Install back door decorating plate.
LFWX-6470-83017
83
Sunshade assembly (full-view skylight)

Change
△ Tips:
The left and right A-pillar aprons are replaced in the same way, taking A-pillar apron for example.
1. Remove the sunshade assembly
(a). Remove the sun visor and sun visor hook (refer
to Chapter 81 Interior and exterior trims - sun
visor, replacement)
(b). Remove the safety handle.
(c). Remove the indoor roof lamp (refer to Chapter
77 Lighting system - head lamp, replacement).
(d). Remove the A pillar upper panel (refer to
Chapter 81 Interior and exterior trims - A pillar
panel, replacement)
(d). Remove the B pillar upper panel (refer to
Chapter 81 Interior and exterior trims - B pillar
panel, replacement)
(f). Remove the rear side wall panel (refer to
Chapter 81 Interior and exterior trims - side wall
decorative sheet, replacement)
LFWX-6470-83032 (g). Remove the roof plastic buckle and take the roof
out of the vehicle.
△ Tips:
This operation is difficult for one person to complete and the assistance from another person is
needed.
(h). Disconnect the sunroof motor connector

Note:
Before the adjustment or repair of mechanical
parts or sunroof motor, ensure to initialize the
sunroof motor program.
LFWX-6470-83033
(i). Remove the fixing bolt and clamp of sun blinds

assembly, and take out the sun blinds assembly.
LFWX-6470-83034
(j). Disconnect the sunshade motor connector.

Note:
parts or sunroof motor, ensure to initialize the
sunroof motor program.
LFWX-6470-83033
2. Remove the sunshade assembly motor

(a). Remove the sunshade (See 83, Power Window
and Rear-view Mirror - Sunshade Assembly,
Replacement).
Note:
parts or sunshade motor, ensure to initialize the
motor program.
83
LFWX-6470-83034
(b). Remove the sunshade motor fixed bolt an take

out the motor.
Note:
sunshade motor program.
LFWX-6470-83035
Sunroof glass assembly
3. Remove the sunroof glas components

(a). Remove the sunroofassembly.
(b). Paste a circle of protection strip on four sides of
the stamping parts to prevent damage of paint.
(c). Drill through the glue with an awl to let the steel
wire through.
(d). Cut off the glue around the glass with steel wire.
Note:
(e). Scrape the glue residue on the car side evenly
with a knife
LFWX-6470-83036
4. Install the sunroof glass assembly

connection with the sunroof glass with a clean
cloth or cleaning solution.
Note:
Dry it for above 10min if cleaning solution is used.
(b). Paint enough primer along the glass adhesive
Note:
required interval.
(c). Smear white first coat.

(d). Install glass gasket.
(e). After drying, smear black first coat.
(f). After drying, coat glass sealants.
LFWX-6470-83037
Note:
• Hold the glass with a glass sucker after coating glue.
• The handling method and drying time must follow the instructions supplied by the
bonding agent manufacturer.
• Press the glass into the back door moungint hole with a glass sucker, then strike the
glass evenly with a rubber hammer to fasten it.
• Be sure to refer to the instruction manual of the manufacturer to know the dry time of glue
and be sure to obey precautions before operation.
(g). Stick adhesive tape at four corners of the glass

to avoid glass loosening.
(h). Check if there is any leakage by spraying water
with a hose outside the window after drying
the glue according to the time specified by the
manufacturer. Where the water leak is detected,
dry the glass in the air and plug the leak point
with the sealant. If the water leak still occurs,
remove the glass and install it again in the
above way.
(i). Install the sunshade assembly.
83
LFWX-6470-83036
5. Install the sunshade assembly
(a). Put the sun blinds on their installation sites, and
install the fixing bolt and clamp of sun blinds
assembly.
Torque: 9N·m
LFWX-6470-83034
(b). Connect sun blinds motor connector clip

Note:
LFWX-6470-83033
(c). Install the ceiling.

(d). Install rear side wall shield (see Chapter 81 –
Interior & Exterior – Side Wall Decorating Plate,
Replacement).
(e). Install the B pillar upper (refer to Chapter
81 Interior and exterior trims - B pillar panel,
replacement).
(f). Install the A pillar upper (refer to Chapter
81 Interior and exterior trims - A pillar panel,
replacement).
(g). Install inner dome lamp (see Chapter 77 Lighting
System – Front Lamp, Replacement)
(h). Install safety handle.
(i). Install sun shield and sun shield hook (see
Chapter 81 Interior & Exterior – Sun Shield,
Replacement).
LFWX-6470-83032
△ Tips:
This operation is difficult for one person to complete and the assistance from another person is
needed.
6. Install the sunshade assembly motor
(a). Put the sun blinds motor on its installation site,
and fasten its fastening screw.
Torque: 2.6N·m
Note:
motor program.
LFWX-6470-83035
(b). Connect sun blinds assembly motor connector

clip.
Note:
LFWX-6470-83033
Openable skylight
Change
1. Remove the Sunroof body assembly
(a). Remove the ceiling. (Refer to 81 - interior and
exterior trims, ceiling, replacement)
(b). Disconnect the Sunroof control unit harness
connector.
83
(c). Unplug the Sunroof front and back drain pipes.

(d). Remove the Sunroof bracket fixing bolts and take down the Sunroof.
6. Install the Sunroof body assembly

(a). Install the Sunroof body assembly to the mounting position, fit the Sunroof body assembly
and bracket fixing bolts and tighten them.
(b). Install the Sunroof front and back drain pipes.
Torque: 8~12N•m
(c). Connect the Sunroof control unit harness
connector.
(d). Install the ceiling. (See Section 81 - Interior
and Exterior Trims - Safety Handle and Ceiling,
Replacement)
Front door glazing window

Change
1. Remove the front power window.
(a). Remove the front door apron (see Chapter 81
Interior and exterior decoration – front door
interior panel, replacement).
LFWX-6470-83024
(c). Tear down the door waterproof membrane.

(f). Remove the internal and external water draining
devices of door.
LFWX-6470-83026
(g). Remove the glass and glass lifter fixed bolt.

(h). Rotate to take out the glass.
83
LFWX-6470-83027
(i). Remove the glass lifter connecting bolt.

(j). Disconnect the glass lifter motor connector.
LFWX-6470-83028
2. Install the front power window

(a). Install the glass lifter in the installation location,
install the fixed bolt and fasten.
Torque: 9N·m
(b). Connect the glass lifter motor connector.
LFWX-6470-83028
(c). Install the glass in the installation location.

(d). Install the glass and glass lifter fixed bolt.
Torque: 9 N•m
LFWX-6470-83027
(e). Install internal and external water draining

devices of door.
(h). Paste waterproof membrane of door.
LFWX-6470-83026
(j). Install the front door apron (see Chapter 81

LFWX-6470-83024
Rear door glazing window

Change
△ Tips:
For the replacement and procedures of the rear door window, refer to the replacement of front door
window (refer to 83 - electric window and rearview mirror - front door window, replacement).
Front quarter window assembly

Change
△ Tips:
For the replacement method of procedures of the front quarter window assembly, refer to the
replacement of front windshield (refer to 83 - electric window and rearview mirror - front windshield, 83
replacement).
Rear quarter window assembly

Change
△ Tips:
For the replacement method of procedures of the rear quarter window assembly, refer to the
replacement of front windshield (refer to 83 - electric window and rearview mirror - front windshield,
replacement).
Interior rearview mirror

Adjustment
1. Adjust the interior mirror.
(a). Adjust the interior mirror visual angle manually.
REAR
LFWX-6470-83029
(b). Adjust the interior mirror visual angle slightly by

adjusting the handle slightly.
LFWX-6470-83030
Change
1. Replace the interior mirror
(a). Remove the interior mirror assembly fixed
screw.
(b). Take down the interior mirror assembly.
LFWX-6470-83030
2. Install the interior mirror.

(a). Install the interior mirror assembly in the
installation location.
(b). Install the interior mirror assembly fixed screw
and fasten.
Torque: 9N·m
LFWX-6470-83030
Exterior mirror
Adjustment
1. Adjust the exterior mirror
(a). Adjust the exterior mirror visual angle by
adjusting the exterior mirror adjustment switch.
83
LFWX-6470-83031
Change
1. Remove the exterior mirror
(a). Remove the front door triangular plate.
(b). Remove the front door apron (see Chapter 81
(c). Tear down the waterproof membrane.
LFWX-6470-83038
(d). Disconnect outer rearview mirror connector; and
red frame in the Figure indicates the position of
connector.
(e). Remove retaining nut of outside rear-view
mirror; arrow in the Figure indicates nut position.
Take down outside rear-view mirror.
LFWX-6470-83025
2. Install the rear power window

(a). Install the glass in the installation location and
rotate the glass to place the glass lifter sliding
block in the glass slot.
(b). Install the glass lifter and the glass fixed bolt
and fasten.
(c). Install the glass lifter assembly and fasten the
glass lifter fixed bolt.
LFWX-6470-83025
(d). Install the waterproof membrane.

(d). Connect the glass lifter motor connector
(e). Install the rear door left/right guide rail and the
bolt in the installation location, and fasten the
guide rail to fasten the bolt.
LFWX-6470-83038
83
Seat - Seat
84-a
Seat
Seat ……………………………… 1
Front main driver seat(manual) 2
Front main driver seat(electrical) 3
Front seat (manual) …………… 4
Front seat (electrical) ………… 5 84
Center row left double seat …… 6
Center row right single seat … 7
Rear seat ……………………… 8
Center row left single seat (for
6-seat version) ………………… 9
Center row right single seat (for
6-seat version) …………………10
Seat heating and
massage(comfortable version) 11
Seat heating and massage (2017
luxury version) …………………12
Seat noise determination ……13
Driver' s seat ……………………13
Change …………………………15
Front seat …………………………19
Change …………………………19
Center row left double seat ……19
Change …………………………20
Center row right single seat …24
Change …………………………24
Rear seat …………………………24
Change …………………………25
Center row left (right) single seat
(for 6-seat version)………………28
Change …………………………28
84-b Seat - Seat
Seat - Seat
84-1
Seat
Maintenance data
Items N.m
Front seat fixed bolt 65 ～ 85
Middle seat fixed bolt 65 ～ 85
Rear seat fixed bolt 65 ～ 85 84

84-2 Seat - Seat
Component drawing
Front main driver seat(manual)
1-1
1-12
1-13
1-2
1-9
1-8 1-3
1-7 1-4
1-5
1
2
1-6
1-10 1-11
LFWX-6470-84001
Driver’s seat assembly Driver’s seat outside sliding chute

1 1-8
rear foot cover
Front seat headrest assembly Driver’s seat inside sliding chute
1-1 1-9
rear foot cover
Driver seat outside front protecting Driver’s seat inside sliding chute
1-2 1-10
hood front foot cover
Driver seat outside rear protecting Driver’s seat outside sliding chute
1-3 1-11
hood front foot cover
Driver’s seat angle adjuster
1-4 1-12 Front row headrest spike A
unlocking lever
Seat angle adjuster unlocking lever
1-5 1-13 Front row headrest spike B
plug
Driver seat height adjuster handle Hexagon head bolt, spring washer
1-6 2
and plain washer assembly
Driver seat outside front protecting
1-7
hood
Seat - Seat
84-3
Front main driver seat(electrical)
1-1 1-12
1-10 1-11
84
1-2
1-3
1-4
2 1-3-1
1-4-1
1-7 1-5 1-4-2
1-6
1-9
1-8
LFWX-6470-84001
Driver’s seat assembly Driver’s seat outside sliding chute

1 1-6
rear foot cover
Front seat headrest assembly Driver’s seat inside sliding chute
1-1 1-7
rear foot cover
Driver seat inside protecting hood Driver’s seat outside sliding chute
1-2 1-8
front foot cover
4W Lumbar support switch Driver’s seat inside sliding chute
1-3 1-9
components front foot cover
1-4 4W Lumbar support switch button 1-10 Front row headrest spike A
1-4-1 Driver’s seat power switch assembly 1-11 Front row headrest spikeB
1-4-2 Backrest electric control button 1-12 Large backplate assembly

Driver seat outside protecting hood Hexagon head bolt, spring washer
1-5 2
84-4 Seat - Seat
Front seat (manual)
1-1
1-11
1-10
1-2
1-3 1-5
1-7
1-6
1-4
1-8
1-9
LFWX-6470-84002
1 Front seat assembly 1-7 Front seat inside protecting cover

Front seat headrest assembly Front seat outside sliding chute front
1-1 1-8
foot cover
Seat angle adjuster unlocking lever Front seat intside sliding chute front
1-2 1-9
plug foot cover
Front seat angle adjuster unlocking
lever
1-4 Front seat outside protecting cover 1-11 Front row headrest spike A
Front seat outside sliding chute rear Hexagon head bolt, spring washer
1-5 2
foot cover and plain washer assembly
Front seat inside sliding chute rear
1-6
foot cover
Seat - Seat
84-5
Front seat (electrical)
1-1
1-12
1-10
1-11
1-3
1-4
1-5 84
1-2
1-8
1-9
1
1-7
1-6
LFWX-6470-84002
Front seat outside sliding chute front

1 Front seat assembly 1-7
foot cover
Front seat outside sliding chute rear
1-1 Front seat headrest assembly 1-8
foot cover
Front seat inside sliding chute rear
1-2 Front seat inside protecting cover 1-9
foot cover
Seat angle adjuster unlocking lever
1-3 1-10 Front row headrest spike A
plug
Front seat angle adjuster unlocking
lever
1-5 Front seat outside protecting cover 1-12 Large backplate assembly
Front seat inside sliding chute front Hexagon head bolt, spring washer
1-6 2
foot cover and plain washer assembly
84-6 Seat - Seat
Center row left double seat
1-1
1-3
1-2
1 - 13
1-15 1-14
1 - 13 1-4
1 - 14
1-5 1 - 12
1-6
1-7 1
1 - 10 1-11
2
1-8
1-9
LFWX-6470-84003
Middle left side double seat assembly Center row seat outside front foot
1 1-9
cover
Middle row middle seat headrest Middle left side seat inside protecting
1-1 1-10
assembly hood
Center row left seat head restraint
1-2 1-11 Slide rail adjusting lever
assembly
Center row seat left side rear foot
1-3 Seat belt guide ring 1-12
cover
Center row seat backrest unlocking
1-4 1-13 Rear row headrest spike A
lever combination
Center row left seat inside sliding
1-5 1-14 Rear row headrest spike B
chute protecting cover
Center row left seat outside sliding
1-6 1-15 Armrest cup holder assembly
chute protecting cover
Middle left side seat outside protecting Hexagon head bolt, spring washer
1-7 2
hood and plain washer assembly
1-8 Center row seat inside front foot cover
Seat - Seat
84-7
Center row right single seat
1-1
1-2
1-9 1-7
1 - 10
84
2
1-3
1-8
1-4
2
1-6
1-5
1-5
LFWX-6470-84004
Center row right seat head restraint

1 1-6 Slide rail unlocking lever
assembly
Center row left seat head restraint Center row seat backrest unlocking
1-1 1-7
assembly lever combination
Easy entry unlocking handle Center row seat right side rear foot
1-2 1-8
combination cover
Middle right side seat outside
protecting hood
Middle right side seat inside protecting
hood
Center row seat outside front foot Hexagon head bolt, spring washer
1-5 2
cover and plain washer assembly
84-8 Seat - Seat
Rear seat
1-1
1-1
1-8
1-9
1-2
1-8
1-9
1-3
1-4
1
1-6
1-5
1-5
1-10
1-7
LFWX-6470-84005
1 Rear seat assembly 1-6 Belt lock catch decoration cover

1-1 Rear seat headrest assembly 1-7 Seat belt buckle fixing box
1-2 Rear row seat folder unlocking strap 1-8 Rear row headrest spike A
Rear row seat right angle adjuster
outer cover
Rear row seat left angle adjuster outer Rear row seat mounting bolt
1-4 1-10
cover decorative cover
1-5 Rear row seat front foot cover 2
Seat - Seat
84-9
Center row left single seat (for 6-seat version)
1-1
1-9
1-10
84
1-2
1-8
1-6
2
1-3
2
1-7
1-11
1-4
2
1-5
LFWX-6470-84030
Center row left single seat angle

1 Center row left single seat assembly 1-7
adjuster lever
Center row left single seat outside
1-1 Center row left single seat headrest 1-8
side plate
Center row left single seat armrest
assembly
Center row left single seat inside side
plate
1-4 Center row seat inside front foot cover 1-11 Slide rail adjusting lever
Center row seat outside front foot Hexagon head bolt, spring washer
1-5 2
cover and plain washer assembly
Center row single seat angle adjuster
1-6
lever plug
84-10 Seat - Seat
Center row right single seat (for 6-seat version)
1-1
1-8
1-9
1-5 1-6 1-7
1-2
1-3
2
1
1-10
2
1-4
LFWX-6470-84031
Center row right seat head restraint Center row single seat angle adjuster
1 1-6
assembly lever plug
Center row right single seat inside

1-1 Center row left single seat headrest 1-7
side plate
Center row right single seat armrest

assembly
Center row right single seat inside

side plate
Center row right seat outside front

1-4 1-10 Slide rail unlocking lever
foot cover
Center row right single seat angle Hexagon head bolt, spring washer
1-5 2
adjuster lever cover and plain washer assembly
Seat - Seat
84-11
Circuit diagram
Seat heating and massage(comfortable version)
Seat heating and massage (comfortable version)
84
Central control panel
Driver' s seat Front passenger seat
LFWX-6470-84032
84-12 Seat - Seat
Seat heating and massage (2017 luxury version)
Seat heating and massage (2017 luxury version)
Driver' s seat Front passenger seat
LFWX-6470-84033
Seat - Seat
84-13
Fault diagnosis
Seat noise determination
Pay special attention to the seat position and objects on the seat when isolating the seat noise.
These conditions need to be reappeared when confirming and isolating noise sources.
The causes of seat noise include:
1. Headrest pushrod and bracket
2. Seat cushion and seat bracket
3. Rear seat back lock and bracket
The reappeared noises can be isolated by moving or pressing doubtful objects. Most faults can be
eliminated by replacing objects or using polyurethane tape.
84
Driver' s seat
Adjustment
1. Forward/backward adjustment of the driver
seat
(a). Pull up the slide unlocking handle on the front
end of the driver seat, move forward/backward
the seat to a suitable position and release the
unlocking handle.
LFWX-6470-84006
2. Adjustment of the driver seat back angle
(a). Pull up and hold the driver seat angle adjuster
hand, adjust the seat back to a suitable position
and release the handle.
LFWX-6470-84007
84-14 Seat - Seat
3. Adjustment of the driver seat height

(a). If the driver seat is low, pull up the seat height
adjuster handle back and forth to raise the seat
to a suitable position.
LFWX-6470-84008
(b). If the driver seat is high or low, pull down the

seat height adjuster handle back and forth to
lower the seat to a suitable position.
LFWX-6470-84009
4. Adjustment of the driver seat headrest

(a). Press the head restraint left spike buckle and
move the head restraint up and down to the
desired position.
LFWX-6470-84010
Seat - Seat
84-15
Change
1. Take the driver seat.
(a). Disconnect the negative cable from the battery.
(b). Disconnect the driver seat safe belt indicator
lamp connector.
84
LFWX-6470-84011
(c). Adjust the driver seat to move it backward to the
maximum.
(d). Take down front foot cover to expose front fixing
bolt of seat.
LFWX-6470-84012
(e). Unscrew the fixed bolt at the front end of the

seat with a spanner.
LFWX-6470-84013
84-16 Seat - Seat
(f). Adjust the driver seat to move it forward to the

maximum
(g). Remove the rear cover, expose the fixed bolt at
the rear end of the seat.
LFWX-6470-84014
(h). Unscrew the rear end fixed bolt of the seat with
a spanner.
(i). Take down the four front and rear fixed bolts of
the seat and place them in the specified position
so that thebolts won’t get lost.
LFWX-6470-84015
(j). Adjust the seat back to a suitable position so

that the seat can be easily moved.
(k). Take out the driver seat.
Note:
Be careful not to touch the body paint for the
prevention of scratching the paint when moving
the seat.
LFWX-6470-84007
Seat - Seat
84-17
2. Install the driver seat

(a). Adjust the seat back to a suitable position so
that the seat can be easily placced.
84
LFWX-6470-84007
(b). Place the driver seat.
LFWX-6470-84016
(c). Install and pretighten the front end fixed bolt of

the seat.
LFWX-6470-84013
84-18 Seat - Seat
(d). Adjust the seat to move it forward to the

maximum position and align the rear end fixed
bolt mounting hole of the driver seat to the body
bolt mounting hole.
(e). Install and pretighten the rear.
Torque：75（65 ～ 85）N·m
LFWX-6470-84015
(f). Install rear foot cover.
LFWX-6470-84014
(g). Adjust the seat to make it move back to the

maximum position.
(h). Screw down the fixed bolts of the seat to the
specified torque with a torque spanner.
Torque：75（65 ～ 85）N·m
(i). Install front foot cover.
LFWX-6470-84012
Seat - Seat
84-19
(j). Install the driver seat safe belt indicator lamp

connector.
(k). Install the battery cathode cable joint.
84
LFWX-6470-84011
Front seat
Adjustment
△ Tips:
The front seat adjustment method and procedures are the same as those of the driver’s
seat except the front seat does not allow the height control (refer to 84 - seat - driver’s seat,
adjustment).
Change
△ Tips:
The replacement methods and steps of the co-driver seat are the same as those of the driver seat
(see Chapter 84 Seat-seat – driver seat, adjustment).
Center row left double seat

Adjustment
1. Adjustment of the middle left side double
seat back
(a). Pull up the middle left double seat back
unlocking handle to regulate the back to
appropriate position, and then release then
handle for locking.
LFWX-6470-84017
84-20 Seat - Seat
2. Adjustment of the middle left side double

seat headrest
desired position.
LFWX-6470-84018
Change
1. Remove the middle left side double seat
(a). Pull up the middle left double seat back
unlocking handle to unblock recliner, and fold
and lay the seat back flatly.
LFWX-6470-84017
(b). Take the seat front cover.
LFWX-6470-84019
Seat - Seat
84-21
(c). Unscrew the 5 front fixing bolts of seat by

wrench.
84
LFWX-6470-84020
(d). Take the seat rear cover.
LFWX-6470-84021
(e). Use wrench to unscrew two rear fixing bolts of

seat.
(f). Take down the front and rear five fixing bolts
of seat, and put them on appointed position to
prevent their loss.
LFWX-6470-84022
84-22 Seat - Seat
(g). When seat is adjusted, adjust seat back and

make the seat back fold down flat.
(h). Take out the middle-row left double seats.
Note：
Carefully remove the seat, to avoid that the seat
touches the body paint surface, resulting in body
scratches.
LFWX-6470-84028
2. Install the middle left side double seat

(a). Adjust the seat back to appropriate position to
facilitate seat installation.
(b). Place the middle left side double seat in the
installation location
LFWX-6470-84028
(c). Install and pretighten the front end fixed bolt of

the seat.
LFWX-6470-84020
Seat - Seat
84-23
(d). Install rear fixing bolt of seat and pre-fasten it.

Torque：75（65 ～ 85）N·m
84
LFWX-6470-84022
(e). Install the seat rear foot cover.
LFWX-6470-84021
(f). Use torque wrench to fasten front fixing bolt to

regulated torque.
Torque：75（65 ～ 85）N·m
LFWX-6470-84020
84-24 Seat - Seat
(g). Install front foot cover of seat.
LFWX-6470-84019
Center row right single seat

Adjustment
△ Tips:
The backrest angle adjustment method and procedures of the center row right single seat are
the same as those of the left double seat (refer to 84 - seat - center row seat left double seat,
adjustment); the center row right single seat is equipped with the Easy entry adjusting lever. When
this level is pulled, the backrest will fold forward by 40° . In this position, the seat slide is unlocked
at the same time. Then the seat back can be pushed to move the seat forward to the required
position. (For the Easy entry adjusting lever position, refer to the component drawing of center row
right single seat)
Change
△ Tips:
The replacement tmethods and steps of the middle right side double seat are the same as those of
the middle left side double seat. (see Chapter 84 Seat-seat – driver seat, replacement).
Rear seat
Adjustment
1. Adjustment of the reart seat headrest
desired position.
LFWX-6470-84023
Seat - Seat
84-25
2. Folding or opening adjustment of the rear

seat assembly
(a). Pull up the rear seat folder unlocking drawstring,
and fold and put down the rear seat back flatly.
84
LFWX-6470-84024
Change
1. Remove the rear seat
(a). Remove front foot cover and bolt trim cover of
rear seat.
LFWX-6470-84025
(b). Unscrew the 5 front fixing bolts of seat by

wrench.
LFWX-6470-84026
84-26 Seat - Seat
(c). Fold the rear seat assembly. (refer to Chapter

84 Seat - rear row seat, adjustment)
LFWX-6470-84029
(d). Use wrench to unscrew two rear fixing bolts of

seat.
(e). Take down 7 fixing bolts of lower seat, and put
them on appointed place to prevent their loss.
LFWX-6470-84027
(f). Fold seat down flat to take out rear seat.

Note：
Carefully remove the seat, to avoid that the
touches the body paint surface, resulting in body
scratches.
LFWX-6470-84029
Seat - Seat
84-27
2. Install the rear seat

(a). Fold seat down flat.
(b). Place the reart in the installation location.
84
LFWX-6470-84024
(c). Install rear fixing bolt of seat and pre-fasten it.
LFWX-6470-84027
(d). Pull up the rear seat folder unlocking drawstring,

and pull up and put down the rear seat back
flatly.
LFWX-6470-84024
84-28 Seat - Seat
(e). Install and pretighten the front end fixed bolt of

the seat.
(f). Screw down the fixed bolts of the seat to the
specified torque with a torque spanner.
Torque：75（65 ～ 85）N·m
LFWX-6470-84026
(g). Install front foot cover of seat and rear seat bolt
trim cover.
LFWX-6470-84025
Center row left (right) single seat (for 6-seat version)

Adjustment
△ Tips:
The center row left/right single seat (6-seat version) does not allow the height control. The
adjustment method and procedures are the same as those of driver’s seat (refer to 84 - seat -
driver’s seat, adjustment).
Change
△ Tips:
The replacement method and procedures of the center row left/right single seat (6-seat version)
are the same as those of driver’s seat (refer to 84 - seat - driver’s seat, replacement).
Seat - Seat
84-29
84
Dashboard and Sub-dashboard - Dashboard and Sub-dashboard 85-a
Dashboard and Sub-dashboard

Dashboard and Sub-dashboard 1
Subpanel and dashboard ……… 5
Change ………………………… 5
Subpanel and dashboard ………16
Installation ………………………16
85
85-b Dashboard and Sub-dashboard - Dashboard and Sub-dashboard
Dashboard and Sub-dashboard - Dashboard and Sub-dashboard 85-1
Dashboard and Sub-dashboard

Precautions
1. Do not remove the dashboard and auxiliary dashboard with a sharp tool, please remove them
with a tool covered by cloth.
2. If the connector needs to be disconnected during the steps, first disconnect the battery
cathode.
3. It is recommended to replace the part if its buckle is damaged.
4. The apron cannot be removed forcibly, be sure to remove all fixed bolts.
Component drawing
Dashboard
27
7
85
3 9
2
4
11
13 28
6 12
8 3
19
10 18
14 21
16
20 23 24
17
15
25
26 22
LFWX-6470-85001
85-2 Dashboard and Sub-dashboard - Dashboard and Sub-dashboard
1 Instrument cluster panel 15 Steering column lower shield

Cross slot tapping screw and plain
2 Instrument cluster cover assembly 16
washer assembly parts
3 17 Steering wheel assembly
screw
Dashboard left speaker cover plate
4 18 Hexagon flange nuts
assembly
Dashboard right speaker cover plate
5 19 Central panel assembly
assembly
Dashboard left end cover plate
6 20 Instrument desk lower left cover plate
assembly
Dashboard right end cover plate
7 21 One-touch start cover plate assembly
assembly
Instrument desk lower access cover
8 Left air outlet panel assembly 22
plate
9 Right air outlet panel assembly 23 Dashboard glove box body
10 Dashboard left molding assembly 24 Dashboard glove box assembly
11 Dashboard right molding assembly 25 Hexagon flange bolts
Cross slot countersunk head tapping
12 Central air outlet body assembly, left 26
screw
13 Central air outlet body assembly, right 27 Dashboard upper body assembly
14 Steering column upper shield 28 Dashboard lower body skeleton
Console
4-1
4 1-1
5
1-2
4-2 4-4
1
5
4-3 6 1-3
5
1-4
5
6 3
2
1-5
1-6
LFWX-6470-85002
1 Subpanel rear body assembly 4 Subpanel front body assembly

1-1 Subpanel rear body armrest assembly 4-1 Subpanel gear shift cover plate
1-2 Hand brake cover plate assembly 4-2 Subpanel front body molding
1-3 Subpanel body glove box pad 4-3 Subpanel front body
1-4 Subpanel rolling blind mechanism 4-4 Subpanel front end left trim board
assembly
1-5 Subpanel rear body 4-5 Subpanel front end right trim board
1-6 Subpanel rear body rear cover plate 5 Cross recess big half round self-
tapping screw
2 Cross recessed pan head self-tapping 6 Hexagon head bolt, Spring washers
screw and plain washer assemblies and plain washer assemblies
3 Hexagon head bolt, Spring washers
and plain washer assemblies
Dashboard (new version) 85
7
9
4
11
8 3
3 10 16
15
18
13
17 20 21
14
2 17
12
23
22 19

19
LFWX-6470-85041
Cross slot tapping screw and plain

1 Instrument cluster panel 13
washer assembly parts
2 Instrument cluster cover assembly 14 Steering wheel assembly
3 15 Hexagon flange nuts
screw
Dashboard left speaker cover plate
4 16 Central panel assembly
assembly
Dashboard right speaker cover plate
5 17 Instrument desk lower left cover plate
assembly
Dashboard left end cover plate
6 18 One-touch start cover plate assembly
assembly
Dashboard right end cover plate Instrument desk lower access cover
7 19
assembly plate
8 Left air outlet panel assembly 20 Dashboard glove box body
9 Right air outlet panel assembly 21 Dashboard glove box assembly
10 Dashboard left molding assembly 22 Hexagon flange bolts
Cross slot countersunk head tapping
11 Dashboard right molding assembly 23
screw
12 Steering column lower shield
Subpanel (new version)
1
1-1
4-1
4-4
6 6 6 1-3 1-2 1-5
4
1-4
2
2
5 5 1-6
3 3
6 1-8
4-3 4-2
3 5
1-7 2
1-9
5 LFWX-6470-85042
Cross recessed pan head self-

1 Subpanel rear body assembly 2 tapping screw and plain washer
assemblies
Subpanel rolling blind fascia panel Hexagon head bolt, Spring washers
1-1 3
molding and plain washer assemblies
Subpanel rolling blind fascia panel
1-2 4 Subpanel front body assembly
molding
Subpanel rolling blind mechanism
1-3 4-1 Subpanel front body molding
assembly
1-4 Subpanel rear body armrest assembly 4-2 Subpanel front body
1-5 Subpanel rear body upper cover plate 4-3 Subpanel front end left trim board
1-6 Subpanel glove box pad 4-4 Subpanel front end right trim board
1-7 Subpanel rear body 5
screw and plain washer assemblies
1-8 Subpanel rear body rear cover plate 6
screw -C type
1-9 Subpanel rear cup holder assembly
85
Subpanel and dashboard
Change
△ Description：
The subpanel and dashboard of XUANLANG series vehicles vary from the configuration. Here is
the basic model.
1. Remove the left and right panel components
of the instrument panel.
(a). Remove the left and right panel components of
the instrument panel.
LFWX-6470-85003
2. Remove the left and right instrument panel.

(a). Remove the left and right instrument panel.
LFWX-6470-85004
3. Remove the lower left cover of the

instrument panel.
(a). Remove the fastening screw of left lower cover
plate of instrument desk.
(b). Remove the left lower cover plate and the lower
maintenance cover plate of the instrument desk.
(c). Disconnect small switch block connector.
LFWX-6470-85005
4. Remove the press-to-start switch.

(a). Remove start stop engine system cover plate.
LFWX-6470-85008
(b). After disconnecting the press-to-start switch

connector, push the press-to-start switch from
inside to outside to take out the press-to-start
switch.
LFWX-6470-85009
5. Remove the left and the right cover plates of

the auxiliary instrument board.
(a). Remove left and right cover plate screws of
auxiliary instrument panel.
(b). Take out the left and the right cover plates of the 85
auxiliary instrument board.
LFWX-6470-85010
6. Remove center control board control switch

component.
(a). Open auxiliary instrument panel armrest panel.
(b). Take down the hand brake panel in upward
direction.
LFWX-6470-85011
(c). Disconnect vehicle power supply connector.
LFWX-6470-85022
(d). Disconnect USB connector.
LFWX-6470-85023
(e). Take down U-shaped bright strip of auxiliary

instrument board in upward direction.
LFWX-6470-85012
(f). Take down the gear shift panel in upward

direction.
LFWX-6470-85013
(g). Remove fastening screws on the left and right of

control switch component of center control.
85
LFWX-6470-85015
(h). Take out center control switch component.

(i). Disconnect center control switch component
connector.
LFWX-6470-85014
7. Remove the air conditioning control panel

assembly
(a). Remove center control board control switch
component.(See 85 – Disassembly of Center
Control Board, Control Switch Component)
LFWX-6470-85017
(b). Disconnect the A/C control panel assembly

connector.
LFWX-6470-85016
8. Remove the glove compartment

(a). Remove damper and take down glove
compartment.
(b). Remove 8 screws of glove compartment body

(c). Take down glove compartment body.
LFWX-6470-85020
9. Remove instrument cluster

(a). Remove steering wheel (see 61 – Hydraulic
Steering System).
85
LFWX-6470-85021
(b). Remove 2 screws and 1 bolt of upper and lower

shields of steering column.
(c). Take down steering column lower shield.
LFWX-6470-85025
(d). Remove combination instrument cowl apron.
LFWX-6470-85026
(e). Remove 2 screws of combination instrument

cowl.
(f). Take down combination instrument cowl.
LFWX-6470-85027
(g). Remove 4 combination instrument screws.

(h). Disconnect the combination instrument
connector clip.
(i). Take down the combination instrument.
LFWX-6470-85028
10. Remove the combination instrument.

(a). Directly take down combination switch.
11. Remove the MP5/ player

(a). Take down entertainment panel cover plate,
central air outlet and entertainment control
panel.
85
LFWX-6470-85030
(b). Remove MP5/radio and tape player fastening

screw.
(c). Take out the MP5/ player and disconnect the
player connector and antenna plug.
LFWX-6470-85031
12. Remove the subpanel of rear body

(a). Remove the subpanel rear cover plate.
(b). Disconnect rear air-conditioning switch
component connector.
LFWX-6470-85034
(c). Open the rear main body armrest component

of auxiliary instrument board and take out the
container pad.
LFWX-6470-85032
(d). Remove 4 bolts and 2 screws of rear main body

of auxiliary instrument board.
(e). Take down rear main body of auxiliary
instrument board.
LFWX-6470-85033
13. Remove the subpanel of front body

(a). Remove 11 screws and 2 bolts of front main
body of auxiliary instrument panel.
(b). Take out the front main body of the auxiliary
instrument board.
LFWX-6470-85036
14. Remove main body on instrument panel.

(a). Remove A column upper apron. (See Chapter
81 Interior & Exterior – A Column Apron, 85
Replacement)
(b). Remove left and right horn cover plates.
LFWX-6470-85037
(c). Remove solar sensor.
LFWX-6470-85040
(d). Remove 8 mounting screws and 2 buckles of

main body on instrument board.
(e). Remove 2 bolts of assistant airbag.
(f). Take down main body and left and right air
outlets on instrument board.
LFWX-6470-85039
Subpanel and dashboard

Installation
85
Wiper and washing system - Wiper and washing system
86-a
Wiper and washing system

Wiper and washing system …… 1
Precautions …………………… 2 86
The scrubbing solution injection
area incorrect …………………… 13
Wiper ……………………………… 15
Replacement of front wiper …… 15
Replacement of rear wiper …… 18
Wiper motor ……………………… 20
Replace the front wiper link
mechanism and motor assembly 20
Replace the rear wiper motor … 22
Windshield washing pot ……… 24
Change ………………………… 24
Wiper blade ……………………… 26
Change ………………………… 26
Nozzle …………………………… 27
Inspection ……………………… 27
86-b Wiper and washing system - Wiper and washing system
86-1
Wiper and washing system

Preparations

86
Measure voltage,
1 Digital multimeter resistance, current
and circuit
Conductor
2 Testing circuit
assembly
Remove the pipe

3 Screw driver
clamp
Speed wrench
Fasten or remove
4 and long/short
the bolt and nut
extension rod
86-2 Wiper and washing system - Wiper and washing system
Maintenance data
Items N·m
Rain wiper connection rod and motor assembly 6 ～ 12
Windscreen wahser fixed bolt 6 ～ 12
Wiper arm fixed bolt 16 ～ 18
Precautions
1. Be sure to remove the battery cathode and wait for at least 1min before removing the
system appliance wire, or it may cause personal injury.
2. If the wiper is blocked accidentally, the power should be cut timely for the prevention of
burning the wiper motor. Now it’s not enough to turn the wiper switch to OFF, instead,
first disconnect the battery cathode cable quickly and then disconnect the wiper motor
connector.
3. The wiper brush shold be kept close to the window without clearance in use, or the
wiper may not clean.
4. It is prohibited to wipe drily for the prevention of damaging the wiper brush, and if the
wiper switch is turned uncarefully, turn it off without delay. Pay attention to the cleaning and
maintenance for the window and wiper for the prevention of dust accumulation.
5. After the wiper is been used for more than 1000h, it is required to remove and maintain
the wiper motor, clear the connutator, polish the brush wear on the commutator furface with
double zero paper or replace the brush.
6. The washer cannot work for a long time and it cannot work for more than 5s every
time. Each use interval cannot be less than 10s, do not turn on the washing motor without
cleaning solution.
7. The spray pipe must be fastened, it is prohibited to unplug the spray pipe casually. Do
not spray the pipe interface for a long time when washing the car, so as to prevent it from
corrosive aging.
8. For low temperature regions, be sure to add the cleaning solution meeting local
temperature requirements.
9. Do not use the engine antifreeze or other substitutes to avoid damaging the window and
paint.
86-3
Component drawing
7
8 13
9 86
10 12 11
4
5
1
2
14
LFWX-6470-86001
1 Pot assembly, washer 8 Right wiper assembly

Rear windscreen hose front Rear windscreen hose rear
2 9
section components section components
Front windscreen hose Rear windscreen nozzle
3 10
assembly assembly
Front windscreen nozzle
4 11 Rear wiper motor
assembly
Hexagon head bolt, spring
Rain wiper connection rod and
5 12 washer and plain washer
motor assembly
subassembly
6 Left wiper assembly 13 Back door wiper assembly
7 Wiper nut cap 14 Hexagon flange bolt
Terminal definition
U04 connected to washer motor U13 connected to wiper motor
1 2 3
1 2 4 5
Terminal Wire size / Terminal Wire size /

Function Function
No. Color No. Color
1 0.85/BIW Front washer motor power 1 1.25/GY Front wiper motor low speed
2 0.85/BW Front washer motor switch 2 NC
3 0.5/YBI Front wiper motor return signal
4 1.25/GW Front wiper motor high speed

L5 connected to rear wiper motor
5 1.25/B Front wiper control ground
1 2
3 4

Function
No. Color
1 0.5/VY Return
2 NC
3 1.25/B Grounding
4 1.25/GrR Work
86
86-5
I()

B+ B+ B+ B+ B+ B+ B+
FS29
FS18
FS31
15A
10A
20A
FS26
FS13
10A
20A
FS43
FS15
10A
15A
0.85 GR
31 UI1 28 UI1
U4 2
13 1C 10 1F 7 1B 3 1B 14 1C 3 1D
0.3 RB
31 IU1 28 IU1
5

0.85 GY
10 R4
13 I1C 10 I1F 7 I1B 3 I1B 14 I1C 3 I1D M

5
R4
2
R4
9 I04

4
8 U17 12 U17 9 U17 8 U8 12 U8 9 U8 U4 1

K13
0.5 VY
0.3 R
E8
10 I04
13 U17
U8

0.5 RG
1 R4
0.5 GGr
2.0 W

1 I50
13
1 3 1 U8 5 U8 U8
R4
1 U17 5 U17 6 U17 6

R4
I17
UI1 15 UI2 2
2 I50
0.85 RG

2
1.25 R
0.85 GY
3
MP5 2 15 EU1
2.0 RBl
3 I50 4 I50
15 UE1
1 R4 IU1 15 IU2 2
4 UI1
0.3 GrBl
0.3 GrY

0.3 Bl
19 UI1
R4
0.85 BlW
R4
0.85 BW
19 IU1
4 IU1
3
2
1 RI1
0.3 O
0.3 W
1 IR1
I11 18 I11 19 2 I09 1 I09 13 I11 1 I11 7 I09 1 I10 21 I09 22 I09 11 I11 12 I11
IMMO+ IMMO- B+ B + B + ACC
FBCM
B+
0.5 PBl
7 ID1 8 IU1 6 IU1 17 ID1
I 5 IU1 I
6 IK1 10 IU1 7 IU1
7 DI1 8 UI1 6 UI1 17 DI1 5 UI1 6 KI1 10 UI1 7 UI1
8 I04
0.3 BrY
0.5 YW
0.5 BrW

0.5 BrW
0.5 RY
0.5 RY
0.5 YG
0.5 YG
0.5 RY
0.5 YG
0.5 PBl
0.3 WG
0.3 BrR
0.3 BG
0.3 GBl
0.5 Br
0.5 RY
21 UE1
21 EU1
0.5 GBr

9 D7 10 U17 5 D8 1 U19 1 U5 14 U17 14 U8

I26
I27

15 10 U8 5 K5

16 I26
13 I26

E25 2 B
7 U17 7 U8

3 U17 6 D8
3 U8 6 K5
2 U19 2 U5
Circuit diagram
E25 1
1.25 B
0.5 B
1.25 B
0.5 B
0.5 B
0.5 GR
0.5 B
0.5 B
0.5 B
0.3 B
0.3 B
0.5 B
0.5 B
0.3 B
0.5 B
0.5 B
3 I10 3 I10 3 R3 3 I10 3 I10
PEPS
IGN1
G24 G25 G26 G11 G23 G13 G27 G11 G13 G11 G11 G25 G11 G13
G24
路
图
II()
B+
B+

FS10
FS34
10A
10A
0.5 RY

2 5

25 IU1
K17
2 5 2 5
6 D8
K10
K11
6 K5 25 UI1
K1
K1
0.85 G

1 3

1 3 1 3 0.5 GB
8 D8
8 K5
11 1C 12 1C
2 U 20 2 U1
0.5 G
0.5 YB
11 I1C 12 I1C

7 D8 7 K5
16 UI1 17 UI1
11 U17 11 U8
1 U1 16 IU1 17 IU1
25 DI1 16 KI1 24 DI1 10 KI1 1 U20
0.5 BrW
4 U17 4 U8
0.5 BrY
0.5 BrR
25 ID1 16 IK1 24 ID1 10 IK1

0.5 Y
0.5 YB
19 I11 20 I11 18 I11 16 I11 17 I11

FBCM
BCANL BC ANH
8 I10 24 I11 25 I114 I11 3 I11 14 I10 13 I1
I10 5 I10
I1 6 I10 22 I11 23 I11 21 I11 5 I11 8 I11 7 I11 10 I11 9 I11 8 I09
8 5 I09 4 I09 3 I09 26 I11
1.25 GW
1.25 GY
0.5 YBl
0.5 BlY
0.3 GBl
0.5 BlR
0.3 Gr
0.3 G
0.85 B
0.85 B
0.85 B
0.3 O
0.3 P
0.5 B
0.5 B
1 IU1
I 2 IU1
1 UI1 2 UI1 2 I08 1 I08 15 IB1 7 IG1 8 IG1
I 14 IB1
0.3 WB
1.25 GW

0.3 W
1.25 GY
15 BI1 7 GI1 8 GI1 14 BI1
2 I08
0.3 WR
3 I01 7 I01
0.3 WG
0.3 YBr
0.5 RG
0.3 Bl
0.3 GBl
0.3 GW
0.3 GR
0.3 Gr
0.3 GB
0.3 Br
0.3 O
0.3 P

4 U13 LIN

7 I04
M
1 U13
3 U13

B1 B1 B1 B1
5 U13
0.5 B
1.25 B
0.5 B
0.5 B
14 I21 13 I21 12 I21 11 I21 10 I21 9 I21 5 I21 I21

G27 G23 G10 G
G21 G
G25 G14 G14 G14 G14
86-6
86
86-7
(RBCM)

ACC ACC B+ B+
0.85 G/B
B+

3 2

FS27
FS36
FS19
FS22
15A
15A
10A
FS05
10A
10A
K05
1 V2 4 V2 2 V2 1 V4 4 V4 2 V4 BCANH BCANL
3 I01 11 I01
4 1 5 1E 4 1E 11 1C 1 1C
0.85 Bl
5 I1E 4 I1E 11 I1C 1 I1C

4 UI1
25 IB1 5 IB1 11 IB1 26 IB1
4 IU1
25 BI1 5 BI1 11 BI1 26 BI1
8 IB1 7 IB1
0.50 PW
7 IB2 9 VB 2 VB 1 VB 8 VB
8 BI1 7 BI1
7 BI2 9 BV 2 BV 1 BV 8 BV
1.25 RRr
0.50 GBl
0.30 WB
0.50 GR
0.50 GB
0.50 GY
0.85 RY
0.85 RB
0.50 PW
0.30 W
1.25 R

I18 10
6 B10 5 B9 5 B9 18 B9 19 B9 8 B9 9 B9 15 B9
22 B9 1 B9 2 B9 1 B10
RBCM B+ B+ B+ 1B+ DATA DATA BCAN_H BCAN_L

RBCM ()

12 B10 9 B10 11 B10 12 B9
11 B9 13 B9 21 B9 4 B10 5 B10 2 B10
0.50 Bl
0.50 GO
0.50 BlW
0.50 GBl
0.50 BlR
1.25 GrR
0.50 VY
0.50 Y
0.50 BlB
6 BG 4 BL1 3 BL1 2 BL2 3 BV 8 BL1
9 BL1 9 BL1 6 BL1 1 BG
6 GB 4 LB1 3 LB1 2 LB2 3 VB 8 LB1
9 LB1 9 LB1 6 LB1 1 GB
1 U03 1 U24
3 L11 2 V1 2 V5 1 L8 1 L9

2 L3 2 L11 3 L3

1 G5 1 B8 4 B8 4 G5

L5
4 D15

L6
2 D15

1 D15
1 U02 1 U23
L5
2 G5 1 L3 1 L11 1 L3 1 L11 1 V1 1 V5 2 L8 2 L9
L6
1 D15 L5
3 D15 2 G5 2 B8 2 B8
0.85 B
0.50 B
0.50 B
0.50 B
1.25 B
0.50 B
0.50 B
0.50 B
0.50 B
0.50 B
0.85 B
I16 C11
0.50 B
0.50 B
G37 G38
G33 G32 G38 G33 G34 G33 G34 G38 G34
Fault diagnosis
G11 G33
1. Check the wiper switch and the washer switch
(a). Measure the resistance of each terminal with a
PUL
L
universal meter to take the condution inspection.
Resistance standard of the wiper switch:
Wiper cluster switch gear Terminal Resistance
OFF 2-4 ﹤ 2Ω
INT 2-4 ﹤ 2Ω
LO 2-3 ﹤ 2Ω
HI 1-3 ﹤ 2Ω
MIST 2-3 ﹤ 2Ω
Resistance standard of the wahser switch:
Wiper cluster switch gear Terminal Resistance
OFF 1-2 ≥ 1MΩ
ON 1-2 ﹤ 2Ω
Replace a new combination switch assembly if the

resistance fails to meet the standard.
2 .Check the washing motor assembly
(a). Connect the battery positive pole (+) and washer
motor terminal 1.
(b). Connect the battery negative terminal (-) and
washer motor terminal 2.
(c) . Check if the wahser motor assembly outlet flows
cleaning solution. If not, replace a new washing motor
assembly.
Note:：
Be sure to complete this operation in a short time so as not to damage the washing
motor assembly. Add a right mount of cleaning solution into the windscreen wahser
during operation.
3. Check the wiper motor assembly

(a). Connect the battery positive pole (+) and washer
motor terminal 4.
(b). Connect the battery negative terminal (-) and
washer motor terminal 5.
(c) . Check the wiper motor assembly
Note:
Be sure to complete this operation in a short time
so as not to damage the motor assembly.
86-9

The whole wiper and 1. Fuse (damaged) 3. Replace fuse
2. Harness (open circuit or short 86
washer system fails to Repair or replace the harness or connector
circuit)
work 3. Cluster switch (damaged) Change
1. Harness (open circuit or short
Only front wiper HI gear circuit) Repair or replace the harness or connector
not working 2. Front wiper motor (damaged) Change

3. Cluster switch (damaged) Change
Only front wiper LO gear circuit) Repair or replace the harness or connector
not working 2. Front wiper motor (damaged) Change

Only front wiper washing circuit) Repair or replace the harness or connector
gear not working 2. Front washing motor (damaged) Change

The wiper arm fails to 1. Harness (open circuit or short
return or returns to a circuit)
2. Front wiper motor (damaged) Change
wrong position (the wiper
switch is OFF) 4. Wiper arm (incorrect installation) Reinstall it
1. Windscreen (oil stain or car wax) Wipe clean
2. Cleaning solution (poor quality) Replace high quality cleaning solution
Replace the wiper brush assembly with the
3. Wiper blade (Incorrect model)
same model
Wiper effect poor 4. Wiper blade (rubber aging or
Replace the wiper blade assembly
cracking)
5. Wiper arm (distorted or damaged) Change
6. Wiper arm (spring elasticity
Change
decreased)
1. Worm (rust or insufficient lubrication) Replace the wiper assembly
Abnormal sound of the 2. Linage (abrasion or distortion) Replace the wiper linkage assembly
wiper 3. Wiper blade (rubber aging or
Replace the wiper blade assembly
cracking)
1. Cleaning solution (insufficient) Fill the washer fluid
No washer fluid injection 2. Cleaning solution (frozen) Replace the washer fluid
3. Cleaning hose (damage or block) Clear or replace
or powerless injection 4. Nozzle (block) Clear or replace
5. Washing motor (damaged) Change
The scrubbing solution Adjustment (see Chapter 86 Wiper and
1. Nozzle (adjustment is needed)
injection area incorrect wahsing system – nozzle, adjustment )
Front wiper system does not work

Check the system
• Ensure the power supply system is normal. Go to
1
• The power is in ON position，check if the wiper and the washing Step 2
system work normally?
Check the fuse

Go to Go to
2 • Open the cab central control box.
Step 7 Step 3
• Check if the wiper fuse FS31 is fused?
Check the circuit for open circuit

•The power is in OFF position
• Disconnect the cluster switch connector I21, front BCM connector
Go to Go to
3 I11 and I10, and the front wiper connector U13.
Step 5 Step 9
• Check whether I21 terminal 4 and I11 terminal 22, U13 terminal
4 and I11 terminal 24, U13 terminal 1 and I11 terminal 25 are
conducted with the digital multimeter ON/OFF gear.

•The power is in OFF position.
• Disconnect the cluster switch connector I21, front BCM connector
Go to Go to
4 I11 and I10, and the front wiper connector U13.
Step 9 Step 5
• Check whether I21 terminal 4, U13 terminal 4 and 1 are conducted
with the negative pole; check whether U13 terminal 1, 2, 3 and 4
are conducted each other with the digital multimeter ON/OFF gear.
Check the cluster switch

Go to Go to
5 • Refer to the combination switch inspection method of the on-
Step 6 Step 8
vehicle inspeciton, check if the combination switch works normally?
Replace the front BCM

• Before replacing the front BCM, eliminate the electric circuit faults
and cluster switch faults according to the circuit diagram and then Test the Go to
6
replace the controller of the same model. Restore the connectors above Step 10
to the original position and verify whether the wiper operation is
normal.
Replace fuse
• Before replacing the fused fuse, first eliminate the circuit fault Go to
7
according to the circuit map and then replace the fuse with the Step 9
rated ampere of 20A.
Replace combinaiton switch

Go to
8 • Replace the combinaiton switch according to the maintenance
Step 9
steps in the maintenance manual.
Check the harness Go to

9
• Repair or replace the faulty harness. Step 9
10 Check whether the fault is solved and finish the diagnosis.

86-11
Only front wiper HI gear not working

Check the system
1
• With the power in ON state, turn the wiper switch to HI gear and 2
check whether the wiper runs at high speed.
Check the harness for open circuit 86
• Disconnect the front wiper motor connector U13, cluster switch
connector I21 and front BCM connector I11. Go to Step Go to Step
2
• Check whether U13 terminal 1 and I11 terminal 25, I11 terminal 22 3 5
and I21 terminal 12 are conducted with the digital multimeter ON/
OFF gear.
Check the harness for short circuit
• Disconnect the front wiper motor connector U13 Go to Step Go to Step
3
• Check whether the resistance between U13 terminal 1 and the 4 5
ground exceed 1MΩ with the digital multimeter.
Check the wiper motor Test the
• Refer to the wiper high gear working condition inspection method of Go to Step
4 above
the on-vehicle inspeciton, check if the wiper motor high gear works 6
normally? procedures

5
Replace the front wiper motor
Go to Step
6 • Replace the front wiper motor according to the repair procedures in
7
the service manual.
Only front wiper LO gear not working

Check the system
1
• With the power in ON state, turn the wiper switch to LO gear and 2
check whether the wiper runs at low speed.
Check the harness for open circuit
• Disconnect the front wiper motor connector U13, cluster switch
connector I21 and front BCM connector I11. Go to Step Go to Step
2
• Check whether U13 terminal 4 and I11 terminal 24, I11 terminal 22 3 5
and I21 terminal 12 are conducted with the digital multimeter ON/
OFF gear.
• Disconnect the front wiper motor connector U13. Go to Step Go to Step
3
• Use the digital universal meter resistance to check if the resistance 4 5
between U13 Terminal 4 and the ground is greater than 1MΩ?
• Refer to the wiper low gear working condition inspection method of Go to Step
4 above
the on-vehicle inspeciton, check if the wiper motor low gear works 6
procedures
normally?

5
Go to Step
7
the service manual.
Only front wiper washing gear not working

Check the system
1
• With the power in ON state, turn the wiper switch to washing gear 2
and check whether the washer motor runs normally.
• Disconnect the front washer motor connector U04, cluster switch
connector I21 and front BCM I11. Go to Step Go to Step
2
• Check whether I21 pin 14 and I11 pin 22, I11 pin 11 and U4 pin 1, 3 6
I11 pin 12 and U4 pin 2 are conducted with the digital multimeter ON/
OFF gear.
• Disconnect the cluster switch connector I21, front BCM I11 and
washer motor U4. Go to Step Go to Step
3
• Check whether I21 pin 14, U 4 pin 1 and U4 pin 2 are conducted 4 6
with the ground or the power with the digital multimeter ON/OFF
gear.
• Check whether the front BCM ground wires are conducted with Go to Step Go to Step
4
the ground with the digital multimeter ON/OFF gear and the check 5 6
whether the resistance is 2Ω.
Check the front washing motor. Test the
• Refer to the front washing motor working condition inspection Go to Step
5 above
method of the on-vehicle inspeciton, check if the front washing motor 7
procedures
works normally?
6
Replace the front washing motor
Go to Step
7 •Replace the front washing motor according to the repair procedures
8
in the service manual.
The wiper arm fails to return or returns to a wrong position (the wiper switch is OFF)

Check the wiper arm Go to Step
1 Reinstall it
• Check if the wiper arm is correctly installed? 2
86-13

• Disconnect the front wiper motor connector U13 and cluster switch
2 connector I10.
3 5
• Check whether I10 terminal 8 and U13 terminal 3 are conducted
with the digital multimeter ON/OFF gear.
3 • Check whether I21 terminal 8 are conducted with the ground or the
4 5
power with the digital multimeter ON/OFF gear. 86
• Refer to the wiper auto stop working condition inspection method of Go to Step
4 above
the on-vehicle inspeciton, check if the wiper motor auto stop function 6
procedures
is normal?
5
Go to Step
7
the service manual.
Wiper effect poor

Check the windscreen Go to Step Go to Step
1
• Check if there is oil stain or wax on the windscreen? 5 2
Check the washer fluid Go to Step Go to Step
2
• Check if the cleaning solution is mixed with purities or oil fluid. 5 3
Check the wiper blade
3 • Check if the wiper blade model matches with the windscreen.
5 4
• Check if the wiper blade rubber is aging or cracked.
Check the wiper arm
Go to Step
4 • Check if the wiper arm is distorted or damaged.
5
• Check if the wiper arm elasticity decreases?
5
eliminated. Then the diagnosis is finished.
No washer fluid injection or powerless injection

Check the washer fluid
1 • Check if the cleaning solution in the washer is sufficient?
4 2
• Check if the cleaning solution in the washer is frozen?
Check the washing hose Go to Step Go to Step
2
• Check if the washing hose is damaged or blocked? 4 3
Check the nozzle Go to Step
3
• Check the nozzle for clogging. 4
4
eliminated. Then the diagnosis is finished.
The scrubbing solution injection area incorrect

Check the nozzle
1 • Check if the spraying direction of thenozzle is incorrect? Go to Step 2
• Check the nozzle for clogging.
Solve the detected faults and check whether the faults are eliminated. Then
2
the diagnosis is finished.
The rear wiper system does not work

Check the system
1 • Ensure the power supply system is normal. Go to Step 2
• With the power in ON state, check whether the wiper operation is normal.
Check the fuse
2 • Open the cab fuse box. Go to Step 7 Go to Step 3
• Check whether the rear BCM fuse FS19 is blown.
Check the line for open circuit
• Open the cab fuse box.
• Disconnect the cluster switch connector I21, rear BCM B09 and B10, front
BCM I11 and I09, fuse box connector I1E and I1C, and the rear wiper motor
connector L5.
3 • Check whether I21 terminal 13 and I11 terminal 23, I09 terminal 4 and B09 Go to Step 4 Go to Step 9
terminal 8, I09 terminal 5 and B09 terminal 9, B09 terminal 13 and L5 terminal
4, B9 terminal 21 and L5 terminal 1, B9 terminal 15 and ground, B9 terminal
12 and ground, L5 terminal 3 and ground, B9 terminal 1 and I1E terminal 5,
B9 terminal 2 and I1E terminal 4 are conducted with the digital multimeter
ON/OFF gear.
• Connect the fuse box connectors I1E, I1C again.
4 • Check whether B9 terminal 8 and 9 are conducted to the ground, B9 Go to Step 9 Go to Step 5
terminal 8 and 9 are conducted to the power with the ON/OFF gear of the
digital multimeter.
• Check the cluster switch.
5 • Check the whether the cluster switch operation is normal according to the Go to Step 6 Go to Step 8
method of checking the cluster switch on-board.
Replace the rear BCM
• Before replacing the rear BCM, eliminate the electric circuit faults and
Go to Step Repeat the
6 cluster switch faults according to the circuit diagram and then replace the
10 above steps
controller of the same model. Restore the connectors to the original position
and verify whether the wiper operation is normal.
Replace fuse
Go to Step
7 • Before replacing the blown fuse, eliminate the electric circuit fault according
10
to the circuit diagram and then replace the fuse of the same rated capacity.
Replace the cluster switch
Go to Step
8 • Replace the cluster switch according to the maintenance procedures
10
described in the maintenance manual.
9
86-15
Wiper
Replacement of front wiper
1 . Remove the front wiper arm assembly
(a). Turn the wiper switch to INT / LO / HI to swing
the wiper assembly.
PUL
L Note: 86
Do not turn on the front wiper switch when the
front windscreen assembly is dry, so as not to
scratch the front windscreen assembly.
△ Tips:
For the operation instructions, refer to LIFAN
LF6470 Operation Instruction.
(b). Turn the wiper switch to OFF position to make
the wiper assembly return automatically.
LFWX-6470-86004
(c). Take down the front wiper cap.
LFWX-6470-86005
(d). Remove the front wiper arm fixed nut.
LFWX-6470-86006
(e). Take down the front wiper assembly.

△ Tips:
Turn up the wiper arm assembly. Shake the wiper
arm up and down and then take it out.
LFWX-6470-86007
2 . Install the front wiper assembly

(a). Clean the wiper arm splined hole with the
round file or similar tool.
(b). Clean the wiper connecting rod pivot spline
with the steel brush.
LFWX-6470-86008
(c). Put the front wiper assembly in place.

△ Tips:
• The front wiper assembly should be on the lower
edge of the front windscreen.
• Upturn the front wiper assembly and put it in
place.
LFWX-6470-86009
86-17
(d). Install the front wiper arm fixed nut and screw
it down to the specified torque.
Torque: 23(20~26)N•m
△ Tips:
• After completing the installation, turn down the
86
wiper assembly.
• Confirm that the wiper assembly is on the lower
edge of the front windscreen assembly.
LFWX-6470-86006
(e). Install the front wiper cap.
LFWX-6470-86005
(f). Check the auto return of the front wiper assembly.

• Turn the front wiper switch to INT / LO / HI to swing
the wiper assembly.
PUL
L Note:
Do not turn on the wiper switch when the front
windscreen assembly is dry, so as not to scratch
the front windscreen assembly.
• Turn the front wiper switch to OFF to make the
wiper assembly return automatically.
• Check if the wiper assembly is on the lower
edge of the front windscreen assembly.
LFWX-6470-86004
Replacement of rear wiper
1. Remove the rear wiper arm assembly.

(a). Turn the wiper switch to INT / LO / HI to swing
the rear wiper assembly.
Note:
L
PUL
Do not turn on the front wiper switch when the

rear windscreen assembly is dry, so as not to
scratch the rear windscreen assembly.
△ Tips:
For the operation instructions, refer to LIFAN
LF6470 Operation Instruction.
(b). Turn the wiper switch to OFF position to make
the wiper assembly return automatically.
LFWX-6470-86004
(c). Take down the rear wiper cap.
LFWX-6470-86010
(d). Remove the rear wiper arm fixed nut.
LFWX-6470-86011
86-19
(e). Take down the rear wiper assembly.

△ Tips:
Turn up the wiper arm assembly. Shake the wiper
arm up and down and then take it out.
86
LFWX-6470-86012
2 . Install the rear wiper arm assembly

(a). Clean the wiper arm splined hole with the
round file or similar tool.
(b). Clean the wiper connecting rod pivot spline
with the steel brush.
LFWX-6470-86008
(c). Put the rear wiper assembly in place.

△ Tips:
• The rear wiper assembly should be on the lower
edge of the front windscreen.
• Upturn the rear wiper assembly and put it in
place.
LFWX-6470-86013
(d). Install the rear wiper arm fixed nut and screw
it down to the specified torque.
△ Tips:
• After completing the installation, turn down the
wiper assembly.
• Confirm that the rear wiper assembly is on the
lower edge of the front windscreen assembly.
LFWX-6470-86011
(e). Install the rear wiper cap.
LFWX-6470-86010
Wiper motor
Replace the front wiper link mechanism and motor assembly
1. Remove the front wiper link mechanism and
motor assembly
(a). The wiper assembly returns automatically.
(b). Remove the main and auxiliary wiper
assembly.
(c). Open the hood and support it with a brace rod.
(d). Disconnect the battery cathode cable.
LFWX-6470-86014
(e). Remove the front ventilation panel fixe buckle

and take down the left and right ventilation panel.
LFWX-6470-86015
86-21
(f). Remove the front wiper motor connector.

(g). Remove the front wiper link mechanism and
motor assembly fixing bolt.
(h). Take down the front wiper link mechanism and
motor assembly. 86
Note:
Store the front wiper link rod and motor
assembly carefully and do not control the front
wiper link rod assembly link rod assembly at
will.
LFWX-6470-86017
2. Install the front wiper link mechanism and

motor assembly
(a). Install the front wiper link mechanism and
motor assembly to the mounting position.
(b). Install the front wiper link mechanism and
motor assembly fixing bolt.
Torque: 6 ～ 12N•m
LFWX-6470-86017
(c). Install the front wiper motor connector.

Note:
Connect the connectors until a silvery click is
heard, which means the connector is installed
in position.
LFWX-6470-86016
(d). Install the front vent panel fixing buckle and

the left/right vent panel.
LFWX-6470-86015
(e). Install the main and auxiliary wiper assembly.

(f). Connect the battery cathode cable.
(g). Check the auto return of the wiper assembly.
LFWX-6470-86018
Replace the rear wiper motor

1 . Remove the rear wiper motor
(a). The wiper assembly returns automatically.
(c). Remove the rear wiper assembly fixed bolt.
(d). Remove the rear wiper assembly.
LFWX-6470-86012
86-23
(e). Remove the back door decoration block. (see

Chapter 81 Interior and exterior decoration – back
door interior panel, replacement)
(f). Remove the rear wiper motor fixed bolt.
(g). Disconnect the rear wiper motor connector. 86
(h). Take down the rear wiper motor.
Note:
The rear wiper motor assembly should be
stored carefully.
LFWX-6470-86019
2 . Install the rear wiper motor

(a). Install the rear wiper motor in place.
(b). Install the fixed bolt.
Torque: (6~12)N•m
(c). Connect the rear wiper motor assembly
harness connector.
LFWX-6470-86019
(d). Install the rear wiper motor and its fixed bolt.
Torque:6 ～ 12 N•m
(e). Install the back door panel (see 81- interior
and exterior decoration back door panel,
replacement)
Note:
Connect the connector and it denotes the
connection is in place if a “click” is heard.
LFWX-6470-86011
(f). Install the rear wiper assembly.

(h). Check the auto return of the wiper assembly.
LFWX-6470-86020
Windshield washing pot

Change
1 . Remove the windscreen washer assembly
(a). Disconnect the negative cable from the
battery.
(b). Remove the front bumper assembly (refer
to Chapter 81 Interior and exterior trims - front
bumper, replacement).
(c). Disconnect the washing motor connector.
LFWX-6470-86021
(d). Pull down the washing motor outlet pipe.
LFWX-6470-86022
86-25
(e). Remove the windscreen washer assembly

fixed bolt as shown in the figure.
(f). Remove the washer assembly top end and
bracket fixed bolt.
86
LFWX-6470-86023
2 . Install the windscreen washer assembly

(a). Install the windscreen assembly in place.
(b). Install the washing lower fixed bolt.
(c). Install and fasten the windscreen assembly
top fixed bolt.
LFWX-6470-86023
(d). Install the washing motor outlet pipe.
LFWX-6470-86022
(e). Connect the wahsing motor connector.

(f). Install the front bumper assembly (see 81
Interior and exterior decoration – front bumperl,
replacement)
LFWX-6470-86021
Wiper blade
Change
1 . Remove the wiper brush
2 (a). Upturn the wiper assembly.
(b). Raise the wiper brush locking plate, push out
the wiper brush along the indicated direction and
remove the wiper brush assembly.
LFWX-6470-86024
2 2. Install the wiper brush

(a). Install the wiper assembly in the direction
of arrow.
△ Tips:
It denotes that the wiper arm assembly is installed
in place if a “click” is heard.
LFWX-6470-86031
86-27
Nozzle
Adjustment
1. Check the spraying range of the nozzle
Turn on the front washer switch to check the
spraying position on the front windscreen
assembly of the cleaning solution. 86
2 . Adjust the spraying range of the nozzle
assembly
620
56 Adjust the nozzle jet height by hand until the spray
range is acceptable.
LFWX-6470-86030
Inspection
1. Check the washing nozzle
Blow along the spraying direction of the cleaning
solution and confirm that the air flow can only get
through unidirectionally but not reversely.
LFWX-6470-86025
Change
1. Remove the washing nozzle
(a). Open the engine compartment and disconnect
the battery negative cable.
1 (b). Take down the nozzle from the engine
compartment cover plate in the direction of arrow.
LFWX-6470-86026
(c). Pull out the washer nozzle in the direction of

arrow.
LFWX-6470-86027
2 . Install the washing nozzle

(a). Connect the cleaning hose and nozzle in the
direction of arrow.
LFWX-6470-86028
(b). Install the washer nozzle in the direction of

arrow.
△ Tipe：
Press the washer nozzle in the installation groove
1 directly until a click is heard, which indicates the
nozzle is installed in position.
LFWX-6470-86029

LIFAN M7 Service Manual (LF-20171010)

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LIFAN M7 Service Manual (LF-20171010)

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Introduction

LiFan Industry(Group) IMP&EXP Co.,Ltd.

Approved by: CHONGQING LIFAN VEHICLE CO., LTD.

Approved by: CHONGQING LIFAN VEHICLE CO., LTD.

How to use this manual

Component assembly relationship

Front differential bearing sleeve Planetary gear shaft

List of component names

What to do and where to do

Terms and definitions

“Warning”, “Caution” and “Tip”

International System of Units (SI)

“Units” in this manual are International System of Units (SI).

How to perform troubleshooting

1. Inspect the circuit with blown fuse

Remove the intermittent fault

(c) Wiring harness

Remove the historical faults

Precautions before repair

Electrical system maintenance

Before replacing the relevant components in the

When using high-pressure vehicle cleaning equipment or steam vehicle cleaning

3. Bolts, nuts and screws

(b) Do not drop the electrical component (such

Shape (example) Removal/installation

(a). The lower front beam under the co-driver's

(b). The upper left corner of the dashboard on

2. Vehicle nameplate description

(a). The nameplate is located at the lower of

3. Position of engine VIN

Technical characteristics and parameters of vehicle

Vehicle technical parameters

Length (mm) 4720 4720 4720 4720 4720

Front (mm) 1540 1540 1540 1540 1540

Wheelbase (mm) 2780 2780 2780 2780 2780

Curb weight (kg) 1540 1540 1540 1540 1540

Maximum authorized total mass

Approach Angle (°) 19 19 19 19 19

Departure Angle (°) 23 23 23 23 23

Tire Specification 215/55R17 215/55R17 225/45 R18 225/45 R18 215/55R17

Spare tire T135/90R16 T135/90R16 T135/90R16 T135/90R16 T135/90R16

Front Suspension (mm) 950 950 950 950 950

Rear Suspension (mm) 990 990 990 990 990

Maximum Vehicle Speed (km/h) 180 180 180 180 180

Engine model LFB479Q LF483Q LF477ZLQ LF477ZLQ LF483Q

Type Straight Straight Straight Straight Straight

Displacement (ml) 1794 1988 1452 1452 1988

Maximum Torque N•m (r/min) 168 185 234 234 185

Idle Speed (r/min) 750±50 750±50 750±50 750±50 750±50

Combined fuel consumption

Maximum gradability (%) ≥30% ≥30% ≥30% ≥30% ≥30%

Emission Standards National V National V National V National V National V

Maximum net power (kW) 92 100 100 100 100

Brake lining Front / rear

No-load (kg) 850/690 850/690 860/700 900/730 890/690

Item Normal parameter

Toe-in of front wheels 1.3±0.5mm

Kingpin caster angle 5.5°±0.5°

Kingpin inclination angle 11.65°±0.5°

Cold countries and regions: SAE 75W-90 (API

Manual transmission gear

Brake fluid D0T4 (800±20) ml

Power steering fluid ATF220 (1100±50) ml